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The following are descriptions of selected projects that
we have designed and installed.
Click the arrow to expand each project write up.
Click the pictures to view our work.
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1995 Mustang Convertible 5.0 |
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Rear End Gears - Complete Exhaust - Subframe Connectors |
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The owner brought us this “bone stock” Mustang and said he wanted more acceleration
from a standing start and more horsepower. We developed an array of options for
him with estimated installed cost of each. The customer selected the options that
addressed his goals and met his budget. The project was divided into two phases.
The first phase was the easier steps that included a high flow air filtration system
and new rear end gears, the factory 2.73:1 rear gears were replaced with 3.55:1
gears.
The second phase was more serious and focused on increasing airflow through the
engine. We installed high flow intake manifold; full-length headers and H-pipe with
high flow catalytic converters and a performance exhaust system. We also installed
weld-in sub-frame connectors to help the chassis handle the increased power.
These “bolt-on’s” resulted in an increase of 56 horsepower to the rear wheels.
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2004 Subaru Impreza WRX ...
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Exhaust System - Wheels - Plugs & Air Intake - Spec Clutch Kit
December 2009 Web Addition |
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The owner of this 2004 Subaru Impreza WRX has been bringing
it to WJPE since he bought it. In addition to the general maintenance, WJPE has
performed some modifications to enhance the cars' power, handling, and style.
For the first modification, WJPE wanted to get the engine to breathe better. We did
not want the exhaust to be too loud though because the car is daily driven. WJPE
decided to install Magnaflow's 2.5" stainless steel cat back exhaust system. This
system not only flows better than the stock system, it produces a deep, mellow exhaust
tone.
The next step was to upgrade the handling and appearance of the WRX. The customer
picked out a sharp looking set of ROTA wheels. WJPE ordered in the 17x7.5" ROTA
Torque wheels finished in flat black. We wrapped the ROTA wheels with 225/45/R17
B.F. Goodrich KDW2 rubber.
The next time the WRX came to WJPE it had an intermittent
misfire. After some diagnostics we found the #1 cylinder spark plug had carbon tracked.
We replaced the #1 cylinder coil boot and swapped out all spark plugs for Denso
Iridium plugs and set the gap to factory specs. While working on the misfire issue,
we noticed that the air filter was dirty. Instead of replacing the air filter, we
installed an AEM long ram cold air intake system. This intake system flows more
air than the factory air box, plus it mounts the air filter in the inner fender
well so the engine get cool, fresh air from outside of the engine bay.
A few months
later, the stock clutch started to slip at times. WJPE decided to replace the stock
clutch with a SPEC Stage 2 clutch kit. The SPEC Stage 2 clutch has smooth, stock-like
engagement and is capable of handling 400lb-ft of torque. This leaves plenty of
room for future power upgrades!
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2003 Corvette Z06 ...
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Camshaft Bolts Repair - after dyno testing error
December 2009 Web Addition |
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2003 Corvette Z06 The owner of this immaculate 2003 Corvette Z06 has been
bringing his vehicles to WJPE since we opened in 2003. While he likes to work on
his vehicles himself, he trusts WJPE to perform the work he does not want to do
himself.
Recently he installed a supercharger system by A&A Corvette along with a set
of American Racing Headers (purchased from WJPE). After dyno tuning, the car produced
590RWHP but the check engine light came on as he was leaving the dyno shop. The
dyno shop scanned the computer and found a code for the camshaft position sensor.
The customer stopped by WJPE to ask us about the camshaft position sensor code.
Luckily for him, we had seen this issue before. We informed him that the code usually
sets because the bolts that hold the timing gear to the camshaft loosen and allow
the camshaft to "walk" away from the sensor. After hearing this, he made an appointment
with WJPE and did not drive the car until we could work on it.
We removed the timing cover from the motor and found two of the three bolts that
hold the timing gear to the camshaft had backed out about a quarter inch. We proceeded
to remove and clean off one of the bolts, then clean out the bolt hole in the camshaft.
We applied Loc-Tite to the bolt and tightened it to spec. Now the other bolt that
appeared have backed out only a quarter inch was about a half inch out and the bolt
that was flush with the camshaft gear was now a quarter inch out. After cleaning
and applying Loc-tite, we torqued all three camshaft bolts and reassembled the car
and gave it back to the customer.
He was very happy to have his Corvette back and very thankful that our knowledge
and expertise saved him from costly catastrophic engine damage.
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1979 Camaro Z28 |
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Suspension - Big Brake Kit |
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In the first phase of the performance upgrade on this Z28 we installed a Corvette
style front suspension. This conversion of the coil springs to traverse monoleaf
fiberglass springs increased the car’s cornering ability and also allows for easy
ride height adjustment. We rebuilt the Richmond 5-speed transmission and optimized
the shift linkage. Finally, we installed a dual electric cooling fan system and wired
it to turn on and off automatically with a thermo switch.
The second phase consisted of installing a big brake system, a 12-bolt rear end,
new upper control arms, aluminum body bushings and a complete fuel system. The front
brakes were upgraded to 13 inch, slotted and cross-drilled rotors with dual piston
aluminum calipers. We swapped out the stock rear drum brakes in favor of a 12-inch
slotted and cross-drilled rotors with single piston aluminum calipers with integral
parking brake.
We installed a 12 bolt rear end that was built by Moser Engineering to specifications
designed
by WJPE. This design consisted of a 3.08:1 gear ratio, heavy-duty posi and 33 spline
bolt-in axles. We chose this rear end set-up to work in harmony with the Richmond
5-speed and to withstand the high horsepower and torque the motor produces.
For the fuel system, WJPE started with a new replacement fuel tank with a rear
sump welded into it. We used stainless steel, braided hoses and AN hose fittings
to plumb the tank to the electric fuel pump. Stainless steel, braided hose was also
used to plumb from the fuel pump to the fuel pressure regulator and from the fuel
pressure regulator to the dual feed Holley carburetor.
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1983 Camaro |
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Complete Race Car Construction |
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In 1996 Wayne Jones purchased a 1983 Camaro with a 305ci. engine and 5 speed manual
transmission that popped out of first gear intermittently. Since that time numerous
performance enhancements were designed and installed that have resulted in the transformation
from a sleepy street car to a full-blown drag car.
The Camaros’ current configuration still consists of a small block Chevy engine,
a 5 speed manual transmission, and stock style rear suspension, but that’s where
the similarities end. The anemic 305ci engine was replaced with a 383ci small block
fitted with a forged crankshaft, I beam rods and Wiseco pistons. We topped off the
short block with a set of Air Flow Research cylinder heads, Weiand Team G intake
manifold and a Race Demon carburetor. The Borg-Warner T-5 transmission was replaced
with a G-Force racing 5 speed transmission capable of withstanding 1400HP. We replaced
the bell housing with a Lakewood SFI rated scatter shield and installed a McLeod
clutch with an adjustable pressure plate and an aluminum flywheel. The stock driveshaft
was swapped out for a three inch diameter steel driveshaft with 1450 u-joints. To
complete the drive train we removed the stock 7.5” rearend and installed a Ford
9” from Moser Engineering complete with 4.11 gears and a full spool.
For the front suspension we wanted a setup that would not only transfer weight to
the rear tires but also remove weight off of the front end. To accomplish this we
decided to go with a tubular k-member kit from Anthony Jones Engineering. The kit
included the k-member, tubular a-arms, a pinto style rack and pinion, and a coil
over conversion. We completed the front suspension with a pair of Koni adjustable
drag struts. This setup removed over 40 pounds off the front end of the Camaro.
WJPE decided to go with Spohn Performance for their adjustable rear control arms
and panhard bar. We wanted to eliminate any bushing deflection so we had the suspension
pieces equipped with heim joints instead of urethane bushings. We replaced the flimsy
factory torque arm with an adjustable race series torque arm from Spohn Performance
as well. This suspension system has resulted in consistent low 1.4 second 60 foot
times.
The WJPE Camaro has run the quarter mile in 10.99 seconds at 122mph on motor and
10.07 seconds at 137mph with nitrous oxide injection.
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1970 GTO |
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This beautifully restored GTO came to WJPE in need of one thing… a custom exhaust
fabricated to the same high quality as its restoration. Starting with 10 foot lengths
of 13 gauge aluminized pipe we cut, bent, formed and welded a 2.5” exhaust system
with an h-pipe and a pair of 40 series Flowmaster mufflers.
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2004 Corvette Z06 |
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This supercharged 2004 Corvette Z06 came to WJPE in need of a stronger clutch. The
stock clutch was slipping and the clutch pedal would stick to the floor when trying
to shift at high rpms. We decided to install a SPEC stage 3+ clutch set, which is
capable of handling 850 lb/ft of torque. WJPE also installed a complete header system
from American Racing Headers. This system features all stainless steel construction
with extra thick flanges, large diameter primary tubes, high flow catalytic converters
and a full flow x-pipe. On a supercharged car, this system is worth 35 hp over the
factory manifolds.
To help the transaxle deal with the added power, we installed an ECS transmission/rearend
brace. This brace strengthens the transmission and rearend cases and prevents case
flex which could result in case breakage.
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2006 Dodge Ram 3500 |
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Bumbers - Wheels & Tires - Lift Kit |
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The owner of this 2006 Dodge Ram 3500 pick-up truck came to WJPE looking to
transform it from a mundane stock truck into a tough work and play ready vehicle.
We started off by replacing the stock front and rear bumpers with a pair of heavy
duty bumpers from Road Armor. These bumpers are made from 3/16” thick steel and
feature integrated winch mounts, D-ring mounts, fog light mounts as well as a bull
bar with provisions to mount dual off road lights. To ensure the bumpers would remain
looking good after years of hard use, we had them coated inside and out with Line-X
truck bed liner. We finished off the bumpers by installing a pair of PIAA fog lights
and a pair of PIAA driving lights in the front bumper. For the rear bumper we installed
a pair of PIAA back-up lights. Next we installed a pair of N-Fab’s full length rock
rail sidesteps. We had the sidesteps coated with Line-X for added durability and
to match the bumpers.
The truck now needed a new set of wheels and tires to match it’s rugged bumpers
and sidesteps. We chose a set of 17”x9” American Racing Mojave Teflon coated wheels
wrapped with Dick Cepek Fun CountryII tires measuring 35”x12.50”. This large of
tire will not fit on a stock ride height Dodge, so it was time to install a lift
kit. We decided to install a Fabtech 4 ½” lift kit with their Dirt Logic shock absorbers.
Along with the lift kit we also installed a set of Bushwacker’s pocket style fender
flares. We completed the exterior modifications by installing a SRT-10 hood and
grille.
No diesel powered truck would be complete without some power enhancements and this
one is no different. We informed our customer of all of the options to increase
the power and mileage of his vehicle, and decided to install a Banks Six-Gun system.
The system contains a Banks Six-Gun Power PDA diesel tuner, a Banks Ram-Air intake
system, and a Banks 4” Monster exhaust system. This system adds up to 126hp and
290 lb\ft of torque. By using a Palm PDA to control the Six-Gun system, the driver
can adjust power levels on the fly, read and clear DTC trouble codes, and monitor
a slew of vehicle parameters. The Six-Gun system also has built-in safety measures.
If the system detects a parameter that is out of the safe range, it will put the
truck back to the stock power level and alert the driver automatically.
With the power upgrades complete, we needed to upgrade the fuel system and the automatic
transmission to ensure a long, trouble free life for the vehicle. We installed a
FASS fuel system to keep the engine well fed with fuel no matter what power level
the tuner was set to. The FASS fuel system consists of a high volume fuel pump with
a large spin-on water seperator and separate fuel filter along with a new, larger
fuel feed line. The system eliminates the factory fuel filter and feed line because
they are too restrictive. For the transmission, we installed a BD valve-body and
a Pro-Torque heavy duty torque converter. The BD valve-body optimizes the transmissions
shift points and increases the internal line pressures to increase it’s power handeling
capabilities and reduce clutch pack slippage. The Pro-Torque heavy duty torque converter
has a lower stall speed than the factory unit, which allows the truck to have a
wider useable power rpm range. The lower stall speed also reduces the amount of
heat generated by the torque converter especially under heavy loads. Lastly, the
heavy duty torque converter has a larger converter clutch to eliminate slippage
while operating in lock-up.
The owner of this truck often uses it for long trips and wanted to increase the
amount of fuel he could store in the tank. The factory tank takes up all of the
available room under the truck, so we installed a 50 gallon in-bed fuel tank from
Transfer Flow. This tank mounts at the front of the cargo bed and fits underneath
the hard taunnu cover. As the engine uses fuel from the factory tank, the Transfer
Flow system automatically pumps fuel from the in-bed tank into the factory tank.
It also comes with an in-cab display that tells the driver how many gallons of fuel
are in each tank as well as the total gallons of fuel remaining. With both tanks
full, the truck as 84 gallons of fuel available and can travel over 1600 miles between
fill-ups!
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2006 GMC Sierra 3500 |
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Lift Kit - Wheels & Tires - Turbo Upgrade |
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The owner of this 2006 GMC Sierra 3500 came to WJPE looking to transform his unassuming
stock truck into an awe inspiring, daily driven show truck. The first step in the
transformation was for Wayne to design, fabricate and install a custom 4 inch diameter
exhaust system with dual 6 inch diameter chrome stacks. Next we needed to make the
truck match the massive stacks. We decided the best way to accomplish this was to
install an 8 inch suspension lift kit. We chose to install a Superlift lift kit
because of their reputation for building high quality products engineered to withstand
the stresses this vehicle will exert on them. Once the lift kit was completed, we
turned our attention to the now puny looking stock wheels and tires. We swapped
the stock wheels and tires out in favor of a set of 10 lug 22.5 inch diameter wheels
from a Freightliner tractor trailer. We wrapped these massive wheels with a set
of Goodyear all terrain tires. While test driving this now massive truck, we noticed
two issues caused by the increased height and weight. The factory brakes needed
some help to slow the truck down, and under acceleration the rear axle would wrap
up the leaf springs too much. To help out the brakes, we installed a Pac-Brake exhaust
brake and to control the axle wrap we installed a pair of RCD ladder bars.
After driving the vehicle for a couple months, the customer decided he wanted WJPE
to install a dual front shock setup with remote resivoir shocks. The only problem
was we could not find a shock hoop that would work with the Superlift lift kit.
Well, it was not really a problem with Waynes fabrication skills. We ordered in
a dual shock hoop and some ¼ inch thick steel mounting tabs. After mocking the hoop
in place we cut, sectioned, welded, grinded, and painted the now custom shock hoops.
We welded the mounting tabs to the top of the frame rail to mount the lower legs
of the shock hoops. To finish the dual shock hoop installation we installed a set
of Pro Comp MX6 adjustable remote resivoir shocks. With the trucks looks now transformed,
we turned our attention to the drive train and fuel system. First, we installed
an Edge Juice with Attitude module, an AFE cold air intake, and a FASS fuel system.
These modifications netted approximately 100 hp and 200 lb/ft of torque. Now the
truck runs as good as it looks!!
The customer returned a few months later looking for more power. WJPE warned the
customer that additional power would hurt the longevity of the transmission. The
customer decided that if the transmission did not hold up, he would have us get
a transmission built to withstand the additional power. With that understood, we
activated the “hot unlock” on the Edge Juice with Attitude module and installed
a Snow Performance water/methanol injection system. The “hot unlock” netted approximately
20 hp and the water/methanol injection not only netted approximately 70 hp, but
also reduced exhaust gas temperatures by 150 degrees.
When the transmission finally gave up, we installed a Suncoast stage V transmission
and torque converter. We decided to use the Suncoast transmission and torque converter
because of their unconditional 2 year warranty, plus they have rated the transmission
to handle 800 RWHP and 1400 lb/ft of torque. With the transmission issues resolved,
it was time for even more power! We were already pushing the limits of the factory
cp3 injection pump, so we decided to install a dual cp3 pump kit by ATS. This kit
adds a second cp3 injection pump driven off of the engines’ accessory belt and electronics
that allow the two pumps to work together to supply the engine with all the fuel
it needs.
We needed more airflow to burn all of the fuel the dual cp3 pumps were supplying,
so it was time for a turbocharger upgrade. Due to the massive amount of air the
engine needed, we chose to install an Aurora 5000 turbo upgrade kit by ATS. This
turbo is absolutely massive compared to the stock turbo. The Aurora 5000 turbo is
capable of flowing over two times more air and twice the boost psi of the stock
turbo. With the capability of producing 70 psi of boost we absolutely need to install
a set of ATS head studs.
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