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Old 07-05-2015, 05:11 PM   #1
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Default 99 MK Turbo beta test

Hi all, so here goes my MK Turbo build.



Here is my waste gate porting, we will see how it does.





My kitty checking out one of Lars' custom boxes.





Everything fits very well.








The 4 hanger system working well, honestly mazda should have done this IMHO.






Very nice fit.



Charge piping almost figured out.
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99 MK Turbo beta test-80-img_20150705_113330936_hdr_2b7e8149795e44fb69dad964ad4a829bba8761cf.jpg  
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Old 07-08-2015, 10:43 AM   #2
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It is looking good so far. I am interested in following how you do the rest of your IC piping. I will be installing a setup on my 99 very shortly so I am looking for ideas.

Also you may need to port your wastegate a bit more then that.
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Old 07-08-2015, 01:15 PM   #3
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Thanks!
I am basing my intercooler pipes on patsmx5's build IIRC except my wife has requested I retain a/c. I also didn't want to move my radiator so I cut the support quite a bit. I have made some more progress but some of my family is in town right now, will post more pics in a day or two.
I will take it apart and port it some more after I at least try it out. I already set up overboost protection and I plan to run the actuator as is from the compressor housing with a slightly shorter line for now. I also found a few seal washers in my mom's garage left over from my old rx7 days, so I thought I would see if they work to seal the compressor bolts that pass through the housing.
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Old 07-08-2015, 11:53 PM   #4
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Hot side








This part still needs some adjustment and I am short 3 clamps. The hot side is all 2" except for this bending reducer.





12 x 11 x 3 cx racing bar and plate intercooler, fairly decent construction. Could have gone longer and inverted it for a very direct route if I gave up a/c.





Cold side





It is pretty tight here all 2.5" on the cold side probably should have gone with 2.25. Need to figure out what to do about my horn.





60 bend off the TB to my cheapie silicone BOV port, which seems much nicer than I expected. Then 2 90's to the straight verticle aluminum tube which I will mount my IAT sensor to soon, and one last 90 to the intercooler outlet.





Oh yeah, that was fun! I ran the shop vac, kept everything greased and poured a quart of mineral spirits through. But after reading some build threads I decided to carefully save the old oil in a clean container, only about 1.5k on it. I am thinking of pumping the saved oil back into the top of the motor with the drain plug out in an attempt to wash more shavings out, any thoughts on this idea will be much appreciated.





Hey Lars, is this right? It must be, pretty clever.

Attached Thumbnails
99 MK Turbo beta test-80-img_20150708_171849126_9a334899ef11adb3bff28de8778041f3cfe1bec6.jpg   99 MK Turbo beta test-80-img_20150708_171931604_90525a15796c23796ef750ff68bdf068ba2b3d5b.jpg   99 MK Turbo beta test-80-img_20150708_172020840_3cab999ef40cf901309573d8ab255229585dcb16.jpg   99 MK Turbo beta test-80-img_20150708_172036118_34033396872d2637f4ec659d94b0a544794d3d27.jpg   99 MK Turbo beta test-80-img_20150708_172007229_93ea8402e127ce647ab31897b8d39f6f5eff5c94.jpg  

99 MK Turbo beta test-80-img_20150708_171939741_b2de9f69655891e5173c6801b4324ded3e4e5521.jpg   99 MK Turbo beta test-80-img_20150708_171907105_765403336056734d15eafa389c1d420925598930.jpg   99 MK Turbo beta test-80-img_20150708_172254483_1a5abb4979aec904786e1d0f72ff8d696f4a1718.jpg   99 MK Turbo beta test-80-img_20150708_171820621_hdr_2fee5758cc6562e293e1333b923374ef978f7651.jpg  
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Old 07-10-2015, 09:47 PM   #5
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Finally got everything back together, just need to lower the car put the bumper back on and add fluids. Everything fit very well, no problem with the a/c compressor or the power steering pump. I will post a few pictures soon.
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Old 07-13-2015, 12:32 AM   #6
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Here are a couple log views, I need to port my waste gate more.








This thing is pretty fast and I am very happy with my MK Turbo. Thanks Lars!
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Old 07-13-2015, 12:54 AM   #7
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Still needs a few things.

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Old 11-02-2015, 01:41 AM   #8
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I guess it's time to stop neglecting this thread but I have been having so much fun blasting around with this thing. 5k so far and I ran into my first problem, the cam seals started leaking.
With over 230k on my original motor it was not unexpected, although I suspect the PO may have used cheap seals on the last timing belt change. The belt was also not properly tensioned among other things.




New dealer seals and timing belt.

It seems much faster with the timing belt tensioned properly, maybe I am just imagining it.
Anyway back in action again as fast as ever
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Old 11-03-2015, 08:03 PM   #9
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Default Fuel pump?

So everything is running great since the new timing belt until today. I stop at a stop sign and the car dies. It starts for a second and then dies almost like I don't have enough ASE.
The fuel pump sounds a little different when I first turn the ignition on than it did before.
It is a stock NB return less pump with 230k miles.
I need to have it towed home Still no problem with the turbo kit though. It must be the most reliable part of my car.
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Old 11-03-2015, 09:52 PM   #10
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Looks like I can leave my car where it is for a day or 2.
New pump ordered, hopefully no one will notice me changing it on the street.
Looks like most stock fuel pumps don't last 230,000 miles so I can't really complain. I thought I would blow up more serious parts sooner. I know, I know, it's coming so don't worry.
The worst part about this fuel pump is I spent some time on my tune last night. Then after 3 drives and tons of fun it dies so I panicked and started reloading various old known good tunes to start the thing. So now I lost the new tune that was f***ing awesome
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Old 11-04-2015, 10:31 AM   #11
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Always save your work! If the fuel pump was dying during your awesome tuning session, than the fuel map is likely bad anyway.
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Old 11-04-2015, 10:53 AM   #12
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Quote:
Originally Posted by acedeuce802 View Post
Always save your work! If the fuel pump was dying during your awesome tuning session, than the fuel map is likely bad anyway.
Good points, the older tunes are pretty good, thanks for making me not be so annoyed with this.
On my way to pull the pump before I have to go to work, should be back in action by this evening.
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Old 11-04-2015, 11:40 AM   #13
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Fuel pumps on NA are pretty easy. I have yet to do one on a NB, but you should be able to knock it out in an hour or two. Do you not constantly save all your tunes?
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Old 11-04-2015, 11:44 AM   #14
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Typically I do, but I was at a stop sign blocking traffic and panicked a bit.
Don't panic, just save your tune first.
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Old 11-04-2015, 08:59 PM   #15
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I was able to drive my Miata to work It was the fuel pump, took about an hour and a half, including a trip back to my house for crimpers and connectors. I should have got the TSE pump, looks like a nice kit, but I needed it ASAP. I think I will get one to have on hand for next time, if I ever get my butt down there to visit Nigel and meet savington.
Looks like it's the same as an NA basically. Honestly the hardest part was getting the push tabs that hold the carpet in place out. Even with a nice little nylon prybar with a notch for those kind of fasteners. I had to start them with the prybar, then I just grabbed them with small needle nose. I would only remove driver side next time and fold it over the passenger side to save time.
Thanks for the support!
I will work on the tune again and save it before I go out for a drive this time
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Old 11-19-2015, 12:54 AM   #16
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Went to the last regular local drag race of the season, it is a notoriously slow 1/4 mile. I ran a 14.1 @ 99.8mph.
Unfortunately one of my hooptie dented denso connectors failed after that.






2nd one I noticed the injector connection failure.

The Pontiac ahead of me ran a 14.7, an older 5.0 was running 14.8. I was also faster than a brand new STI with no plates yet, with an experienced driver who was getting .016 reaction times.
On my first run I beat a new Camaro after he got the jump on me, caught up by 3rd gear. He didn't even say hello.
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Old 11-19-2015, 12:57 AM   #17
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Should have listened to Aidan and soldered them in.
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Old 11-19-2015, 01:02 AM   #18
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For the record 14.1 @ 99.8 is exactly the same time as my friend's old 13b bridgeport with a 750 double pumper used to run at the same track. We used to beat late 90's vetts back when they were new. People were very impressed with my time.
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Old 11-19-2015, 03:18 PM   #19
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Swapped out the old connectors for a set Nigel gave me a while back. They are still the short ones so I put the 2 dimples closer to the end of the connectors and loaded them up with Vaseline. We'll see how they hold up, I ran probably 7k on the look last ones. Anyone have a 99 engine/injector harness for sale that I can cut up?
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Old 11-19-2015, 03:21 PM   #20
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Running perfectly again, no major knock was recorded in my log during the failure, so it looks like I was very lucky
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