Ernies Rotrex K20 Build


Good progress this week..



Started off with mounting the rad, made up some mounts to secure it at the top and then knocked up top and bottom rad hoses... cut the top one for the adaptor that will house the fan switch and dsh temp gauge sender... Then moved onto mounting the expansion tank, which proved a little more challanging as there was no room on the drivers side where I had mounted it on other swaps... managed to squeeze it in next to the washer bottle.. neat enough I think.



Next was the throttle cable... the stock D series cable is nearly a perfect fit.. just had to space the throttle cable bracket off the t/b about 20mm, job done.



Brake booster feed off the intake manifold was just a case of extending the exsisting pipe to reach to the front..



The heater hoses where then made up and re routed to line up to the k20..



Then I tackled all the earths.. fitted new earths all round to the engine/chassis as these can cause all sorts of isues if not right as we have found in the past..



Exhaust manifold was fitted with a new gasket from JapServiceparts.. the Tegiwa manifold is alot longer than the K-tuned one I found so exhaust fab will be needed. It only has one o2 sensor hole which is a pain as I hope to run the 2 like factory... but will sort something out later.



Clutch line from HEL was fitted and then I moved onto the harness, routing it best I could and feeding it into the cockpit through the bulkhead.. I nicked the bulkhead plate and grommet off the old harness to tidy things up... I moved onto the charge harness then, modified the ends to go in the ek fusebox..

Lastly was the fitting of the fuel setup from Karcepts... pretty straight forward stuff, mounted AEM fpr and ran all the lines.



The main wiring inside the car is still left to do (this weekend). Along with driveshaft fitting and a few other minor jobs..



I started on an intake setup earlier, will finish that up over the weekend.



My friend dropped the inner arch repair panels in redy to be welded in.



Only took a few pics... too busy and forget about the camera!





 
The bank holiday weekend meant we got loads done...



My mate came down to get the wiring sorted on the kswap... I had ran most of the wires and sorted the charge harness side of things, but there was still the swap harness to plug and wire in and the postitive battery wire to extended, by the end of the day we had it up and running after a few minor issues (fuel cut had tripped!). We had stumbked across a problem, the swap harness being from the U.S is wired for wideband 02 sensors as this is what U.S and JDM cars run... EDM run narrowband so we needed to rewire the harness... this took some serious head scratching and some emails to Sparkks Racing... but we got there in the end!



Made up and intake, just a short ram... 2.5", stuck some collant in and ran it up... all seems well, just the exhaust to sort out now.



My other mate was busy on the rear arches.. welding in new inner arch panels, and patching 2 small bits on the outers... some filler and primer later we are rot free... :)

I etch primed, primed and painted the inners from inside the car earlier... follwed by a coat of stonechip... once the outside is painted I will finish of with some underseal on the inside and in the arches.













 
In for this. Looks like it's going to be a good one!
 
EK9 style lip and Fiberworx bumper ducts fitted and a fresh coat of paint for it all...


 
Nice one.
Anything else you plan on doing?
 
jesse888 said:
Nice one.
Anything else you plan on doing?
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No as tbh it will be for sale soon as I want to buy a trailer and tow car for my EG and EF.. I can now walk to work as changed jobs so dont really need this!
 
Been putting some miles on this over last few days..

It has not gone well, it seems the gearbox is on its last legs.. the guy who I got it off has had me over it seems.. the box is whining in 2nd 3rd 4th and 5th gears and jumps out of 3rd gear. Some people have no morals..

Live and learn I guess.. will pick up another box and get it fitted asap.
 
samphier said:
How much for the duff box posted. Need to get the stock back up lol
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I wanna send the guy it back and get my money back! But he aint playing ball says it was fine when he sold it... If I dont get anywhere with him I'll message you Ben.
 
So having a change of plan..

I'm now going to keep this and sell my EG track car... so I have abit of an all rounder... just dont use the EG enough to warrent it sat there and the EF I'm building will make the EG redundant anyway.

So, to make the EG sell easier I will be removing some of the gofaster bits so I can sell it cheaper... that means this will soon have the DC5 box fitted with 5.1 FD carbon synchros and the plate LSD! I'll also be fitting the RBC and 70mm T/B and kpro...

With this in mind the brakes and suspension will be getting upgraded along with a better exhaust once the EG is sold...
 
We had a mad Sunday swapping boxes and intake manifold setups... so the EK got RBC with 70mm T/B and the 3.5" intake with velocity stack and the EG was returned to stock ready to be sold with a 2.5" short ram. We also fitted the DC5 box from the EG to the EK it 5.1 F/D, Gripper plate diff and carbon synchros.. tbh this is only temp as this box is destined for the EF once it gets further on... Still have the Kpro to fit to the EK, should get that done at weekend.

Had a few parts kicking about I've decided to fit to the EK to make it better now its abit quicker!

These include EK9 5 stud front hubs with 282's... along with that I will fit my NT03's once I've painted them white.. these will be wrapped in 225 45 16 AD08's.

Better suspension is also on the cards once I find some!





 
Fitted the Ek9 front hubs today along with the 282's.. should help slow it down abit better!

NT03's painted and on with the AD08's. Still need to tweek the arches and liners for clearence and adjust ride height once I get the rear tyres fitted too.


 
Looking good, how much did you have to adjust the arches thinking of putting this tyre setup on my dc2.
 
msc52 said:
Looking good, how much did you have to adjust the arches thinking of putting this tyre setup on my dc2.
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Still working on it, just rolled lips flat and trimmed arch liners so far... wont take much more I dont think. These rims are et30 which dosent help the situation!
 
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