Building a USDM Spirit R Replica

[Supernaut]

Welp, did not realize I didn't post this here. I could have sworn I did. Anyway, there are updates coming soon so I thought I'd just repost.

I've been planning to write this thread for a while but it's been taking forever finishing this project. I figured this should be as good a time as any.



When I first saw a Spirit R Rx7, I wanted one more than anything I have ever wanted in my life. When I finally did the research and found out that I would have an easier time importing a fighter jet, I knew I was in for some trouble. This started me on a 3+ year long journey (on going) filled with terrible decisions. If I have only one recommendation for someone trying to do a replica, that would be to find out what the project entails and draw a line in the beginning and stick with it. Chasing after the latest part you just found out about and building an FD right at the same time is a tough proposition. The only good thing about doing a replica is that there is a definite end.

Here's a list to help people out with their own Spirit R replicas. I don't have all these pieces but I'm pretty close! I'm sure I'm missing stuff in the list so feel free to add to it. I'll list JDM items only and I'll try to be as general as possible when applicable for the sake of brevity...

-99 spec front
-99 spec ducts
-99 spec spoiler
-99 spec front and rear emblems
-99 spec coin holders
-99 spec AC controls and dials (not installed)
-99 spec exhaust
-JDM foot rest (These came in the 2000+ RZ and Spirit R, not sure where else)
-JDM fenders with side markers
-JDM tranny tunnel cover
-Efini tail lights
-Spirit R badge
-Spirit R paint
-Spirit R wheels
-Spirit R engine bay tag
-Spirit R gauge cluster
-Spirit R grey interior panels
-Spirit R shifter + boot
-Spirit R ebrake handle + boot
-Spirit R ABS
-Spirit R carpet
-Spirit R recaro seats + tilt rails
-Spirit R Tow hooks?
-Spirit R grey block off for adjusting light levels for cluster
-Spirit R suspension
-Spirit R brakes
-Knee pad?
-Newer spec bracing for the rear

I couldn't have done this alone and have so many people to thank. I guess we should start at the beginning.

Thank you Charlie for selling me my FD. Reading the forums is definitely not the same as owning an FD and I remember asking you and Dan some terrible questions. Thanks for selling me the Spirit R wheels Dan. Thanks for the help guys!


Thank you Ihor (IRP) for the awesome work. Thank you both for being an honest and awesome mechanic. Thank you Rich for being my rx7 sherpa and taking the extra time and effort to make my FD extra special with great advice on parts and thank you both for being awesome friends.

(Ihor pre lift)

Thank you Noel and NOC Automotive for the awesome job refurbishing the chassis.

Thank you for proving to the world that if you throw enough money at a shop, they will pose any way you want for a picture haaaa!

Ahhh close enough.

Thank you Bryan, Jason, Ray and Rizwan for helping me source parts for my dream car. Thank you guys for answering all those dumb questions and for being awesome dudes.


Thank you Gene for being an awesome friend and helping me so much when I was unemployed and crippled.

Thanks for taking this awesome picture of me and not helping me out of my engine bay.

Thank you rx7 community for helping me finally build my replica dream car. I don't know how else to really express my gratitude to you guys other then this thread. You guys have been the best part of owning an rx7 and I doubt I'd be able to do anything similar at any other community. I've met some great friends here and have so many people to thank but I'll just quit while I'm ahead.

I'll try to post pics of some Spirit R goodies if enough people ask.

Now on to the next FD!

[Supernaut]

I don't have any nice interior pics. Right now my interior is a mess of wires for my GPS, V1 and whatever charging accessories I have. I've been trying to get someone with a nice camera to take some pics of the interior but it never happens so I'm always left to my own devices. Right now, my car is packed with stuff I'm trying to ship out .





I'll try to bug Polak Graphics, Sinned or Theorie until I get someone to take some pictures. I swear my interior looks better than in the pics. UGH.

[Supernaut]

Before


After


Thanks Tom
http://www.facebook.com/photo.php?v=551853439949

[Supernaut]

Well, it's been a while. Things have been really busy lately after an awesome summer. I'm glad to report that the car is doing well. Over the summer, finally had the chance to let Brian (TitaniumTT) get his hands on my car haha. I've always liked the guy and admired the craftsmanship on his FC so I had a single turbo conversion done at speed1 while he was there. The car has been really good to me and super fun. My bumper has a lot of carbon on it now. The summer of fireballs.

http://i.imgur.com/3NxquGG.jpg

Can't say that the engine bay is pretty but the car really runs like a champ. Brian and Speed1 really did a great job.

http://i.imgur.com/4hnwVeq.jpg

Need some fine tuning with idle, some paint correction and some ins and outs I'll probably visit IRP for. Other then that, I finally think that the only thing left for this car is cosmetics and that feels really good to finally say now.

454rwhp

[Supernaut]

More coming soon. Brian, that's your cue.

[TitaniumTT]

Oh hell yeah! Lemme get some pics up in the next few days of some of the goodies installed and some of the really phenomenal things coming.

The ultimate goal being a car that can drive cross country (although it's being shipped which makes me super sad she'll be 3k miles away) but start and drive like a stock FD. No hesitations, good pep down low, solid idle and no hesitation caused by any of the little quirks we've spent the last year ironing out. I want to give you a total sleeper that makes you smile when driving it around town, but one twist of the trim switch and firm nudge with the right pedal causes eye widening pucker that a turbo-charged rotary should!

[Fendamonky]

Originally Posted by TitaniumTT

Oh hell yeah! Lemme get some pics up in the next few days of some of the goodies installed and some of the really phenomenal things coming.

The ultimate goal being a car that can drive cross country (although it's being shipped which makes me super sad she'll be 3k miles away) but start and drive like a stock FD. No hesitations, good pep down low, solid idle and no hesitation caused by any of the little quirks we've spent the last year ironing out. I want to give you a total sleeper that makes you smile when driving it around town, but one twist of the trim switch and firm nudge with the right pedal causes eye widening pucker that a turbo-charged rotary should!

I call next!!


Sounds like you're going to have a badass toy!!

[Supernaut]

Originally Posted by titaniumtt

the ultimate goal being a car that can drive cross country (although it's being shipped which makes me super sad she'll be 3k miles away) but start and drive like a stock fd. No hesitations, good pep down low, solid idle and no hesitation caused by any of the little quirks we've spent the last year ironing out. I want to give you a total sleeper that makes you smile when driving it around town, but one twist of the trim switch and firm nudge with the right pedal causes eye widening pucker that a turbo-charged rotary should!

yesssssssssssssssssssss

[TitaniumTT]

Let the journey begin!
So after I handed Andy the keys @ S1 a few years ago, we had tuned to 454rwhp and the car was a monster. About a year ago something bad happened and the engine got hurt. The WM line blew off and all 6 apex seals bananaed and most of the side seal springs went flat and some even got pinched. Sad sad day. I actually heard you about a half mile away and my heart sank. I heard at least two faces down. When I drove the car that night I got her up to temp and punched her in 2nd and though.... aweeeeeeeeee... oh there's the boost. Yeah, we can do WAY better than this!

After tearing, inspecting, cleaning, inspecting, re-porting changing rotors to my favorite ones setting all the clearances, cleaning, inspecting, setting everything up.... we're ready to build!



Aweeeeeee yeah... slumbering beast!





Most people who know me, know that I effing HATE silicone couplers.... so it had to go... enter the Van Jen.



Slumbering monster ready to be dropped in



Incase anyone is thinking about being a dick, I did portmatch the elbow to the vanjen, not a quick task, and I should also mention that everything else was portmatched as well. Elbow to TB, TB to UIM, UIM to LIM, and of course, LIM to block

I like the concept of the Xessive LIM, but in practice it turns out it's a bit of a PITA. Every stud stripped on me when torquing to factory spec. Brian was displeased because I had already heli-coiled one of the housings (while installed, I do not recommend this at all) so I wasn't ready to take the turbo or the mani off to get the LIM out, so instead I had to heli-coil the 4 studs and I went ahead and heli-coiled and studded the long center bolt as well. All with the LIM installed. If they pull out (giggitty) I'm going to be very surprised.

[TitaniumTT]

Again.... ON WITH THE VANJENS!!!!!!!!





Muaaahaaahahaaa!!!!!!! Getting very close!



Oh yeah..... stock AST is a common failure point and just getting rid of it isn't the right way to do it either. EVERY rotary in my eyes needs an AST in some form or another..... here is the common way I go about it on the REW's or any 13B with the REW WP and housing. Works well. I wanted to do something similar on my FC, but sadly I didn't have the room... VMIC and all



First start up! The neighbors must be used to it by now. The first time I started up a fresh build, the FD showed up.... as in Fire Department



I can't imagine why!

[TitaniumTT]

I really don't see what the issue is









Aight.... enough is enough... time for some break-in miles!!!!!!

[TitaniumTT]

This happened frequently



Guilford beach!!!!




Misquomicut beach!!! Probably a two weeks before Maggie and I went back and got engaged!

[chibikougan]

Sweet!


Whats that blue stuff past the sand in the last pics?

[TitaniumTT]

Tfff

[TitaniumTT]

So that was the end of round 1. Round 2 is basically bringing this beautiful machine to the level that she belongs at.
Most know I've been a long time critic .... put politely, honestly I can't stand the fucking PFC and people didn't actually still buy them constantly, I would've rather put a few .45ACP's through the damn box as it literally cost two engines in this car. So after Andy drove her around on a very rough tune and making 2psi he was hooked. The engine I build completely changed the dynamics of the car and he wanted more. After some chatting and decision making we decided on the AEM Infinity 506 for a variety of reasons.
A few of them include ENGINE PROTECTION!!!!! Boost trim, closed loop fuel, knock control, traction control, launch control and the list goes on and on. I think Andy's comment was something along the lines of, soooo this ECU will make it drive like a $100k Porsche? Yes.... basically
A few of the other things in store for round 2 (which should be nearing the end in two weeks time) Boost trim, so we can go from ~5psi to 22psi with a simple twist of a knob, Actual IDLE control because lets face it, the PFC fails miserably in this regard, traction and launch control... YAAS!!!! and one of my favorites, real sensor data and the ability to see it without a disgrace of wires running everywhere.

When I was breaking the car in I noticed that the WB wasn't always working..... I opened the glove box and this is what I found.....



After trying to diagnose it I gave up in about .2s and closed the glovebox. The O2 started working again.... yeah... nope nope nop... we're gonna do something about that.

Also, there was a 10*C difference between the PLX gauges and the what the PFC was reporting. The senders are literally less than in inch apart.... yeah... nope nope nope nope.

So after a little searching I found this little guy, the BTI can bus gauge... I love the concept, and can't wait to try it out.

So we're going from all the PLX stuff....




To this little guy



Ohhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhh RIGHT!!!!!!!!!!!!!!!!!!!!!!!!



Oh, and there's this little guy... I love this little guy