posted on November 21, 2011 20:50
I have to be honest, though, the piston pin retaining clips that are used in this application are a pain in the ass! There is a trick to them, though, and it involves two sockets and a middle length 3/8ths ratchet extension. I used the smaller socket to force most of the clip in, kind of squeezing and rotating it at the same time. Once it was in, I used the bigger socket to push the clip into place. Having the pin in actually made that easier, but I had to have the other clip in place first. Took me about an hour, but the maniacal laughter would have made you think I'd been doing it since the Earth was formed when I was done.
|What a pain!
Once the pins were in, I could install the rings into the pistons and drive them in. The first step was to gap the rings and the measurements from JE indicated what gaps I needed. I used the "Street Moderate Turbo/Nitrous" Calculations, which is tabled below. I ended up with a .017" Top Ring Gap, a .019" Second Ring Gap, and the Oil Rings stayed at the .015" required gap. To gap a ring quickly, you should use a piston ring filer, but if you're short on cash, tools, or both, a coarse, diamond layered knife stone works wonders if you're patient. Guess what I used!
|Ring Gap: USE AS A GUIDE ONLY!
||Oil Ring Rail
||Min. Gap Per Inch of Bore
||Bore x .0045"
||Bore x .0050"
|Street Moderate Turbo/Nitrous
||Bore x .0050"
||Bore x .0055"
|Late Model Stock
||Bore x .0050"
||Bore x .0053"
||Bore x .0055"
||Bore x .0057"
|Nitrous Race Only
||Bore x .0070"
||Bore x .0065"
|Blown Race Only
||Bore x .0060"
||Bore x .0060"
|Courtesy of JE Pistons/SRP
Also, for the love of Pete, use a piston ring installer! You are taking a big chance if you use your hands, but you can do it. To do it right, use the installer, I got one for less than $10 at my local NAPA!
The next step is to install the pistons, and while the idea is the same, there are a couple of ways to get it done. The professional installer will have a tapered installer, designed for the bore of the piston. The rest of us hacks have a ratchet fit installer that works just fine! Either way, you want to use engine oil or transmission fluid as you install the pistons and rings. Never, EVER, install pistons and rings dry into the engine, you will damage the bore, rings, and pistons. While the shelf pistons are less expensive, you did still just invest a good chunk of your hard earned cash into this engine, you want to spend it again? I don't!
|Lube down the cylinder bores first, then...
That's what I have for now, next up will the be upgrade to the S14/13 suspension along with tearing down the head so it can be sent to Jim Wolf Technology, wait until you see what cams I have in-store for this thing! For now, check out what another S12 owner was able to put in his car!
|... Then knock them in!
Editors note, we decided to let Justin have a run at building this project car. He is doing it all by himself as a pure beginner as a low buck project. If the level of trickiness and prep is not what you are used to seeing on the pages of MotoIQ, it is because we want to see and Justin wants to share just what he is going through, pitfalls and all. Justin is really building the thing in a shack in the middle of the woods in Virginia, far away from our land of technical expertise and suppliers of nearly everything. Maybe his situation will ring a chord with many of you out there or maybe not. We want to see how far he can run with what we call Project Redneck Rampage.
Jim Wolf Technology
Project Defiant1 - The Concept
Project Defiant1 - KA24DE Build Part 2
Pages: 3 of 3 Previous Page
Tuesday, November 22, 2011 6:30 AM
I can relate with doing a build in the "country". Before Lowes and Home Depot came into my town even finding a metric bolt was a headache. My last engine build involved 2 different machine shops 2 hours away and a coatings shop 5 hours away. Ended up with a stout 7M-GTE though =) Looking forward to the rest of this build.
Tuesday, November 22, 2011 7:25 AM
Definitely nice to see a real budget build here, especially a car that most people don't tune. Good luck Justin, definitely waiting to see more! And to MotoIQ, I for one would love to see more budget builds like this.
Tuesday, November 22, 2011 8:46 AM
Cool project. A weak economy provides opportunitiy for the binned engines and get's us petrolheads something interesting to read about. Well done.
Tuesday, November 22, 2011 9:21 AM
"good luck with that Japanese car of yours that isn't a Honda! Specifically, in this region of Virginia, where Detroit Iron and Drag Racing are still popular."
Sounds like here in Mississippi.
I was skeptical at first about this project but good job. It's nice to see an "every mans" engine build on MotoIQ
Tuesday, November 22, 2011 9:48 AM
Justin, I offer to drive down there and help out, but you first have to promise me I won't start hearing banjo music on the way down there.
Tuesday, November 22, 2011 10:39 AM
I love my small town, I really do, but working on stuff like this can indeed be a headache sometimes. Weve got a pretty legit hardware store now, which makes things a bit easier.
"Dont buy that car kid! You cant get find any parts for those dang things! They all gots to come from Japan, yah know!"
Tuesday, November 22, 2011 11:18 AM
Thanks everyone! I have to say, the guys here at MotoIQ have done a great job in keeping me reeled in. It's over tempting to just blow out a build. After seeing most of the reaction to the concept and a little bit of reality kicking me square in the arse, I have no choice but to keep in with-in reality.
Tuesday, November 22, 2011 12:17 PM
As the owner of a 240sx living in the south I just want you to know I'm rooting for you the whole way.
And MotoIQ, I find this project just as exciting as your other project due to I'm a novice myself.
Tuesday, November 22, 2011 1:12 PM
"Totally Jawesome" -Street Sharks. If you saw it you know what I'm talking about.
I like this low-buck-beginner-underdog story. Keep it up.
Tuesday, November 22, 2011 9:14 PM
What?! No micro-beadblasted-super-deep freeze cryo-stroker crank? No hyperslick-heat-shielding-great-tasting-less filling NASA developed coatings? Is this Moto-IQ? ;)
Great to see a real world enthusiast build.
Wednesday, November 23, 2011 4:31 PM
"The professional installer will have a tapered installer, designed for the bore of the piston. The rest of us hacks have a ratchet fit installer that works just fine!"
Once you use a tapered piston installer, you will gladly pay whatever the cost might be. They make installing pistons so easy. Those ratchet fit installers always seem to hang a ring.
Good luck with the build. I like the old KA24. Its not a bad engine. Its not a great one, but its not bad.
Wednesday, November 23, 2011 5:51 PM
I'm pretty sure I would, but mine didn't hang anything, but I did pretty much soak the installer, too.
Wednesday, November 23, 2011 8:22 PM
If those pistons were going to do 8.5:1 with the KA24E head, won't that be over 10:1 with the KA24DE head? I believe the combustion chamber is smaller on the DE head.
Wednesday, November 23, 2011 8:37 PM
Don't forget that the KA-E pistons are nearly flat tops and the KA-DE are dished. Putting the KA-DE pistons in a KA-E will drop the compression ratio by 1, but KA-E pistons WILL raise the CR in a KA-DE up to, from what I've heard, anywhere between 11:1 to 11.3:1.
Wednesday, November 23, 2011 8:56 PM
Hey Justin. I go to the junkyard 3-4 times a week for work. I can get you anything you might need. You know how to contact me.
Wednesday, November 23, 2011 10:12 PM
Cool budget friendly build.
You mentioned supercharger, will we see a retrofitted Eaton blower in the future? ;-)
Thursday, November 24, 2011 1:31 AM
The JE shelf pistons are 8.5:1 with the DE head. JE does not make shelf pistons for the E.
Thursday, November 24, 2011 9:56 AM
Yeah, I fat fingered that one and kept saying it was 9.5:1 because that is what is stock on the KA-DE. DOH! Correction made!
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