Project: Mavro Gato - 99 Turbo'd 3L

[FastCougar]

Index of Updates with Topics:

Post 1: History of project discussed and the first day of the engine buildup begins
Post 15: Covers are painted and prepped
Post 23: Covers are installed and the block modifications continue
Post 27: Longblock starting to take shape ... FEAD side complete
Post 65: Tapped the block for the oil return line and started porting the the UIM to accept 70mm TB
Post 69: Finished porting the UIM to accept 70mm TB by creating custom metal gasket/separator
Post 81: Started to sand down the exterior of the UIM
Post 89: Pointed out the difference between my UIM and the stock UIM
Post 94: Sanding down the exterior of the UIM continues
Post 109: Finished sanding exterior of the UIM
Post 119: Decided to paint the UIM vs. Polishing to better compliment the engine bay
Post 124: Installed UIM and fitted some wiring harnesses
Post 147: Engine Fully assembled, Cleaned out the engine bay and started the suspension overhaul
Post 176: Full suspension overhaul & custom made intake
Post 203: Started the car for the first time (Naturally Aspirated)
Post 233: Started fabrication of the up-pipe's 2 into 1 merge collector
Post 263: Find and fix an intake vacuum leak & misc. overview shots of the car
Post 301: Found the source of my fuse problem
Post 311: Turbo has arrived, along with other goodies
Post 319: Car is running again ... it was the speedo sensor
Post 328: Engine from swap crated for shipping
Post 342: Announce the "kit" will not be produced
Post 353: Battery tray fabricated
Post 360: A/C system completely removed
Post 376: AEM Wideband gauge install
Post 377: Video of the wideband working
Post 402: First dyno runs (Naturally Aspirated)
Post 407: Turbo system fabrication continues with up-pipe
Post 435: Up-pipe redesigned and fabrication continues
Post 444: Down-pipe fabrication started
Post 446: Turbo system starting to take shape
Post 460: Oil feed line is run
Post 468: LIM secondaries removed along with the EGR
Post 482: New intercooler arrived and fitted
Post 512: Wastegate fabrication done, but need to raise the intercooler
Post 518: Intercooler raised, wastegate tube shortened, support bracket added & bumper cut
Post 539: Intercooler shrouding plans discussed
Post 561: Intercooler piping complete along with turbo inlet tubing
Post 608: Finish intake/vacuum plumbing, moving onto the exhaust
Post 649: Add some forgotten gaskets and finally finish the exhaust - SHE'S COMPLETE!!!
Post 747: Dyno results are in ... still need some tuning!


Project Mavro Gato:

Mavro = Greek word for "Black"
Gato = Greek word for "Cat"

History:

It all started at breakfast one morning during CougarFest 2004. My wife leans over to me and says "You know what, you should buy another Cougar for a project car" ... she has lived to regret those words

See, in September of 1999, I bought a 1999 Cougar and began modifying it immediately. However, in 2000, the wife and I decided to buy a house and we went into "savings mode". We where eating peanut butter & jelly sandwiches for lunch and mac-n-cheese for dinner for months straight to help save for the house. I pitched in and sold the Cougar to avoid the $418/month payment (I bought the car with $0 down and financed 100% of the car).

So, I planned CougarFest 2004 (with A LOT of help from committee members) and while attending, I guess my wife witnessed first hand how much I truly love these cars ... that or she just didn't want me to auto-cross the truck anymore I promptly started to follow eBay ads for 1999 Cougars upon the completion of CougarFest 2004.

Following CougarFest 2004, I began buying parts that I knew I needed. However, I didn't have any solid plans for the car other than knowing it would have a 3L in it. About 4 months later, I bought a Black 1999 Cougar from an eBay seller who ran a shop in Philadelphia. I snagged the car for a mere $2,000 since it had a blown slave cylinder and couldn't be moved easily. You had to select a gear and then start the car in that gear ... I was never able to drive it. To this day, I haven't driven the car. Overall, it was a great buy ... except for some hidden front bumper damage (car had a bra on it). So, the front & rear bumpers (many punctures/scrapes/etc.) have to be replaced ... no big deal since the car needs some fresh paint anyways.

So, I now have the car, all the engine parts (Turbo/Supercharger in mind), 3L block, spare transmission ... everything to make this car into something great. Problem was, I was running out of money and the $6,000 at the time for an ADC kit was appearing more and more ludicrous in my eyes after watching Warmonger's success designing and testing his own setup multiple times. I had the $6K for the kit, but didn't see the value in it (at the time) and wanted to use the money to get the car a nice paint job and fix up the interior (roll cage & racing seats). I will live to completely and utterly regret this decision.

So, I hunt down an already turbo'd Cougar/Contour and buy it. The plan was simple, buy a turbo Cougar/Contour, duplicate the piping and then sell the car for a small loss, or remove the turbo kit, return the car to stock and still spend WAY Less and $6,000. The rest is history and well, rather a long story that I don't really want to get into in this thread. Long story short, I get totally hosed on the deal, have to drop a new engine into the POS and then end up rolling the car the same day that I get it titled!

So, this thread is here to document the process of me creating my turbo kit and completing Phase 1 & 2 of Project Mavro Gato.

Phase 1 = Build up the car and break in the engine/transmission naturally aspirated
Phase 2 = Build up the turbo kit and "prove the concept"
Phase 3 = Swap the driveline into the rear of the car and go RWD. This phase is a long way off ... IF it ever leaves paper is to be seen. This will be a multi-year project and involves me becoming a proficient TIG welder & metal fabricator first.


----------------------------------------
Engine Buildup Begins
----------------------------------------

1999 Taurus 3L block, Pauter Rods & Diamond 9:1 CR pistons. Note the painted (500 degree engine enamal) engine mount.




Oil pump attached.


Windage tray & oil pickup attached.




Oil seperator installed.


ARP head studs ready to be installed.


Studs installed.


Head gaskets fitted over studs.




Right head installed.


Left head installed.


At this point, I needed to remove the cam caps in order to torque down the head stud nuts.


Cams removed, studs exposed.


stud "head" closeup.


All the nuts installed and the Roller Finger Followers (RFF's) are installed.


Cams are reinstalled and caps fitted and torqued to spec.


Timing chain guides are installed.


Left head timed.


Close up of the colored links on their respective cam markings.


Same on the sprocket end.


Fully timed. Notice the colored links are all off by 21 links to the timing marks on the cams & crank sprocket. I rotated the assembly to ensure proper timing. Aside from hunting down a missing "gold" bolt (timing chain guides & tensioners), the entire process took roughly 15 minutes.

[JScullin]

I haven't even bought my 1st 3.0 and most of you are on you 2nd and 3rds.

[LostRacer]

some spoiled brats get everything..

[scrupul0us]

that is one clean mother****ing engine

[FastCougar]

Originally Posted by scrupul0us

that is one clean mother****ing engine

Just wait for tonight's pictures. The FEAD side (front) motor mount was painted with 500+ degree engine enamel. I love the stuff, so I'm going to paint the timing cover and both valve covers as well ... all silver (aluminum). She is going to sparkle

As of right now, I'm waiting on a new SVT flywheel to arrive. So, until then I need to clean out the LIM & paint it, paint and install the valve covers, timing cover & oil pan. Once all the painted parts are installed, I plan on masking the block and painting it as well. However, I don't want to put masking tape/paper on still curing paint, so the block detailing will not be done until tomorrow night.

I also forgot to get a closeup of the installed stud nuts, so I will add that to tonight's list as well.

[FastCougar]

Originally Posted by LostRacer

some spoiled brats get everything..

Yes, I do spoil myself rotten ... you know, with all the money I make from whoring out your mamma

[J-Man]

Lookin good Trevor! This is your "race" block right?

[FastCougar]

Originally Posted by j99coug

Lookin good Trevor! This is your "race" block right?

Yep ... I will add to the original post to clarify some things like Specs, intended use, plans for the car, etc. I will also use the original post to hotlink to posts by me within this thread with all the pictures and/or technical discussions ... sort of like an appendix within the original post. This way, people don't have to read all the fluff posts and can get right to meat of the thread when they first start reading it

[bensenvill]

Originally Posted by FastCougar

Just wait for tonight's pictures. The FEAD side (front) motor mount was painted with 500+ degree engine enamel. I love the stuff, so I'm going to paint the timing cover and both valve covers as well ... all silver (aluminum). She is going to sparkle

so what paint is this that you are using?

[XplosivePlushToy]

Domo arigato Mavro Gato!

Domo!