Mazdabaters peice of crap FC.

[Mazdabater]

I was going to go through and try and find some old pictures of the car when I got it, and some of the progress shots but it's too much effort and I got some more stuff planned for the car in the near future. So I figure Ill throw up a list of mods and my plans, then throw some pics later as my build goes on.

I brought the car fairly close to stock back in september 06. Currently its mod list is

Full bare metal respray in a custom red with yellow pearl
Rmagic body kit
17 X 8" front rims and 17 X 9 Rear. Unsure on the brand however they are very light so I don't think they are cheap crap.
Extend ported, dowelled with 2mm seals (possibly loosing compression under boost. Going to be bridgeported with RA super seals next month)
Steam pipe manifold
Pro boost 55mm wastegate
Pro Boost to4z turbo (This pro boost junk is getting replaced as soon as I can afford it, or when it fails whatever happens first. Looking at going to a garret gt42r)
Turbo beanie
3" stainless exhaust with Rotaflo muffler
PWR 55mm core radiator
Spal curved blade 3000+ cfm thermo fan (wired to ecu)
Microtech LT10s with hand controller
Walrbo 255LPH fuel pump
Billet fuel rails
Aeromotive FPR with braided lines
STD primarys and Bosch Indy Blue secondarys (1600cc)
SDR 3" throttle body snout
3" Stainless IC piping
600 X 300 X 76mm Chinese bar and plate intercooler
Tein coilovers with EDFC (electronic suspension controller)
Front and rear strut braces
Front sway bar
Braided brake lines
Diff cradle has been reinforced to stop it from throwing mounts
Coushined ceramic button clutch
Blitz auto turbo timer
Sparco race pedals
RX8 leather shift knob
Momo commando wheel
Aerospeed quick release boss kit
Recaro reclineable seats
Storage bins (my cars a jspec so I struggled to find these)
Optima yellow top battery relocated to passenger bin
Carbon dash insert
Carbon radiator cooling panel
Knightsports boost gauge

That's pretty much what I can think of off the top of my head, there could be more If i find it later I will list. Over the next couple of months it's getting

Rebuild - Will most likely get bridgeported
New ECU loom installed, the original owner had it spliced into the factory loom, looks hideous.
Carbon fan shroud + the panel that goes in front of the radiator. I had made one, but after installing the new intercooler I had to ditch the stock overflow bottle, So I'm gonna make a new one without the hole in it.
New underbody tray (going to add some extra ducting to this to get the air where it needs to go)
PWR oil cooler
Bigger alternator
Working out why the hell my fuel comes back out the fuel cap.

The car is currently making around 310rwhp. Far too low for this setup have tested everything trying to find the problem, have settled with the car loosing compression under boost. Which is why it's getting pulled next month. Aiming for around 450whp.

I'm currently re installing the dash in the car, as I pulled it out to fix up the aircon ducting (stupid foam seals) and re route some wires. Ended up finding a few birdsnests of wires back there that had to be removed.

I found a couple of pics from it after the repsray. Doesn't look quite as nice now as carparks have taken their toll on my doors, and a stupid little girl scratched the back of it riding her scooter too close to my car in the units I used to live in. The car also doesn't have the wing on it or the door handle painted in these pics. I'll take some more pics of it later after I finish putting the dash back in and give it a bath, it's been sitting in the garage for a month or 2 so it's pretty filthy

http://c3.ac-images.myspacecdn.com/images01/90/l_91e3848f35301d3987c9ce47945ca0fa.jpg
http://c4.ac-images.myspacecdn.com/images01/15/l_0addb77564d95610703be22c0ab5f1bf.jpg

[My5ABaby]

Nice. I demand more pictures! :D

[project86]

i wouldnt say its a total piece of crap :)

[lh6601]

Oh god this is quality

[Mazdabater]

Possibly going to start on my new fan shroud tomorrow if I can work out why my windows stopped working. Encountered an electrical gremlin whilst reinstalling the dash. God I hope I don't have to pull it again. Here's a couple of pics of some other carbon bits I have made for her.

http://c4.ac-images.myspacecdn.com/images02/87/l_2077e0ec29074c0ab74aa5ec9d4e488f.jpg

http://c3.ac-images.myspacecdn.com/images02/110/l_31369de28dda48ed845d219ee1f299f2.jpg

http://c2.ac-images.myspacecdn.com/images02/84/l_e910c971bb9548c7a6b18810de97bc3d.jpg

[ZGN]

Nice, glad to have rotaryholics from all over the world!

:cheers2:

[Nismo]

I really like that Mount for the Plate!

[wanganwarrior]

Thats nice. I love seeing different styles from all over the world! Looks great

[Mazdabater]

Yeah, I kind of got over that mount plate bracket. Trying to come up with a new one. Trouble is I have to buy the carbon myself all the resin and consumables I can use at work.

Here are some more pictures. Sorry about the picture quality of some, they are taken with my phone.

This is a dash insert I made up a while ago, had white face guages in there but didn't like them so I replaced with the standard ones

http://i939.photobucket.com/albums/ad231/Mazdabater/026.jpg

These were listed in my mod list but it actually had some busted ass MOMO pedals in. They were all corroded and horrid looking so i picked up these sparco ones whilst I was down at the WTAC. Just finished installing them an hour ago. A point worth noting, if your cutting steel and you protect your carpet with a rag make sure its not an oily one. My car almost went up in flames LOL saw it quick enough.

http://i939.photobucket.com/albums/ad231/Mazdabater/024.jpg

My stereo install. Not quite finished, have to wait for a mate to get some spare time to trim it for me. Had these amps sitting there and couldn't quite work out where to put them. So I made the bracket up that covers the rear strut brace, gave me somewhere accessable to install the fire extinguisher too.

http://i939.photobucket.com/albums/ad231/Mazdabater/005.jpg

This ones how the battery ended up going into the storage bin. If i take the battery out I can get a proper photo of the mounting bracket I made up for it if anyone really wants. I went with the dry cell battery so I didnt have to worry about making it a sealed box with a vent

http://i939.photobucket.com/albums/ad231/Mazdabater/045.jpg?t=1276411788

This is a current engine bay shot. Ive only really posted it for reference I know there is alot of dodgy stuff there which is all getting fixed up when the engine comes out.

http://i939.photobucket.com/albums/ad231/Mazdabater/022.jpg?t=1276411258

[speedjunkie]

Damn that's sexy. Those wheels look like a set Konig used to make, I don't remember the name of them though. I wanted to get some back in the day though.

Great work on the FC, it's gorgeous!

[Mazdabater]

Had a win followed by a loss yesterday. I just removed all the fuses to triple check they weren't blown and my acc wire one must have been loose. It started getting 12vDC but still wouldn't earth out, either way it worked so I got my head unit and suspension controller running again. The loss is I'm now getting an error code for my front suspension, most likeley one of the wires I cut down and resoldered behind the dash so I'm going to have to pull most of the dash again to fix it. DOH!

[prrex4ever]

Great looking FC, really like your CF work. You sir, have skills.

[Mazdabater]

TODAYS HANDYWORK!! Sorry bout crappy iphone pics. So much useless wiring in this engine bay from the stock ECU I cannot wait to get rid of. Removing this thing was easier then I thought. Aside from the fact a silverback gorilla installed my power steering pump and oil cooler lines.

http://i939.photobucket.com/albums/ad231/Mazdabater/101.jpg?t=1277635245

http://i939.photobucket.com/albums/ad231/Mazdabater/100.jpg?t=1277635245

[Mazdabater]

So to update my build so far.

Engine came apart. Got ripped off by the original engine builder (Dyson Rotary) but at least there was stuff wrong. The tuner I was paying Ben left work at the workshop I was going too, but is doing this stuff out of work for cash which helps me out alot as he is about the only guy in town that knows enough about them. Things wrong include


All corner seals springs completely flattened
2 corner seal springs in half
1 side seal 2mm too short, had been wearing on the apex seals
Oil control rings were dead, only half of one was found
Corner seal o ring things were all missing
Crack in the housing - repairable
Extend port was barely a port job at all


So this explains why I was only getting 300whp. The car made 90psi on both rotors before pulled apart, but must have been loosing all/most of its compression under load. Ben (engine builder) is getting me a quote on parts for this as he can get them cheaper then I can then thats going to get ordered/built as soon as my tax cheque clears.

Now I'm going to put my list of stuff I need to do to the car while the engine is out/before I get it back on the road on here as I just wrote it down on a bit of cardboard that will probably get lost. Ignore the prices just putting down what it's gonna cost me for my reference and its all in $au anyway.

Parts to buy


Front slotted rotors (ebay $155 paid)
2 front wheel studs and nuts (repco)
Engine mounts (see ben possible poly ones)
Bosch coils and microtech X4 igniter box ($300 ausrotary)
Oil cooler ($462 PWR)
Air temp sensor (mazda)
ECU loom (microtech)
Microtech DASH unit ($500 microtech)
A/C Condenser (Troy $200ish)
S6 Alternater (Troy $200ish) may wait till after rebuild
Engine pulleys (purely cosmetic needs alt first)
Silicone rad hoses (Ebay)
Oil cooler lines (Pirtek, need cooler first)



Parts to make!


Underbody tray
Windscreen washer bottle <---- DONE!
Rad overflow bottle <----DONE!
Turbo heat shield (titanium free from work)
Rad fan shroud (composite, free from work. Unless I put a carbon layer over the top which I probably will that will be $70 for the metre)
New LIM blank off plates (free work, orignal ones done by mechanic were horrid) <---- Done
Exhaust side heat shielding (Probably be 301 stainless from work, titanium if there is enough for me to take without the boss knowing. Going to box off all the exhaust manifold, dump pipe and wastegate up to try and keep engine bay heat down)
Coil mount brackets (need coils first, will be 7075 t6 from work)



Parts to modify


Engine bay wiring (messy as needs to be tidied up)
Brake lines (got bent out of the way during respray, never got reinstalled correctly)
I/C Piping (need to oxy it and ovalise it between the power steering pump and strut tower)
Muffler tip leaking around tip (give to darrell to weld)
Seat mount bracket busted (give to darrell to weld) <---- DONE!


Parts to paint

Parts are painted in gloss black 2 pac polyurethane paint, as it's free i just surface prep it and give it to the painters at work. I don't like polishing stuff so I just paint it all black, was going to go matt, but gloss is easier to clean just degrease and hose off.


UIM <---- Done!
Power steering pump and A/C compressor mounting bracket <---- Done!
Waterpump <---- Done!
Front cover (Need back from ben after OMP part welded)
Throttle body
Throttle body snout


And that's about it for now. I'll put some pics up of the progress if I get round too it. I got alot to do in the next month or so. I'll just update this list as I get it done.

[Mazdabater]

Todays handywork! Going to clean em up and paint them monday night at work. Also managed to ruin part of my intercooler piping today, ment to flatten out the sides so it cleared the power steering pump and strut tower better, but accidently hit the top part before I realised. So probably going to remake that part next weekend DOH! Also got my seat mount bracket welded up so it's good to go!

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0352.jpg?t=1279262786

[Mazdabater]

Hmmn damn, just went and checked the fitment. Washer bottle is sweet but my outlet fitting on the overflow one is going to interfere with my IC piping, And i think my inlet might be close to the rad lol. Hopefully if I get some 90 deg fittings it will clear -.-

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0354.jpg?t=1279274665

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0355.jpg

[djmtsu]

Wow, looking great!

I like those overflow/fluid tanks. Did you make those?

[Mazdabater]

Yeah I did. Well I made them up and got a mate to weld them. Not really out of choice, my IC piping involved removing the washer bottle, and its a roadworthy thing over here so I had to put it somewhere, same with the rad overflow bottle. Well I could have made it fit back in near the old one but tried for there, see if I can save it when i put everything back in if not it might go back near the stock location

[Mazdabater]

Well the red car is on hold. As I got another FC at a crazy cheap price ($1500) off a mate that didn't really know how much it was worth I guess. The cheapest one I could find on carsales.com.au was $5900.

It's completely standard aside from a full 3" stainless exhaust, pod filter and rims (the ones on it in my pic are off the red fc. Put them on as it has roadworthy tires) I'm chasing a standard airbox at the moment. But I'm torn between selling it and spending the money on repairing the engine in my other fc or saving up to fix the other one because I really like the look of the 2 in the driveway. The standard auto is also alot nice to put around town in.

This ones in good nick as far as I can see, interior is absolutely perfect aside from a broken idiot light surround and stupid race pedals, the genuine savanna floormats are a little worse for wear. Aside from that only problems are a tiny bit of rust in the sunroof and the back window frame. Im making a carbon sunroof for it soon.

Best part is, it has working climate control and cruise control.
Worst part is it's auto and I forgot how incredibly slow a std FC is.

Here are the pics!

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0414.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0413.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0412.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0410.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0408.jpg

[Max777]

Damn, this is a moment in history!

It may not make sense to you, but here in the US, we never got the automatic turbo models, only got the standard ones. This is the first time in my life that I see an auto Turbo II FC, so it's a bit shocking.

On that note, your car also does not have a 3rd brake light, which is another first stock.

[Rotary no Densetsu]

I really dig the build man! I love seeing people do FCs up right. Not enough FC guys left in this world, we are a dying breeeeeeed.

Good luck with everything.

[Mazdabater]

Yeah I couldn't turn it down for $1500 it was a steal. Come payday I'm buying an airbox and standard wheels for the white one. Thinking about getting a muffler for it but probably wont bother, the cannon is too loud but I'm just going to sell it. It's a shame it's a really good car and I absolutely live the climate control and cruise control. Oh well.

[Mazdabater]

Well I never put up some pictures of the wheels that came on the white one, 16" watanabes. I finally pulled my finger out and did a little work on the red one. Put the new brake rotors on and stuck the watanabes on there for a look. I reckon they make it look heaps more like a race car. They do need a clean and sorry about the pic quality. The iphone 4 takes awesome day photos, but the flash leaves alot to be desired. What do u guys think

http://i939.photobucket.com/albums/ad231/Mazdabater/047.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/048.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/052.jpg

[JL1RX7]

Nice looking car dude! The white looks like it could be a killer also!

[diabolical1]

if i may ... i say if you're not going to hurt too much, keep the white one as a nice little daily putt-putt, and then build the shit out of the red one. you seem to be enamored with the climate control and other creature comforts, so why not?

i can't wait to hear about the bridge whenever it gets done.

[Mazdabater]

I was going to keep it as a put put. That was my original idea, but it's really just not practical as a run around, chews too much fuel and not much place to put stuff, along with the fact that it can't tow a trailer. So I figure I'm just going to sell it and fix the red one. Then I'll either get a cheap 4cyl or buy a motorbike for going to work.

[Dazed and Rotarded]

Good lord what have I been missing!! What a clean build..

[wanganwarrior]

Gotta love the old school look of watanabes

[Mazdabater]

So after a long time, I've finally got the money issues together to get her back on the street. Ordered a 13B-REW for it today that has good compression so all the major parts should be in good nick, just going to get some new seals, a port job and some dowell pins and in she goes. Some parts started coming today, such as my replacement oil cooler. Looks nice eh!

http://i939.photobucket.com/albums/ad231/Mazdabater/016.jpg

[Mazdabater]

Well my engines scheduled to be built and ready to go in around 2 weeks time. So I've gotta pull my finger out and get everything ready to go so I started on the fan shroud today.

It's a bit rough, essentially I'm going to make 2 peices, bond it all together and get it looking good, then lay a layer of carbon over the top and it should look mickey mouse.

Got the base made up, and got the tapered section layed up. Have to wait till tomorrow for it to dry but it's also my birthday so i probably wont end up getting more done until tuesday.

Some pics

http://i939.photobucket.com/albums/ad231/Mazdabater/003.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/004-1.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/005-1.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/006-1.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/009.jpg


And since there wasn't a decent pic of it with the watanabes on here, I took one of it sitting in the driveway (I know the cars filthy I haven't washed it since it's been off the road)

http://i939.photobucket.com/albums/ad231/Mazdabater/008.jpg

[Mazdabater]

Gonna bump this thread, finally starting to work on the car again. Should have my new water to air intercooler by the end of the week, Pineapple racing dual EGT gauge rocked up last week and is tapped into the manifold and my engines going down south to my mate that was rebuilding it here this week. Hope to be back on the road in a month or to if I stop spending my money on other things.

[speedjunkie]

Is that Pineapple EGT gauge backlit? I bought one similar to it from Pegasus and it wasn't lit so I couldn't see it at all at night. I don't remember if the Pineapple one comes with a light though.

[Mazdabater]

Yeah it is, comes with the bulb in the packet. Haven't installed it yet though, think I'm going to do an oil pressure gauge at the same time so I can't tell you what it looks like at night. Everything in the kit looked good quality, came packed the same as alot of aircraft parts do. Not going to rate it yet though as I haven't used it. I brought it more for a warning gauge then for tuning.

[speedjunkie]

Oh that's good, I guess I should have gotten that one instead then haha.

Yeah that's the same reason I got mine, just to monitor. Wish I could help you on the oil press gauge. I saw your other thread. The guy that molded his Prosports into the cluster was the first thing I thought of but it sounds like that won't work for you.

[Mazdabater]

Yeah I think they are going to be just too big to replace my stock one

[Mazdabater]

Not much of an update here. Pushed it back in the garage this weekend and had a look at it. Really need to get the engine back in but I think I'm going to have to do some pretty serious modification to get this W2A cooler in. The barrell is fucking massive. I may end up selling it and getting a smaller one, but since I'm a tight ass I think that I'll be modding the car to suit it.

[rx71king]

:leaving:...i would like to see more

[Mazdabater]

Whee a parcel arrived today with my rails and injectors in it =D Got the lot for $625 au. Also got these vents the other day off ebay for $40 thought it was a baragain!

http://i939.photobucket.com/albums/ad231/Mazdabater/020.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/021.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/022-1.jpg

[Mazdabater]

Also, can you see what the intercooler may not fit?

LOL


http://i939.photobucket.com/albums/ad231/Mazdabater/017.jpg

[rx71king]

nice looking rails.....why are you trying to use that type of intercooler..?

[Mazdabater]

Shorter intercooler piping, freeing up radiator air flow, also allowing me to make a better CAI. Also just want to test them out and see how they go. I just listed it on ebay as I intend on buying a smaller one.

[Mazdabater]

Had some more bits rock up today, all completely useless and do nothing performance wise but I figured I'd share none the less

http://i939.photobucket.com/albums/ad231/Mazdabater/085.jpg

[Mazdabater]

Wow sorry about the crappy photo above but you get the idea. I also am trading my s4 this week for an 02 toyota corolla with 60000kms on it that should be alot easier to sell over here. So that should provide me with all the funds needed to finish my build

(provided I can finally get ahold of my engine builder)

And I brought this off ebay to remember her by

http://i939.photobucket.com/albums/ad231/Mazdabater/087.jpg

[Mazdabater]

Happy days! Just won a knightsports 260km/h speedo off ebay!

[tweiss3]

Nice, I absolutely LOVE my rotor key, and its much more sturdy than the OEM key.

[Mazdabater]

Whoo new gear knob arrived today straight from Japan. Swapped my s4 for an 02 corolla on the weekend should be quite easy to sell and that's going to fund the rest of my rebuild. So hopefully I can stop posting pics of small things and get some real progress happening

http://i939.photobucket.com/albums/ad231/Mazdabater/013-1.jpg

[Mazdabater]

Engine leaves me tomorrow car should run in a month!

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0541.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0542.jpg

[Mazdabater]

So with the engine now away and 2 long weekends in a row due to easter over here I figured I had better get started on getting the car ready. Jacked her up today to inspect the damage to the floor pan where the seat had pulled a bolt through when I was ass fucked by an FB on a cruise. Although I'm an aircraft sheety I've never done a repair using a weld before so this is going to be interesting. Will look at trying to fabricate some sort of doubler to weld on tomorrow as I'm out of time for the day but going to be hard with my limited tools in my shed.

[Mazdabater]

http://i939.photobucket.com/albums/ad231/Mazdabater/007-3.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/004-2.jpg

[Mazdabater]

On a side note I finished this project yesterday, my mates evo 3's turbo seized while he was running down the strip. I modified the water pipe to clear the new turbo and fabricated the inlet and intercooler piping (excuse the amount of silicone he insisted on using it over me making proper pipes, although the inlet sort of has to be there given that the AFM is a funny oval shape)

And I thought our engine bays were cramped, fuck this thing.

http://i939.photobucket.com/albums/ad231/Mazdabater/001.jpg

[Mazdabater]

Fuck me the floor pans in these cars are thin! No wonder it tore there. I've managed to repair it but it was a bit above my level of skill with the TIG lol. I might take a pic later. Was using stainless filler wire and every time I put a little heat on the floor it would just melt away. Ah well learnt a bit doing it and it's stronger then it was before =D

[Mazdabater]

Did some work on the exhaust today. Am changing all my IC piping so I had all the old stuff there, figured I would recycle the bends and fix up the rear half of my exhaust thats mild steel. Considering I've only been TIG welding for a short time now (cant mig or stick weld either) (around 2 months) and am self taught I'm pretty stoked with it. Going to do from the cat to the muffler section tomorrow

http://i939.photobucket.com/albums/ad231/Mazdabater/004-3.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/005-3.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/006-2.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/007-4.jpg

[tweiss3]

Those are pretty damn nice looking tig welds for teaching yourself and only having a couple of months under your belt.

[Mazdabater]

Yeah, going to be nice when I get them looking neater. I feel like I'm learning something with every job I'm doing at the moment =D main thing seems to be getting comfortable with something to lean my arm on.. Been reading some books and YouTube on it. Hopefully starting a night course next month

[tweiss3]

I wish i could tig, but i wouldn't even call myself passable at it, even though i had instrucion and about 20 hours in practice.

[Mazdabater]

Did a little bit more today. Not much because the missus was home but she is out again tomorrow so I got some more time to play with it. Realised though I'm probably going to mess it up without the engine being back in so I don't think I'll end up finishing all of it =/

http://i939.photobucket.com/albums/ad231/Mazdabater/001-1.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/002-1.jpg

[RICE RACING]

Yeah, going to be nice when I get them looking neater. I feel like I'm learning something with every job I'm doing at the moment =D main thing seems to be getting comfortable with something to lean my arm on.. Been reading some books and YouTube on it. Hopefully starting a night course next month

You wont learn much in a basic welding course, but I can tell you this, its practice that makes you good.

You will get there mate ;) and what you have done so far is good an shows you have the ability, the neatness will come with time and a few bottles of gas!!!!!

[Mazdabater]

Yeah it's not going to bad when I have decent access, take that away from me and the look alot worse. But I still think I should do a course as I'm not sure how much penetration I should have etc.

[just startn]

WOW that 4g needs some work! Hey let me grab the CAS off of it :p. welds look good for a rookie!

[RICE RACING]

Yeah it's not going to bad when I have decent access, take that away from me and the look alot worse. But I still think I should do a course as I'm not sure how much penetration I should have etc.

Without back purging this is how much penetration you should have (my flange weld for my own exhaust) see pic. It should just start to mushroom the mating pipe and be even, this takes a fair bit of practice and experience without over heating the filler or the pipe or distorting the fuck out of the job......... its not as easy as some cunts claim.

http://img16.imageshack.us/img16/8611/tig6.jpg

http://img16.imageshack.us/img16/7853/tig5.jpg

This is a pipe joint, these are real easy to over heat (like you have) all it is just practice and stainless is real easy to over cook

http://img16.imageshack.us/img16/6061/tig4.jpg

http://img8.imageshack.us/img8/7581/tig1s.jpg

Turbo support fixing

http://img132.imageshack.us/img132/3847/support1w.jpg

http://img197.imageshack.us/img197/7444/support2.jpg

You can make some cool shit once you get a handle on it :)

P.S. I am self taught with TIG, it was just practice, there is lots of good info from Miller on how to do it, they even sent me some literature free when I asked them on-line!

[speedjunkie]

^Haha I always thought that turbo support was an engine torque brace when looking at other pics LOL.

I thought Mazdabater's welds looked pretty good, a lot better than I could have done. Then again I don't know jack about welding...not yet anyway lol.

[Mazdabater]

So it's been a while since I sent an update. My engine is paid for and should be back in about 2 weeks, he needed some bits off my old block which I was un aware of. Seems the REW is going to run the s5 sump and front cover.

Also it now has been bridgeported! In light of this and the fact my turbos chinese, I'm looking at going big on the turbo. Like Borg Warner s400-80 big for those that read my other post.

Was also discussing selling my W2A to get a thinner one as to avoid modifying the support. But I gave the local automotive engineer a call who also happens to race an FC on the weekends. It seems I am going to modifying this too, as he seemed to not be too phased about me doing it. All is waiting on the block getting back in so I can get to work finishing the exhaust, fitting the new IC etc.

[Mazdabater]

ZOMGWTFBBQ I did something on the car, still don't have an engine LOL mate has been taking his sweet ass time, but not a real problem as I don't have the funds at the moment (saving for a house is a killer) and he is doing it cheap. Apparently it's all done he just needs some oil control rings, so I'm assuming he has made the engine mounts too. On the plus side, my port now looks like

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0777.jpg

Anyway, I have decided the car is going to run a BW EFR-9180 turbo, just trying to source one, have spent the money I had aside for it as apparently there have been production delays, trying to get one from the states as they are ridciulously overpriced here.

However today I finally got off my ass with the car as my engine returning appears to be on the horizon, and my bag full of AN fittings arrived from aircraft spruce. So I started on my fuel system, every line aside from the firewall to rails are going to be done in -8 (1/2") 316 stainless line.

I also found the fuel cooler I intend to run, just waiting until next pay to purchase it. It is this one here http://www.ebay.com.au/itm/390341411595?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

Anyway todays progress!

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0814.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0815.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0816.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0817.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0819.jpg

[speedjunkie]

Nice! I've actually been looking at those EFR turbos too, but I wasn't going as big as a 9180. I've heard about production delays too. That sucks.

[Mazdabater]

Yeah I had the money aside for it for ages. Ended up buying a dirtbike with it when I got sick of waiting LOL

[Mazdabater]

So serious question for 500rwhp if I run the fuel rails in series is it going to matter, or should I set them up as parallel? I don't think the injectors could drain the rail fast enough to starve the secondary rail but I'm unsure.

[dream36realms]

run in series unless you think you are near the 80% rule. but even parallel would starve the front. should be fine as long as your pump and Inj are able to handle it

[Mazdabater]

In series means running through the primary rail and then the secondary. Parallel means splitting the line before the rails do both get supplied the same amount. Running 4 x 1000cc injectors is the plan but I do have a 2 1600cc injectors there if needed to replace the secondarys. The pumps a fuel lab prodigy 1000hp pump so I know its up to it. However I'm thinking of running parallel to be on the safe side. I've come this far why compromise it.

[RICE RACING]

1 x Fuel Leb
1 x Keene Bell "boostapump"

That is all you need.

[Mazdabater]

I don't have a boost pump, I've currently got a walbro 255 in there, I'm hoping it will be sufficent to keep the surge full. Gonna test it and hopefully save buying a new pump.

Just did some more on the tank, had a hard time welding in my fittings, I think I should have cleaned off all the anodizing from underneath as well, I have no real idea what gave me so much trouble putting them in, just had a bad welding time for half an hour or so there, went and drank a beer and came back all good. It's not looking as pretty as I'd like but I'm still a beginner welder and it's going under the car.

Last pictures of the captive nuts I'm using for the dzus fastners I was talking about last night, I thought they were cad plated steel but it seems they are some kind of cast material. Had to rivet them on and will seal them up with some sealent tomorrow at work, we happen to be reinstalling the fuel tanks so it worked out well =D

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0825.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0823.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0822.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0824.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0826.jpg

[Mazdabater]

Went camping this weekend, hindered progress a little. Just did some more on it then. I gooped the back of the captive nuts and was worried about it breaking down with the welding, and it did, so I'm going to have to seal it internally at work tomorrow as it's leaking. My welds look pretty average, would normally grind them back and make them look pretty but it's going under the car so I'll probably just leave it. Should be able to do some of the plumbing for it after work tomorrow. Anyways heres how it looks

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0830.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0831.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/IMG_0830.jpg

[Mazdabater]

Had a shitty setback this arvo, stayed back at work because I was going to bend some of the pipe up. 2 problems I have encountered, the minimum diameter I can bend my tube too is around 3" and my flaring tool requires me to have around a 45mm straight section to allow me to fit the feral on and flare it. So now I have to either

Make some of my pipes out of braided line with 90deg fittings
Buy a new flaring tool that requires less straight section to clamp
Find a way of bending the tube around a tighter radius

However I don't think its possible to have much smaller of a radius to bend the tube properly, going to do some research tonight.

[Mazdabater]

Wow, I actually have my engine back ready to go into the car. Series 7 block, s5 front cover center plate drilled and tapped to use standard S5 mounts. Full bridgeport. Took some pics however my mobile just died. Took a long time but I haven't really been able to afford it and told my mate not to worry about it. Shitty thing is I told my missus I would buy her a ring when I get the car running now it's not too far away hahaha. I am also going to run the chinese turbo for a bit as I'm too keen to get it running so going to see how that goes. Only got a few things left to buy now, RR water injection kit, greddy elbow, mounts and loom for the computer. Let the games begin!

Also have scrapped that previous surge tank, the 301 started to rust a little, and it didn't fit as well as it could have where I had planned. Am now looking at making one out of 316 to fit in the spare wheel well, or where the jack mounts.

[RICE RACING]

Nice to hear an update, exciting times ahead :reddevil:

[Mazdabater]

Yeah pretty funny how long it took. Have brought a blown up xr400, done a full rebuild on that rode it for a while and traded it in on a newer bike whilst it's been off the road ROFL.

[Mazdabater]

So despite all the time in hospital lately got a tiny bit done on the mazda today. Few minor issues that I think I'm going to have, the fuel rails aren't ment for the block having the s5 front cover and I think the angle on the greddy elbow may effect the power steering pump bracket. Was looking at getting all the new turbo and stuff but looks like that's going to wait a couple years (probably go a bit silly with the car if I get a payout for my foot) anyway I has a pic!

http://i939.photobucket.com/albums/ad231/Mazdabater/007-5.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/011-1.jpg

[Mazdabater]

Another quick question which I shall take a pic of tomorrow are ID2000's smaller in diameter then the rochester 1000cc I have in there at the moment? I have a hunch that I am going to need a bit more fuel in it and because I have gone to -8 fittings, the 90deg fitting on the primary rail is fouling on the fwd injector in the second rail. Not by much only needs to be 1 or 2mm smaller in diameter. I have got some Bosch 1600's sitting in my drawer but they were turned down to fit standard rails.

[Mazdabater]

PROGRESS! Engine is bolted in. And I think I have solved my fuel rail problem, ripping out the 1000cc rochesters and running ID2000's all round. Also because I'm running the S5 front cover the greddy elbow interferes with my power steering pump, which I'm not yet ready to give up, so I have another hurdle to cover there.

http://i939.photobucket.com/albums/ad231/Mazdabater/534043_3629638541274_1283427228_33407314_206360322 5_n-1.jpg

[Mazdabater]

Not much of a post, tried to do some work on the car yesterday but my foot got too sore for any real progress, pulled out all the aircon and started toying with how to fit the W2A cooler, it's massive. Also worked out it shouldn't be hard for me to modify the power steering bracket so it sits where the ac did, allowing me to use my greddy elbow and actually fit the intercooler piping. Might attempt to do some more tomorrow.

[Mazdabater]

More grinding and shit tomorrow, but my power steering pump bracket is coming along nicely it's not 100% lined up so I think I might have to flog the holes about, but I only lined it up by eye so far. Have to grind out a fair bit of metal to make it sit all nicely, but I think it's going to be a success

http://i939.photobucket.com/albums/ad231/Mazdabater/24c2ea4f.jpg

[Mazdabater]

Wow even better, was just talking to my mate about the injectors and can get me 4 of the bosch 2000cc injectors (the same as the ID ones) for $500 bucks o_O bargain!

[GySgtFrank]

I've been following along and it's looking pretty darn nice. Get anything else done?

[Mazdabater]

Nah the foots really holding me back, next appointments on the 24th hopefully I get the all clear and I'll start hooking in

[GySgtFrank]

Understand, looking forward to more updates when you can get to it.

[FDguy]

Looks real good, I have the same fuel rails and they are top quality.

[speedjunkie]

That's awesome lol, in the wheelchair and still putting in work! Can't keep the man away lol. Looks good man.

[Mazdabater]

Well not a whole lot to update, plan on doing some more tomorrow. The engine was in but not bolted down as I have no idea where the hardware went, brought some new stuff to day, and needed 1 bolt to be 5mm longer to go in the starter motor. Got that all bolted in and re-installed the heat shield under the car. Was planning on finishing off the exhaust but it seems some of the welding I did when I first got the welder has let me down, instead of welding in various spots, I just did 1 bead around the flanges and have warped them. However I did discover on ebay that it is actually cheaper to get stainless v-band clamps then it is for stainless exhaust flanges. So hopefully I'll order them in a couple days when I get some cash.

I've finished modifying that power steering pump bracket and it sits nicely now. My mate that built the engine for me is going to be in town for a wedding in a couple of weeks and wants to get it running then. Which would be good except I have no money as my missus is currently not working and need to finish the fuel system, intercooler is the other big job but I can get it to a run in state without it installed. Hoping my parents can help me out. Either way, I got some work in front of me lol. Going to rip out the old engine loom and fuel lines tomorrow and go from there.

[Mazdabater]

Got a little bit done today. Told a mate I'd fix his bike fairings as he had made an absolute abortion out of them trying to repair them as he thought they were fibreglass, I got them home and they are plastic. So I had to spend hours removing his shithouse attempt at a repair. Luckily for me he didn't know what surface prep ment. So by the time I got to the car I was half drunk, and decided I'd mount my FPR in a new spot, had seen it stuck to the UIM on a few FD's and thought what a great idea, made a nice bracket up and then went to put the alternator on. Back to the drawing board lol. I wanna move it further back but need to see where the throttle cables going to run first. I fuckin love cars -.-

http://i939.photobucket.com/albums/ad231/Mazdabater/abd4b3f8.jpg

[RICE RACING]

Got a little bit done today. Told a mate I'd fix his bike fairings as he had made an absolute abortion out of them trying to repair them as he thought they were fibreglass, I got them home and they are plastic. So I had to spend hours removing his shithouse attempt at a repair. Luckily for me he didn't know what surface prep ment. So by the time I got to the car I was half drunk, and decided I'd mount my FPR in a new spot, had seen it stuck to the UIM on a few FD's and thought what a great idea, made a nice bracket up and then went to put the alternator on. Back to the drawing board lol. I wanna move it further back but need to see where the throttle cables going to run first. I fuckin love cars -.-

http://i939.photobucket.com/albums/ad231/Mazdabater/abd4b3f8.jpg

Here is how I done mine, few iterations with various brackets and to make it serviceable (read take on and off easy!) in sub 1 minute! also proper hose for FRP signal, no fuck ups with blown off hoses etc etc....

The effort is worth it, you will have to cut off the BS for the mounting of the solenoid rack and make a proper bespoke bracket, not easy as I said but worth the effort.

Pics below. Clears all cables, throttle, looks sick!, easy to plumb up too. :conehead:

http://img196.imageshack.us/img196/3161/pressure1.jpg

http://img585.imageshack.us/img585/3795/muff4.jpg

http://img716.imageshack.us/img716/746/muff3.jpg

http://img193.imageshack.us/img193/2163/muff1.jpg

http://img99.imageshack.us/img99/4220/img3880pfrdon.jpg

[Mazdabater]

That does look nice pete, but I think because my engine has the s5 front cover the alternator is closer. I think I can move it to the left a little and it should clear everything, just hard at the moment because I can't get into work to use the folder or any of the equipment for that matter. Still have some 7075-t6 extrusion I stole from work to try again. Have to sort out a throttle cable too as the FC one mounts at the aft edge of the UIM and the FD on the fwd edge.

I found out tonight my mate the built the engines coming to town tomorrow, too early for me to get everything ready for it to run, ah well. Needs more $$ and I'm lacking

[Mazdabater]

On another note, I had to go buy a dremel bit to finish cutting out some of the cast alloy from the power steering pump mount, fuck me it was $25 from bunnings, and the tungsten carbide ones were 40 =O can get em for free from work lol. Same with drill bits, the cobalt ones I use are like 20 bucks each. I forgot how much consumables cost lol.

[Mazdabater]

So I'm back on full hours at work next week finally. Means I can go in on fridays and start making some shit up for the FC :001_302: so I went back in and started doing a bit.

My V-Band clamps for my exhaust turned up, I got them off ebay for cheaper then it was to buy the flanges locally. Turned out I could have gotten them cheaper too as the guy that sold them too me was an ausrotary member, and noticed my username but I had already paid. Ah well.

So I cut the flanges off my de-cat pipe and put the new v-band ones on, put one on the end of the dump and stuck it in the car. It sat in there alright. I think it was like this with the previous setup, the rear of the de-cat was lower then the front, and I wanted it to angle to the left of the car more. Also a long story short when my manifold got changed, way back when I first brought the abortion of a turbo kit they had to route the plumb back of the wastegate differently, which annoyed me as it was no longer a straight flow but an S shape. So fuck it :94:, I cut the dump pipe up, I'll correct the angle the cat comes out on and plumb it back in straight at the same time.

I was going to continue however my dropsaw disc bit into part of the dump when I was cutting it and took a chunk out of it, will get a new disc from work tomorrow.

How it did sit

http://i939.photobucket.com/albums/ad231/Mazdabater/d1610054.jpg

Going to fix the dump/wastegate

http://i939.photobucket.com/albums/ad231/Mazdabater/0b857d89.jpg

[Mazdabater]

Well I managed to get a little in today :hurray: got the cat sitting where I want first go, so that's all sweet but fuck the angle on the plumb back for the wastegate was deceptive :ack2: took me ages to get it right. It's not perfect but the gap around it's small enough for me to fill. Almost out of gas on the welder and need to get a couple more drill bits from work so I can chain drill out the hole in the dump for the wastegate plum back. Here's how it's sitting now.

http://i939.photobucket.com/albums/ad231/Mazdabater/07e87386.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/757ffee5.jpg

[RICE RACING]

Looking good you cripple bike accident **** :302:

[Mazdabater]

Eh, I really want a new manifold and turbo. Fucking hate looking at that chinese shit lol. Well the manifolds not chinese but it's based off a chinese one. The V-Band clamp on the back of the turbo leaks, and I can't change it because of how it's welded onto the exhaust housing. But I'm at the point where I wanna just get the basic shit done and get the car running, then play with the other shit later. Been 2.5 years now since I got to drive her. Time to pull the finger out.

Odd question cunts, can you see any issues with my cramming some roof insualtion in behind the heat shield for the exhuast under the car, just wanna make it a bit cooler on my feet. It's gonna corrode the heat shield isn't it.

[Pete_89T2]

Odd question cunts, can you see any issues with my cramming some roof insualtion in behind the heat shield for the exhuast under the car, just wanna make it a bit cooler on my feet. It's gonna corrode the heat shield isn't it.

If you mean that pink or yellow insulation that's used in residential construction, that stuff doesn't like getting wet. When it does, it will take a pretty long time to dry out which is just asking for corrosion. Also not sure what temp that stuff goes up in flames - near an exhaust might be too hot.

[Mazdabater]

Eh, had some money for a short period there was about to get all the parts and then the washing machine crapped out. Dropped $1000 on one and a new dishwasher on the weekend. But I did manage to get this box full of strange parts

http://i939.photobucket.com/albums/ad231/Mazdabater/F383E7C0-131B-4FD6-8E98-DE5DA0D5C74F-5120-000004070C6ADDF8.jpg

[Raksj04]

I think the cloth heat shleid stuff they sale at part stores would be good for keeping the heat off of your feet. they even make tape like that.

[Mazdabater]

Not much progress with the car. Spent some money and made a decent work bench, still need to get one more sheet of ply to put the last 2 shelves in. SOOO MUCH BETTER having a decent bench to work on. My FPR rocked up as well. Am planning on having the exhaust and manifold finished by next month, possibly even the fuel system and should be able to buy the new turbo around then. Fingers crossed

http://i939.photobucket.com/albums/ad231/Mazdabater/013_zpsc46b38ce.jpg

http://i939.photobucket.com/albums/ad231/Mazdabater/012_zps28af32c8.jpg

[RETed]

I think the cloth heat shleid stuff they sale at part stores would be good for keeping the heat off of your feet. they even make tape like that.

Just read this part of the thread...

One thing a lot of people don't realize is that...AIR is a great insulator.
No need to worry about that fiberglass sh*t.
Don't know if asbestos is banned in your part of the world, but that's nasty stuff.
Don't need to worry about getting the insulation soaked in water...

Use the thinnest stainless steel sheet that'll hold up without burning a hole through it.
Make two shields so they sandwich - air becomes your insulator in between.
Try to keep contact between the two shields to a minimum.
Bigger the gap between the two, the better the heat shielding, of course.
If you want to get more complex, run a small air duct in between the two for more cooling.
Very little maintenance to worry about...
Little bit more involved to fabricate, install, and remove, but I think it's worth it... :D


-Ted

[Mazdabater]

Throwing an update on my 2 year old thread, damn things have changed. The car had been on the backburner for a fair while. I've got some of the main parts for it now so things can start happening. Changed my mind on a few things too. I heard alot of shit about the fuel lab pumps you can see above so that suckers going on ebay, along with my microtech, HKS twin fire, eboost 2, rotaflo muffler, old turbo setup, water to air intercooler LOL.

So for those that haven't seen I picked up a few things at WTAC this year! (one of those being the eboost 2 and I've already changed my mind on that)

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10171739_10204708951105341_451898036540349395_n.jp g?oh=ba4a9e5da4127b1231538af2cf6451c8&oe=5521DD10&__gda__=1428749097_073136e59f9cb1952934fd8f7a07f80 2

That was the start of my honeymoon so yeah it's been a few months but yesterday the car has gone back on stands in my shed at the new place and today I've gone out and got the 304 pipe to start on my exhaust manifold. (Still need to finish cleaning the shed, I got the new shelving up I just need to get my moto back together and sold)

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10375138_10205474990175839_5019684867069640327_n.j pg?oh=0d3f720f648af06b31b45d4aa2067f62&oe=552994BE&__gda__=1428513448_4caf6fe98cc6e97ccdc5b9b3388dc3d b

Also a dream of mine came true this week, I found a set of MS01's on ebay for $1000 AU, they should be on the way to my place next week, also coming with goodyear eagle f1 which are some of my preferred tyres.

https://scontent-a-lax.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/10443605_10205463540569606_4592638059229439178_n.j pg?oh=ba8890f6dfe9c2ba0fc82799dbf87f04&oe=5528C3FF

[Mazdabater]

For any of the wiser guys reading this, I have 2 questions

How important is it to get my runners the same length before the t4 flange, or is close enough good enough in a turbo application

How suicidal would it be for me to try and run the wastegate straight off the comp housing? Or should I play it safe and run it just below the flange?

[Mazdabater]

Made some progress today. First time at a manifold, the 42r doesn't leave many options due to the sheer size of it. Will have to run an airline from my landlords shed tomorrow so I can bust out my die grinder and finger linisher. Took a bit to much meat off where the 2 pipes join before the t4 flange and ones 10mm bigger then the other. I was only using a 5" grinder however. Was unsure how I was going to go about it so I just had a crack

http://i939.photobucket.com/albums/ad231/Mazdabater/image.jpg2.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/image.jpg4.jpg
http://i939.photobucket.com/albums/ad231/Mazdabater/image.jpg5.jpg

[Mazdabater]

I think I'll still use the curved bit that I welded the divider wall onto, if I remake the down piece more carefully (so it buts up on the divider and doesn't over lap it should come out pretty sweet