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BlwnAway 10-09-2012 04:55 PM

Bolo's 200k + Build Thread
Ok, so I finally decided to do an "actual" build thread, instead of throwing bits & pieces all over the forum, and since I broke the 200k mark a few weeks back, figured this was as good a time as any.

So I guess it's fitting to start off with NOT Just repeating all the Sprintex stuff....:laff:
The final tuning for the Sprintex is just about done, and anything directly related to it, I'll still update on that thread:

Anything here will be after 200k mods only.

Lets start with the Proof and the pre200k history. :D

Current milage is just under 202500

Da Car:
6 Speed
Pure Silver / Black
Full Leather
Sport Pack
Cold Weather Pack
Chrono Pack
Xenon Headlights
OEM Driving Lights
17" "Bullets"

Current Mods are such:

Stock Lower End
Stock Cam
Thumper Adjusted Cam Gear (post 200k)
Match Ported Intake
550cc Injectors
Dinan Lg Bore T/B
Stock JCW CAI Flapped w/ ITG Foam Filter
ATI Super Damper
TSW Solid Upper Motor Mount
Ireland Lower Mounts
Sprintex S/C w/ 60mm Pulley (S/C installed @ 178,800)
Mynes V2 Header w/ Stock JCW Exhaust
Byteronik F/A Tuning Software & Tune

Da Ride:
H-Sport Springs
Koni Yellows
H-Sport Rear Lower Control Arms
25mm Rear Sway Bar
Power Flex Lower Control Arm Bushings
215/45/17 Kuhmo Ecsta AST's

Da Inside:
LED Conversion of all interior Lights / Blue :pimpin': :laff:
VEI Dash Mounted Gauges (Boost / Volts / Fuel psi. / Dual IAT)
Craven Speed Gauge Mount
Innovative Motor Sports AFR Gauge
Craven Speed Stainless Shift Knob
Craven Speed Shift Well Cover
Blacked Out Trim Rings
Black / Silver Fuzzy Dice :psuedopimpin': :laff:

Da Outside:
Blacked Out w/ 35% Tinted Windows
Drag DR-11 Gun Metal 17x7 Wheels
M7 Ram Hood Scoop
8000k HID Bulbs
Hella Black Majic 500 series Driving Lights (Lower Grill Mounted on Outmotoring Brackets) w/ 8000k HID Bulbs and 55w hid ballasts
Projector Fog Lights w/ matching 8000k HID Bulbs
Custom LED Headlight Projector Surrounds (Here: since it was after the 200k mark)

The car's lost some power due to just plain ole age & wear, but it still runs pretty strong, and I still have plans in the works to make more Power improvements and of course will be doing the inevitable "rebuild" when the time comes, with even more power improving "goodies", so stay tuned if you like. :D

I think thats about it, I really don't have any plans on slowing down on changes & such, hell where would the fun be in that, besides, "Excess" & "Over Kill" is just Too Much Fun! And who knows the whole thing may just give people some insite into modding at high milage, don't forget, I didn't even do the Sprintex & pulley/boost changes until 178,800.

Also don't forget....."What Does NEED Have To Do With It."

Oh, and I'm going to try & get some updated pic's real soon.

Konstantinos 10-09-2012 08:12 PM

Congrats on 200 grand!

BlwnAway 10-13-2012 11:48 AM

Since someone mentioned this on 03EmCeeS's build thread, and since this was actually my first mod after 200,000 I decided to just re-post it up here for reference:


Originally Posted by BlwnAway (Post 758616)
Well, first mod after the 200k mark, Thmpr's Adjusted Cam Gear:
Since I was doing both the ACG & the 60mm, I thought why not get an individual comparison to go along with the combined effect.... So here it is, these are my results, the only change is the ACG, all the conditions were as close as I could get them, this is with a STOCK cam.
OEM Gear
(bottom graph is boost only, wanted to show, that's not where the power came from)

I'm plenty happy.


Originally Posted by BlwnAway (Post 758706)
Thanks, I really like it, the extra torque is where the fun is, I went from being able to hear & feel the tires spin in the top of 1st gear, to actually being able to smell them....:D. It's good to still be able to make improvements (and to feel the results)


Originally Posted by BlwnAway (Post 758819)
After a couple of days of living with it:

Between the extra low end of the Sprintex and now the added torque of the ACG the car is a completely different animal.

I can't say enough about the ACG, esp. for me, I just got lucky and got "one of those" ECU's that doesn't like cams, so I had no choice but to stick with the OEM, but now it's the same or better than either of the cam's I tried, simply because the power comes on sooner, as the graph above tells you I got a peak difference of 7 ft/lb's, but if you look at it closely you'll see that early on it was more like a 9 to 10 ft/lb gain, and neither of my cams turned on near that early. As the guy who designed it say's "It Just Rocks!", not to mention it's a pretty simple mod.

I just wish I could use both, a Cam & the ACG, and according to Byteronic guys, with the last update in software, I could now work around my ecu issues, but I'm just a little hesitant to try, not because I don't think it could be done, but because of the fact that the cam cap bolts, on this "aluminum" head have already been torqued a total of 6 times, with all of my experimenting, and I'm just not comfortable enough with having to worry about stressing those threads "too much" and finding out it was one too many times....not to mention I sold both my cams. But the extra top end power of a good cam & the addtnl. low end torque of the ACG would be a great combo, who knows?

BlwnAway 10-16-2012 09:27 AM

Ok, there were 2 other major items I had on my list of things to do before the rebuild, W/M & Nitrous, and with the change in seasons I decided to do the Nitrous first, I'll do the W/M early in the spring.

I want to start by saying, this system is Complete Overkill and will never be used to it's full potential on the Mini, but there is actually a method to my madness. One of the reasons for all the extra stuff is, I just decided to do it all now & never have to add later, no matter what vehicle I use it on. (not to mention, just a couple of things & this 1 system becomes 2) The main reason though, is control, I wanted maximum control over when & how much.

So, I started with this; the Zex Universal 4-6 cyl. Wet kit, Black Out edition.

Sorry, I didn't do the obligatory "spread out everything on the floor" picture. :D

I choose "Wet" for the safety & ease of tuning, I'll be running a small enough "shot" that I won't need much timing adjustment and with "Wet" the AFR can simply be tuned with the fuel jet.

As I said, I started with that system, off of it I've built a One Off, Custom, 2 Stage system, including a 2nd "Wet Management" unit & RPM controller, I've also added a Purge kit & Bottle Heater.

Here's the intent behind all the "extra's" :
2 stages, mainly for traction & delivery control, each stage acts on both a WOT throttle position sensor & a push button. (2 seperate push buttons, one for Stage 1 only, one for both Stages combined)

Stage 1 will be stricktly determined by traction, what ever level I can use, up to approx. a 65 "shot" that the car will hold traction @ 3500 RPM in 2nd gear, is where it will be set at.

Stage 2 will give me an additional "shot" to give me a combined total of about 100, (for this incarnation of my motor) it will also be controlled by an RPM "window" switch and will only activate from the bottom of my next gear RPM point up to 7000. (in other words, if I run out the gear to "shift point" the RPM that I am then at, after my gear change, is where I'll set the bottom of the RPM controller, approx 5400 or so)

Here's a few pic's of the install so far, I'm 1/2 finished with all of the engine compartment install & have some of the wiring started:

Cut out for mounting panel:

Fabbed new panel:

Mocked up:


I still have to install my Nozzles into my S/C horn & run my Fuel line from the Fuel Rail to my Gauge Sensor, then connect it to the system, I'm also adding a NOS pressure sensor for a gauge into the car. I'm finishing up making the bracket for those sensors now, and making custom push button & indicator panels for inside the car as well.

I'll get more pic's as everything happens.

Chase 10-16-2012 01:19 PM

killer man, this is going to be great

nothingman 10-18-2012 11:55 PM

Blue interior lights, meaning the surrounds right? Because I want to do the dash and gauges but can't find a place outside of UK that has premade stuff, only instructions on how to re-solder them all

BlwnAway 10-19-2012 06:03 AM

No, I replaced all the interior bulbs (footwells, maps, dome) w/ blue led's, as far as gauges, my understanding is you are correct, nothing pre-made, only done custom as you've found.

03EmCeeS 10-19-2012 02:09 PM

Very psyched to see this nitrous setup come together!

BlwnAway 11-13-2012 07:56 AM

Things have been slow going with other stuff taking priority, finally had a little time on Sat, so everything under the hood is basiclly done, all I'm waiting on to complete the "under the bonnet" work is to install the pressure sensor for the NOS gauge for in the car. It should be here by the w/e.

Fuel line plumbed and new sensor bracket made:

Switch panel done also:
(W/M, NOS, Bottle Heater, Purge, Remote Bottle Opener)

Really hope to be done & testing by Turkey Eatin' w/e.

Captain Claw 11-13-2012 02:10 PM

Damn dude 200k!!! Hahaha awesome :tu:

Chase 11-13-2012 03:25 PM

Ill give you a call today. I am curious about that fuel line you ran

Rustyeuro 11-13-2012 03:31 PM

what kind of fuel pressure regulator are you using with the fuel return line?

BlwnAway 11-13-2012 03:57 PM

Thats not a return line, it's a feed line for the NOS, with a mechanical fuel pressure sensor plumbed in.

The sensor itself has been there for a year or so now, besides T'ing into the NOS control unit, the real difference is that it's finally plumbed properly. Before I was just using regular rubber fuel hose & heavy duty clamps for the connection, that and I had to make a new bracket for the addition of the 2nd (NOS) sensor.

Chase 11-13-2012 04:00 PM

Ah, for a second i thought you ran a return line and i was about to have you come here and make me one haha

BlwnAway 11-13-2012 04:11 PM

Same principle though, just pull the valve stem & plumb your regulator and return line from there.

The reason I plumbed it the way I did is to be able to see if there is a significant or any drop in fuel pressure at the rail (which of course is regulated by the fuel regulator) when the Nos is triggered in either stage.

There are safety's built into the control unit for "too low" fuel pressure, for the use of the Nitrous, but with it plumbed there, I can monitor the pressure to see if the additional fuel being used by the Nitrous is possibly pulling too much from the injectors, and if additional fuel pressure will be needed.

BlwnAway 11-13-2012 04:28 PM

Chase, correct me if I'm wrong.....

I was under the impression that our fuel systems, being vacuum / boost regulated, worked in a way that the factory regulator would limit the fuel pressure coming from the pump, (stock or higher pressure) up until a certain point of boost, then it is just "wide open". So if you were running a higher pressure fuel pump, you could plumb from the end of the rail to the regulator, then into the fuel tank, so anything higher than the set amount on that regulator would simply return.

Or have I over simplified this and am missing something?

Chase 11-13-2012 05:06 PM

I really do not know enough about the stock fuel system to comment. That sounds right to me, but again, i have not looked into the fueling enough to know. Ill ask around and see what i can come up with. I have been wanting to do a return fuel system, i just havent looked into it further since i have some much else to finish first

BlwnAway 11-13-2012 05:14 PM

Cool, let me know too, may be useful knowledge for that other thing I want to talk to you about....btw, no hurry.

Chase 11-13-2012 05:23 PM

today is my slow day, I am teaching right now, but i get out at noon. Ill try and give you a call later

minsanity 11-13-2012 10:39 PM

Been following your build, Blwn. EPIC!:tu:

BlwnAway 11-20-2012 02:34 AM

Under the bonnet is finally done, decided to take the long way around when doing the I/C horn & take it off, instead of the ole "stuff a rag down it & use a vacuum" trick. I decided to just take the time & remove it, that way there was no chance of getting any metal shavings into the S/C. And while I had it off I also drilled & tapped it for my pre-I/C temp sensor. (was just reading incoming air, pre S/C before)

So here' the final results of the engine compartment: (still needs a good cleaning though)

Both sensors in, battery junction box re-mounted.

Nozzles & Lines attached.

Just have to finish the gauges & wiring in the car, and mount the bottle & line.

BlwnAway 11-29-2012 10:37 AM

So, only 1 1/2 good weather days over the holiday w/e @ my place, so everything didn't get done as I had hoped, but 99% of all of my wiring is done. (since I solder & shrink tube everything instead of crimp connectors or twist & tape, all of it is actually really time consuming.) It did take every bit of what time I had. All of the wiring under the hood is complete, and the only thing left to do in the cabin is to splice in the Throttle Position Sensor wiring & move + install 2 gauges. (fuel psi & new NOS psi gauges are going on the Chrono Pack.

Got my Double Cup gauge cups from Lukifer on Fri.

Drilled & placed my 3mm leds that I'm using as indicator lights.

Siliconed them in place. (yes silicone is my duct tape, go ahead & shake your heads :D)

Was too ugly, so I made some covers.

Didn't like them horizontal, too high, so I opted for vertical.

The bottom hole on this side is for the future W/M gauge, but again didn't like the unfinished look, so $3.00 ea. at my local Ace Hardware store & I got some of these, 2" nylon hole plugs.

Then a little Black Satin spray paint & I'm satisfied.

Everything done but the other 2 gauges. (NOS & Fuel psi)

Indicator lights are:
Left (all Red)
NOS on
NOS Bottle Heater on
NOS Remote Bottle Opener open/close

Right (all Blue)
Rally Lights on
W/M on

And again, I know it's a little much for most people but WTF, I do like as much info as possible.
(Hey, at least give me credit for not stringing 3 or 4 more across the top of the dash....:laff: )

Should have the gauges & wiring done before the w/e, which only leaves the bottle & line install.

Leave it to me to turn a simple "one day to install" universal Nitrous kit, into a full blown 2 month project. :laff:

Chase 11-29-2012 02:22 PM

I called you sucka. Call me back sometime

BlwnAway 11-29-2012 02:56 PM

Haa,Haa, I saved your #, will do....

03EmCeeS 11-30-2012 03:42 PM

Just wanted to brag that I received these pictures before they were posted :laff:

All looks good. You're a nut with these gauges, but you know that.

BlwnAway 11-30-2012 07:08 PM

No, this guy is....:laff: :laff:

professor 12-01-2012 02:36 AM

Enjoying the progress.

03EmCeeS 12-01-2012 05:02 AM

Hmm. That looks like a conversion van. Aren't you currently DD'ing a conversion van? Is there something you need to get off your chest?

BlwnAway 12-04-2012 10:29 AM

Of course another woulda, shoulda, coulda w/e, either the weather sux, or it's so nice you gotta do something else. (70*+ on Sun. so just had to take the bike least that's what I was "told" anyway.)

But, did get all the gauges in & all the wiring done, except for the push buttons, (gonna take a little more research for what I'm trying to do), also got the bottle mounting board, cut and ready for fabric. (gonna just mount everything to a board so that the whole thing can be taken out for easy battery access.) I'll get the fabric this week.
Complete shot of the finished dash & gauge setup.

Found something else to do with those plugs, if you have the craven cups & don't like the backs left open, the plugs I used give a pretty clean finished look on the back also, here's the difference.

BlwnAway 12-12-2012 09:48 AM

Cold-Ass w/e but got most everything done, (ended up with some numb "cheeks" lying on the ground doing the line install :D ) Only thing left is to figure out the wiring for the buttons & I'm done.

Gonna try to get the bottle filled before the w/e so that I can at least check for leaks when I do my final once over.

Not much room left in the boot, once the W/M tank goes in, in a couple of months, that'll be about it, gonna make packing for MOTD a little more of a challange, to say the least, I didn't have much space to begin with, but I did use every bit of it, oh well, just the price you pay sometimes.

Also have a psi gauge on the bottle itself, besides the in car one. (go ahead & say it....yes, another gauge....:laff: ) and ordered the bottle heater today.

(And for those of you who noticed it, [Thmpr caught it right away :D] yes the
bottle is upside down in this pic. it was just
a quick snap I took right after fitting
everything on a very cold day. All is correct

Captain Claw 12-17-2012 11:32 PM

Sweet man

BlwnAway 12-22-2012 12:25 PM

Temporary stand still for a couple of weeks, my main controller is seeping a little fuel from the inside, so I'll have to send it back for a replacement, but with the holidays they're not going to get the new part out until New Years week. Fortunately the way I put it all together shouldn't be much trouble to swap out...oh well sh*t happens.

Besides I've been wanting to crawl back under the car & wrap the NOS line with some hose, just to give it a protective layer from the elements & road hazards, esp. since my car sits low & when I was installing the line I noticed sone slight damage to the fuel line clips already. I may even build an entire shield for the run under the car once I install the W/M line down there too.

Hell, the way it's going I'll just be finishing up with the NOS tuning & it'll be time to start the W/M install....:laff:

MartijnGizmo 12-22-2012 10:04 PM

You could install the GP (or R56) under trays to protect the lines... :)

BlwnAway 12-22-2012 10:53 PM

Will check into those, thanks.

BlwnAway 12-30-2012 10:48 PM

Controller is out and ready to go back, thanks to these:
only took 15 min. to pull out of the system so that worked out really good, did have to run to the A/P store for some fitting caps though, otherwise the fittings into the controller on the "out" side would be open and create a boost leak, just another thing to put into my NOS only spare parts & tools box. :D

As far as the push buttons go, my original idea has proven to be a real PITA and very dificult as far as the wiring goes, I was going to try and use the Up/Down buttons for my radio, on the steering wheel for those, the output wiring from the controller is pretty straight forward but trying to tap in the NOS input wires through the system is a real challange....sooooo, thanks to Minsanity giving me the steering wheel bug, I'm going to go ahead and replace the wheel completely and do some custom control buttons on the wheel itself, it will be a lot easier to do the wiring from scratch than to try and tap into exhisting factory connections. Should order my wheel this week sometime, once it arrives I can start making my mounting plates and brackets that I'll need to make my creation come to life. (I'll just be happy to do all that stuff in the shop, instead of outside right now...:D )

Happy New Year Everyone.

BlwnAway 01-11-2013 09:45 AM

My new Nitrous Management unit got back to me, so that'll go right back in when I get off work today.

New steering wheel due to be here Wed.

Once I get it I can start my fab. work for it, should only take a couple of weekends, and once that's in, everything will finally be done.

Since the delay on the push button thing I've re-thought my stages & operation of the system, my original plan was to do this:
2 Stages, 2 push buttons:
Button 1 - stage 1, 35-55 shot, 3500-6800 rpm
Button 2 - stage 1&2 combined, with an additional (stage 2) 35-55 shot, 5000-6800
But I think I'll start off like this for now & see how it works out.
3 Stages, 2 push buttons:
Button 1 - stage 1, 35-55 shot, 3500-6800 rpm.
Button 2 - stage 2, 45-65 shot, 3500-6800 rpm
Buttons 1&2 together - stage 3, with a combined total of what ever I end up with. (prob. still no more than 100 combined, but we'll see)
I just figure this will give me more options by being able to activate either controller independantly, and still together, if I choose, the biggest factor will still be traction in 2nd gear, right now I'm getting a consistant 19.8 lbs of boost from 4500 & up, so don't know how a 65 shot in 2nd will work out at lower speeds. (allthough, I have to admit, breaking traction @ 50mph on dry pavement may be fun, strictly for the "schwing" factor.....:D. I'm still 16 way too much.....:laff:

minsanity 01-11-2013 12:14 PM

Can't wait for Bolo's updates.:tu:

03EmCeeS 01-26-2013 06:36 AM

Spoiler Alert: There are pictures that have not been shared in this thread!!!

minsanity 01-26-2013 06:53 AM

Pics! Pics! Pics!

BlwnAway 01-26-2013 02:55 PM

I was going to wait till I was done but here are the pic's of the partially completed steering wheel project:

Wheel came in last week:

Patern for the pushbutton panel:

On to the metal work:

Preview of it installed product:

Been sick all week but hope to get the panel finished before work on Mon. night, the hub is on backorder, but is supposed to be available 01/31 so won't have to wait long.

As far as the buttons & button panel goes, the red steering wheel buttons will be (left) Nitrous, (right) Horn, and the buttons on the panel will simple be the relocated Cruise and Radio controls to keep all the factory functionality.

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