BenFenner's 1994 Black SE-R

[BenFenner]

Table of contents:


1) Introduction including summary of 4 years worth of work.
......-Pacesetter adjustable short throw shifter
......-Momo Anatomico leather shift knob
......-Momo Competition (black) steering wheel
......-Front control arm ES bushings
......-ES steering rack bushings
......-ES shift linkage bushings
......-11" Fastbrakes front brake kit
......-Maxima rear brakes and Altima MC
......-Panasport UL wheels (15"x7", +38mm offset, 14 lbs., 59.0mm hub bore)
......-Active tuning RSTB
......-Progress adjustable rear torsion bar
......-Sentra XE front torsion bar
......-Prothane engine mounts
......-KYB AGX struts and RoadMagnet springs
......-Rear mounted Optima redtop battery and kill switch
......-Stand-alone engine management (VEMS)
......-Coil-on-plug
......-12mm custom wheel spacers
2) Stand-alone engine management installation (VEMS).
3) KYB AGX and RoadMagnet installation (springs and struts).
4) Up to date price list (how much have I spent so far?).
5) First set of real performance tires (205/50/15 Falken Azenis).
6) Driver's side rear window replacement (due to break-in).
7) Rear radius arm ES bushing install.
8) Rear parallel link ES bushing install . (Major trouble results from this). Replacement with factory bushings in the same thread.
9) I got to the dyno to get numbers since installing the stand-alone.
10) Walbro 255HP fuel pump install.
11) New thermostat, tires (225/45/15 Hankook Ventus RS-2) and fuel filter. Also random pics of car and Fidanza pressure plate bolts.
12) 1G DSM BOV pre-install and pre-welding.
13) 5-bolt turbo flange and stainless steel reducer.
14) 520cc injector install (Subaru STI injectors).
15) ARP wheel stud and rear wheel hub install.
16) Block heater install.
17) Clutch cable spacer.
18) Clutch cable bracket (Andreas Miko special).
19) Clutch, pressure plate, flywheel, throw-out bearing install and oil drain drilling.
20) EGR removal kit install.
21) Exhaust gaskets, valve cover gasket, bumper bolts and PCV hose.
22) Exhaust resonators and muffler.
23) Intercooler install (round 1).
24) Intercooler old and new (old for sale).
25) New starter (3rd installed).
26) Throttle body gasket.
26a) Turbo oil feed line
27) Valve cover gasket replacement.
28) Damaged progress swaybar endlink.
29) Intercooler install (round 2)
30) Radiator failure
31) Koyo radiator (R1977)
32) Charge pipe install
33) Turbo inlet porting
34) Charge pipe install
35) GTi-R cast compressor outlet pipe modification
36) Grinding block for turbo inlet clearance
37) Oil catch can return clearance
38) Intercooler retaining blocks
39) Alternator bracket chopping
40) Charge pipe install
41) Misc turbo install pics
42) Exhaust manifold studs
43) Front of engine (progress)
44) Shop mess
45) Exhaust manifold gaskets
46) Internal wastegate cracks and porting
47) Turbo oil drain
48) Turbo water lines
49) Painting charge pipes
50) Front of engine (progress)
51) EGT install
52) GoFastDepot turbo oil feed line
53) Downpipe fabrication
54) Exhaust layout
55) Turbo water banjo bolts and tap
56) Misc new parts
57) Oil dipstick tube relocation
58) Install progress
59) Cutting heat shield for EGT probe
60) Cusco front strut tower bar
61) V-band modification
62) Welding example
63) Intake air temperature sensor inside charge pipe
64) Grinding block for turbo inlet clearance
65) Turbine housing heat shield
66) Install progress
67) Radiator clearance
68) Intercooler support blocks
69) Exhaust fabrication
70) First start
71) Shift linkage urethane bushing install
72) Intercooler and hood latch support fitting
73) Charge pipe finalization
74) Exhaust fabrication
75) Painting the exhaust
76) Acceleration run
77) Cusco front strut tower bar installation
78) Alignment
79) Dyno tuning after turbo install
80) 2009 SR20 National Convention
81) Engine trouble
82) Roebling Road videos
83) Tearing down the engine after Savannah
84) 4th engine and new parts
85) Transmission rebuild
86) Tap block for turbo oil drain (again)
87) Cleaning and painting the transmission
88) Trimming wiring harness
89) New B14 power steering fluid reservoir and water pump
90) Valve cover gasket, front main oil seal, and the rest of the bearings
91) Engine assembly
92) Transmission mounting
93) Engine install
94) 1991 SE-R intake cam
95) Engine wiring
96) New power steering hose
97) New/used transmission ventilation hose
98) Brake line retaining clips
99) Nissan SR20 CAS discs (attempting first start on AEM EMS)
100) Buy power transistors (ignition "ignitors") to convert 2-wire COP to 3-wire
101) 1991 SE-R intake cam install
102) Center exhaust hanger
103) Car wash (preparing for resurrection)
104) Power transistor install
105) Wiring up and calibrating the Innovate LC-1 wideband O2 sensor controller
106) Car wash
107) New Denso Iridium spark plugs
108) Warm starting issue
109) Ignition issues












I finally have the time to post my project. I'd love it if this were a step-by-step account of all the work I've done, but I just don't have that sort of time. I'll post the major stuff, and then try to keep updating as major tasks get completed.

Here's an introduction:






It is a USDM 1994 Nissan Sentra SE-R. I've taken the modification road that I think most people recommend, but rarely follow.

I upgraded brakes first:

Front:




Rear:










Needed new wheels to clear the brakes, so they went on too:









I then moved to suspension, installing a Progress 3-way adjustable sway bar in the rear and a Sentra XE bar in the front (no pics yet).
Active tuning rear strut tower brace (initial group buy):



Road Magnet Springs and KYB AGX struts:




The battery moved to the trunk in anticipation of turbo, and for better weight distribution:



Notice external cut-off switch:




Other things I've put in that I don't have pictures of (yet?):
-Pacesetter adjustable short throw shifter
-Momo Anatomico leather shift knob
-Momo Competition (black) steering wheel
-Front control arm ES bushings
-ES steering rack bushings
-ES shift linkage bushings
-Prothane engine mounts

Now I'm finally on to the power (it's been four years since I started, continually being plagued by money issues). The money problem is no more, so it is time for a turbocharger. After scratching the idea of dropping in a JDM SR20DET, I've decided to turbo my motor, trying to keep the cost and hassle down to a minimum.
I decided against the typical JWT ECU. It would be a good choice, but I wanted to learn engine management, and I took this chance to do just that.

I installed VEMS stand-alone engine management on the N/A motor, got it working to stock or better performance, economy, etc. and learned what I had to learn about tuning an N/A motor.
I'm in the position now to install the turbo bits, and extract the amount of power that I'm looking for with general ease.

Here's the thread of my engine management installation and tuning:

1994 Nissan Sentra SE-R going VEMS, then turbo.

I'm still fixing a few teething issues, but it's close to finished.
Here's a few pics from the VEMS install:

Wiring harness adapter




VEMS in the car (not mounted):


Coil on plugs installed (don't mind the distributor timing):


I'll have more updates, info, pictures, movies and such later. Stay tuned. Any questions or comments are welcome.

Originally Posted by nismo94tuner

Very cool man. I love that brake setup. Those rear calipers/rotors are part of the fastbrakes kit?

The rear brakes are the typical Maxima upgrade. I don't recall exactly what year, but the calipers are for a 1996 Maxima I believe. The rotors have the 4 x 100mm bolt pattern, sourced from an odd-ball Nissan car I can't remember. They are the same size as the Maxima rotors, but with the correct bolt pattern. I ordered all the rear stuff from Greg at G-Spec (plug).

I don't keep track of costs anymore, it gets too depressing, but here's a run-down of the aprox. costs for the rear brake install:


Altima master cylinder:.....$120
Calipers after core return:..$160
Rotors:............................$160
Stainless steal lines:........$60
Pads:..............................$54
Brackets for e-brake:........$40 (junkyard G20, needed grinding)
Motul RBF 600 fluid:.........$16 (two bottles)

Total:.............aprox....$610


A bit less than the $900 or so I spent on the front brakes, mostly because the rotors and calipers are factory parts.

Originally Posted by CovertRussian

Finally got to see your car

She looks great man

Keep us posted with your mods

You bet. It was your car thread that really pushed me over the edge. I need to share what I'm doing, and get advice on stuff like quiet mufflers. =]

Originally Posted by CovertRussian

Haha Awesome

I'm still looking for a quite muffler, I might just stick to the stock OEM muffler

Check this page out about mufflers, it's old but good information

Originally Posted by Se-R ippin As-S

I like how you have everything orginzed etc. keeping it clean , no half ass sh*t.

Thanks. I like to keep things organized and clean.
You don't have to worry about things being done half-assed when I'm around. Trust me. =]

Originally Posted by swiss

Looks great so far. Have you decided on a turbo setup?

Yah, I have most of the parts I need in my living room.
GTi-R exhaust manifold
GTi-R T28 turbo
GTi-R J-Pipe
Large (for this crowd) 31"x12"x3" eBay intercooler
2.5" charge pipes
1G DSM Blow off valve
misc. water/oil lines.
etc.

I'm still looking for 440cc or similar injectors. Also need to figure out if I want to go with the typical Walboro 255 fuel pump or not...
I've only really given the exhaust a passing thought... That's last.

Originally Posted by Keo

the intercooler is big, but I'm getting somethign close to it, 27x12x3 to keep my fogs. everything is looking good! I tought you would've gotten everything all together already.

edit: as for the injector, why not get the STI?

Yah, that's the size with end tanks. The core is 24"x12"x3". I'm certainly a fan of big intercoolers. Yours sounds great too.

(For those who wouldn't know, I bought some of my turbo parts off Keo.)
I've been taking things slow. Really trying to iron out everything with the engine management before doing anything to the engine. Also I have a road trip ahead of me in May, so it looks like the power goodies will wait until after that. We'll see.

First things first... The Road Magnets and KYB AGXs go in this weekend. I'll have pics.

As for the injectors... I'm very open to the STI option. I'll give it some more thought.

Originally Posted by psalm

More and more everyday I want to get a B13, especailly when I see one this nice.

Thanks man. I hope they grow more on you. =]

Originally Posted by rodrigo

Lookin good Ben !

The T28 GTIR turbo set up is a great .Ive had 4 turbo setups and The T28 is my favorite . It spooles quick and is instant boost.

I highly recomend the walbro 255. allways good to have plenty of fuel

Thanks for the info. I'm sure I'll have a good time with the boost. I wasn't sure if the Walboro 255 is up to the 275 WHP I'm looking for. Also, I don't know if it likes to run at 3 bar or 4 bar. I just haven't looked into it. That's the one thing I'm not read up on yet. School me if you want. =]

Originally Posted by Setzer

Go with the STI injectors they are cheap and drop right in. Just need to swap plugs. And with your standalone tuning their cold fuel and latency is no different than tuning for any other injector.


And I want coilpacks

Originally Posted by jamse-r

Very nice. Those rims look like the chaparral rims that are popular on the Miata seen.

I don't know about the Chaparral wheels, but I know what you mean about the Miatas. Mine are Panasports, and they are extremely popular with the Miata guys, any autocross car, old domestics, Datsuns, etc.
I'm not 100% sure, but the original design was done by Minilite I think. So they are all Minilite knock-offs. The Panasports just happen to be the most coveted.

I love the look. I can't get enough of them.
Mine are 15"x7" UL (Ultra Lights) with +38mm offset (reduced to +26mm with my 12mm spacers). The ULs are not DOT approved which is sort of unfortunate, but they have a cool warning because of it and hold up better than many DOT approved light wheels (11 lbs. or less prone to bending). These wheels are 14 lbs. I'll post more pics of them when I'm finished with my take-home exam. For now, you get this:








More wheel pics for fun.










Checking to see if the Fastbrakes kit would fit. It wouldn't. Needed 12mm spacers.












These are the 12mm spacers I designed myself, and had made at Online Machine Shop - Instant Pricing after my first guy fell through.

Originally Posted by jamse-r

Chaparrals

Mazda Miata Parts & Accessories at MiataMania.com

Panasport

Mazda Miata Parts & Accessories at MiataMania.com

I love them, and they look sick on the miata, and I think look great on your classic. It does give the car an older more mature look

Originally Posted by Setzer

So, where do you live? I always wanted a set of Panasports

That lizard reminds me of the ones I would always see in Switzerland as a kid

I live in Columbia, South Carolina. I'm not used to the lizards. I've been here 5 years. I'm from Cape Cod Massachusetts. We have salamanders there instead. =]

Originally Posted by CleanSE-R

I'm down here in SC from Long Island, NY. Been here just over 2 years now. I know Cape Cod very well. Used to spend my summers up in Chatham, Cape Cod.

I see the South Carolina people are coming out of the woodwork. =]

Originally Posted by Benito Malito

Looks good but you need to put a real 94 bumper on it.

Yah, I've never really noticed the difference in bumper styles. My brother has a black '94 as well, and I haven't noticed the difference. I'd love a pic or two of a real bumper if you have some you could link me to. For all I knew, I thought I had a '94 bumper. =(

...

I saw the difference in the 1994 bumper today. My brother's '94 has it, I don't. I quite like mine... Makes it even more of a sleeper. =]

Originally Posted by GT2876RBLUBIRD

kudos on the wiring lol, more than i would attempt lol

Honestly, it would have been easier to ditch the whole engine wiring harness instead of making sense of the factory wiring, and making that adapter. *shrug* you live and you learn. It's not that bad. Have a little faith. =]

Originally Posted by des_se-r

looks good Ben, once your finished with the turbo install i want a ride

I see you're in South C. as well. You can count on a ride when I'm boosted...
Where in SC are yah?

Originally Posted by DRE DUB

Car is looking good Ben! I'm working out my little gremlins in my car, then I'll push her from the "upstate" to the "low country" to see you. I'll call you this weekend if you're no too busy.

[Vadim]

Looking good ben

[RBI*04]

looking good. those spacers are loking amazing

[autoxse-r]

car looks great and way to do it right starting with brakes and suspension now just lower it... slap a turbo on and your set

BTW I love those wheels and whenever you want to get rid of them let me know

[autoxse-r]

what are your plans for the car? will it be a daily driven street car or more of a race car?

[BenFenner]

Originally Posted by autoxse-r

now just lower it... slap a turbo on and your set

Yah, the car doesn't have the suspension in it yet. I'm just waiting on the Koni bump stops. It'll leave the four finger club soon enough. =]
The turbo parts are waiting for May to go in, as I have a road trip to complete before messing with the engine any more.

Originally Posted by autoxse-r

what are your plans for the car? will it be a daily driven street car or more of a race car?

The car will see as much track use as I can afford (which isn't much) but will (and is) my only car, and faithful daily driver. I will be enjoying it to the fullest.

[Viprdude]

nice lookin se-r! i wish i had a 94!

[jere]

It is really cool to see someone actually planning, and not just going turbo and then thinking about the stock suspension after they realize it sucks. Props on the ECU that nest of wires makes me cringe, I don't know how you do it.

[Dan9]

Well-thought-out project for sure. That's a classic Classic!

Never heard of VEMS before. Have to look into that. And coilpacks, that may save a lot of headaches with the dizzy, eh?

[captainzib]

Nice project man. I'm diggin the K*nex table.

[BenFenner]

Thanks for all the complements guys/gals. I really never knew how different my modification style was until recently. I'm glad the work/thought/planning that went into it is appreciated.
I'll answer the COP question:

Yes, the coil-on-plug set-up really helps with distributor problems, and it's very nice to have (cheap too). I never found anything wrong with the stock set-up though. The only reason I did it, was because I didn't really know how to get VEMS working properly with the distributor at the time. Now that I know better, I'm sure it could be done. At $25-$50 for the COP stuff though, it's hard to make a case for keeping the distributor set-up.

About the K'Nex table:
You should have seen it when I had the blue LEDs in the Plexiglas top. The edge would glow blue. So nice. =]

[Pretty White]

There is a market for custom spacers. If you can do a 10-12mm 4X100 59mm HUBCENTRIC spacer I am willing to pay as others are too. 5 is not enough and 15 may be a little too much for some people.

[ga16lucino]

I'm interested as well, provided it would work between b13 and b14.

Nice car!

[BenFenner]

The spacers were $325 or so if I remember, for four. I'm willing to give out the design to anyone who wants it, and it would be nice if someone were to do a group buy for them. If you could get 10-20 people in on the group buy, the price for four could go down to as little as $100 for all four I bet.

The problem is, the spacers require modification to the car's hub to fit. There is no way to design a 12mm hubcentric spacer otherwise. You have to grind/cut down your existing hub 5mm to make them fit. It's a pain in the ass, but doable...

Like I said, I'll give the design to anyone who wants it.

[Shawn B]

Sweet as hell.

Love the work, the wheels, the color, those big-ass brakes....and pretty much everything else about it.