The Mighty Boy

You've done well there
Still amazed at just how can be squeezed into a small hole

Paul

A bit over a year has elapsed since I last reported on this madcap venture.

Back in April I had it running and driving really well. it steered, stopped and went well.

I drove from the North of Sydney to the South and managed to destroy a CV joint. It eventuated the drive shaft that was shortened was about 20mm too short so as the vehicle accelerated and rose on the front suspension the joint pulled apart. I was a long way from home so I walked 6k's to Liverpool train station then caught a train to Central, then a train to Chatswood and then a train to Cherrybrook, cost $2.50 as a Senior, where I was collected by one of my son's and driven home. I then towed the trailer back to the car and retrieved it.

Now a sensible person would just fix the axle. No not me.

My son said seeing it goes very quickly why not turbo it. Well I thought long and hard about it and answered instantly, of course we can.

The engine bay is already pretty full so squeezing a turbo and intercooler in there will be interesting. I figured by rolling the engine back at a 9degree tilt there would be room for the turbo with 10mm clearance to the radiator. The intercooler had to go out front as it was just impossible to fit it behind the grille. Of course this necessitated all new engine mounts, custom idle valves and remote oil filtration. At this stage I'm stuck with fitting a windscreen washer bottle, but it will happen.

About this time I blew up the LS3 engine in my Fake Fargo and it took precedence for repairs. It took 6 months for the engine shop to rebuild the engine. I got it back in and running around 3 weeks ago so I then went back to the MightyBoy.

After lots of fiddling around it would run but one of the issues with the broken axle was a clutch problem. No idea what it was but the throwout bearing wouldn't retract. Turns out it had jammed on the bearing carrier.

Today I removed the engine (again) and split the engine/trans and it all looks good and the throwout bearing moves freely so I'll put it back together and see what happens.

The engine is a non-turbo version (we do have a turbo version but it needs a rebuild) so I've swapped a bit of gear onto it and installed the turbo ECU and it seems to run OK.

Hopefully I'll have it back together early next week and we may be able to give it a spin.

I figure it will weigh around 700Kg and have 200horsepwer. It should perform well.

When it was running non-turbo it could keep up with Subaru WRXs at the traffic lights.

It's a blast to drive. Death on wheels.

Zuffen,
I thought about your Mightyboy project a couple of months ago and thought that as we had heard nothing, it was under covers (or dust, like my projects) and nothing would be heard about it for ages.

As I remember, you were building it for your son, who does not have the mechanical ability, so why did he not come to your rescue to save you the walk, the trains and the $2.50?

It sounds like it will go like SH-one-T off a shovel.  Better you than me.  I hope it will not get you any speeding tickets.
 

windscreen washer bottle can go inside the cabin just like the old days. Make it a hand pump to keep the passenger distracted!

We need photos

Today's Mighty instalment was re-uniting the engine and transmission and sorting a few small issues. One issue was an oil leak from the cam cover that gave the impression the starter solenoid was leaking oil as it ran down some cable to the starter.

I spent two and a half hours installing and tightening two heater hoses and their clamps. Lucky I'm not paid by the hour.

The engine is sitting in the car and I'm chasing a bolt I cut in half yesterday to allow me to complete the install. I've put the word out on Facebook and hopefully will get one tomorrow.

As for speeding fines, I may get one but Lachlan has a get out of jail card. He's a Police Constable! No guarantees but it helps.

Pictures?

A crazy build but good to read along and very enjoyable read it is

Paul

The little car now runs but hasn't been driven.

After removing and replacing the engine it has 3 oil leaks, all fixable and a coolant leak that is a hose that for some reason is way beyond reach and you would need arms like knitting needles to get in there. At least I'm aware of the problem and I sure I can work a way to fix it.

The engine runs well and has a nice turbo flutter when you back off, so should keep the boy happy.

I had a Hot Rod mate over on the weekend and he suggested looking for a new spot for the intercooler. Like I have space to burn on this project!

This is how it looked on Sunday.

And following a bit of rearranging.

The changes will mean it looks way better and will entail a bit of alloy welding and a few new hose joiners but it's all part of the fun.

One day it will run and drive.

I dunno how you fitted all this in there, a shoe horn and a tub of Vaseline comes to mind
Really impressive

Paul

Contrary to most people's expectations I haven't given up on the MightyBoy.

I've been a bit side tracked on the Wife's Sprinter van for dog transport and my own custom pickup. The pickup has an LS3 in the tray and it's decided to not run and I'm having a heap of fun trying to sort it out.

On the Boy front we've had it out on the street terrorising the neighbours, until we drove it a little quicker. At this point we found that not putting bonnet pins in when you don't have a safety catch is a bad look. Result 1 broken windscreen and 1 destroyed bonnet. MightyBoy parts are getting a bit thin on the ground but I found a bonnet in Wodonga so got it sent to Sydney and have now done a bit of bodywork on it and painted it to match the car. I also fitted a safety catch.

Due to the oil leaks I needed to remove the engine to fix them. The worst oil leak was from a remote filter set up, as the original hits the suspension tower, and as the engine went in it would foul on the tower and unscrew the adaptor. This would then leak and there was no access to retighten it.

I figured seeing I have to take it out, why not put another in. So I purchased an SR20DET from a Japanese Avenir which is built for a turbo and puts out 160kw and is bulletproof.

I need to cull the flock of SR20s that I have. Current number is 6 and I figure if I sell 4 of them this engine will be free and I'll still have the original good engine.

Currently I have the engine out and all the hot and cold side swapped onto the new engine and just waiting on a new clutch and it can all go back in.

I'm tossing around replacing the Daewoo steering box (which has a minor leak) with a Nissan Pulsar box and making an adaptor to narrow the the pivot points of the steering arms to keep bump steer at a minimum. The car doesn't have much suspension travel when driving due to it's light weight and fairly heavy springing.

Hopefully it will be up and running late next week.

Whilst I I'm doing the swap I'm tidying up a few issues now that I know how much or little room I have to play with.