Im going for 300-350. For my clearances I talked with a few peeople on d-series.org and what mine are at was the consensus, I'm on dso a lot now.

For piston rings I needed to leave room for them to expand. I'm goig to be running probably a t04e, so it'll take a good amount of psi to hit 300+, which means more heat and expansion of the rings.

As for the piston to wall I'm running forged pistons. Forged expand much more than a cast, you were running vitaras right? .0025 would be good for a vitara to reduce the slap and since they won't expand like mine. My supertech's will expand a lot more, si when it's cold my pistons will slap like a ****, but when warmed up they will quiet down and be good.


I got a lot of work done yesterday and today. Checked all my bearing clearances. They are all a little looser than I'd like but I can live with it. Went with ACL bearings so I'll stick with them. My clearances were a little over the spec but I'm confident it's fine.

Notched the block and main caps. Holy crap I had to remove a ton of material from the caps, not much from the cylinders though.

Today I lapped all my valves, finished my port and polish, and put the valves back in with the supertech springs. All that's left for the head is to put the cam and rockers back on. Also got my skunk2 intake manifold yesterday too, thing is huge compared to my stock y8 I had. Has 9" runners lol.

Decided to go with the competition stage 4 6 puck, waiting on a distributor to contact me.

Hopefully I can start assembling the bottom end tomorrow, I need to wash my block like 5 times to get all the shavings out which won't be fun.

I do promise pictures tomorrow... It's almost 1 am and all the pics are on my phone (which I'm typing this on).

 

Ohhhh I see. I thought u were going with a vitara set up. Makes sense now.

 

It was originally going to be vitara. Then I thought about it and I've got the money so why not do a much stronger setup. The fact that I'd still be using a cast piston just didn't seem right to me. So I went full forged, hopefully it pays off in the end. The Supertechs are expensive pistons but fully coated and perfect compression ratio. I want to be able to really push this setup and see what it can do. I've spent a lot on it so far.

Pistons: $310 (bought used but were bnib)
Rods:$330
ACL bearings: $120
Machining work: $300
Gaskets: $80
Skunk2 manifold: $160
Supertech valve springs: $150
Competition stage 4 clutch: $300


After break in I'll get a Delta 272-2 which is about $180.

It sucks adding up what I spent but whatever, it'll be worth it in the end as long as it stays together.

 

As I said I would, I bring many pictures. Have to go back a little bit since I've been slacking.


Never took a wastegate apart, I was suprised with how big the springs are, and this is the "small".


My new y8 tranny when I got it... full of water, grass, nuts, tranny fliud, and a nut. Seems I don't have a pic of it now... but looks literally brand new inside.


Primary and secondary gear stacks, really good condition, syncros look new, gears look better than what stock would so thinking they may have been changed out, just syncro sleeves are chewed up.


After picking my block back up, beautiful hone!


Notching the block... I'll have to get a pic of the mains soon.


Close up of the notch on one.


Skunk2 intake manifold.


Head all back together with Supertech valve springs, diy port and polish, polished combustion chambers, and lapped valves.


Here's pictures of my ports. Exhaust port.



Intake port.


And I polished my combustion chambers, noticed some stuff I missed after the pic. Polishing them is important, less chance of hot spots and detonation!


Few more pics of the completed head.



And my new Supertech forged piston and Eagle rod (capable of well over 600 hp) and my stock y8 piston and rod that maxes out at like 220 hp lol... hope the $750 combo I have pays off!

 

damn, you weren't kidding! those used supertech pistons look like they're in prime shape (from the picture anyways)

I'm really jealous. This is the same setup I wanna run, however I hadn't thought of running a skunk2 intake. It looks HUGE! haha. I'm really interested in seeing a dyno chart after this thing gets tuned. You should be making power pretty low with such a small turbo. But I'd rather have power down low with a low peak number than no power down low with a really high peak number. Sure, you'll have traction issues, but it'll be fast and reliable.

You worried about torque steer? Thats the only thing I'm really worried about when trying to decide if I wanna go turbo d16z6 or swap it for an H2B setup. I'd be faster as a turbo d16z6, but possibly more reliable with the H2B swap. Still pretty unsure as to which way to go...

 

Looking great scott!
And about the Delta cam, if you mention that your a member on a different forum (D-ser....org) you get a discount on it, i believe it was $150 (so like 30 bucks off). Im also getting the regrind.

 

Ill have to call up delta again then, i have to wait anyway since I have to pass emissions this year and they said it probably won't hold an idle well on stock ecu.

The supertechs were brand new, guy just never used em. Super nice pistons. I'm looking for high numbers, 300+. Just to prove that single cams can make serious power, there aren't many making over 250 here. The t04e will still have quick spool but while still bring me to 300 without leaking out the turbo. Torque steer is a given, dealt with it in plenty of cars, not that big of a deal. I'm going to get traction bars to hopefully eliminate wheel hop and breaking axles. I do have extra sets of axles too so there's no downtime when they do break.

Also ordered my clutch the other day, competition stage 4 6 puck. Probably keeping the stock flywheel, might consider buying a 12 lb flywheel, idk yet.

 

have you ever considered stronger axles? surely Hasport makes some... but I could be wrong. Alotta companies are dropping their support for the D series.

I'm really pumped to see how this build goes, it may help me make up my mind as to what swap/build I want to do in my hatch.

I'm surprised you're not swapping in a z6, that seems to be the going trend among D series turbo builds.

 

Hasport basically contracts DSS to make their "stronger level" axles, so I would suggest to check out Drive Shaft Shop, too. That is, if you have the money. Them sum' bitches are 'spensive!

Keep up the good work scott. You guys with your clearances, and all this transmission talk is just wayyyy over my head. haha

 

We will see with axles, oem axles usually take a beating before breaking, although my friend snapped some on a stock b20 launching at the track. If I start Breslin too many and show up at autozone to warranty them too much I'll look in to staged axles, those are crazy expensive though. I've gotten damn fast at changing axles so I can do em in a parking lot or at a track if needed.

I ran in to some trouble with one of my acl main bearings. Had a really deep scratch in it, idk if i did it, seems too long for it to be something on the crank. So I contacted the seller and I'm sending them back to him and he is sending me a new set.

My clutch also showed up today.