My T2 build

[SpooledupRacing]

OK guys I have been working on this build since last September....

I have done a full write up and thread on www.rx7club.com (sorry if I was not alloud to link this

http://www.rx7club.com/showthread.php?t=689880

HOWEVER for those of you who are not members or cant access that forum I have pulled all the critical tuff out with pictures and I will post it below...

Notice most of my questions have been answered however and questions, comments or answers u may have please post.. I want this to be as big of a thread here as it was in that shit hole...

THX for looking..


THE THREAD STARTED!!!!!



DATED 9-19-07


http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/turbotrans.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/turbosmallerfuelrail.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/turboenginefront.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/turboengine2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/turboengine.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/turbo.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2engine.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/s4T2uim.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/exhaustonturbo.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/blowoffvalve.jpg


So today I picked up my turbo engine... I got it for a great price however I will be taring it apart because well it is a piece of work..

This is what I do know of it..

SUPOSIDLY it is supse to be a BRAND NEW engine with no miles the guy I got it form (an aquaitnece of mine) said that it was all nice and clean before he put it in his car then it got nasty dirty between working on it and pulling it back out..

Anywho this is what I do know..

the engien was turned over and fired it idled for a minute but shot flames out the exhaust the entire time then it died... He found out he has a bad wire harness..

as far as the engine here is exactly all I know (have been told)

S5 T2 keg with s5 T2 internals
s4 T2 front cover (s4 T2 omp, S4 T2 alternator)
S4 T2 intake manifold (lim and uim)
S4 Turbo and S4 turbo manfiold
S4 T2 trans (no reverse)

I plan to completly pull the engine apart, label everything, and check for age, wear, etc. Replace the gaskets, o-rings anything else that may need replaced.

Street Port the engine

get a S5 twin Scroll turbo and header

powder coat the intake, and paint the housings etc.

Replace EVERYTHING wearable (water pump, double atl pulley, belts, slave cylinder, thermostat, gasket, check all sensors for ohm resistance etc)

Anywho the cost of everything u see is 500.00 So what do u think?

This is going in my S4 n/a coupe (I will keep the S4 intake setup so I can use the
S4 wire harness)

[SpooledupRacing]

DATED 9-22-07

Well last night I went outside and started removing everything and bagging up parts etc... here is what I acomplished in abotu an hour, hour and a half..

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/T2kegnomorestuffonit.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/boxofpartsinbags.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/T2limexhmanturbo.jpg



And here is a pic of the engine openings (best I could get)
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/T2openings.jpg


Well today was the day for the big tare down and boy was it a fun one lol... I learned quite a bit and got to see alot first hand and it was a blast..

On the other hand I got to see what a NOT NEW engine looks like... both rotor housings appear to be a GREAT shape.. not flawless but in very good shape. The irons also appear to be in GREAT shape.. The rotors are a different thing though.. they are COMPLETLY covered in ash and carbon.. I am going to have to give them a good soak and cleaning to see if they are ok.. otherwise the sides and the apex seal lips seem to be ok (more specing will be needed to verify)

The irons have not been ported (never told they were just stating facts), so those will get a good street port.

anywho onto the pics.


The tool:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Doaneinthegarage.jpg

WAIT thats not the tool thats RX7Tuner aka Brian, (the Muscle/Brains of the opperation)

The tool (flywheel nut removal tool):
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Theflywheelbolttool.jpg

I was suprised that is a HUGE tool and that nut is HARD AS HELL to get off especially with the engien not on a stand.

Another tool (flywheel tooth holder):
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/flywheeltoothholdertool.jpg

sorry thats a bad pic of it I should have taken it out of the bag but we need to move on!

The rotors:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rotorface5.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rotorface2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rotorface.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2enginerotorface.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2enginerotor.jpg

The last one shows you where it was nicked a bit form a screw that was droped into the engine (prior to be buying the engine, however it looks like the only damage was on the rotor and not the housing)

The housings:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rotorhousing4.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rotorhousing3.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rotorhousing2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rotorhousing.jpg


I know the picture quality is not that great however I can take more pics tomorrow we were busy and I wanted to snap some quickies and move on!

The irons:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2RearIron.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2frontiron.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2intermediateiron2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2intermediateiron.jpg

Using your fingers on both the irons and the houisngs you dont feel ANY imperfections or scratches/gouges.

The e-shaft:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2e-shaft.jpg

Again not a great pic but it also is in GREAT shape

Today I am going to un bolt the tranny and hopefully get the engine on higher ground.

Later today Brain AKA RX7Tuner is gonna come over and help me disasemble the entire engine and this way twe can start looking at what this is REALLY like...

I will update this thread later with more pics. BTW I did turn the engien over last night (ratchet on the pulley bolt) and it turned over VERY EASY and had compression (I could hear it POPPING out of the intake port)



Keeping the rotor seals correct Brian said "lets draw our diagrahms":
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Rotorsealdiagram2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Rotorsealdiagram.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rotorsealdiagrahm4.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rotorsealdiagrahm3.jpg

The clutch that came out of it (for sale slightly used looks fine should be a S4 T2 clutch kit 50.00 shipped USA)
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frontofpressureplate.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/clutchdisc.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/clutchdisc2.jpg

The aftermath:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/moremessygarage.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Themessygarage.jpg


All in all we had a fun day. We started by going to pickup a S5 engine for Brian, then we grabbed lunch (THX Brian for that), then we came back to my place and got so nasty and dirty but it was a BLAST...

Look forward to more pics, info etc very soon!!

[SpooledupRacing]

DATED 9-23-07

Well I cleaned up the rotors and they look ok.. the one rotor has a few marks in it and for osme reason it looks like it has a defect that is on EACH SIDE IN THE SAME PLACE (but nothing on the housing) I cant figure that out.. anyways on to the pics how do u guys think they look? Useable? are they going to be prime rotors to use or do I need to get different ones? I think one looks just fine (the front one) but the rear one I have no idea on.. RX7Tuner said it is fine I just want another opinion to make sure before I spend any money on other things. The rear rotor is the one that concerns me only because I dont know if this is ok or not?


ANYWHO

Front rotor:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2frontrotorface1.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2frontrotorface2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2frontrotorface3.jpg


Rear Rotor:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/s5T2rearrotorface1.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rearrotorface1mark.jpg

^^^^^^^^^this is the mark I am talking about it is on the same rotor all 3 faces in the same spot!!

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/s5T2rearrotorface2.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rearrotorface3.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rearrotorface3mark1.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2rearrotorface3mark2.jpg

^^^^Those last two show the spots I was talking about on the 3rd face of the rear rotor..


What do u guys think?


BTW as for cleaning (which I am not done yet) I sprayed the rotors down with brake cleaner used a flat blade screwdriver to scrape off the THICK carbon buildup and then used a PLASTIC wire wheel (drivin by a drill) to clean off everything... I have roughly 1 hour per rotor time into them as of yet but I dont want to put anymore time into them if they need to be replaced

DATED 9-30-07

Ok so it has been 4 days and what have I acomplished.. well not much...

I have bought a digital micrometer, and magnetic dial indicator. a new set of screw drivers, 2 pick sets and today I started to do some more cleaning..

I started by cleaning all the grooves on the rotors (around the rings and in the apex grooves) I used a side seal, brake cleaner, 2-3 different size crew drivers, a wire brush and a pic and all the grooves appear to be almost so clean u would eat off of them. I then used a flat file and smothed down the apex seal corners (where there was a bit of roll back, and I hit that one small spot on the rotor face that was raised a touch.

I will get pictures of the rotors for you later . Afterwards I decided to clean the mating surfaces of the rotor housings... I started with the rear housing.. after some time with the wire wheel (being cautious not to hit the chrome section with the wheel) I managed to clean it up very well and then snap some pictures.

unfortunatly I did find this as I was snapping pics

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/markinrearhousing.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/markinrearhousingsmall.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/markinrearhousing2small.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/markinrearhousing2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/markinhousing4small.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/markinhousing4.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/mainginrearhousing.jpg

[SpooledupRacing]

here is what the rest of the housing looks like

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanrhousingwithmark.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanrhousingwithmarksmall.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearrotorhousing.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearrotorhousing2.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearrotorhousing3.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearrotorhousing4.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rotorhousingrear.jpg



Hopefully this is still a useable housing and will not give me a drop or a big drop in compression... I want to do this build correct but I dont want to have to buy more housings if I dont have to.

I went out and cleaned up the front housing and I see the same thing.

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/markonfrontrousing.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fronthousingmark2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fronthousingmark.jpg


the good of the frt housing

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fronthousingwall.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fronthousingclean.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fronthousingbyplugs.jpg

Now on to the clean rotors (I think a good soak will bring osme of the color back and then one more hit with the wire brush after they soak for a a while)

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanrotorrings3.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanrotorrings2.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanrotorrings.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanrotorrings1.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanrotor.jpg

Anywho so what do I do.. replace the housing or are they good housings?

DATED 02-02-08

OK some time has passed, I have had a while to deliberate and figure out what is next...

I have decided to use the housings... After inspecting them in person a bit better I think they will be just fine for what I am planning..

I have since bought the following

NEW Mazda 2 piece apex seals (2mm)
New Mazda apex seal springs (inner and outter)
New Mazda side seal springs
New Mazda 93+ Corner seal springs
New japan exterior gasket set (same set as sold by atkins half the price)


This weekend I will start wire wheeling all the plates and housings and getting them prepped for paint... After painted I will begin on doing the Street port.
Once the street port is completed hopefully I will have ALL my internal stuff so I can start on assembly...

I will update this weekend with progress pics of the cleaning and parts..

Sorry it has been so long but this project is now back on track.

OK after about an hour or so of cleaning the rotor housings with a wire wheel n a drill this is the final product

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanS5T2enginehousings2.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanS5T2enginehousings.jpg

Now tomorrow I plan to go buy my paint and get that done.

Also here is a few pics of my current parts I have for the build.

2 piece Apex seals
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2apexseals2piece.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2apexseals.jpg

Apex seal springs
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2apexsealspringsptnumber.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5T2apexsealsprings.jpg

S4 N/A engine gasket set (most gaskets can be used the rest sold and I will buy the few gaskets I will need extra.)
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S4naenginegasketsetnumber.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S4naenginegasketset.jpg



more pics and updates to come!
btw I am trying to pick a color.. humm just not sure yet what to paint the engine



DATED 02-09-08

Well after about a 2 hour bath in ATF the carbon came right off the corner seals and I was able to see that they will be just fine u to reuse... I just need to buy some plugs cause mine were toast... (yes I will be installing new plugs)

More updates tonight after I clean the irons..


DATED 02-10-08

Todays updates....

Today I painted the engine rotor housings.. the pics are not great but you get the pics..

the best red I could find today in high temp paint was Chrysler Import Red (wish it was darker)

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rotorhousingspainted.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rotorhousingsinpaint.jpg

And I pulled my oil control rings out of the ATF today.. I wiped them off, cleaned the carbon off of them and put them in a bucket of oil to soak... after they were in the oil for 20 minuted I pulled them out and put them in a ziplock bag (still coated in oil) and have them stored until I get to that parts f the build

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/oilcontrolringscleanedandinoil.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/cleanoilcoveredoilcontrolrings.jpg



DATED 02-11-08

ok let me catch up..

I have not painted the irons yet, I still have to clean up the intermediate and rear iron before I paint them and yes Gunmetal (iron cast color to be exact) is the color I will be using...

I only want to use the plugs because I think on my first rebuild I would feel more comfortable with using them.. I don't doubt u one bit Kevin.

As for the SS model.. BWAHAHAHA thats hilarious lol... Why would u want to compare your 7 to a gm product tagging it "SS" I think its more a "SS7" I don't know hahaha.. your car is not close to STOCK lol...

ok I will be pulling the tape off tonight and possibly painting the irons (I highly doubt it) I will get more pics later..

THX guys!


DATED 02-14-08

well I just dropped another 225.00 on parts last night.. I purchased the following

Atkins Viton oil control o-rings
Atkins thermal pellet
Mazda OEM side seals
Mazda OEM corner seal plugs
Mazda OEM mim gasket
Mazda OEM o-rings for the lim
Mazda OEM oil control seal SPRINGS (all brand new ones)

All the mazda stuff is due in tomorrow.. The Atkins stuff will prolly be next week sometime...

I think I have almost everything I need to make the build go through.. so more cleaning through out the week. paint the irons, buy the street port templets and tools and get to work porting the engine.

I hope to be ready to assembly by March 30th (my date to have the engine ready for build)

I will shoot pictures of the parts once they roll in the door..


Well I just ordered my Front and Rear e-shaft seal to so those will be here tomorrow also.. another 10.00 in parts lol.


DATED 02-15-08

ok well my parts have shown up (some of the masses I just bought)

In the picture attached u will see

ALL side seals
ALL oil control seal springs
Front and rear e-shaft seal
Turbo outlet gasket
S4 T2 mim gasket
Corner seal plugs
LIM coolant o-rings

[SpooledupRacing]

I am still waiting for my Viton oil control o-rings and thermal pellet to show up.

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/newT2parts021508.jpg


DATED 02-17-08

ok here is some pics of the keg sandwiched together..

yes I forgot to paint the top of the rear iron but it is painted now... and the "13B Mazda" has been sanded down so it is metal color...

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/turbokegpainted.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/turbokegpainted2.jpg




DATED 2-17-08

Well I just bought some

84-85 13B NT low impedance square top center port 680cc orange 195500-0900 injectors.

I heard they flow like 720cc injector on FC's so these will be my secondary injectors..

I am sending out my other injectors (550cc's) to get them cleaned and flowed so I can use two of them for primarys



DATED 02-18-08

See thats cool to hear. I like hearing success stories cause then that gives me confidence...

today I bought:
a tube of hylomar (in my posession)

from Pineapple Racing I purchased:
Medium street port template
exhaust port template
S4 T2 omp block off plate
S4 T2 air control valve block off plate
crank sensor cover plate (with ninja )
omp injector block off plugs


so I should see those before the weekend...

I cant wait I get to start porting here very soon.. I am so siked!!!


DATED 02-19-08

Well while I await my pats to show up I have cleaned up the work bench down stairs and I am going to pull all of the parts on it ...

Yes Brian this is where the porting will take place lol..

I will update with any more info or pics as things change


DATED 02-20-08

My purchase from Atkins showed up today

Viton oil control o-rings and the thermal pellet.
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/vitono-ringsandthermalpellet.jpg


more to come after my Pineapple Racing purchase shows up

DATED 02-22-08
ok so today I have received

From Xboxthug360:
S4 T2 ECU
S4 T2 afm
S4 T2 water pump housing

From Pineapple Racing:
street port template
exhaust port template
crank sensor cover (ninja)
ACV block off plate
S4 omp block off plate
OMP injector plugs (however I just realized I only bought 1 pair...)

I will take pics tonight when I get home...

I also just bought from Japan2LA:
both S4 T2 fuel rails
SS clutch hose

just bought my walbro 255lph fuel pump.

OK guys here is some pics of the parts that came in and the painting I have done...

Painted CAS
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/PaintedCAS2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/PaintedCAS.jpg

CAS with Pineapple "ninja" cover
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Pineapplecascover.jpg

S5 thermostat housing (not sure yet if I will use it)
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S5waterneck.jpg

S4 T2 water pump housing
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S4T2pumphousback.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S4T2pumphousfrt.jpg

S4 T2 ECU
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S4T2ECU.jpg

S4 T2 AFM
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S4T2afm.jpg

Pineapple Racing SP template
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S4T2SPtemplate.jpg

Pineapple Racing exhaust porting template
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Pineappleexhaustporttemp.jpg

Pineapple Racing block off plates
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Pineappleblockoffplates.jpg

Painted water pump pulley
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/paintedwaterpumppulley.jpg

Painted crank pulley
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Paintedcrankpulley.jpg

Painted front cover
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Paintedfrtcover.jpg


OK thats my updates for today.. I plan to do more work and painting this weekend...

As I receive more or get more done I will post pics and updates...

As of right now including the engine and all the parts I have bought I roughly calculate about 1800.00


DATED 02-24-08

OK today was the day I began to port the irons...

I was quite scared but RX7Tuner was there to push me and make me do it lol...

I used the Pineapple racing template above and gave it the newbie porting Spooled up Racing push lol...

The grinding is done, I need to lots of sanding right now so I will have these done by wednesday I hope....

here is the current pics of the irons... (don't be to mean) lol

Front iron intake port
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frtironintakeportjob.jpg

front iron port
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frtironportjob.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frtironportjob2.jpg

Intermediate iron front port
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/IMIfrtportjob.jpg

Intermediate iron intake ports
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/IMIintakeports1.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/IMIintakeports.jpg

intermediate iron rear port
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/IMIrearportjob.jpg

Rear iron port job
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearironportjob2.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearironportjob.jpg

rear iron intake ports
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearironintakeport.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearironintakeportjob.jpg


The mess on the table from afterwards
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/themessafterporting.jpg


So what do u think?


I did the front and rear irons and RX7tuner did the intermediate iron... (I did not think he was good enough to handle the bigger ports)

Brian thank you very much for all your help today.. I am going to port the housings tomorrow and get to sanding so Hopefully Friday we can start assembly...

THX again... keep the comments coming..


Well I could not go to bed without getting the exhaust ports cut..

here are the pics, not sure which port is which housing but these are the pics I took.. again I still need to sand but I atleast got it cut tonight..

[SpooledupRacing]

looking in from the outside
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/exhaustportlookingfromtheoutsidein.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/exhaustportlookinginside.jpg

from the inside out
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/exhaustportlookingout2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/exhaustportlookingoutfromtheinside2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/exhaustportlookingout.jpg

Talk more please!!! lol



DATED 02-25-07

Here is a couple pics my buddy took with his phone of work in progress

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Photo_022408_001.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Photo_022408_002.jpg

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Photo_022408_003.jpg

Well I got to the sanding tonight... I am done with the rough paper now and for the next two days I will be using 220g (maybe just the 150g) to get the perfect shine on them.. but here is some pictures from tonight

Exhaust ports
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/exhaustportsandedfirstsession.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/exhaustportsandedfirstsession2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frtexhaustportsandedfirstsession.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frtexhaustportsandedsession1.jpg

Front side on the intermediate iron
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frtimiportsandedfirstsession.jpg

Rear side of the Intermediate iron
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearimisandedfirstsession.jpg

Intake ports on the intermediate iron
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/imiintakeportssandedfirstsession.jpg

Rear iron port
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearportsandedfirstsesion2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearportsandedfirstsesion.jpg

What do u think?



DATED 02-26-08

Well I FINISHED sanding the ports tonight.. Tomorrow I will start bak to the rotors and get them 100% ready for the build then on to the next item in row....

I plan to have my table COMPLETELY organized by friday night... Saturday is the build...


Dave

[djmtsu]

Looks good. Did you slip a few times porting?

[SpooledupRacing]

I did the front and rear iron and my buddy (the tool lol) did the intermediate housing...

we did both slip while porting but NONE of them I feel will cause any problems most of them you cant even catch with a nail or read with my dial indicator.

[djmtsu]

That is what I thought, they didn't look too bad to cause problems.

The build really does look like it is coming along quite well. You need to post pics of the car !!!!

[SpooledupRacing]

The car

http://img.photobucket.com/albums/v88/turboTSI/RX-7/coupeatthecruise.jpg

http://img.photobucket.com/albums/v88/turboTSI/RX-7/7spoilerrear.jpg

[SpooledupRacing]

OK so today I got home to see I got 2 package

1 from japan2La:
2 S4 T2 fuel rails
1 SS clutch hose

1 box from Pineapple Racing:
1 60c syringe
1 engine stand adapter

here are the pics of the parts
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/standadapterandclutchline.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/S4T2fuelrails.jpg


Here is a pic of the NEW engine stand (yes the one I borrowed would not work, so I had to buy one) and my front plate bolted on.

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/enginestandwithfrontplateon.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frontplateonstand.jpg

Saturday is the big day I cant wait

[SoGlow7]

Good build so far, can't wait till end result. Im still deciding if i wanna do a t2 swap on my 86 also, or to just do basic rebuild on my NA for reliability. But good progress

[Jarred]

That looks sweet so far! I'm getting idea's for my future TII swap into my '86 gxl.

[SpooledupRacing]

Tonight's update

I received my 720cc injectors (secondaries)
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/new720ccinjectors.jpg

then I went down stairs to the basement (aka dungeon) and I cleaned all my engine internals and got them sorted on the table for Saturday... Yes u will notice I bought all new hardware too..

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/controlrings.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/engineparts.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/newhardware.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/partsontableorganized1.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rotorsetc.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/partsontableorganized.jpg


Well thats it for tonight I will update later after I get more done... I actually think I am done until i start to build it Saturday

Good night all I'm off to bed!

[SpooledupRacing]

This afternoon we start the build... wish us luck

[djmtsu]

Good luck man!! I wish I was working on the 7, unfortunately I have to help a friend put a new cylinder head on a 92 Escort, and WP and timing belt. Piston engines FTL.

[SpooledupRacing]

Ok so me and RX7tuner built the engine today... it was alot of fun, we had alot of laughs a few head scratchers and well something that just made us go WOW

but here it is as of tonight...

The control rings with the o-rings installed
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/oilcontrolringsassembled.jpg

Installed in the rotors
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/controlringsonrotor.jpg

The rotors are all lubed up with Crisco
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rotorsaecriscoed.jpg

This iron has the o-rings installed and layered with crisco
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/ironringsinwithcrisco.jpg

umm yeah there I am .... with the shaft!!!
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fittingtheshaft.jpg

1 plate at a time
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/erect.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/halfwaythere.jpg

Getting closer
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/engienalmostdone.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/almostdone.jpg


Together
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/soclose.jpg

assembled
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/enginetogethr.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/egineassembled.jpg



I forgot to mention with my fingers in the plug holes and the engine turned over it had GREAT compression!!!

[87 t-66]

thats pretty good..ive never seen anyone use crisco before haha

[SpooledupRacing]

On the videos at www.pineappleracing.com he said to use Crisco.. so I guess some one does lol

here is some new stuff

Here are the pics I just took...
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Mazda13BTenginebuild.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frtofengineassembled.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/nowthisispower.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearof13BT.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/13BTexhaustside.jpg


look at the layers
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/engienlayers.jpg


waste leaves here
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/13BTexhaustrunners.jpg

The real deal!
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/13BMazda.jpg

[Rx7Tuner]

She is pretty.

[SpooledupRacing]

Thank you sir!!

[SpooledupRacing]

Well last night I got my lim cleaned and painted... my crank pulley cleaned and painted.. my water pump housing is cleaned (painting tonight) and I plan to clean the uim tonight...

I will get pics tonight of everything done and the process as it unravels..

[need RX7]

updates?:)

[SpooledupRacing]

The lim is bolted on
the exhaust manifold is completly stripped down and ready for high temp paint
the upper fuel rail has been painted (red)
the turbo was broken apart to clean and paint and I found the exhaust side was cracked inside.. (awaiting a new one)

still waiting for a clutch kit and flywheel

tonight I will paint the compressor housing (gunmetal)
tonight I will paint the lower fuel rail (red)
tonight I plan to paint the exhaust manifold (black)
tonight I plan to clean the uim and get it prepped for paint

next weekend I will send the injectors out to get cleaned and flow tested.

[SpooledupRacing]

Time for updates...

since last time I have:
cleaned and painted the water pump housing
cleaned and painted both fuel rails
cleaned and painted the thermostat neck

pulled the turbo apart (found the exhaust housing is junk) clean and painted the compressor housing

mounted the upper intake
mounted the upper fuel rail (need to put injectors in of course)
put the water pump housing on (awaiting water pump)

here are some pictures

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/engine2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/engine3-13-08.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/enginealmostcompleted3-13-08.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/waterneckcomphousingfuelrail2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/upperfuelrailinstaled.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/waterneckcomphousingfuelrail.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/waterpumphousing2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/waterpumphousing.jpg

From a nice neat table to this mess
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/worktable3-13-08.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/uimtooltable.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/tooltable3-13-08.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/uimtooltable.jpg

[Willub and Company]

looks very nice, make sure you take a video of the start up!

[SpooledupRacing]

OH will do.

[SpooledupRacing]

nothing really new to update.. I did however buy my ACT lightweight flywheel yesterday...

[SpooledupRacing]

Well ACT's website is wrong.. the flywheel I bought will NOT work on my car so now I am out the time and money in order to get the flywheel and resell it then buy a new one to get the engine installed!!!

this is why I HATE ACT!!!!

[turbovert91]

That sucks, you were making good time on the rest of your project, too...

[SpooledupRacing]

tell me about it.. now I have about a 3 week hault!

[Iox106]

If you are going to resell the flywheel shoot me a price.

[SpooledupRacing]

I got some gaskets ordered, a boost sensor, I am going to put my turbo back together this weekend...

I need to get my flywheel and clutch kit... then get my exhaust manifold gasket and then I can drop it in.

[SpooledupRacing]

Well Yesterday I purchased my flywheel... Fidanza n/a flywheel @ 8lbs...

I think today I may buy my clutch kit... I will have to see!!!

[SpooledupRacing]

My gaskets will be here Tomorrow, my flywheel will be here today. and my clutch wont be here till prolly monday if I am lucky...

so close to getting it done this weekend...

[need RX7]

Can't wait to see it all come together.:auto: This is getting me so pumped to do my swap. Be sure to document the installation in great detail so I know what the hell I'm doing LOL.

[SpooledupRacing]

Its here...

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fidanzabox.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fidflywheels.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fidanzaback.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/fidanzafront.jpg

just under 8 lbs...

Today I will be going out to buy some new grade 8 bolts to bolt the flywheel to the counterweight.. Tonight I plan to get this baby torqued down and ready for the clutch...

I cant wait its getting closer!!!

[Ender]

I'll have to come back another time to read everything but DAMN, I'm impressed. I get the impression this is your first or one of your first builds, but (actually, much like me and I'm currently in my first build) you're being very cautious and precise.

[SpooledupRacing]

OK today was the day... Unfortunately I could not find any grade 8 metric bolts to bolt the flywheel to the counter weight and my clutch has not arrived yet so I got everything else ready..

First I started but going outside jacking the car up and getting everything disconnected (trans, oil cooler lines, engine mounts etc). RX7Tuner showed up and gave me a hand and after a little coaxing I got him to give me a hand and yank the engine out by hand (My buddy Aaron was gonna be over in about 45 minuted with a cherry picker but I knew we could do it)

Here is what happen before I pulled the engine

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/enginereadytopull.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/pullme.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/pullingtime.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/thesplit.jpg

Engine is out:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/oldengine2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/theoldengine.jpg

the engine bay
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/enginebay.jpg

RX7tuner had to take off and about 10 minutes later Aaron shows up.. so
then I decided to pull the clutch off and take a peak since I knew it was toast

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/ReleasebearingOLD.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/oldreleasebearing.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/agedclutch.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/bacclutch.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/badclutch.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/badpressureplate.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/oldflywheel.jpg

We then decided to bring the engine up from the basement and outside...

Imagine the engine bolted to the stand and this is what we had to deal with

Coming up these stairs
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/thestairsdeath.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/thestairs.jpg

then through the hall and down these stairs
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/thebackstairs.jpg

Now that we have the old one out and the new one in the garage this is what we have to work with..
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/theoldoutthenewalmostin.jpg

I got the oil pressure regulator on, the oil pan on, the oil level sensor on and 1 engine mount. Then I covered up all the openings and called it a day

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/engineoutside.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/engineingarage.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/engineendday1.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Endday1.jpg

So that was my day... I got alot done, but I was really hoping to have the engine in since this is my last 4 day weekend for a few months... Oh well next weekend the engine will go in and I can get to wiring, fuel pump, ecu etc..

I will update more once I get more accomplished

[SpooledupRacing]

I'll have to come back another time to read everything but DAMN, I'm impressed. I get the impression this is your first or one of your first builds, but (actually, much like me and I'm currently in my first build) you're being very cautious and precise.



Yes my first rotary build, engine pull anything...

I got my first 7 (this one) almost 2 years ago.. and NEVER had to do any work on it just change the oil and upgrades...

This is my first anything detailed when it comes to rotaries

[SpooledupRacing]

well no pictures this time.. just an update..

today I got my turbo built... I took it outside got the exhaust manifold bolted with a new Mazda oem gasket.. put the turbo on and I only had the 1 main oil drain line so I figured I could just cut the line and make it work with some heavy duty hose... After messing around for over an hour all I did was ruin a god piece...

so I just had to buy both pieces from a member here so I can get it bolted up..

I then went to put the coolant line on to the intake and noticed that got damaged in shipping so I had to buy both of them too..

just a setback I should still have everything here and ready to have on for this weekend when I put the engine in..

I will update u guys even more.

[SpooledupRacing]

Today I came home to some good news..


ITS HEEERRRE!!!

Spec Stage 3 6 puk n/a clutch kit

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Specclutchkit.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Specstage3kit.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Specpressureplate.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/spec6puk.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/Specbearings.jpg

So now I just need to get it all ready to bolt on.

[Willub and Company]

soooooo close to being done. good choice of clutch. i had one on my old FD and i loved it. now you can actually get the engine in and going!

[SpooledupRacing]

This weekend the engine will be in

[SpooledupRacing]

Well the dealer did not come through they got me the wrong bolts and wont allow me to return them even though they looked them up..

im out 26.00 on 6 bolts and a spacer none of which I can use or need...

GRRRRR!

why is it I cant find grade 8 metric bolts anywhere??

[SpooledupRacing]

Well I found some bolts tonight.. got home put the water pump, water pump housing on turned the engine around got the flywheel on and realized the bolts are to long.. so I used an extra washer to shim them out a touch now they seem fine EXCEPT the head sticks out to far now and the clutch disc cant sit the way it should

basically the bolts are to damn long.. back to the drawing board again!!!

[SpooledupRacing]

They had the right size botls.. tonight I will have the flywheel on, clutch on, water pump will be tight and bolted on, thermostat will be in and the neck will be on.

the turbo will be bolted on and the lines run.

I will be spraying the engine bay out with brake clean to get things cleaned up..

I will install the release bearing

and then tomorrow after work me and my buddy are gonna drop this baby in

then I can get the upper intake all cleaned up and painted

get the electrical done

get the fuel pump installed

get the ecu in

and next week I order up my intercooler kit

I plan to have this car running by the end of the month.

[SpooledupRacing]

that clutch wont be bad its a sprung hub.. I have drivin many 6 puk clutches before..

anywho on to the pics..

flywheel on:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3592.jpg

clutch disc on:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3593.jpg

pressure plate on:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3595.jpg

Water pump pulley is on.. its smiling:
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3597.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3599.jpg

more pics
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3604.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3606.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3607.jpg

I am currently fighting with the turbo it needs to come back off and everything spun the right direction then put back on.. I was trying to angle the compressor housing but if I do that the wastegate actuator wont bolt on :(

Tomorrow the engine goes in.. I will prolly drop it in without the turbo so I can redue that after I get it right

[SpooledupRacing]

The engine is in... I have to give a big thanks to both my friends Aaron and Mike... without them I would have never been able to do it...


I got the turbo off (so I can fig the problem with its location), I swapped in new engine mounts and then we got the engine on the hoist..

It was a pains since we left the tranny in... we started to get it lined up and I asked to pull it out so we can get it strait and I noticed I forgot the release bearing lol..

I got that on then we tried someone more with no luck..

I left for 5 minutes to take my nephew to work leaving them there.. I came back and they had the engine being bolted together..

I helped finish that up got the starter on and no I just need to finish the rest...

anywho onto pics..

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3617.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3616.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3618.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3619.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3622.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3623.jpg

More to come

[SpooledupRacing]

ok its a bit cold today so I did not spend much time (as of now out there) I mannaged to do the following

connect the front oil cooler line
connect the wire to the oil pressure sensor
connect the wire to the oil pressure sender box
put in the spark plugs
put on the new slave cylinder and SS braided line and bleed
put the inspection cover on over the flywheel

I will need:
new banjo bolt for the rear oil cooler line

I still need to reclock the turbo corectly, clean and paint the uim, get my injectors back, change the fuel filter, get new fuel hose, get that all mounted and then get the intercooler mounted and plumbed (once it arrives)

then I can start on the inside with installing the ecu, fuel pump, get the battery charged and give it a try!

[SpooledupRacing]

Here is a few pics.

I got the oil filter pedestal on
got the turbo clocked and all bolted on
got the outer coolant line hooked up to the lim

what a pain to bolt the turbo to the manifold with the manifold in the car

on to pics

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3625.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3626.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3627.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3628.jpg

[SpooledupRacing]

last night I went out and bleed the slave cylinder completely through with some elf dot 4. tonight I am going to go pickup an end for the turbo feed to the front iron. The injectors should be here today and if so I will install those and then get the upper intake cleaned, ports blocked, outer lower plates removed, and painted

this weekend if everything goes well I plan to have the intercooler being installed, the engine done, the ecu swapped in, and the only thing left will be the fuel pump...

I hope this all works out and I get it done in the next week or so.

Start up is getting real close.

[SpooledupRacing]

Here are some pics from tonight

Got the injectors in and the fuel rails on.. I have 2 of the 3 fuel lines on.. and the wire harness ran and lots of plugs hooked up..

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/lowintakeandwiring.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/secfuelrail.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/theugly.jpg

Tomorrow I need to put a new end on the wire for my coolant temp sensor (on back of rear iron)

tonight I plan to clean up the uim and if I have paint down stairs I will paint it up..

Hopefully I can get a new fuel filter come thursday.. install that and the fuel line to it and then put the uim on...

[SpooledupRacing]

Nothing to eventful today...

I got my rear oil cooler line on, got the upper intake painted (got something special for you) when I get pics of that.

sprayed the engine bay down with brake clean... tomorrow I will clean it with engine degreaser then more brake clean and hopefully it will be decent..

I got to order up a few items but I should have the upper plenum on by Saturday (wont get much time tomorrow or friday to do any work on it)

Plan to get the intercooler on or close to on this weekend..

A bit closer I am !

[djmtsu]

Quick question.

Why keep the S4 turbo? All that goodness, and then that!

[stylEmon]

Is it really that much different from the S5? Basically, S5 has a slightly larger turbine and no twin scroll, right?

[SpooledupRacing]

because I have the S4 turbo, and manifold and because I am running the stock ecu for now sine I will be on the stock n/a drivetrain so I want to get the engine broken in, enjoy it this year then swap the drivetrain then upgrade the turbo and manifold...

Just the way I work.. first rotary build.. since I did it all I am still scared to turn the key.. no need to make it even harder on me for the first one..

[stylEmon]

great logic... why make things more complicated then they already are (na to turbo swap)

[Nutsid]

I'll have to finish this read tonight, but wow. Great build thread for sure.

[SpooledupRacing]

Ok so the intercooler arrived today and WOW it is HUGE...

I got the bumper off tonight and noticed that I will be doing alot of cutting and hammering in the front to get this to fit...

Anyways onto the pics

The intercooler
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/newIC.jpg

The piping, couplers, clamps
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/newICpiping.jpg

the bumper had to come off
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/bumperoff.jpg

the intercooler next to the car
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/ICnexttocar.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/theIC.jpg

The intercooler in front of the opening.
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/ICinfrontofcar.jpg

the thickness of the intercooler (3" thick)
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/thickIC.jpg

The dimensions are

31" long x 21" tall x 3" thick with 3" in and outs

Oh and from last night I got the uim all painted.. here is what I did..

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3665.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3666.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3668.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3667.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3669.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3670.jpg

What do u guys think?

[Iox106]

Paint the whole thing

[djmtsu]

That intercooler is going to create alot of lag with the stock turbo. I am running a ceramic coated S5 turbo with ported turbine inlet and a monster wastegate port. I have that same intercooler, but there is no need for it with any 'stock sized' turbo, so it sits in the garage.

Just an FYI.

[SpooledupRacing]

Yeah I know it is overkill when I bought it I never imagined it would be that big...

I plan to run it but I also plan to upgrade the turbo later down the road (in the near future)

and yes I will be painting the entire intake tonight I am not fond of it as did it

[SpooledupRacing]

I painted the uim all gunmetal...

I also mounted the intercooler today

http://img.photobucket.com/albums/v88/turboTSI/IMG00019.jpg





Sorry for the big pic.

[SpooledupRacing]

Well here is what I have got accomplished today

http://img.photobucket.com/albums/v88/turboTSI/IMG00020.jpg

I have the holes cut so the pipes are going into the engine bay I just need to get things snugged up and clamped down and a couple pipes cut and it will be on...

first I need a higgi/greddy elbow another thing I forgot last minute

taken with cell phone sorry for the big pic

[SpooledupRacing]

ok here are some I got from late tonight... I got the holes cut, the pipes run into the engine bay now I just need a couple couplers, and the higgi/greddy elbow

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3708.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3698.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3704.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3700.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3703.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3701.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3702.jpg

Yes the car is on an angle..

OK what do u think?

[SpooledupRacing]

Ok no pictures today (atleast not now)

I have done the following

turbo ECU installed
Walbro installed
TPS wires lengthened


I need 2 couplers
1 banjo bolt
and the higgi/greddy elbow and I can get the car ready to start

[BadAzz84]

I am runnin gthe same intercooler o my fb setup and boost does not hit until 4 grand. Makes me wonder how fast it would hit with no inter-cooler!

[SpooledupRacing]

full boost at 4k? or are u in hg until 4k?

what size turbo are u using?

im not to worried I will be breaking the engine in for a while anyways.. after I am broken in I may upgrade turbos.

right now im just waiting for a few parts

[BadAzz84]

full boost buy 4k at 0 buy 3,500 then its like someone turned on a switch and blam off i go. It could be part of it being a 12a thats driving the turbo but other 12a guys with s4 turbo hit around 3k so i think its the cooler. I have the same one its massive about the size of my radiator almost.

[SpooledupRacing]

well thats nice then.. 0 boost at 3500 and full boost at 4 k right at the power band

[SpooledupRacing]

So today I got the oil injectors on the rotor housings blocked today, I ordered up my banjo bolt for the pd removal and a coupler for the turbo to intercooler pipe. I should have my throttle cable tomorrow and my gasket for my oil feed line

[SpooledupRacing]

Got the new accelerator cable on today, the banjo bolt and coupler will be here tomorrow so I should be able to get the fuel lines on, the upper plenum on, the turbo side of the intercooler all done.

I bought a tb elbow today it should be here by friday along with my new modded tb so I can get them on and the intercooler pipes for that side by friday..

Then add oil, coolant, and get the last few things on... I hope to turn the key by Saturday or Sunday

[SpooledupRacing]

The official startup will be roughly 3:30-4:30pm on Saturday

My throttle body showed up today
my banjo bolt and 1 coupler is due in today
my downpipe and tb elbow should be here tomorrow or friday latest

I work till 3pm on saturday.. I will be going home. getting the camera out and starting the car..

I am SO SCARED!!!

[SpooledupRacing]

Ok so tonight was a good night.. my banjo bolt showed up so I was able to get my fuel rail on. The throttle body showed up so I was able to get that on and the upper intake on. The coupler showed up for my turbo to IC piping so I ws able to get the passenger side plumbed...

So all I have left is to:
put my throttle body elbow on when it shows up
put my turbo oil feed line on when it shows up
put my turbo coolant line to intake on when it shows up
Put my AFM on
put radiator in and add coolant
put the down pipe on when it shows up
Put on the new ngk wires
put the alternator on
put 2 new belts on

I did get the engine filled with 4 litres of Elf 10w50

on to pics
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3716.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3715.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3714.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3713.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3712.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3710.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3709.jpg

So I am about positive that I will turn the key on Saturday

[SpooledupRacing]

Ok so tonight I have done the following...

put the tb elbow on and the coupler on got the intercooler piping on the drivers side on and the bov mounted

got the radiator in
thermostat in
coolant added
a couple hoses on
got the oil feed one
got the coolant feed on
got the coolant return on

I need the following yet

put the afm on
get a new bolt for the t-stat housing
get a radiator cap
get a vac hose for brake booster to uim
get some plastic put back on

here are pics of what I have done tonight

http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3722.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3721.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3720.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3719.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3718.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/DSCF3717.jpg

[SpooledupRacing]

Ok well I got the last few things on.. checked my fluids etc and of course nothing can go off perfectly..

We pulled the fuel pump fuse cranked the engine to build oil pressure and 3 seconds into it the upper fuel rail sprung a leak... found out the banjo bolt was loose..

so we realised there was a leak and that we had the wrong fuse pulled... so we cleaned the engine off with water and tried again this time on purpose with the pump on to see if any other leaks happen

What do u know crank a few seconds and bam the lower rail leaks..

I tighten that bolt and pull both the fuses and crank till oil pressure comes up.. once that works we put the fuses in and crank 2 it took like 2 seconds and the car started and ran just fine...

we had it die because the throttle adjustment was not set right...

we turn the adjuster screw in so it will idle on its own and it fires right back up...

I let it run for about 45 minutes or so and it just smoked and smoked and smoked...

it still smokes if I start it.. Not sure how long it will smoke for but I know with the crisco, gear lube and engine oil used during the engine build process I figured it would smoke for a while..

after a while I turned the ca and found the low oil level light was on.. so I check the oil and it is fine... a little later it hit me.. I may have grabbed the n/a dipstick instead of the turbo dipstick... sure did so after adding another 2 liters it is just under full

The next thing I noticed was I had lots of bubbling in the cooling system so after that cooled down I pulled the bleed valve on the side of the radiator neck (again) and refilled the cooling system.. this time I am confident that it could be all done up..

now the biggest problem.. the batter wont hold a charge and it really is to big now with the ic pipes run ..

tomorrow I will get another battery, get it started back up and let it run for a while longer..

hopefully the smoke will go away...

Anyways I got 2 short videos.. NO SOUND SORRY.. but u can see the horrific amount of smoke...

as for the smoke shooting from the turbo in the engine bay well the downpipe was only held on by one nut, and I did not have a gasket on it because i only had one nut holding it on.. so one that is all tightned down I should be all set there..


http://img.photobucket.com/albums/v88/turboTSI/Videos/th_DSCF3723.jpg (http://smg.photobucket.com/albums/v88/turboTSI/Videos/?action=view&current=DSCF3723.flv)

http://img.photobucket.com/albums/v88/turboTSI/Videos/th_DSCF3724.jpg (http://smg.photobucket.com/albums/v88/turboTSI/Videos/?action=view&current=DSCF3724.flv)

[need RX7]

Congrats!! :biggthumpup: looks like she's running strong.
:driving: :driving: :driving:
:party:

[SpooledupRacing]

is that amount of smoke or that long normal.

[Iox106]

Yep

http://www.rotaryresurrection.com/2ndgen/tech_rebuilt_engine_startup_breakin.html

6) Be prepared for smoke…there is assembly lube in the engine, which will be burned out in the form of smoke. Expect this to get into your exhaust and smoke can remain for up to 8 hours afterwards until it is all burned out slowly.

[SpooledupRacing]

Thank you sir.. I feel much better now...

tonight I go for the first test drive

[SpooledupRacing]

Well I have an external oil leak at the turbo, and it is still smoking now onto hour 3 of the break in.. blue smoke and lots of it...

The intercooler piping is dry, but I have oil just dripping out of the bottom of the turbo somewhere.. I cant figure out where...

all the lines are tight... I just don't know..

I think tomorrow I will pull the turbo off and recheck the mating surfaces of the turbo.. tighten it back down, check all of the oil drain bolts and make sure they are tight... make sure the oil drain tube is god and tight.. and go form there...

THIS SUX...

I have about 20 miles on the motor it runs very well, pulls very good, but cant be driven yet, not with the smoke and the leaking oil...

[SpooledupRacing]

ok I pulled the turbo... the leak was coming from the oil drain.. easy fix...

here is what I see when I pulled the turbo off and started the car...

the first video is of the car just starting up then reving, unfortunatley the towel it was sitting on covered up the lens when I started to rev the car .

the second video is of the car just idling.. I stuck it down by the opening and then pulled away so u could see the smoke coming out of the engine bay

so are we thinking maybe the oil control ring spring may be moving and causing a leak.. or is this not that bad since I only have about 2 hours of running on it...

the liquid u see by the manifold is coolant.. I don't see any liquid oil coming out of the manifold.. and both the outlet of the turbo was dry and the cat was dry...

Vid 1
http://img.photobucket.com/albums/v88/turboTSI/Videos/th_DSCF3725.jpg (http://smg.photobucket.com/albums/v88/turboTSI/Videos/?action=view&current=DSCF3725.flv)


vid 2
http://img.photobucket.com/albums/v88/turboTSI/Videos/th_DSCF3726.jpg (http://smg.photobucket.com/albums/v88/turboTSI/Videos/?action=view&current=DSCF3726.flv)

[SpooledupRacing]

Here is what the plugs look like after about 80 miles and 4-5 hours of running

Here you go Kevin. I did this this morning after the car had set overnight

Front plugs (leading plug on left, trailing on right)
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frontplug1.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frontplug2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/frontplug.jpg


Rear plugs (leading on left, trailing on right)
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearpug2.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearplug.jpg
http://img.photobucket.com/albums/v88/turboTSI/Turbo%20engine/rearplug3.jpg

What if anything does that tell you?

[Max777]

mm, not an expert by far, but it looks like you got an oil leak in the front, since the plugs are so fucked...

and the rears look nice and dry..not perfect, but much better.

Are these new plugs that you just put in right after the rebuild? Damn.. the fronts are scaring me.... but then I AM a bit of a n00b. :D

[SpooledupRacing]

the fronts do look a touch wet but I don't think that bad...

and the turbo and manifold is clean

[SpooledupRacing]

ok leak solved...

There was a bolt head on the compressor housing that was hitting the drain pipe. This was causing the drain pipe to not sit flush on the cartridge causing a leak anytime the car was running...

I will be putting the turbo back on tonight and going for a nice drive... if everything is cool she will be on the road full time tomorrow..

Total invested 13.00 in gaskets, labor FREE (had a show I do business with check it out and fix it for me)

[BadAzz84]

uh....wasup!