GTM Stage I TT Build - Shadetree Style
 

I have been longing for another boosted vehicle ever since I had to get rid of my V6 turbo Firebird Formula.

My original plan was to get a 350Z and do a TT kit on it. But when I saw the 370 I had to have it.
My plan always has been to do some sort of FI on my Z. I had gone back and forth as to a SC or TT. I thought I had made my mind to wait for the Stage II SC from GTM.
Well, after a few conversations with Sam I changed my mind and went with a TT kit.

I really wanted turbo, there really isn't anything like the feeling when boost kicks in. I ordered my Stage I TT kit with external waste gates on March 31st.

I received it today.
http://www.the370z.com/members/dembf...hese-heavy.jpg

Everything was packaged perfectly.

http://www.the370z.com/members/dembf...arts-parts.jpg

Mmmm.... I can hear the turbo spooling already.

http://www.the370z.com/members/dembf...ge-1-turbo.jpg


I wanted to share my build as I go. I am doing all of the install myself in my garage. The engine will stay in the car.
I am by no means a mechanic but I have been playing with cars all of my life and I have a good bit of mechanical ability. I feel like I know just enough to get myself in trouble.

I started the install today and I made some great progress.

Here is the fuel pump ready to go back in:
http://www.the370z.com/members/dembf...-fuel-pump.jpg

Tear down:
http://www.the370z.com/members/dembf...388-pieces.jpg

http://www.the370z.com/members/dembf...ure32387-a.jpg

I got to page 43 in the install manual.

The headers are off and tomorrow I hope to get the turbo manifolds bolted up.

The install has been relatively pain free up to this point.

I ran into one issue so far. The upper O2 sensors are cross threaded into the headers. I have read on here that this is sometimes an issue so it looks like I'll be buying some new ones.

I will post some more pictures of my progress tomorrow and then I am off to work for a few days so nothing will be done again until Wednesday.

5/1/11 Update:

I am very happy with all that I have been able to get done over the last two days.

I got all of the steering and engine spacers installed:
http://www.the370z.com/members/dembf...tt-install.jpg


I was also able to get the most intimidating part of this install done.

Tapping the passenger head:
http://www.the370z.com/members/dembf...-tap-guide.jpg

This is the most difficult part about leaving the engine in the car. Very little room to maneuver a right angle drill. I used a 90 degree chuck adapter from Harbor Freight.
http://www.the370z.com/members/dembf...ove-engine.jpg

I also had to shorten the drill bit by about 1 1/4 inch.

But I got it done and even mounted the manifolds.

Passenger side:
http://www.the370z.com/members/dembf...-installed.jpg

Driver side:
http://www.the370z.com/members/dembf...-installed.jpg

I found that you really have to monkey with the manifolds to get them to sit properly before you bolt them down.

That's probably just another byproduct of leaving the engine in the car.

All in all, I have to say that things have gone well. I read the manual probably 100 times over the last few months so there weren't any real surprises. Just the normal stuff when you take a car apart.

I get back on Tuesday night so I'll be able to pick up the install on Wednesday morning.

5/4/11 Update:

So today was not as productive as I was hoping. I woke up late and didn't have as much time as I wanted. I did get both turbos mounted but I should have gotten more done.
I swear it's the stuff you never expect to hold you up that does. Those spring loaded hose clamps that Nissan is so proud of are causing me to get far too many blood blisters.

here are some quick shots of the turbos in their new homes:

Passenger side
http://www.the370z.com/members/dembf...side-turbo.jpg
http://www.the370z.com/members/dembf...urbo-above.jpg

Driver side
http://www.the370z.com/members/dembf...side-turbo.jpg
http://www.the370z.com/members/dembf...urbo-above.jpg

So I guess I am going at a good pace. So far I have about 25 hours over three days of working.
I leave again tomorrow morning and I am back on Saturday afternoon. I have to attend to my lawn if its not raining so it looks like Sunday before I can get back to it.

5/8/11 Update:

The progress has slowed even more. I have to say that this would be a lot easier if the engine were out. I am finding myself fighting the smallest things. If you do things the way the instructions say then you wont be able to tighten some of the lines. If you are going to try this with the engine in just be prepared to think outside the box rather then follow the manual to the letter.

I was able to save myself some cash today. The upper 02 sensors are salvageable. I used a thread repair die and it worked perfectly!
http://www.the370z.com/members/dembf...repair-die.jpg

I am not sure if the instructions that I have are an early version but there seems to be some information missing.

For example, the starter wire needs to be removed and the connector straightened. Then it says to reinstall the wire. Well, if you do that then the wire is in the way of the outlet for the driver side turbo. I figured out that you have to remove a part on the starter that relocates the wire. Once you remove that part the turbo fits without issue.


But all in all I am making progress. Today I got the coolant and oil lines all run and tomorrow I will start on the oil cooler and intercooler piping.

I am hoping to be able to get it running on Thursday. It all depends on how I make out tomorrow. I am out on a trip again Tuesday and back Wednesday. If I don't get far enough then I am optimistic that I should have it running early next week.

5/9/11 Update:

I got a lot done today. Mounted and connected the oil cooler and intercooler. I even got the passenger down pipe and waste gate installed. Now that there is more stuff in the way it is getting more and more difficult to get things tightened down. Lots of extensions and universal joints.

If I can get an early jump on Thursday I might be able to fire it up.

Here are some pics:

http://www.the370z.com/members/dembf...oil-cooler.jpg
http://www.the370z.com/members/dembf...ting-there.jpg
http://www.the370z.com/members/dembf...aste-gates.jpg

5/12/11 Update:

IT'S ALIVE!!!!!

Wow, today was not starting out well.

I had a real hard time getting the recirc pipes to align on the driver side. After about two hours of messing with it I decided to just leave the waste gates open. But that meant that I had to undo the passenger side. That was a bigger pain then I thought it would be. I am going to get the dump pipes from Sam anyway. I just wasted a bunch of time today. I should have just left them open from the start.
Then the steering coupler didn't want to cooperate. That took another few hours and some filing to get it to go on.
Then my Uprev software was giving me problems. I had to restart my computer and update Uprev.

After that I flashed the ECU and fired her up. Started without any issues and idled like stock after about a minute.

No fluid leaks but I think I have a coupler that is not tight. During my shakedown run I heard a slight "kazoo" sound when the boost starts.

That will have to wait as I cannot work on it until Tuesday.

With the way today started, I couldn't be happier that it is actually running. Next week I will be doing some debugging.

Here are a few more pics:
http://www.the370z.com/members/dembf...ure33042-a.jpg
http://www.the370z.com/members/dembf...ack-wheels.jpg
http://www.the370z.com/members/dembf...ack-wheels.jpg

5/17/11 Update:

I started out by making sure that all of my couplers were tight. I found one that could have been a bit tighter and another that didn't seem to be aligned well. After those were fixed I went for a quick ride to see if I'd fixed the "kazoo" sound. The noise was gone but the car just didn't feel right. I figured that I should just go ahead and install the AFR and boost gauges.
After those were mounted I went for another ride and still something was wrong.
I decided to just put the car away for the day and get back to it tomorrow. That's when I noticed something. When I was realigning one of the couplers I had to fully remove one of the inter cooler pipes and I guess I never tightened it back up. Oops.
Well, needless to say that once that was back in place, I went for another easy ride and the car feels great again.

I haven't really gotten on it yet. I need to do another data log and have Sam make sure everything is good before I do.

I was able to hook up the Berk exhaust without doing any modifications to the flex pipe. Just got some gaskets from the local Monroe shop and it worked great. I have also noticed that my Berk exhaust it WAY too quiet now. Not sure I like that. I really loved the way it sounded. I may just have to look into the 3" exhaust.

Here is a shot of the gauges installed. I know that pillar mounted gauges aren't popular but I LOVE them. It reminds me of my Firebird.

http://www.the370z.com/members/dembf...-boost-afr.jpg

5/19/11 Update

Today I can call the car finished... well finished for now.

There are a few small issues that I have to attend to. First the boost was supposed to be at about 10psi but for some reason it is 12-13psi. That's just asking for trouble that I do not want. Sam is sending me some new springs for the waste gates.

There is a small hot start issue that Sam has assured me can be fixed with a tweak to the tune. I just have to let him know the specifics of when it is hard to start.

I am going to need a clutch sooner rather then later. I was pushing it a bit on the highway and I felt it slip. I'm thinking about going with the OS Giken twin plate and the Z speed CSC. That will have to wait just a little bit.

Also there are some random clunks here and there that I have to hunt down.

But for the most part the car is running great. This thing is a BEAST! I am loving it even though I am still being fairly easy on it.

Oh. and that whole part about it not being loud enough. Uhh, yeah. Four words.... Open Dump Waste Gates.

Here are some pictures and vids!

http://www.the370z.com/members/dembf...ooler-here.jpg

http://www.the370z.com/members/dembf...scary-fast.jpg

http://www.the370z.com/members/dembf...k-together.jpg

http://www.the370z.com/members/dembf...oking-good.jpg

Looks like you are off to a good start. Trick to the install is going to be patients, and don't be afraid to buy some new tools to make the job easier. Especially leaving the engine in the car.

Great thread +rep, in for progress and congrats on the kit!

Congrats Demb ...lookin forward to your build...so far so good...subscirbed!!!

your going to love it, trust me

So far how tough is the install with the engine still in the bay?

:tiphat::tup:

So far not so bad. I don't have a reference as to how much easier it would be with it out. What you don't know can't hurt you right?



I updated the first post with today's progress.

nice job! Its always more satisfying in the end when you do it yourself!

Looking good!

know enough to get yourself in trouble? :lol:

I would like to have you install this kit in mine!

this is a future mod for me...saving meh pennies...

Coming along nicely, congrats on the kit man!

I love to see people with the balls to do it themselves!!!

Subscribed!!!

Go Go GO!!!

The pic where your tapping the block is that a flange to help with aligning the tap?

subbin, a shop is installing my GTM TT right now as well but on my 350z. Good luck OP.

Wow! I'd be afraid to ruin my car doing it myself

Yes. That's exactly what it is.

Even with this it's still extremely nerve racking to drill into the head. I wasn't sure I had done it right until I was able to tighten up the manifold. Hell, I'm still worried that I did something wrong. I guess I'll find out the first time I push the start button.

So the 370z engine heads do not have holes that align with the GTM manifold? Back when I did the install on my G37, the heads had the hole drilled but were not threaded. I just had to thread the holes. I guess now it adds another level of challenge. Did GTM provide the template flange?

http://www.the370z.com/members/dembf...tt-install.jpg

that aluminum brace that attaches to the bottom of the steering rack needs to be flipped upside down from how you have it now. The rolled bead should face up (180º) from the stock position. Otherwise the brace under it will no longer fit with the spaced steering rack.

its one of the 09+ changes .. Nissan quit wasting time drilling and tapping holes that were not needed. I assume the extra holes were left over from the DE engine, where i assumed they were to accommodate a different exhaust manifold design from maybe a FWD platform.

I think it's an optical illusion. The rolled edge is up. Look at the left side of the pic.

Congrats on the kit I love to see people get there hands dirty good luck on the rest of the install.

I know the feeling. I have it everytime I do an install. If the manifold tighten up it should be fine. Props for doing this yourself. Can't wait to do mine also. Might be awhile for. By the time I do it, I might as well go with a built short block.

Congrats on the DIY man.. Did my SC install myself so I can somewhat feel your pain.. luckily didn't have to mess with exhaust manifolds though.. That part does not look fun.. :)

Can't wait to see more progress.

Thanks for the support. :tiphat:

Now I just need to get home and do more. :D

Keep up the good work!:tup:

Awesome job on the self install so far!

Ok, so I got home tonight and I just couldnt go to sleep so I decided to try one more time to get the upper O2 sensors out of the factory headers.
A bit of PB Balster and by working them back and forth, I was able to get them out.
The threads are a bit gnarled up but I think they can be saved. They still thread into the down pipes no problem but Sam suggested that I clean the threads up a bit with a die.
I ordered a M18x 1.5 spindle thread repair die on snapon.com for $13 shipped.
If this works I'm gonna be a happy dude.
Those fricken sensors are $500 EACH!! from the dealer. I did find them for $350 each from Z1 but hopefully I won't need to spend the money.

Also, I was looking at my down pipes and trying to see how they would mate up to my Berk exhaust. The only way that I could see it working was if I used smaller bolts. That didn't seem like the best way to go either so again Sam made another great suggestion.
He said that I could have a shop weld a 3" flange onto my Berk X pipe.
I don't know why I didnt think of that but it's a hell of a lot cheaper then buying a 3" exhaust. I love how my Berk sounds and don't want any drone so a 3" exhaust isn't an option for me.

One last thing, I need to say a huge thank you to Sam. Even as busy as he is, he always takes the time to answer all of my questions. It seems that these days customer service is a lost art to most companys. Not at GTM!
I have bothered him countless times and I'm sure I am not any where near done bothering him and he has always been a absolute professional with me.

Time for some sleep. I am getting up early tomorrow to get some more work done before I have to leave again on Thursday.
I am hoping to be able to get at least one turbo mounted tomorrow.

You should of went with a open dump setup? Doesn't seem like anyone is running this setup yet. It's nice to ride around and scare the hell out of people also.

If you mean an open dump on the waste gate then I am. :tup:

Sam is working on it for me.

First page updated with today's progress.

That's what I'm talking about.

Still slaving away! First page updated with today's progress!

Keeping me hooked! Cant wait!

Props on doing the install with the engine still in the car.I did it years ago and its a pita.

Great work, keep it up!

Coming down the home stretch... I hope!

First page updated.

looking good mang!

Thanks for the pic of the fuel pump. I figured that the green wire went to the red wire on the fuel pump. Seeing your picture just made me feel a lot better.

My Z is in my garage in pieces right now also... I am out of town till Thursday, can't wait to get home and back at it.

I keep waking up at 4AM thinking about the power steering hardline that I need to tighten up before I cram too much stuff back in the car. It has turned into a reoccurring nightmare.

I'll do something like this when my rich relative dies and leaves me all their money.

Great progress Demb...BTW...did you change out ur exhaust or are you planning to keep the Berk with this TT build?