So I've put a couple hundred KMs on the car the last couple of weeks. Slowly taking longer trips as my confidence builds that I didn't forget to tighten steering components or something.
A few issues still linger that don't prevent the car from being driven but need to be dealt with to really enjoy the experience.
Soft brakeSoft Brake
Hydraulic vavle ticking (still!!! )
The brake is slowly getting firmer with each outing/bleed. It's such a PITA to remove the upside down caliper and squeeze in a brake-block to prevent piston movement that I'm willing to go with a less effective solution and bleed the caliper as-is after every couple of outings. The good news is that it is getting better.Exhaust Noise
The muffler seemed to be bedding in and somewhat mellowing but it was still too loud. Based on reviews and dimensions, I decided to order the Flowmaster HP2.
It's a pretty cool design with preforated cones - the two tips touching in the middle of the resonator.
As previously mentioned, I removed the 3rd connector and made it a single unit. It still installs relatively easily.
I managed to tuck it in pretty tight. Before:
The end result is a MUCH quieter exhaust that still has a nice growl when I'm pushing it. I've recorded a video of the old exhaust and next week I'll record the new exhaust and post.Hydraulic valve ticking
The other issue is with the hydraulic valve lifters - which is most disapointing because I spend a chunk of coin last summer replacing all of them. I'm starting to regret not going with solid lifters... I'll try and troubleshoot this first and see what I can do. When the car is not ticking, it runs sooo damn good! Perfect power/Tq for my needs. Then, somewhat randomly, the ticking appears and power loss can be felt. No oil pressure loss is seen, if anything it seems to happen sometimes when I brake and revs/pressure drops. If I stick to it, maybe do a highway 100+kph run, the ticking disappears.
As FYI, my Speedhut external oil pressure gauge is showing 60-70 psi on start-up, 20-25psi on cold idle, 10-12 psi on hot idle and about 50-60psi while cruising ~3K. Not really knowing if pressure is enough I looked into a high pressure pump. Thankfully, my research showed me that the KA24e D21 pickup already runs the larger pump. This information came courtesy of DazenMike on Ratsun http://community.ratsun.net/topic/36178-quick-oil-pump-question/?p=556242
. Essentially, the easiest way to tell is for exposed rotors.
While I already have a high-flow pump, I did notice that the gasket was toast - which would explain the small puddle after each drive.
A quick RTV hack seemed to have boosted pressure 5-10psi but the fix was short lived and the puddle returns so I've ordered proper replacement Felpro gaskets. I'm also thinking of switching to a thicker oil as the ticking returns when the car is warm and during the random braking even. I'm currently on 10W30, maybe 10W40?
For now the car is good enough to enjoy. She's been rotated into regular bike hauling duty.