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Old 04-09-2012, 10:16 AM   #1
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Default An Australian noob's attempt to make a mx-5 faster

Hey guys,

A bit of background, I am from Australia (Newcastle for the people who care). and Currently in 3rd year studying mechanical engeering at newcastle university. Where I am surrounded by other rev heads in projects such as Formula SAE. But I had no turbo expereience proior to this project.


I came across this forum about 2 years, and basically was the influence for me to buy a mx-5 (miata),

so I eventually found one I liked, a bit before christmas last year ie 16 months ago.

It was in excellent condition it had about 100,000km on it and was set up for hill climbs

and had the following modifications before i started

AutoExe 3-point front strut bar
AutoExe rear strut bar
AutoExe underbody brace member (set of front and rear)
AutoExe Ram Air Intake
AutoExe Spark Plug Cord
AutoExe (Racing Beat) Front and Rear Sway Bar
AutoExe Adjustable sway bar links (front)
AutoExe Front Body Kit
AutoExe Carbon shift **** (black)
Brown Davis Roll Bar
Sparco sprint V bucket seat (driver's side)
Tein Mono Flex with EDFC
Cusco Type RS 1.5way LSD (oil changed every 5000km) have been used for less than 30,000km
Exedy Heavy Duty clutch
Maxim Works Header with hi flow cat
D-Technic mid pipe (for GH-NB8C)
5Zigen A-Spec Muffler
Oil catch can
Buddy Club QF Rims (Forged) 15x7
Rays lock nuts (black)
RDA Slotted rotors front + Rear
Endless CCX Pads front + Rear
APP Braided Brake Hose
JDM tinted headlights
HID Kit (4300K)

An Australian noob's attempt to make a mx-5 faster-img_0562.jpg

So basically the car was great fun when I got it, about 2 months after getting the car, I "accidently" lost control of the car on a wet roundabout where the rear wheels attempted to overtake the front, Inconveniently a police man witnessed this event and didnít believe my story, and insisted that nobody controls a car in that manner without being completely aware of it

Inconveniently I had my license suspended for 3 months for this event.

Then mid last year I got bored of the NA power of the mx5 and decided to start force feeding it.


The first stage of my turboing the car was to install proper engine management (and yes i found the search bottom )

I went with a adaptronic E420c I acquired off Y8's with a bunch of wires which i decided to start again, and do all the wiring myself so I would get a better understanding of how everything worked.

An Australian noob's attempt to make a mx-5 faster-img_0013.jpg
Basically started with just the wires and plugs

An Australian noob's attempt to make a mx-5 faster-img_0028.jpg
Just an extension for the stock harness, firstly I can test if it works and something I can simply splice into without damaging the stock harness.

An Australian noob's attempt to make a mx-5 faster-img_0032.jpg
My wiring loom with e420c connected

An Australian noob's attempt to make a mx-5 faster-img_0173.jpg
Basically a dog breakfast by the end , but all the wiring has good solder connections and an additional plug for: Map sensor, iat, ect, wideband, launch control, 2nd fuel map, and others I cannot remember

An Australian noob's attempt to make a mx-5 faster-img_0176.jpg
Final install of my wiring loom/ecu, in the Australian model it sits nicely in the passenger foot well and there I a plate that goes on top, then carpets, so it all fits very nicely.

An Australian noob's attempt to make a mx-5 faster-img_0015.jpg
Uego wideband, and RX-8 injectors, which should be adequate for my 220ish power goals.
Attached Thumbnails
An Australian noob's attempt to make a mx-5 faster-img_0014.jpg   An Australian noob's attempt to make a mx-5 faster-map_sensor_vac.jpg  
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Old 04-09-2012, 10:37 AM   #2
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Photo at king edward park . Didnt even click thumbnail.

Hey man.

PMd.

Dann
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Old 04-09-2012, 10:53 AM   #3
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A little bit of background, In NSW (my state in Aus), modifying vehicles is illegal, and if caught you get a defect notice where you a required to take the car back to standard to keep your registration,

But in the case you want to modify your car but also want to be legal you require an engineer’s certificate from a NSW approved vehicle engineer, where they look over your car and make sure everything is road worthy etc, once they sign off you can be legal and never have to worry about the modifications. This means complying to the requirements of your engineer. this means getting an emissions test(only the one ever) and they require air boxes over pod filter, heat shielding on turbo, plumb back bov, quiet exhaust etc, hence the reason why I have done things a bit differently.

The second part of my build was the intercooler, I initially wanted to do an "over radiator intercooler" so I brought an intercooler to suit, but then changed my mind due to the problems of having to put smaller fans on the radiator and in case I ever want a thicker radiator it may cause lots of issues, So I finally decided to go with a traditional in intercooler position.

An Australian noob's attempt to make a mx-5 faster-img_0030.jpg
cxracing intercooler 18x12x3 should be enough for 220ish hp hopefully?

An Australian noob's attempt to make a mx-5 faster-img_0083.jpg
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after modification to suit front mount opposed to "in front of radiator" its handy having friends who can tig aluminium

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An Australian noob's attempt to make a mx-5 faster-img_0124.jpg
An Australian noob's attempt to make a mx-5 faster-img_0169.jpg
An Australian noob's attempt to make a mx-5 faster-img_0178.jpg
2" hotside intercooler piping

An Australian noob's attempt to make a mx-5 faster-img_0133.jpg
An Australian noob's attempt to make a mx-5 faster-img_0146.jpg
An Australian noob's attempt to make a mx-5 faster-img_0148.jpg
An Australian noob's attempt to make a mx-5 faster-img_0179.jpg
An Australian noob's attempt to make a mx-5 faster-img_0180.jpg
2.5" coldside intercooler piping, I drilled a 2-3/4" hole near head light to fit it in.
Attached Thumbnails
An Australian noob's attempt to make a mx-5 faster-img_0135.jpg   An Australian noob's attempt to make a mx-5 faster-img_0138.jpg  

Last edited by joelhartley55; 04-09-2012 at 10:56 AM. Reason: spelling
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Old 04-09-2012, 11:11 AM   #4
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The next stage for me was the turbo install with all the oil and water lines

An Australian noob's attempt to make a mx-5 faster-img_0019.jpg
An Australian noob's attempt to make a mx-5 faster-img_0020.jpg
I decided to go down the boring route of a brand new garrett GT2560r ie s15 spec r,

An Australian noob's attempt to make a mx-5 faster-img_0129.jpg
An Australian noob's attempt to make a mx-5 faster-img_0152.jpg
For the manifold I brought Dgmorr/steins old manifolds, I machined the faces to make sure they sealed nicely,

An Australian noob's attempt to make a mx-5 faster-img_0154.jpg
An Australian noob's attempt to make a mx-5 faster-img_0158.jpg
An Australian noob's attempt to make a mx-5 faster-turbo-1-.jpg
For the turbo lines I used "Proflow engineering" teflon braided stainless lines, at mates rates, definitely didnt want to skimp in this area!
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Old 04-09-2012, 11:20 AM   #5
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An Australian noob's attempt to make a mx-5 faster-img_0100.jpg
An Australian noob's attempt to make a mx-5 faster-img_0103.jpg
An Australian noob's attempt to make a mx-5 faster-img_0188.jpg
An Australian noob's attempt to make a mx-5 faster-img_0189.jpg
An Australian noob's attempt to make a mx-5 faster-img_0190.jpg

I also brought the dump off dgmorr, but for some reason it didnt really fit the aus model so i did a fair bit of modifying, 2.5" all mandrel bends and clears everything nicely on the second attempt! , first attempt didnt go well, hit the transmission tunnel when torque turned the engine ,
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Old 04-09-2012, 11:25 AM   #6
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An Australian noob's attempt to make a mx-5 faster-bov-2-.jpg
Plumb back BOV because I am a good member of society!
An Australian noob's attempt to make a mx-5 faster-img_0183.jpg
POD filter
An Australian noob's attempt to make a mx-5 faster-img_0803.jpg
Pod filter in enclosure, Intake simple 90* 3" mandrel with bov port and breather
Attached Thumbnails
An Australian noob's attempt to make a mx-5 faster-bov_vac_source.jpg   An Australian noob's attempt to make a mx-5 faster-img_0186.jpg  
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Old 04-09-2012, 11:46 AM   #7
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An Australian noob's attempt to make a mx-5 faster-img_0091.jpg
An Australian noob's attempt to make a mx-5 faster-img_0093.jpg
washer bottle, simply an aluminum water bottle with a hole in drilled in it, and stock pump used.

An Australian noob's attempt to make a mx-5 faster-img_0804.jpg
An Australian noob's attempt to make a mx-5 faster-img_0805.jpg
An Australian noob's attempt to make a mx-5 faster-img_0809.jpg
Turbo heat shield

An Australian noob's attempt to make a mx-5 faster-img_0801.jpg
An Australian noob's attempt to make a mx-5 faster-img_0806.jpg
An Australian noob's attempt to make a mx-5 faster-img_0807.jpg
An Australian noob's attempt to make a mx-5 faster-img_0811.jpg3
More photos, just because.....

An Australian noob's attempt to make a mx-5 faster-wheels-5-.jpg
Don't get to many ideas.....these are a custom 3 piece wheel hand made in Australia, and company shut down some time ago, so they are a rare piece


So Basically I was able to get the car running well with the turbo, the car has been completely engineered, the car is a blast to drive at the moment, but its already starting to feel slow already,

It currently has stock exhaust on it still and only running 6psi boost, Im planning on building a cat back 2.5" exhaust this weekend, I already have my magnaflow 22 11 5

then the following weekend it is going down to Sydney and getting dyno tuned and putting the ebc on and turning the boost up to about 12psi. and hopefully a few more horses come out!

Hopefully I havernt bored everyone to much, and its getting late so my punctuation/spelling might be a bit average.
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Old 04-10-2012, 01:17 AM   #8
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Quote:
Originally Posted by nitrodann View Post
Photo at king Edward park . Didn't even click thumbnail.

Hey man.

PMd.

Dann
Close but the photo was acctually taken at the end of Hickson st in Merewether
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Old 04-10-2012, 02:52 AM   #9
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Ahh I remember this car being for sale.

Pretty much in the same situation as you, 4th year Mech Eng student haha.

Have you spoken to any engineers yet? Who are you going through? Just finishing up the last bits and pieces on my na6, struggling to find brakes.
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Old 04-10-2012, 08:24 AM   #10
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Originally Posted by Nemo View Post
Ahh I remember this car being for sale.

Pretty much in the same situation as you, 4th year Mech Eng student haha.

Have you spoken to any engineers yet? Who are you going through? Just finishing up the last bits and pieces on my na6, struggling to find brakes.
I must of missed that part, it has all been engineered, and now is registered as a turbo car,

Simon Fell engineered the car if you want his number let me know, he did everything by the book, but at the same time didnt worry about every last little detail, as for brakes I would recomend nb stock brakes, as they were on a turbo car from factory, they will be able to be engineered as satisfactory brakes, without requiring a track brake test which can cost $2000ish, and have you researched much with the emissions test?

Where abouts do you live/study?

Its good to hear about other turbos getting around, Im going to do a write up in mx5cartalk as well.
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Old 04-10-2012, 08:43 AM   #11
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Welcome to mt.net.

Any specific reason why you have posted all your pics upside down?
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Old 04-10-2012, 09:18 AM   #12
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Quote:
Originally Posted by joelhartley55 View Post
I must of missed that part, it has all been engineered, and now is registered as a turbo car,

Simon Fell engineered the car if you want his number let me know, he did everything by the book, but at the same time didnt worry about every last little detail, as for brakes I would recomend nb stock brakes, as they were on a turbo car from factory, they will be able to be engineered as satisfactory brakes, without requiring a track brake test which can cost $2000ish, and have you researched much with the emissions test?

Where abouts do you live/study?

Its good to hear about other turbos getting around, Im going to do a write up in mx5cartalk as well.
Ahh woops, missed that bit about it already being engineered.

Yeah currently trying to hunt down a set of NB8B/SE/SP calipers and brackets however having a hard time sourcing them. Yep have already done and passed the IM240 etc, engineer is happy in that regards. All that is left for me is brakes.

Live just at the end of the freeway near Hornsby and study at UNSW. Wish I got involved in SAE earlier, dont have time to now. Would be keen to check out your car next time you're down in Sydney. Who's tuning it?
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Old 04-11-2012, 03:38 AM   #13
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Wow, you really modified that DP. Not sure why it didn't fit yours though.
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Old 04-12-2012, 12:54 AM   #14
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Quote:
Originally Posted by Nemo View Post
Ahh woops, missed that bit about it already being engineered.

Yeah currently trying to hunt down a set of NB8B/SE/SP calipers and brackets however having a hard time sourcing them. Yep have already done and passed the IM240 etc, engineer is happy in that regards. All that is left for me is brakes.

Live just at the end of the freeway near Hornsby and study at UNSW. Wish I got involved in SAE earlier, dont have time to now. Would be keen to check out your car next time you're down in Sydney. Who's tuning it?
It might be worth giving mx-5 mania a call, if you havernt already, they were able to source me a few oem part.

for tuning im using Ben Babich, as my friend is good mates with him and I'v seen some of his work, and he knows his sh*t.
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Old 04-12-2012, 12:56 AM   #15
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Wow, you really modified that DP. Not sure why it didn't fit yours though.
Yeah me either, it hit the subframe quite badly, Im more happy now anyway, as its 2.5" the whole way and has nice mandrels instead of the lobster back bends.
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Old 04-17-2012, 08:51 AM   #16
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last weekend I decided to stop being lazy, and finally got my cat back exhaust made,

I just used some mandrel bends from an old rattly exhaust and brought some new stainless pipe, and used a magnaflow 22x11x5 muffler (2.5" diameter)

It wasn't easy to fit it in but can be done given time and patience

I started working at 7am in the morning and got everything setup and tacked into place, and by 3pm it was ready for welding, then got a mate to weld it all together for me (I'm a terrible welder), and it was ready to drive by 9pm

As for the sound, I think it might sound a bit ricey but it doesn't really bother me, Its not drony at all while cruising but it is louder then the standard muffler. When you open the taps it gives a really nice deep smooth sound (heaps louder then stock!), especially when you put the roof down.

Photos:
An Australian noob's attempt to make a mx-5 faster-img_0814.jpg
An Australian noob's attempt to make a mx-5 faster-img_0815.jpg
An Australian noob's attempt to make a mx-5 faster-img_0816.jpg
An Australian noob's attempt to make a mx-5 faster-img_0817.jpg
An Australian noob's attempt to make a mx-5 faster-img_0818.jpg
An Australian noob's attempt to make a mx-5 faster-img_0820.jpg
An Australian noob's attempt to make a mx-5 faster-img_0821.jpg
An Australian noob's attempt to make a mx-5 faster-img_0822.jpg
An Australian noob's attempt to make a mx-5 faster-img_0823.jpg
An Australian noob's attempt to make a mx-5 faster-img_0824.jpg
An Australian noob's attempt to make a mx-5 faster-img_0825.jpg
An Australian noob's attempt to make a mx-5 faster-img_0826.jpg
An Australian noob's attempt to make a mx-5 faster-img_0827.jpg
An Australian noob's attempt to make a mx-5 faster-img_0828.jpg
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Old 04-17-2012, 09:19 AM   #17
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Not hating at all. but that is WAY more complicated than it needs to be haha.

Dann
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Old 04-17-2012, 10:21 AM   #18
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Not hating at all. but that is WAY more complicated than it needs to be haha.

Dann
I will admit it is more complex then it needs to be maybe 3-4 extra welds because of my stuff ups, but the shape of it is very similar to the the stock exhaust shape (stock muffler is 2" shorter then this one).

But I wouldnt say it is WAY more complex then it needs to be.
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Old 04-17-2012, 10:38 AM   #19
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Good to see the Aussies representin'!

I am still waiting on rods before my built engine can be put together. :(
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Old 04-17-2012, 11:16 AM   #20
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Thats how easy it can be. Not to say I havnt done more complicated ones.

Dann
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