T4 Into T3 Build Questions - With Reference Links for Future Swaps

[nogoodwithusernames]

Here are some photos of my take on the fan boot adapter. Some rubber edge guard/trim should seal it up nicely, and I'm contemplating some rubber flaps where the alt belt passes through (a la industrial fridge/freezer)

If there are any big concerns let me know, I have a welder and more spray paint

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[wreck]

That looks really good and should work well .

[Wally]

I agree! Good job and nicely done.

[Clatter]

Wow. Nice.
Lot of work there..

Did you ever get a copy of Nate/Pile's design for this part?
They had plans available up online somewhere, but I think it's long gone now.
Was available where you could print it out 11x17 and transfer right over.

Looked a lot like yours.

The OG 411/412 variant adaptor piece 'tried' to seal at the fan ring, but wasn't very tight.
If you do seal the belt in/out with some rubber flaps, that would for sure help.

Loving this one. Way to dig in.

[nogoodwithusernames]

Thanks for the kind words guys, I'm pretty happy with how it turned out. Certainly not perfect but at least it's perfectly serviceable! I was never able to find a copy of Nate's template so any similarity is purely coincidental although I'll interpret that as a job well done since his was "the way" to do it.

Been getting stuff ready to start building up the case soon so crankshaft got cleaned up a bit and started putting things on it to get it spun balanced. Need to have the pressure plate surfaced and cylinders honed at the same time.

Also took apart the fan (I know I know, but I have a dial indicator to put it back in center, kept track of the positions of the pulley ring and bolts etc, and it's all going to get balanced together anyways soooo yeah I did it.)

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Made up some little brackets to mount the coil packs to (Dubshop LS2 coil mounts), going to get welded to the body just above the engine hanger sheet metal so the coils tuck away under the cargo deck. Looks clean in my imagination and hopefully it turns out good.

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[nogoodwithusernames]

Getting back to the case breather setup I found this diagram online which looks like it is for stock setups.

I have number 13 blowback safety valve and am okay with cleaning it up and using it if it's better than a standard "tee" fitting. My only concern is since I am not running a stock air cleaner (no room) should I run a little inline fuel filter between number 13 and the plenum to keep oil vapor from dirtying up the intake? The PCV line looks like it goes into the intake post filter so does it even matter? Should I run the return lines pre TB instead or is the plenum okay?

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[nogoodwithusernames]

Had the first case cleaning session today since I finally got all the galley plugs tapped and noticed some of the pushrod tube sealing areas look a little rough. Here's a photo of one. Anything to worry about? I'm thinking maybe do a flap of scotchbrite or sandpaper chucked in a drill to smooth it out?

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[nogoodwithusernames]

More questions and some progress as well. Climbing around under the car today getting the coils mounted and adding a bit of weld bead to the engine mount sheet metal.

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Noticed this when I was cleaning up and degreasing the engine compartment a few weeks ago but forgot to snap some photos. Looks like the rear apron has been replaced (very poorly) and there's a big gap all along the cooling ducting... (see the color change blue to tan, and the daylight in between the two.) Is there anything I can do about this without getting into some serious metalworking?

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[Clatter]

Had the first case cleaning session today since I finally got all the galley plugs tapped and noticed some of the pushrod tube sealing areas look a little rough. Here's a photo of one. Anything to worry about? I'm thinking maybe do a flap of scotchbrite or sandpaper chucked in a drill to smooth it out?
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Some like to use Scotch-Brite on a slotted dowel.
Only ever did that on the head side m'self..

Others have been known to use a dingle-ball hone.

I always uses some 565 on those O-rings.
Supposedly you can just use oil, but I'm always skeered to.

WRT crankcase breathing, that's a deep subject 'round these parts.
You'll get as many methods as carpenters..

With open-element air filters, the game changes quite a bit IMHO.
On a mild engine, it's not as much of an issue.

FWIW, I'll just be taking advantage of the big breather chimney,
Plug the ports on the heads,
And keep an eye on it.

The idea of adding positive pressure from the fan shroud to the system thru the heads seems noble enough,
however, with open cleaners, you'll want to be REAL careful about the system ingesting dirt.
Not sure a fuel filter would give you protection filtering air at that volume.
Also remember you're -adding- to the air in the case this way..

I'm saying PCV is only a problem if it's a problem.
Things like a stroker crank, or boost.. If it's a problem.
Already the T4 has this nice big breather tower compared to a type 1..

[nogoodwithusernames]

Clatter, thank you for the input. I'll do some contemplating before proceeding with anything permanent for sure. A dab of sealant on those o-rings sounds reasonable. (Also your idea for the rear apron fix on the samba I think may be the winner, better than anything I had thought of, so props to you and Bobnotch!)
As far as case venting I have no plans to run positive air from the fan housing. I don't even think my shroud has that little tube piece on it. The idea for now is to tee the head vents into that blowback protection valve and then into the intake plenum. Though your thoughts of running just the PCV/breather tower is very tempting, and I may block off the head vents and run with just the main tower for a while and see if the head vents are needed... Things to ponder.

On that same note, I've been getting the air/fuel systems ready to go since I'm waiting on parts and machine shops to do the shortblock assembly. Adapted the stock fuel rails for modern injectors (Added cups and a mounting bar vs the hose barbs and weird rubber donut mount things. Also had to cut out a section of tubing that had a pinhole in it, glad I caught that before install.)
Cut out the EGR crap and drilled that boss for IAT sensor, just need to weld up the old captive nuts on either side of it.
And finally make a blanking plate for the cold start injector.

And of course now the mandatory photos

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[nogoodwithusernames]

Mmmmmm, fresh parts...

Still waiting on crankshaft balance and cam/lifters though before anything can go together. Cleaned up the cylinders though so they are ready to go, may wash them again after checking deck height, but for now they're oiled up and sitting in some zip lock baggies. Need to do a small wiring change to run the new Hall effect sensor vs the old VR sensor but that'll be pretty quick. I think I can see the finish line now, again just waiting on bits and pieces to get here.

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[nogoodwithusernames]

Gotta get some .020" barrel shims from LN Engineering and crank assembly should be golden.
Cyls 1-4 in order, .028" .025" .025" .023" (with domes of 4 CCs and chambers of 53 CCs once shims arrive that hits me right at 8.5:1 )

Side play of the rods (nose to flywheel) are .010" .011" .016" and .010"

End Play started at .004" but after some spinning and tapping back and forth I can get .005-.006".
Also the balancer said I nailed the fan, he didn't even have to touch it when doing the crank and flywheel.

Everyone like photos so here's my janky deck height setup.

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[nogoodwithusernames]

Pistons balanced and rings gapped. Waiting on camshaft now to start getting this thing put together.

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[Clatter]

Stoked!

Is that Mario’s crank sensor wheel and bracket?

[nogoodwithusernames]

Me too! And yes that is indeed Mario's wheel setup, it's super slick.


The last thing I have yet to figure out and because unless it's laid out for me nice and clear I have a heck of a time with wiring... I can figure out basics but beyond that I'm over my head.
This is the alternator kit from CB performance. It's got 4 wires. The T4 alternator has 4 wires. How can I attach my wiring to the T4 alternator?? (I do have the alternator loom)

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