Dinan M635 Turbo Joins The Family

[Slownrusty]

Very nice work... do you have access to a powder coater friend?

Is your plan to fix and sell or keep this one?

Yes, I have access to a great Powder Coater that is close to my home.

My plan is to definitely keep this one.

[Slownrusty]

Some more progress over the past few days.

Made a new lower intercooler pipe.

And installed a new clutch fan on a proper red fan.

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Intercooler Pipe 2.JPG (1004.87 KiB) Viewed 4841 times

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Clutch Fan After.JPG (637.05 KiB) Viewed 4841 times

[Slownrusty]

I hope everyone had a great Christmas.

A little more progress over the past few days.

The new catch can is now mounted, previously the car had an awful catch can set-up that loosely hanging on the right side of the engine.

I also have one of the IC pipes ready for the TiAL BOV flange to be TIG welded.

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New IC Pipe TiAl Flange.JPG (673.4 KiB) Viewed 4808 times

TiAL BOV WG 1.JPG (657.72 KiB) Viewed 4808 times

TiAL BOV WG 2.JPG (717.17 KiB) Viewed 4808 times

[Slownrusty]

Having a few days off with the Christmas holidays, I was able to make some progress.

All the intercooler pipes are now TIG welded, done by a friend who is a talented welder and now installed.

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Intercooler Pipe 4.JPG (523.83 KiB) Viewed 4760 times

One thing I am quite good at it is being able to visualize a bracket from flat stock to mount "something" using the factory holes and not having to drill any holes on the car. One of my mottos from many years ago is "Let the Parts Fit The Car, NOT let the car fit the parts".

In this case, when I bought the car, the intercooler was poorly supported at the base and so I made a new lower bracket out of aluminum. This was tricky due to the geometry and lining it up, it took two tries and quite a few hours, but worked out well in the end. I always start out with a piece of cardboard.

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Intercooler Bracket 2.JPG (653.6 KiB) Viewed 4760 times

[Slownrusty]

A better shot of the lower intecooler pipe.

I might need to make some kind of shield to protect that pipe and oil pan, as the car sits quite low....I need to think about this one.

Intercooler Pipe 5.JPG (730.22 KiB) Viewed 4757 times

[GRNSHRK]

Impressive work, as usual

I wonder if the intercooler pipe could have been routed closer to the oil pan

But you will definitely need some sort of protection under there, regardless

[Slownrusty]

Thanks Bob.

I'm good with the IC pipe as is, but will investigate fabb'ing some sort of protection shield soon.

I did get the 3" Downpipe and exhaust back from being ceramic coated. Polydyn did a great job coating it inside and out as always, cost was $150. Installation was easy on my garage floor and I used new fasteners and gaskets.

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Polydyn 3in DP 2.JPG (758 KiB) Viewed 4671 times

Polydyn 3in DP 4.JPG (659.51 KiB) Viewed 4671 times

[Slownrusty]

Late night as I am getting closer and closer.

I actually started the car and it was great to hear it fire and run and quickly settle down to a 750rpm idle.

It's always nerve-racking and anxious, as I disturbed and touched so many things electrically and mechanically over the past 6-months and you hope that you put everything back like it should be...but factor in human error!

I actually had a small fuel leak, as I replaced all the fuel hoses with brand new -6AN lines but it took 2-minutes to tighten things up and address it.

Here is where we started 6-months ago when I bought the car off BaT:

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And a sneak peak from last night:

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Hopefully by this weekend, I can take the car on a zip around the neighborhood.

[tschultz]

Nice work cleaning up those little items which add up to a bigger difference in the end result than you might otherwise realize!

[Slownrusty]

Nice work cleaning up those little items which add up to a bigger difference in the end result than you might otherwise realize!

Tanks and agreed!

I flushed the cooling system with 40-liters of distilled water and then added G48 Blue coolant.

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Flushing Cooling 2.JPG (679.64 KiB) Viewed 4580 times

And here's a summary video of the work over the past 7-months:
https://www.youtube.com/watch?v=ReJaQAMj4-Q

[Slownrusty]

Here's a summary video of the last 7-months.

https://www.youtube.com/watch?v=ReJaQAMj4-Q&t=480s

[Slownrusty]

Wrapping up a few punch list items:

1) I made a heat shield to protect the right sway bar bushing from the exhaust heat. This was neat as it has some interesting compound bends to it, I always start with a piece of cardboard and go from there.

Sway Bar Bracket 1.JPG (658.22 KiB) Viewed 4026 times

Sway Bar Bracket 2.JPG (515.22 KiB) Viewed 4026 times

Sway Bar Bracket 3.jpg (1.06 MiB) Viewed 4026 times

[Slownrusty]

2) I divorced the wastegate dump tube from the exhaust and now have it dumping to atmosphere, this required welding an extension and then had it high temp. ceramic coated, after which I bolted it all up.

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Dump Tube 1.JPG (1.11 MiB) Viewed 4024 times

Dump Tube 3.JPG (493.9 KiB) Viewed 4024 times

[Slownrusty]

Great news.

I got the front spoiler back and installed some brand new fog lights. When I bought the car, the fog lights were missing, so at least it looks less naked.

I took it for some shake down runs last night, at 7psi it feels strong and pulls hard through the gears, I am certain I can a few more pounds of boost but I will need to monitor the AFRs at WOT to confirm that. I have an Innovate LM2 on order, so I can do some data logging.

Some quick pictures:

[GRNSHRK]

Lookin' good, as usual

Yasin, can you please let the forum know what you used on the grills

They look very shiny, nice

[86_6series]

Grnshrk,

I use Adams. The great thing is that you don't have to worry
if the spray gets on the paint, it just evaporates away.

https://adamspolishes.com/products/adam ... -out-spray

Bob V

[Slownrusty]

Lookin' good, as usual

Yasin, can you please let the forum know what you used on the grills

They look very shiny, nice

Hi Bob - Thanks! I actually sanded them down and re-painted them using satin black paint that is compatible with plastic and has the correct flex agent.

My best,
Yasin

[Slownrusty]

My local upholstery shop recovered my worn-out original steering wheel, knocked it out of the park.

Before:

Steering Wheel Before 4.JPG (731.23 KiB) Viewed 3328 times

And After:

Steeing Wheel After 4.JPG (708.2 KiB) Viewed 3328 times

Steeing Wheel After 5.JPG (384.09 KiB) Viewed 3328 times

Steeing Wheel After 6.JPG (419.39 KiB) Viewed 3328 times

[Slownrusty]

I was quite concerned that the lower intercooler pipe that I originally made a few weeks ago hung too low and would get bashed when driving, so made a new one yesterday, which gained an extra 1/2" of ground clearance. It doesn't sound like much but as low as the car is, I'll take it!

I took the car for a long-ish shake down run yesterday and it is running well..good power and the engine has no problem spooling up the turbo. 3rd gear is a very strong gear. I haven't done any tuning just yet..waiting for Innovate to re-release their LM2 AFR handheld data recorder.

Intercooler Pipe 6.jpg (2.84 MiB) Viewed 2860 times

Intercooler Pipe 7.jpg (1.18 MiB) Viewed 2860 times

Intercooler Pipe 8.jpg (1.19 MiB) Viewed 2860 times

My best - Yasin

[jps635]

You'll have to change your moniker to 'Fastnred"

[Slownrusty]

You'll have to change your moniker to 'Fastnred"

I like it!!! I might just do that.

I had the red wagon out this weekend and the weather was great, so snapped a few pics near the local golf course:

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[Slownrusty]

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[Slownrusty]

I drove the car to a local car GTG.
Nice cool morning and the car felt great.
Nice to see the crowd drawn and quite a few remember when it was Bring A Trailer.

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[Slownrusty]

Well not one to leave anything alone. So literally after 1 day of driving the car. Its back apart.

The big driver was to rebuild the coilovers, bleed the brakes, refinish the calipers, refresh all the suspension, PowerFlex Poly bushings AND also raise the car about 1/2" as its dangerously low to ground.

As can be seen, the car has some neat stuff installed from the past, notably:
- Wilwood Superlite 4-piston aluminum calipers with lightweight 2-piece rotors w\ aluminum hats
- Converted to wheel studs
- Coilovers
- Dinan adjustable and large sway bar

So here we go..before!

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[Slownrusty]

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