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project resurrection: s3 (evo8) w/123k

25K views 41 replies 19 participants last post by  fixit 
#1 · (Edited)
Post Build:
Video of first try startup IMG_1208.mp4 video by netnews - Photobucket
edit; 6/10/16 -- dynoed 453 ft-lbs & 405hp on e85, ran out of fuel.. more to come

Background:
Daily driver

Fast forward to Easter 2011, started using large amounts of oil -- no smoke
priced out a stock motor rebuild from motorworks, $4,000
Acquired a spare head ($250) and block ($500)
Searched others builds and this is the upgrade list I came up with after talking to MAP decided on
  • Mopar Top end gasket set: 60.00
  • Mopar Lower end gasket set:35.00
  • Mopar Water Pump:70.00
  • Mopar Oil Pump:89.00
  • Our crank strap bolts (ARP bolts) ~120
  • King Main/ Rod Bearings: 38.00
  • ARP head Studs: 115.00
  • Eagle Rods, H w/ upgraded ARP 2000 bolts: 299.00
  • Wiseco Pistons 8:8-1: 420.00

Feedback on MAP
communication = fair (oh it shipped, 10 days later-- still no gaskets)
price = good
shipping time = 6 weeks (paypal sent 6/9/11 gaskets received 7/20/11
If your car was DOWN like mine, I wouldn't recommend ordering from MAP


picked up a almost new southbend stage 3 clutch https://www.srtforums.com/forums/f213/hope-i-dont-regret-southbend-stage-3-clutch-612246/
slightly used struts
very used engine host and stand from craigslist

My all in ~$1500, considering i can resell my block head etc..

I found these rebuild links very helpful
https://www.srtforums.com/forums/f169/torque-spec-sheet-505635/
https://www.srtforums.com/forums/f75/how-remove-install-cylinder-head-421718/
https://www.srtforums.com/forums/f75/how-remove-engine-348916/
https://www.srtforums.com/forums/f169/wanna-build-your-own-direct-fit-strap-kit-608075/
https://www.srtforums.com/forums/f169/wanna-build-your-own-windage-tray-607397/
https://www.srtforums.com/forums/f24/crankshaft-sprocket-354735/
https://www.srtforums.com/forums/f75/how-renmove-oil-pan-622974/
https://www.srtforums.com/forums/f169/replacing-rods-pistons-motor-car-602544/index4.html
Link to my S3 w/Evo8 turbo install https://www.srtforums.com/forums/f169/my-install-s3-manifold-dcr-evo8-turbo-318192/ and muffler install https://www.srtforums.com/forums/f24/muffler-question-618698/#post9377890
https://www.srtforums.com/forums/f163/srt-4-suspension-faq-416630/
link to adding a camaro muffler to the rear exhaust section https://www.srtforums.com/forums/f24/muffler-question-618698/#post9377890
https://www.srtforums.com/forums/f169/will-re-building-my-motor-next-week-advice-605399/index7.html#post9135980

Not that i'm ever building again, but next time i would port the oil housing and go with 3 gaskets so i could run a big filter

Here are a few pictures of the build















td05hr upgrade from 16G to 20G compressor wheel




 
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18
#4 ·
updated first post with new pictures (pretensioner) and links for strap & windage
 
#8 · (Edited)
my first post has a cut and past of the quote from MAP, could be a bundle price.. ask for chris

if you want to chat pm me your number and i'll give you a call
 
#10 ·
last weekend e-town and then red bank for guiness festival -- but most of the time hoboken
 
#12 ·
yea i opened it up --- needed to clean it out too, filled with metal shavings from the old motor (don't see any reason it needs to be replaced, just a good cleaning)
 
#14 ·
haven't dyno'd yet, but that seems about right on 93

i think the 47# wheel is my limiting factor, w/o water injection 25#'s of boost, w/WI maybe 28#'s -- and bottom end is built for more (strap etc) -- DCR respected name claims 800hp w/aluminum-6061 strap -- i made mine from steel (stronger) -- so it should be around that, doubt i could push 800-900hp w/o breaking an axle or input shaft
http://www.srtforums.com/forums/f258/new-dcr-direct-fit-6061-crank-strap-kits-594226/#post8925311
 
#16 ·
#20 · (Edited)
#21 ·
here are the spec's and data sheets
<needless to say way more than I need>

low carbon steel = 60,000 psi
t6061-0 =18,000 psi
t6061-6 =40,000 - 45,000 psi depending on heat treatment

http://en.wikipedia.org/wiki/6061_aluminium_alloyhttp://en.wikipedia.org/wiki/6061_aluminium_alloy

http://www.fastenal.com/content/product_specifications/KS.OS.SQ.P.pdf
What you post is part of the picture.

But to each his own.
I'm not gonna garbage up your thread like others would on here. Just stating the facts of what is what.
 
#26 ·
haven't hit the dyno yet.. maybe this week at carlise
just swapped lower ball joints and power steering pump(squeaking )
 
#27 ·
I didn't know we were so similar.... Nice.

Interested to see your dyno graph. Curve and peak. In the next year or so, we will be almost identical in mods.
 
#30 ·
i use a 2" with the 275's & stock suspension -- rubs a little on very tight turns.

on the highway it does tend to follow the ruts in the road, unlike the stock size tires.
 
#34 ·
just turned 170k and i've finally fixed a torque steer & wandering issue by replacing my prothane LCA bushings (~75k) with the moog spherical units.
first post updated with the link to the how to.
 
#35 ·
Hows the "ramp mod" treating you? I had this done on my stage 3 and experienced nothing but problems with it. The turbo seemed to choke out at around 21 psi. Spool was bumped to around 3300rpm, couldn't get it to boost past 22psi or so etc.

It also was a heavy suspect at chipping up my stock stage 3 Tial wheel. :( I think it focuses the heat so much that it starts to degrade the turbine. Had Bob at Form and Function remove it and bingo fixed all of my problems. I'd look into removing it if I were you.
Have you dynoed it yet?
 
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