RXtacy's slooow build up
 

I guess it's about time I started one of these. I've had my FD since 2004, and she just turned 20 this year becoming eligible for historic plates here in MD :sifone:

Background:
The car started life as a vintage red touring model with tan interior.

https://lh3.googleusercontent.com/-2...0-Ic42/030.JPG

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The paint was in pretty rough shape, and the tan interior had to go. I tackled the interior first. Stripped the interior and removed a lot of the sound deadening. Then I used quiet coat before installing a new black carpet, and black interior.

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Used the dust off cans flipped upside down to freeze off the sound deadening.

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Applying quiet coat.

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Dash pulled and ready to install the new carpet.

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Carpet in, and dash reinstalled.

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I don't seem to have any final pictures, but I replaced the AC, shifter surround, and transmission tunnel cover with brand new OEM 93 finish plastics. The 93 finish is gorgeous when new IMHO. Also put in used black quarter panels, door panels, and rear divider.

Once the interior was up to snuff, I moved on to the exterior. The VR paint had to go, and I spent a LOONG time trying to decide what color I wanted to go with. Mentally went through just about every color in the rainbow before deciding. I ended up going with Frozen Grey Metallic off the special edition BMW M3. It is a satin finish silver color. In certain light it has a bit of a purple hue to it. I also went with Shine Auto Feed front bumper and front fenders.

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Shaved the rear antenna and filled the holes that the stock spoiler mounted to.

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Took care of some minor rust along the windshield.

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Fender fitment wasn't the best, but the body shop did a great job getting all the seems right.

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All sanded and primed. Also test fitting the new kicks.

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The results! How she looked when I picked her up from the body shop.

https://lh3.googleusercontent.com/-u...401_205644.jpg

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Once I got her back home I installed Stance GR+ coilovers. I had Tein flex coilovers before, but wanted a bit updated technology.

https://lh3.googleusercontent.com/-p...301_201854.jpg

Once I got the ride height set, I took her in for an alignment. These are the specs I went with.

https://lh3.googleusercontent.com/-O...-10-12_040.jpg

After ride height and alignment.

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DGRR 2011

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Nice whats so slow about this build. You have made much more progress then I have. Haha

Not much changed between 2011 and 2012. My buddy Tharek took some bad ass pictures at DGRR 2012 though. He came all the way from England to check out the best rotary event :icon_tup:

https://lh3.googleusercontent.com/-q...87657581_n.jpg

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That's all historic stuff that's happened over the years :lol: I haven't gotten to the current progress yet :rofl:

Up until this point performance wise she wasn't anything special. Custom SMIC, Apexi intakes, full exhaust, PFC, etc... She made 320 whp when Brian (TitaniumTT) and I tuned her just after DGRR 2012. Then "tragedy" struck :lol: Hit overboost on the highway on my way in to work and detonated. I drove it another ~8-10 miles into work on one rotor. Then drove it 25 miles back home. It died literally just as I was pulling into my driveway :rofl: The carnage was impressive to say the least.

Pulled it out with Brian, Dave, and Levi lending a hand. Much appreciated fellas.

Don't have any pics from the pull, or the tear down. But have some of the aftermath.

https://lh3.googleusercontent.com/-X...701_111736.jpg

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After tear down/inspection

https://lh3.googleusercontent.com/-0...705_075848.jpg

Front rotor.

https://lh3.googleusercontent.com/-N...110_203651.jpg

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The culprit.

https://lh3.googleusercontent.com/-B...110_203917.jpg

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The housings looked about the same. The irons were salvageable, but for the most part the engine was a total loss. So I picked up a used keg from Josh (XLR8) on the 7club. It was pulled while running with great compression, and the internals showed it. They were pristine!

Disassembly of the new block.

https://lh3.googleusercontent.com/-t...009_195731.jpg

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"New" engine on the stand after the internals were removed/inspected. This block was a great candidate to rebuild. All the internals were well within spec, and looked great.

https://lh3.googleusercontent.com/-Z...012_182905.jpg

All the accessories organized (somewhat)

https://lh3.googleusercontent.com/-o...012_182917.jpg

You know I had COMPLETELY forgotten that your FD started off life as a VR!!

Need to get that keg stacked up and the break-in started ^_^

I need to do a LOT of things before getting to the break in :rofl: Stacking the keg is one of the least.

I'll update more probably some time this week. Still haven't caught up with where I actually am in the build.

Let me know if you need a hand putting it back together.

UPDATE! :lol:

After tear down of the good used block the clean up, inspection, measurement commenced.

Rotors after cleaning.

https://lh3.googleusercontent.com/-Y...111_182629.jpg

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Ordered up all the soft seals, new side seals, corner seals etc. Also got my ID 1000 primary injectors and new RX-8 e-shaft.

https://lh3.googleusercontent.com/-u...112_223834.jpg

Cleaned up primary and secondary ports. Didn't enlarge much at all, just cleaned up the casting for the most part. I wanted to keep them as close to stock as possible. I have another way of increasing air into the engine :suspect:

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How do I plan to get more air into the engine while keeping the side ports mostly stock you ask? With these little guys.

https://lh3.googleusercontent.com/-z...112_224418.jpg

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Those little guys? I wouldn't worry about those little guys :lol:

Once all the porting was done, I primed and painted the block.

https://lh3.googleusercontent.com/-N...202_183324.jpg

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Then started clearancing/assembling the rotors to get ready to stack the keg.

https://lh3.googleusercontent.com/-t...113_172444.jpg

Setting side seal clearance.

https://lh3.googleusercontent.com/-e...113_181008.jpg

Rotor assembly. Get the lube! :awesome:

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Once again got some help from great friends to stack the keg. Thanks Brian and Whoopie!

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Keg together.

https://lh3.googleusercontent.com/-Z...427_171316.jpg

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Front cover installed.

https://lh3.googleusercontent.com/-k...627_212908.jpg

Got my turbo from Turblown. TD61R with a 1.15 AR hot side. Thanks Elliot!

https://lh3.googleusercontent.com/-8...204_192010.jpg

I have always hated the extra emissions related junk on the LIM, so I started to shave that off, and make room for the runners to feed the peri ports.

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Just a small portion of aluminum chips created :lol:
https://lh3.googleusercontent.com/-E...711_200041.jpg

Close to the end of material removal and holes drilled to feed the peris.

https://lh3.googleusercontent.com/-A...718_183920.jpg

Looking into the peri port.

https://lh3.googleusercontent.com/-8...718_184000.jpg

Then fabricated the additional runners for the peri ports. The peris are fed by the stock secondary runners only. This should help idle/driveability some what.

https://lh3.googleusercontent.com/-F...928_041547.jpg

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The welds look terrible! :rofl: The access was terrible, add that to the dirty thick casting and thin wall tubing, and you get those hideous welds. Oh well they'll work. :icon_tup:

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Next it was on to the fuel system. I picked up the new internally dampened CJ Motorsports fuel rails. Absolutely love these rails, great product!

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Then made the fuel lines.

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I'm using Jiffy Tite dry break quick discconect fittings for the supply and return lines. Should make for an easy install removal :icon_tup:

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Once the fuel system was sorted, it was on to the turbo manifold. I wanted to make the manifold as short as possible. This made for a VERY tight fight between the LIM and the passenger frame rail.

I used Schedule 40 316 stainless pipe for the manifold. Hopefully I won't have to worry about cracking any time soon :D

https://lh3.googleusercontent.com/-c...001_175103.jpg

I didn't get any pictures of the mockup/fabrication process, but here's the results. Short, dual wastegate manifold all tacked together.

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Wastegates thrown on.

https://lh3.googleusercontent.com/-N...009_003428.jpg

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The forward intake runner for the peri port actually slips right between the compressor and turbine housing of the turbo. Tight hardly describes it :lol:

Test fitting on the block.

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Did we say it was tight? :rofl:

https://lh3.googleusercontent.com/-Q...009_003052.jpg

Whole picture :biggthumpup:

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That's pretty much up to date now. Still need to do final welding on the manifold. Then it's on to V-mount, and custom 4" exhaust. Stay tuned :)

that's looking quite baller, man! love that it's built, not bought :D Just looking, the wastegates are venting to atmo, yes? or do you have some trick idea to circ it into the downpipe?

you're surprisingly skillfull with the lube . . .

Thanks buddy! I haven't made the dump tubes yet, but yea initially they'll be open dump tubes. I'll prob eventually do removable recirc tubes for them so I can run open or through the downpipe.

Especially considering I don't ever use it on my vic... conque... friends :suspect:

do you think chassis flex under hard cornering (let's be honest, you're not going to baby the car) would rub a bit, or do you plan on massaging the passenger frame g-spot so it is always open for business?

:lol: :rofl:

Brokeback power . . . the best kind :squint:

Would what rub? If you're talking about the hotside of the turbo then yea I'm going to be massaging the frame rail for some added clearance.

:awesome:

Is it bad that your Turbo is as big as your engine? Looking good Mike. Can't wait to see that thing in anger on the Dragon.

:bowdown:

:lol: Thanks. That's actually a medium size turbo too. Neither can I, neither can I :D

:blush5: Thanks man.

I'm diggin how short those runners are on the manifold. Mine are short like that too, but it makes it kinda tough to figure out where to put the wastegates lol. Have you checked this in the engine bay to make sure the wastegates won't hit the subframe, and any other fitment issues? I had my current manifold made for my current turbo but I'd love to make my own like this.

Yea I put an empty keg in my engine bay (on engine mounts and connected to transmission) and test fitted everything before tacking the manifold together. The wastegates have a lot of clearance to the frame rail and subframe and the dump tubes can easily exit through the opening in the subframe.

This is Mike I think we met at DGRR last year. At the BP on the last day before we left. I was driving Brian's (TitaniumTT) FC. Love your FD :icon_tup:

Small update. Did some more welding on the manifold.

https://lh3.googleusercontent.com/-u...011_182422.jpg

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Oooooh!

Thank you sir for the tips! I'm no welder by profession!

Sweet!

Yeah I remember you! I didn't realize this was you though lol.

Thanks! I'm loving your FD as well. And those welds do look really good. I still have to learn to do that myself lol.

Looking badass Mike!! I can´t wait to see this baby running :)

Do you have a (guestimated) eta for the initial start-up?

Haha no worries. Is it Eric?

Thanks man! I still have a long way to go, but it just takes a lot of seat time.

Thanks Levi. Haha no idea. I hope to have it done by Deals Gap.

Small update:

Made the cut outs for the wastegates. Used a plasma cutter, then cleaned up with a carbide.

https://lh3.googleusercontent.com/-q...014_125544.jpg

Set up dual flow meter/regulators so I could backpurge the manifold during final welding.

https://lh3.googleusercontent.com/-N...014_181812.jpg

Did the finish welding on the wastegate flanges.

https://lh3.googleusercontent.com/-n...014_220002.jpg

https://lh3.googleusercontent.com/-d...014_215951.jpg

While welding the second flange the foot pedal control for my TIG crapped out. :( I had to finish it with the 2T torch control :18: I hate using the torch control. Had planned to finish all the welding today, but will have to wait until the new foot pedal comes in.

Teee Heee! That setup seems to be perfect on the bottle awesome..

Love it looking great!

Awesome project!

Looking forward to see if you will be able to re-route the wastegates... I have been putting off going single, but I have been getting tired of replacing twins so a single will be in my future soon. I absolutely want a short runner manifold but for me the deal breaker is being able to reroute the wastegates. I have yet to see it done on a short runner like this.

Thanks John :icon_tup:

That won't be for a while. I'll be running open dump initially. The only forcing factor for going re-route will be whenever I wanna hit up LRP. Stupid noise restriction :rofl: I think it will be doable, tough but doable.

Interesting! Looking forward to the results!

Thanks! Me too :sifone:

Got my clutch. Exedy twin disk. My buddy Tyler gave me a unbeatable deal on it. Thanks brotha!

https://lh3.googleusercontent.com/-o...810_122844.jpg

Also finished up the turbo manifold.

https://lh3.googleusercontent.com/-W...021_203556.jpg

https://lh3.googleusercontent.com/-e...021_203400.jpg
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Will have more pics once it's cool.