87T2 Major Overhaul :: Highlight Reel

[stylEmon]

I've been building this car for a couple years now, and have various blogs floating around the net. THIS ONE is the most thorough, although it lacks feedback from the readers.

THIS BLOG has tons of feedback from members of "The Other" forum.

On this board, I'll highlight the best parts of the build up to this point, and continue reporting progress on the project.

It has been a very strenuous project at times, but has gone very well over-all. I purchased this car with a "5000 mile rebuild", but blew the motor rather quickly. The motor had SO many issues before it blew, I often think I should've passed on this car and waited for another. BUT the progress that's been made on this one re-assures me that no matter what car I bought, MANY of the details I've gone through would not have been addressed in a well cared for car. And I am glad I've addressed them!

I bought the car in Feb 2006, and it looked pretty clean. The body was real straight, minus a crack in the front bumper and a crack in the spoiler.


The motor had lots of "wierd" things done to it. FCD, de-powered steering rack with the lines looped together, electrical tape on the TID, no emissions, wide open 3" exhaust... But it had some nice struts/shocks and good plug wires. Over all, it looks like the previous owner was going for cheap "power".


Interior was alright, some normal cracking and no radio or AC.


It had some hot start issues from the start. I cleaned the injectors and adjusted the TPS. No dice.


Motor blew after a couple 110 mph runs. We found LOTS of shoty work.


Ported primary plate... wierd


Blown seal


This spark plug hole was cracked.


The old turbo, S4, not great but not terrible.



Once the rebuild started, I went for a nice smooth secondary port. It's a little larger, but overall, just a good smooth port.


I did spring for the new housings. I am building for power and reliability after all.


And I got a S5 turbo, ported the wastegate and the back plate was milled.


Then the coatings begin!






I went nuts!

[stylEmon]

Along the way, I picked up another T2. It had no motor, so I got a good deal on it.


I found a motor, put two and two together and sold her. I made some decent cash, but man she was a nice looking lady!


Back to the black beast... I had the internals balanced.


Started upgrading the fuel system with a Walbro HP pump, and some 750cc injectors.


Picked up the popular, BBS gold meshies. They were much wider than the Mazda rims that came on the car.


Got FD stationary gears; I've planned to do oil mods to this motor from the get-go, so this was a natural choice.


The motor went together with studs.


And in she went.


Got the MoTeC M2R


Wired it up.



I've never been a fan of the S4 interior...especially the gray.


So I began stripping it out.


And got a S5 interior... Much nicer!

[stylEmon]

In the process of upgrading the interior, I relocated the battery to the rear passenger side bin.


I was able to get my hands on some 2-way adjustable Koni coil-overs




Oil filter relocation kit by Turblown.net


Complete with catch can line.


Here's a cool mod; NA throttle cable on a T2. (ignore the temporary ghetto intake)


FD alternator.


Custom TID. It's right up front, so I suppose it passes as a true CAI.


She started!!
Halfway down this page.

I went with the single exhaust. This system is QUIET, and really makes this thing a sleeper.




Picked up an LC-1...


And the tuning fun began.


I passed emissions once I disconnected the wastegate rod. Soon after, I raced a 95-ish Corvette. I beat the vette, but the oil seal on my turbo went bye-bye.


UPGRAGE TIME!!! T04E, .60/1.24


Hardlined,


Tial 38mm External Wastegate,


Turblown, handmade divided tubular manifold.


Oh yeah, no physical intercooler.

[stylEmon]

So that brings us current. I was forced to upgrade my secondaries to 1600cc!! I was running out of fuel with the T04, so I don't think I'll have that problem with the 1600s. I have a 2-stage methanol injection system that is being perfected now. Here is the first stage. It's a very small injector, pre-turbo that comes on at 1 psi.


I'll get some pics of the rest of the system. Basically, it's the Devil's Own, 150 psi pump, and a much larger injector. Mounted after the turbo, and will be activated at 6 psi, by the MoTeC.

[kynde]

Very interesting way of doing the intake cooling. I was planning on doing AI but with a V-Mount setup. Could I possibly get more info on what you did to the throttle body to swap the cable over to an NA?

Great looking setup. Cant wait to see more.

[stylEmon]

thanks. I may go to a physical intercooler in the future. But so far, the AI is WAY better than the stock intercooler. The best part about using only AI is, there is not pressure drop between the turbo and throttle body.

Basically, you simply take the TB linkage off, and put it back on, backwards. A bracket was made to lock the cable in place (see image). The hard part was, cutting the cable and re-solder the metal tip back on... but make sure the cable is cut at the correct length. The metal piece that you have to re-solder, is the piece that hooks around the throttle linkage. Hope that helps.

[stylEmon]

Here is the Boost Juice system!!!!





Looks like it belongs in that bin, don't it!


Here is the second stage. I am running it post-compressor, pure methanol.



Here is my original AI system. It's a small injector, pre comressor, and is now spraying RO water ONLY. it will stay in tact and is activated at 1 PSI.


The second stage is wired into the MoTeC and went pretty smooth. So the MoTeC controls the AI system. Right now, the pump is on, or off. I don't yet have the ability to vary the duty cycle, but once I find the proper resistor, I'll have that ability.

[stylEmon]

It's been a while guys. I've had a little hick-up her and there and the car has been on the back burner.

What I did take care of:
The AI system is all wired to one pump. I still have two injectors; one pre, one post.
I had to track down a real annoying Fuel Pressure issue. The short story is, stock fpr is junk. I am looking to upgrade the rest of the fuel system but need to save up some cash. In the mean time, I'll get another stock fpr just to keep her on the road.
Got a new wideband sensor. I bought the LC-1 from a friend so it was lightly used. I was tired of guessing when it came to tuning so I replaced it.

That's it for now. I'll get some pics and keep ya'll up to date.

[Phoenix7]

What Air Intake Temps are you seeing with NO intercooler?

I have never seen a turbo rotary with no intercooler like that.

[stylEmon]

with AI, I am seeing 65* and dropping!!! (In the summer in PHX)
The longer I boost, the lower it goes.

[TehMonkay]

Dang

You consider getting a used perhaps hks TB adapter, even has a port for an extra injector.

[stylEmon]

I already have a Higgi elbow. Besides that, my injectors are already tapped and mounted.

[WE3RX7]

One more reason for me to move to AZ! More FC guys out there, lol.

Interesting setup though - good work. You wouldn't happen to know Elliot out that way would ya?

[stylEmon]

LOL, he did my entire set up. See his logo in my sig?
He is one of my real good friends, hang with him just about everyday.

[WE3RX7]

Cool - him and I were doing our conversions at the same time years ago. That was back when he was in IL.. I plan on having him do some coating/misc work for my FC project as well... glad to hear all is good w/ him and the shop these days...