Kouki KA-T Engine Build

All of these build threads have given me the bug to do one too, so here goes.

I munched my motor this year at Downsview Park when it popped out of gear as I mashed the gas. With all of the noise from the tires, I didn't hear the motor bouncing off the limiter until it was too late. The stock computer has a fuel cutting rev limiter, so I leaned it out big time while hitting the limiter and now have low compression on the #3 cyl.

I have the stock computer with an AFC and needless to say, motors don’t last forever with tunes like these… which didn’t surprise me. It did however last over 30K of generous beatings including 2 drift seasons, a bunch of road trips and daily floggings for 2 summers.

Here’s a little back ground of how the engine mods went.

Winter of '06/'07:

Bing’s manifold
GT2871r .64ar (purchased through Bing’s)
JGS oil kit
Bicknell Racing Products fittings and lines for coolant
370’s rebuilt and flowed
Walbro 255 fuel pump
Bing’s intercooler piping
Bing’s silicone couplers
Bing’s t-bolt clamps
FMIC (to fit with uncut rebar, a/c and fogs)
Greddy Type S BOV (w/rare black top)
2.25" exhaust welded up by me
3” mild steel down pipe modded for KA by me
apexi AFC NEO

Changes made over winter of '08/'09:

Wiertech tubular ss tig’d manifold (bottom mount)
Megan 3" ss elbow
Wiertech 3" ss tig’d downpipe
Wiertech 2.5" ss tig’d exhaust
Magnaflow muffler
Urethane filled motor and tranny mounts

Winter of ‘09/’10

Things I have:

550’s
AEM EMS w/map, uego, boost solenoid and serial gauge

Things I don’t have yet:

Full engine rebuild kit including all gaskets, seals and bearings.
New OEM timing kit and oil pump
ARP head and main studs
Forged rods
Forged pistons
Fuel pump relay kit to ensure full voltage
Ignition coil relay kit to ensure full voltage

Machining to be done:
.020” overbore
3 or 5 angle valve job
Port matching

Now for the pics.

Apret le turbo
http://img.photobucket.com/albums/v641/Theo23/My%20S14/EngineBay2.jpg

Avec le Turbo!
http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0115.jpg

This is me at Downsview blowing the motor up :mad: (Ronnie, I hope it’s ok for me to post this pic… let me know otherwise)
http://img.photobucket.com/albums/v641/Theo23/Track/IMG_7390.jpg

In my dads shop where I’m doing the work
http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0112.jpg

http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0110.jpg

http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0118.jpg

After pulling a few things off
http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0119.jpg

http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0119.jpg

The engine should be out this coming thursday if all goes well.

So yeah, that’s her for now.
I’ll try to keep things fresh in here… there will be pics of all of the machining and building so stay tuned!

PS: Ronnie, I sent you an email asking your permission to post this pic you took of me, but if you didn’t receive it, PM me if you would like me to take it down. Thanks for taking such a great couple of pics btw!!

What kind of power does a ka-t usually make with gt2871 .64??

let me know if you want to make any more changes with your setup theo. i’ve got a bender now if you need a cage.

in for more pics!

aaron

i have a clutch i used for 2 months that i bought off varun never abused it was used on my stock kade its a clutch master fx400 capably of holding over 400 hp let me know if u need a clutch it would be perfect for this build

old man status…FTW…

finally a ka-t build, how much boost were u running and what rpm does it start to build and hit full boost

i didnt knew she blew

Polar -I just tried logging onto photobucket to upload the dyno graphs, but they are doing site maintenance. I’ll get them up tomorrow evening hopefully.

The RWHP in stock NA form was a mere 115hp at about 5300rpm… Kinda low I know, but it was no slouch… The torque hit its peak of 129lbft at 4300rpm. but was over 110lbft well before 2500rpm.

That was in the spring of '07, the next spring, the turbo was on and running at 8psi. Boost was falling off to less than 7psi by the time it reached 5000rpm, but she hit her peak of 230HP at 5200rpm. By 3000rpm we were already at 210lbft with a peak torque of 270lbft at 4200rpm.

So basically, everything doubled… and then some. She was so incredibly fun, I couldn’t lay off it …and I still can’t!

I’ve got the AEM boost solenoid that will be very nice, but I am pretty sure there is a vacuum leak or something to cause the boost to drop like that. I think I have the boost chart laying around here too somewhere. Anyways, when the motor comes out I will be getting all of the vacuum stuff worked out… The engine in this car has never been removed, so some of that stuff got overlooked.

Aaron -you know that this car will never be caged… I’m not opposed to them, just not in this car. …yet!!! :slight_smile:

As for the clutch, I was initially running a centerforce stage 2, but upgraded to the dual friction before the 09 season.

Darien, thanks for pointing that out, but you are probably older if you add on demerit points :wink:

no problem… but, “fail to yeild to emergency vehicle” - carries no points… I have been a moderately good boy/man lately

Looks like Photobucket is back up now… here are my dyno charts.

Stock N/A power
http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/12-23-2007025428PM.jpg

Turbo charged
http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/12-23-2007025658PM.jpg

I’m shooting for 300RWHP but want to pay more attention to getting her to spool quickly. This will happen in the spring when Danno at U2NDyno comes to tune it up.

how was your stock ka making 106 hp before?

It’s actually 116, not that thats much better, but as I mentioned above that was never figured out… It was a very fast car even before the turbo, so not really sure what happened there.

So my Kouki is going to have a new neighbor tonight… Dad picked up another car, and it’s being delivered this evening so I figured chances of it being scratched up would be less if I got the engine out ASAP.

Pics of the new addition are coming soon!!! You guys are going to like this one!!! I can’t wait till after dinner. Teaser hint: Mosport Green

Now back to my stuff…

http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0123.jpg

http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0124.jpg

http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0126.jpg

And, she’s OUT!! First time the engines ever been out of this car.
I can’t wait to start cleaning up the engine bay!

http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0130.jpg

http://img.photobucket.com/albums/v641/Theo23/KA-T%20Engine%20Build/100_0132.jpg

Ok, I’m off to go clean up my stuff.

Amazing car!

Its so damn mint! Looks like it came off the assembly line!

Goodluck on the build

Since you have free access to a shop, and the engine is out, I think you should stitch weld the engine bay to reinforce it a bit. O strip it down completely and go buck nutty if you have the will and desire for it.

Thanks Mr X, It has never been winter driven, but there’s a lot of oil in the bay right now from the vent tube when it was running low compression. She will be cleaned up and looking good again this spring.

Feint, I almost cried when I drilled the hole for the cold pipe, so no, I won’t be stitch welding this one. Maybe if it was a dedicated track car, but this thing is my baby.

Update: I should have pics up tonight of the new neighbor.

:smiley:

It’s about time eh Dan!

Garage Status Update:
I got a couple pics of my dads new car

http://img.photobucket.com/albums/v641/Theo23/Misc/100_0140.jpg

She’s a '66 painted Mosport Green Metallic (2100 total vette’s were painted this color), 4 wheel disks, posi, 300hp 327 w/4spd and 72k orig. miles. a couple years ago it was a 98 point car getting the NCRS top flight award.

This is going to be a fun summer!

^^ WOW that is a sweet ride

OMG Theo… that vette is spectacular!!!

And now thanks to you I have to drive home with wetness running down the inside of my leg and a chill running up my spine…

I’m sure you’ve heard that before though. ;p

Oh right build thread… errrrr umm… yea

never seen your engine bay look more promising… you know KA-Less. heheheheh