That is all around badass man.

 

This is an incredible build thread. I just read the whole thing from start to finish in one sitting. Definitely motivating and Inspiring! Phenomenal work!

 

Thanks! I appreciate it. Will probably go on forever as much as I change things lol.


I bought a nicer daily (2018 s6) and got used to the powerband. Now after getting the s2000 back together this past week it feels slow in comparison (mainly until high rpm....but still only shaking it down @15psi / ~450whp). The s6 is all down low and midrange....and the s2000 lag super noticeable in comparison....though the 100° temps don't help. I just feel like the car came into power stronger than it is now....but its been almost a year since I drove it.

I cleaned up the oem bumper and put it back on so I could drive the car. Will probably do bodywork and paint the shine/voltex bumper in the fall.

Also swapped out the diff clutches with new oem cobra carbon fiber discs. I just stacked them like they were....nothing extra to make it tighter etc. I think the clutch packs were about .040" thinner than the new clutch pack stackup. It seems to have fixed the issue as far as the wheel-hop feeling in 3rd gear. I need to get tires before I turn it back up to see how it behaves with more power. Also I left the s-spring out lol....I don't have enough patience for that thing.


Here is some of the sheetmetal ducting I got done before putting the oem bumper back on

The top plate screws into the intercooler's top .125" plate and the side plates.




lower side plates








bottom plate








Upper side plates are more of a pain. The top sheet will be the worst to make of all the ducting.


















Also replaced some tct and vtec solenoid gaskets. Was getting a slow leak on that side of the head. I used a kraken vtec gasket and used the oem screen instead of the kraken screen.











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Old tct gaskets are a little flat










Thats pretty much where the car is at now. I am thinking about a new turbo setup with something a little more responsive....not sure yet. I'll see how it feels in some sub-90° weather first.

Clutch is also wearing. It closes the airgap between the throwout bearing and clutch fingers as it wears. So now my clutch engages at the very top of the pedal instead of somewhere in the middle. I've already had to readjust (create more pressure plate to throwout clearance) once and might have to again soon.

If I have to buy another clutch I might just look into the t56 setup. Don't feel like possibly spending 2k+ more and staying cd009. I don't mind the cd009 for the most part....but I've never really been able to shift quick 1-2....and have had other "lockouts" before.

 

Badass as always man!

You should look into the Samsonas H pattern 6 speed over the T56, like I ended up with. The gearing of the T56 just isn't there for the S2k, with the Samsonas you chose your gearing.

I seriously need to just bring my car to you and let you finish it for me! Want to take on another project? LOL

 

Yeah i think you have to run ~4.50+ final drive to make the gearing make sense. And even with that first gear is still kind of long.

lol if i had space i could take on more. If I get a car that needs work it pretty much occupies everything. And I already have a 94 civic that is too be complete in the 2030s lol

 

Never get tired of seeing your work, and it helps motivate me to keep going on my projects. That ducting is amazing. I'm sure you have plenty on your plate, but I could see that selling as a kit (intercooler mount with ducting). May be break it into a 2-3 piece 3D print or jnjection mold to reduce costs. You'd be surprised how affordable this has become. I'm working on an OE type double din in-dash mount using 3D printing and it'll be competively priced with some margin.

What tools do you use to bend your metal?

 

Thanks, I've wanted some type of scanner to map the car on computer to make trial and error easier. Maybe some day.

But I feel like I'd have to get another stock s2000 for a better template. Printing parts would be nice though.

I made a brake to make sharper bends (about .125" radius) and when I need sweeping bends I usually draw some straight lines on the material and bend it against something in the garage depending on how sharp I need the bend. Usually a piece of 3-4" exhaust tubing..... welding gas cylinders etc.

 

Here we go

Clutch setup #57 / last chance cd009

Had driven the car maybe a week before the clutch just "let go". The throwout bearing gap disappeared again and its back to readjusting the bearing/spacer etc.

Sooo I decided to go Collins f20-cd009 conversion. Single disc ACT clutch with the "extreme" pressure plate. I had to swap my oem master cylinder back on and converted from the hydraulic throwout to the oem cd009 clutch fork/slave setup

I am trying out the organic ACT disc. I do have a 6puck disc if the organic doesn't work out. I figure the s2000 sized disc can hold low 300 wtq and is maybe a touch underrated from ACT. The 350z organic disc with the extreme pressure plate is rated around 520 ft lbs at the motor. I figure I can stay around low 600 whp and not have issues with slipping

The size difference of the friction surfaces are decently larger with the 350z parts















Here is a random pic of how I bleed my coolant. I siphon the coolant from the head bleed port and the crossover heater bleed port. I usually get heat pretty quick bleeding it this way.




Here is the travel I got from the clutch fork setup







After driving it for a bit breaking in the clutch I thought I had a lot of road noise. I thought it was mostly from the r888r tires on the car but eventually narrowed it down to a rear wheel bearing. I removed the old one from the hub and it pretty much fell apart. Replaced it with a Japanese NSK(?)








So far so good with the new clutch setup. The pedal is heavy.....probably similar to what it was before with the .700" master cylinder on the twin disc. Engagement is pretty smooth and the window is probably half of a stock clutch. So far I've ran ~18psi (550whp) in third gear without issue.

Noise....there is almost no noise in comparison to the twin disc. Probably 20% more than a stock s2000. There are moments where there may be some buzzing....but all the clatter from the twin disc is gone.




Also was looking to improve the mid-range and saw borg has a newer SX-R line of turbos so I ordered the s258. The compressor map is really close to what I have now, although a few points less efficient. But the exhaust wheel is about 6mm smaller than the s362

Compressor side is reasonably small for a borg