Annnnndd we're done! It’s been a long a week at Greaser. For the last month we've been busy preparing Minh's track only 180SX Type X, and Du's Brilliant Blue S15 for the upcoming Trak life / Yez Racing track day at Wakefield park on Monday 30th May.
Not a stranger to track days; Du's current personal best (PB) lap time at Wakefield park is a 1min 10sec (in Minh's Track only 180SX Type X). On Monday he will be tracking his S15 for the very first time, and so he had a couple of things he wanted done before track day. He asked if Greaser could help.
Du's to-do list:
-Install "Gameboy" Oil cooler + Greddy Oil sandwich block adapter+ Greddy remote oil filter block
-Install Koyo Alloy radiator
-Install Apexi Single Din Digital Gauge
-Install AFR+Boost Gauge
-Install HKS boost controller
-Install Tein EFDC
-install Intima Brake pads
-Install OEM BM57 Brake Master cylinder upgrade
-Bleed brakes system
*Special request/challenge: No cutting or drilling extra holes in the car.
CHALLENGE ACCEPTED !
First up- Make room! Stock radiator, fan, fan shroud and intercooler pipes came out; this helped free up much needed room to install the Greddy Oil sandwich block adapter, mock up and find a suitable position for the Greddy remote oil filter block, figure out the oil lines lengths and AN dash fittings required to connect the "Gameboy" cooler and everything else.
While we were at it, the stock BM50 brake master got the flick for an upgraded OEM brand new BM57 from a GTR - a must for S-chassis owners who have upgraded their stock front and rear brakes to Brembos. There are cheaper aftermarket alternatives to the OEM Nissan BM57, but from experience we have had mixed results with the cheaper aftermarket parts, especially on an ABS S-chassis(s), we suspect it has to do with the internal valving being a lot more relaxed on the cheaper kind compared to OEM equipment, so in this case OEM is best!
ATS Super Blue Racing Dot 4 brake fluid - because blue.
We haven't had much experience with Intima Brake pads but Du rates them highly and because also blue- so why not!
The Greddy remote oil filter block is a nice bit of kit that includes a built-in thermostat, which allows the engine to get up to operating temperature ( essential for those cold winter morning starts) before opening a valve to let the hot oil pass through to the oil cooler. We mounted the Greddy remote oil filter block in between the strut tower and the engine. The Greddy remote oil filter block is mounted onto a custom made bracket to the strut tower using a pre-existing hole - yes sir, no drilling holes here! Also note- OEM oil filter because also Blue.
Next we dummy fit the "Gameboy" oil cooler and check for clearances.
Happy with its position, a custom mounting bracket made out of Galvanized steel holds the cooler in place. The "Gameboy" cooler might be small, but it’s mighty. Chosen for its size and core thickness, it is positioned neatly in front of the water bottle with the Intercooler pipe next to it, all while fitting behind the S15's genuine aero bar (which we were not allowed to cut or trim). For a car that gets driven daily and hits the track 3 -4 times a year, "Gameboy" cooler provides sufficient cooling and puts it in the Goldie-locks zone ( not too cold, not too hot, just right).
Measure twice, drill once!
The Greddy Oil sandwich block adapter and Greddy remote oil filter block fits in between the two inlet manifold factory SR20 braces and the alternator. “Cramped” is an understatement; in order for the line to clear everything and not kink, we choose 120 degrees -10 AN fitting for the Greddy Oil Sandwich Block Adapter and 150 degrees -10 AN fittings for the Greddy Remote Oil Filter Block. Starting the fittings by hand was quite easy, but to get it tight enough so that oil wouldn't leak meant the alternator had to come out so we could use a 5/8" spanner to tighten everything up. With the alternator re-installed, the oil lines effectively loop around the alternator.
Oil cooler bracket finished and painted.
The oil lines to the cooler was straight forward - measure twice, cut once. We used 45 degrees -10 fittings to help angle the oil lines downward to the oil cooler.
A good idea for any oil cooler installation is to pre-prime the oil cooler, this gets rid of any trapped air pockets in the core and helps maintain oil pressure, as any sudden loss in oil pressure due to an empty oil cooler in the initial start up could potentially lead to engine damage. To do this, we un-bolted the oil cooler, turned it 180 degrees, (upside down) so the oil lines were on top and the filled the oil cooler via the inlet line until both the inlet and return oil lines were full of oil.
To give "Gameboy" oil cooler a fighting chance, we made "block off" air diversion plates.
The idea is to maximise the airflow from the S15 Aero bar's front and side air vent. The block off plates fills up the remaining gaps in the front vent and forces cold air in from the front of the car through the cooling vanes and exits out through the Aero bar's rear side vent.
Front bar on and the oil cooler is nicely hidden away from view.
All business here!
This has got to be one of the coolest, most badass single din gauge displays ever. The perfect balance between form and function. We love it!
Hiding in the glove box is a HKS EVC boost controller and a Tein EDFC. We're not sure why most people haven't caught onto the EDFC as it removes all the guess work from remembering and counting the number of clicks when adjusting coilovers, its memory feature means you get to have multiple setups on the go; ie, street, nasho run and track day, and the EDFC motors does all the adjusting for you. It’s like having a mini crew on standby that you get to boss around while you sit in your car
Real Talk- Not being able to cut or drill holes during the build made it a super bitch to work on; there were times when the rage was strong and the struggle was real, but what kept us going and probably the best compliment to get (for any workshop without a doubt), is having the customer completely be open about his ideas and trusting us throughout the whole build, from parts selection(s) to its execution. When a car is built from unrealistic budgets and expectations based on internet information, no one wins and we all go home feeling like crap. We think Du's S15 is a prime example of what can be achieved when a customer and workshop understands their specific role and is willing to work together and trust one another.
Update 31-05-16: The car survived, Oil temps were steady all day long at 95 degrees and Du did a total of 45 laps.- that’s a massive win. (P.S: He’s already talking about wanting to go faster.. lol..)