Normally Aspirated power upgrade on a Gen 2 (96)
Heads and Headers Replacement
“At last Winter’s here!”
Well, almost here.
Most people aren’t general too pleased to see winter arrive but this year “I am” because at last I can begin my long awaited winter project. I started planning this over a year ago, researching what I needed to do, talking to those that had done it before and buying all the materials, so you can imagine how I now feel to at last get started.
So what am I doing?
I’m doing a normally aspirated power upgrade to my 96 Gen 2 – fitting ported and skimmed Gen 3 heads, Belanger headers and a bespoke 3” exhaust system, plus the proverbial tune up. The intention is to increase power by around 100HP by increasing air flow and compression ratio, without challenging the stock fuel system. I’m keeping the stock 908 cam and will be using stock Gen 3 roller rockers.
I’ll also be doing a few other upgrades including fitting a 180 degree thermostat, fitting Woodhouse engine mounts and fitting a new radiator. I will not be covering these installations in this write-up and will also not be going into teeny weeny detail on the engine stuff – I’ll leave that to you.
Why am I doing it?
I suppose one reason is the engineering challenge and the fact that “I can do it” but the inspiration is really to get hands-on with this massive powerhouse engine and see what I can do without a turbo or supercharger. I will say though that I’m not interested in extra power at the expense of becoming noisy – I enjoy driving track events too much to let that happen, so the exhaust system is a crucial part of the plan. Watch this space.
I’m not gonna rush this work either and don’t expect to be finished until early Spring 2012 but wanted to start a thread now, update it with my progress as time goes on and benefit from VCA members’ opinions.
So please read on over the winter months and enjoy - any feedback will be very much appreciated.
Ade
Spares
Bought so far:-
• Pair of Gen3 heads
Stage 1 ported
Skimmed to increase compression ratio from 9.6:1 to 10.3:1
Stock valves - new valve stem seals
• Cometic Custom head gasket
0.027” - stock was 0.051”
• New inlet manifold gasket - stock
• Pair of Belanger headers
New header gaskets – stock metal ones – do not use fibre gaskets
Permatex ultra copper RTV Silicone gasket maker
Stage 8 exhaust manifold fasteners
• ARP studs and nuts (247-4201)
• SCT Xcalibrator
• New cat back exhaust system
• New pushrods may also be required
Tools
Most tools will be general mechanics tools with the exception of a pushrod depth measuring device, if I need to get new ones made.
LET THE FUN BEGIN
After spending the best part of a day transforming what looked like the town’s refuse tip back into my garage, I got down to removing the hood. I wasn’t sure exactly where I could safely store it but eventually decided the best place would be roped to the garage ceiling. This seemed like a good idea at the time and only with sheer determination, and the help of a couple of neighbours, I pulled it off. Just hope it stays put.
And before anyone says my garage still looks like a refuse tip, "I agree with you" but it's much better than it was.
Heads and Headers Replacement
“At last Winter’s here!”
Well, almost here.
Most people aren’t general too pleased to see winter arrive but this year “I am” because at last I can begin my long awaited winter project. I started planning this over a year ago, researching what I needed to do, talking to those that had done it before and buying all the materials, so you can imagine how I now feel to at last get started.
So what am I doing?
I’m doing a normally aspirated power upgrade to my 96 Gen 2 – fitting ported and skimmed Gen 3 heads, Belanger headers and a bespoke 3” exhaust system, plus the proverbial tune up. The intention is to increase power by around 100HP by increasing air flow and compression ratio, without challenging the stock fuel system. I’m keeping the stock 908 cam and will be using stock Gen 3 roller rockers.
I’ll also be doing a few other upgrades including fitting a 180 degree thermostat, fitting Woodhouse engine mounts and fitting a new radiator. I will not be covering these installations in this write-up and will also not be going into teeny weeny detail on the engine stuff – I’ll leave that to you.
Why am I doing it?
I suppose one reason is the engineering challenge and the fact that “I can do it” but the inspiration is really to get hands-on with this massive powerhouse engine and see what I can do without a turbo or supercharger. I will say though that I’m not interested in extra power at the expense of becoming noisy – I enjoy driving track events too much to let that happen, so the exhaust system is a crucial part of the plan. Watch this space.
I’m not gonna rush this work either and don’t expect to be finished until early Spring 2012 but wanted to start a thread now, update it with my progress as time goes on and benefit from VCA members’ opinions.
So please read on over the winter months and enjoy - any feedback will be very much appreciated.
Ade
Spares
Bought so far:-
• Pair of Gen3 heads
Stage 1 ported
Skimmed to increase compression ratio from 9.6:1 to 10.3:1
Stock valves - new valve stem seals
• Cometic Custom head gasket
0.027” - stock was 0.051”
• New inlet manifold gasket - stock
• Pair of Belanger headers
New header gaskets – stock metal ones – do not use fibre gaskets
Permatex ultra copper RTV Silicone gasket maker
Stage 8 exhaust manifold fasteners
• ARP studs and nuts (247-4201)
• SCT Xcalibrator
• New cat back exhaust system
• New pushrods may also be required
Tools
Most tools will be general mechanics tools with the exception of a pushrod depth measuring device, if I need to get new ones made.
LET THE FUN BEGIN
After spending the best part of a day transforming what looked like the town’s refuse tip back into my garage, I got down to removing the hood. I wasn’t sure exactly where I could safely store it but eventually decided the best place would be roped to the garage ceiling. This seemed like a good idea at the time and only with sheer determination, and the help of a couple of neighbours, I pulled it off. Just hope it stays put.
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And before anyone says my garage still looks like a refuse tip, "I agree with you" but it's much better than it was.
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