ya i'll see how low it is once the car is sitting level again i can even raise it another inch i believe before it hits the hood so there's an option but rough measurements put it above at least the front lip about an inch. i figure i may be able to build the "skid plate" into the undertray when i make it.

z



today i spent a little time running the piping for the intercooler and heres what i ended up with


http://rotarycarclub.com/rotary_foru...1&d=1254714278

http://rotarycarclub.com/rotary_foru...1&d=1254714278


i do have however a small issue with the greddy elbow as the size of the connection was for stock size of 2.75" and the inside diameter of just over 2.25" ish anyway what do most people do with this im thinking of cuting that section off and forcing the 3" coupler over the remaining part as its closer to the 3" any help?

heres what im talking about note the inside ridge of the greddy elbow

http://rotarycarclub.com/rotary_foru...1&d=1254714278

I bet you'll be able to get that 2.75" coupler on the 3" piping.

Nice build buy the way!

Are you using both the Charge Relief Valve and the stock BOV's as BOV's?

yes i am they work the same why not that and i got the HKS intake piping kit with the car and it has the return fitting for both. Besides it will all be changed out when i get back in feb. i have a t66 setup waiting to go in with tial 50mm bov and tial i think it was 44mm wastegate. when i get that on ill be shooting for 20psi w/ water injection 15psi pump HP wise whatever happens happens....

z

well with my concern about the greddy elbows necked down size i have since cut off the ridge and smoothed out the cut to make it 1/4 inch closer to the 3" piping dia i will get it ported out correctly when i take in my vsessive LIM to get portmatched at the same time later down the road.

http://rotarycarclub.com/rotary_foru...1&d=1254902729


and now as for the concern and issue with lower radiator mounts and 'skid plate' for it as it appears to hang low even though the intercooler is lower. heres the bracket ive come up with it will also have tabs welded on for an A/C condenser mount once i fab a kit for it. for mounting the power steering cooler i most likely will mount tabs off the intercooler. but thats for tomorrow


heres the lower radiator mount bracket and rock guard all in one it really solidly mounts the radiator just like it needs to be and will provide excelent mounting for both the a/c mounts and undertray later on when i fab those up

http://rotarycarclub.com/rotary_foru...1&d=1254902729

and heres a few of how it looks mounted....

http://rotarycarclub.com/rotary_foru...1&d=1254902729

http://rotarycarclub.com/rotary_foru...1&d=1254902729


please constructive critisizim may give me better ideas....

z



also iv trimmed the front bumper for the front mount so its ready to go back on once eveything is fabbed..... a couple small brackets need to be made still an extension for the intercooler to greddy elbow now that its beeen modded and mounting the power steering cooler line setup and putting the car back together i should be driving it again tomorrow afternoon if all goes right see how this new cooling setup works out :driving:

well finishing up the last little tid bits i didnt want to have to spend any money on something as trivial as a power steering fluid cooler so i took the old setup cut and rbent some of it and tigged 2 pieces together to end up with a rather oem looking and mounting piece if i do say wo myself.

heres what i ended up with rebent and welded up
http://rotarycarclub.com/rotary_foru...1&d=1255063751

and here it is installed just behind the intercooler and mounted using stock mounts rebent as well the other side looks about the same fyi

http://rotarycarclub.com/rotary_foru...1&d=1255063751


and i didnt order any 1.5" aluminum bends for the radiator pipes so once again i had to find something temp... ran by the local perfomance exhaust shop and they hooked me up with a nice little 45deg bend FREEBIE :001_005:

http://rotarycarclub.com/rotary_foru...1&d=1255063751

so once everything was connected and the bumper reinstalled and some last minute minor trimming of some of the splash shields from this pic you can see how the radiator is definatly not too low

http://rotarycarclub.com/rotary_foru...1&d=1255063751


and for anyone wondering about a percision intercooler check out those turbulators let me know how that compares to your ole ebay core :rofl: definatly cools very very well.

http://rotarycarclub.com/rotary_foru...1&d=1255063751

now that she has taken her maden voyage with the new setup i will say it cools VERY diferently than the stock setu that i did have before. niether of them had/have undertray ducting and i can say right now current setup cools slightly better 1-3 deg cooler till the fans kick on and with in 15ish seconds cooles the car right off and shuts fans down maintains temps better/faster yet not accaptable for what it has cost so far. So before you scream and lynch me i need ducting i know if i just happen to have some extra time in the next 2 days i might start but probably not till i get back... im sure the ducting will help imensly as you can see where all the air is going in my pics thus far. also to finish my cooling system of i will need som oil coolers which ill also get to when i get back which should definatly help the rad set up work wonders :icon_tup:

WORDS OF WARNING TO OTHERS!!!!! im currently running the base PFC map while i have been playing with idle, cruise, stumbles yadyada driving smoothness and A/F ratios. NOW as i did not shange anything but the intercooler setup i can tell you right now 10psi with this intercooler is not 10PSI on the stock intercooler same turbos... at full boost before i saw all the way down to <10.2 AFR wich is over safe so wasent to worried about it. CURRENTLY im seeing balls out 10psi AFR's of 11.5-.8 definatly better for power at this psi but if thats all ya change be weary as it may not fall into as good of a range as mine did for your modification always tune after changing ANY intake part!




so with out further adu heres how she looks now till i get back :driving:


http://rotarycarclub.com/rotary_foru...1&d=1255064747


goahead let me know what ya think i aint scured

z :driving:

a little update since i wasent happy with the cooling aspect of it yet but i hadent changed any fan settings so i went ahead and adjusted the fans down to 87c instead of 90c. And WOW this thing cools amazing even unducted with a FMIC i never saw anything above 86c tonight. cant wait o dual oil cooler it definatly will be ready for that t66 then.


now a little info fan #1 is just both fans on and fan #2 is the left fan kicking in overdrive? is that about right? im curious cause my right fan plug wasent there and i currently have the power(blue) going to the red in the car harness plug and the neg(black) going to black harness. now i threw a multimeter on the other 2 wires in the plug and when the fan runs one has about 3v and the other 8v any reason or are they just not used?


z

Great build, be careful over there man.

Looks like somebody has been practicing with the TIG !!!

Looking for ward to seeing the rest of the build (and more dyno sheets)

Change to 3"
 

well i havent been as busy working on the car as i would like but then again if i was id run out of things to do or money. which is not on my list of things to do :001_005:

So iv changed my exhaust to a much better flowing cleaner install 3" setup. after realizing there is no way to make a 4" setup quiet EVER on an rx7 and the 3" will support power goals of 99% of us. so build pics of that as follows.

3" exhaust setup specs info.

409 stainlesssteel 3" tubing 6ft worth and i have 3ft or so leftover
only used 2 bends total 1x 90 and 1x 45 mandrel 409SS
2x v-band clamp setups for ease of install and service THEY ARE SOOOO NICE TO WORK WITH
1x 3x6" flex pipe for movment
1x dynomax bullet race muffler 24" i believe NOT SS unfortunatly fiberglass packing so i dont know how long itll last
1x magnaflow muffler dont know which one i had it laying around
1x SS wideband bung

i also have 100ft of exhaust wrap i have yet to put on as i think i want it a bit quieter BUT im not sure if the wrap will be enough or should add another dynomax or build my own full SS style from the old 4" setup then wrap it. take a look at the video it has the sound but dosent pick up the deep bass tone of it unforunatly.

I opted to weld it all up with 308SS .025 mig as i dont have a backpurg setup for my tig yet although i should have tried as the 110v mig i have definatly struggles with the SS it just needs more heat that a 220v system would give but oh well.

and for cuting the hole for the wideband i fired up my new plasma at lets just say it was worth it :001_005:

heres the pics ill get the video up soon.

heres what i ordered. it is WAYYYY to many bends i only used 2 but ill build the downpipe for my single out of some of this so hopefully ill be able to use the rest somewhere.
http://rotarycarclub.com/rotary_foru...1&d=1269111660
heres the patient ready for operation
http://rotarycarclub.com/rotary_foru...1&d=1269111660
This is the old 4" i built notice the poor flowing midpipe. This setup is LOUD its not for me so im scrapping it and trying to recoup some cash selling the mufflers and v-bands. the only thing i did like about it for its size it didnt hang any lower than stock suspension parts. not an ideal setup but i learned ALOT from building it and that is what this project car is all about. so the new setup is much better designed.
http://rotarycarclub.com/rotary_foru...1&d=1269111660
another old setup the catback section did flow really nice unlike the midpipe. notice the flowmaster :banghead: DONT use these on your rotary its not designed for this type of engine use it on your old muscle car or v8 truck not the rotary
http://rotarycarclub.com/rotary_foru...1&d=1269111660
and hers a shot of sections being built up and my welding and cutting setup used by this DIYer
http://rotarycarclub.com/rotary_foru...1&d=1269111660

heres the dynomax bullet race muffler inside i was trying to get a shot of the packing but you cant really see it.

http://rotarycarclub.com/rotary_foru...1&d=1269112481

and here is the completed 3" as it is on the car now i will be wrapping almost the entirething in header wrap once i decide if im going to add another bullet muffler to the midpipe or not

http://rotarycarclub.com/rotary_foru...1&d=1269112481

installed
http://rotarycarclub.com/rotary_foru...1&d=1269112481
http://rotarycarclub.com/rotary_foru...1&d=1269112481
http://rotarycarclub.com/rotary_foru...1&d=1269112481

and heres the quick video i made of it and a quick walk around.

http://i849.photobucket.com/albums/a...h_MVI_1801.jpg

and soon to come

1. install of the AQUAMIST HSF-3 AI system
2. rebuild of the suspension with tein s-tech and tokico illumina's bushings pillowballs steering rack boots & bushings
3. fender rolling if needed when my wheels come in
4. ducting for the radiator
5. swapping to AEM EMS and QD install to engine harness and wire reallocation for boost control extra injectors in prep for....
6. Single install t66 dual EGT excessive LIM 4x1000cc inj with stock primaries or possibly rx8 primaries.
7. HKS twin power
8. speakers head unit small 10" woofer and finish the dynomatting in the hatch and doors, retint windows and mole skin for the window seal.
9. kaaz 1.5 diff install
10. dual oil cooler setup with possible hardlines
11. fuel system upgrade with bosch 044 and intank surgetank

all i can think of right now

stay tunned

z

Looks good, you have skills.

only wish i had more time tools and money to go with it. :suspect:

z

well little update. my DD ended up in the body shop for a couple days for a door ding. so i rocked the FD for a few days finding more refinements i need to take care of. the exhaust has a very nice rotary tone to it although i think its still a bit loud for my taste so it looks like ill be getting another bullet resonator/muffler installed and exhaust wrapping the mid-pipe.

BUT during the DD time my coolant temps started getting hotter i figured cause it was warming up BUT then it continued warmer making me look into any causes. NOT overheat hot but just warmer than it should for the cooling setup i have and fan temps. never got above 97c. turns out my fans were dieing. well i picked up some new fans off rx7club and apparently there are differences in the fan setups for different years im assuming although iv not seen any others like what i had stock.

left fan 4 wire right fan 2 wire single speed and they were counter rotating fans

the replacments i made sure i got
both fans 4 wire 2 speeds each for all my fan speeds i should have. and the fans both turn the same direction on these.

also a small little thing the fans housing/mounts were different too mine had wire clips for the wires the other new one didnt. but i swapped housings as the one i got had bolt holes clipped out.

NOW my coolant temps are exactly where i expected them to be even without ducting still. a bit of thrashing havent seen above 87 lol.



to round out the cooling system i got in the sakebomb dual oil cooler GB#2 and ill be getting those in about a week or so dual 25rows ohhhh yea!

ill also be installng the sakebomb HID projectors at the same time as the bumper will be off already.


and currently getting the suspension ready for final overhaul.


pics to come soon most likely this weekend as its raining all freaking weekend


z