AutoFreak57's build thread
 

Well I probably should have started this a while ago, but better late than never.
I'll start with pictures in a semi-chronological order.
The first couple posts will be stock photos, but turbo goodness will come shortly
First day I bought the car:
http://img294.imageshack.us/img294/1791/firstday.jpg

A couple more stock pictures:
http://img200.imageshack.us/img200/7...icksilver1.jpg
http://img29.imageshack.us/img29/4058/quicksilver3.jpg
http://img718.imageshack.us/img718/7...icksilver4.jpg
http://img30.imageshack.us/img30/7306/quicksilver6.jpg
http://img132.imageshack.us/img132/160/quicksilver7.jpg
http://img30.imageshack.us/img30/6388/quicksilver8.jpg
http://img29.imageshack.us/img29/9810/quicksilver9.jpg


Tomorrow: Parts

Mmmm... 04 azure... now where are the 'not bone stock' pics?

needs moar buckeye

single red stripe right down the middle - 14 inches wide = profit!

lovin' the cityscape shot!

So Azure is what that color is called, never knew. I decided to change my update schedule because pictures of a stock miata are boring.

Bought the car in October. In December I started ordering parts. First was a used FMII kit. I bought a kit for an NA, so I sold a few parts and bought the correct NB parts
NA FMII Kit:
- GT2560 Turbo
- Large intercooler upgrade
- Manual boost controller
http://img517.imageshack.us/img517/626/turbokit1.jpg
http://img266.imageshack.us/img266/3493/turbo2w.jpg
http://img257.imageshack.us/img257/6897/turbo1z.jpg

NA Parts I couldn't use:
-Downpipe
-Intercooler brackets
-Throttle body adapter
-Oil Feed
-Air Box
http://img266.imageshack.us/img266/5...turboparts.jpg

Innovate LC-1 and G-2 gauge:
http://img266.imageshack.us/img266/5239/turbokit2.jpg

Track Dog Racing Gauge Panel:
http://img155.imageshack.us/img155/5151/gaugepanel2.jpg

Used FM Turbo Muffler (stock on bottom):
http://img28.imageshack.us/img28/7445/mufflerl.jpg

Other parts I do not have pictures of:
- 10AN SS Drain line and fittings
- 6AN SS Coolant lines and fittings
- FM Feed line
- Adaptronic ECU
- Deatschwerks 600cc
- Summit Racing Coolant temp gauge and sender
- Sunpro Boost Gauge (FM one was broken)
- M-Tuned coolant reroute (ended up selling because of redesigned head gasket)
- DIYAutoTune GM IAT sensor
- Rest of parts for FMII kit from Flyin' Miata
- 323GTX PCV Valve
- Used RoadsterSport 2.5" Midpipe
- NGK BKR6E spark plugs
- EGR Block-Off Plates

Everything Ready for install:
http://img28.imageshack.us/img28/3282/turbokit3.jpg


Tomorrow: Coolant reroute saga and Adaptronic install

Subscribed to see this come together.

This thread will deliver faster than usual because I started it after I built the car :)

This thread has all the elements of win so far. I always loved the azure package to begin with and on top of that, I get to see a turbo build thread that moves really fast. Perfect.. now don't follow the usual trend of breaking things.

AutoFreak57, i love the car. i saw this build on 502streetscene. im 4gotn1 over there. i would love to see the car in person sometime. its looks pretty nice.

this thread needs resized.

From the halves of photos that i've seen, this thing has some serious potential!

Forum should automatically resize photos that are too big.

https://www.miataturbo.net/profile.php?do=editoptions

Leave it blank and it'll resize everything down to 720 width.

Wow, I never knew!!! :idea: It's like...it's like....um....

A whole new world
A new fantastic point of view
No one to tell us no
Or where to go
Or say we're only dreaming

A whole new world
A dazzling place I never knew
But when I'm way up here
It's crystal clear
That now I'm in a whole new world with you
Now I'm in a whole new world with you

Thanks! If you were a hot girl, I'd make out with you :makeout:

(Regardless of whether or not you showed me the path to [IMG] happiness)

Parting ways with the NA parts you dont need?

I really should do go to a meet sometime. You coming on the drive on sunday?

Already did. Sorry



This thread will be updated within the hour. Gotta get it all together

Sell me that airbox cheap.
__________________
Best Car Insurance | Auto Protection Today | FREE Trade-In Quote

Sold all na turbo parts already.


Starting on today's update right now

I should ban you......
__________________
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So I wanted to get as much installed before the turbo install. The first things I went to install were the coolant reroute and Adaptronic.

Coolant reroute:

This install is really straight forward as long as you actually remember that one bolt is longer than the rest and must go in the back of the head. I spent what seemed like 2 hours trying to start the threads in the back before I realized that. When I went to go back to stock it took about an hour to hour and a half for the whole thing.
After installing and bleeding like 10 times, I was never able to get rid of an overheat on startup. I did end up cutting the hose shorter than it is in these photos to eliminate an air bubble that was probably sitting in the hose, but it would always go all the way to hot then return to normal and never overheat again. Between that and the thread on m.net about the redesigned head gasket, I removed the reroute and sold it. After returning to stock and without burping the system, the start overheat was gone.
Overall, I am very impressed with the kit. It is very high quality. The only thing I would change is the make the lower part of the coolant outlet smaller. It is so big it needs the longer bolt, gets stuck on the egr pipe on the way in, and I could not see a reason it was so big

Engine Pic (notice big curve in outlet hose)
http://img22.imageshack.us/img22/2286/engine1h.jpg
Coolant Outlet
http://img641.imageshack.us/img641/6...ntreroute2.jpg
Thermostat Housing
http://img576.imageshack.us/img576/9...ntreroute1.jpg

Adaptronic:

The Adaptronic install went pretty well. Travis came over and helped install it. We did not get it running that day because I forgot to buy a tuning cable and Travis didn't bring his, but he did solder everything in and install it for me. Something I did not realize, it takes 5 minutes to make the car run on the stock ECU. Just unplug the MAP sensor, plug in the MAF, and switch ECU plugs
The location in the manual did not work for me. The harness would not reach. The picture below shows the location I used. It is behind the steering wheel panel, underneath the steering column. It is zip-tied to the dash frame and does not move. I need to make a bracket for it, but it is just so tight down there. Also, if you push the ECU too far up, it will push the dimmer out.
About two weeks later I got a tuning cable and got the car started on the base map. I drove it like that for a while, but never got a decent startup by myself so I returned to stock. After the turbo install, I got the car up and running on Travis's new base map. Starts first try now.
Map sensor - I am not happy with map sensor location. It is mounted to the ground location at the throttle body. It is either tighten the bolt down until the sensor breaks (did that :facepalm:) or have an occasional loose ground. I am going to move the map sensor to the washer bottle location soon.
I did install the LC-1 at this point. I zip-tied it to the brake lines. It has since moved twice. BTW, if you mount the LC-1 under the hood, it is a stretch to get the O2 plugged in after going turbo.

Location (camera is by clutch pedal looking up)
http://img641.imageshack.us/img641/4706/adaptronic1.jpg

Map Sensor Location (blue hose replaced within a week)
http://img526.imageshack.us/img526/5415/mapsensor1.jpg

First LC-1 location
http://img32.imageshack.us/img32/4508/wideband1.jpg


Next Update: Gauge install

That would not be very nice

i was not aware of any drives this sunday. i was thinking about working on my car sunday, but not really wanting to do much since it will be my only day off till next weekend. i might be up for a drive tho. when and where?

Meet around the back at St. Matthew's at 11. It's the parking lot at the back corner by the highway. By Dillards I think. There is a thread on 502 about it. In the social section. It's titled Southern Indiana Road meet or something like that

Ok, it has been a couple days, so I guess I should update this.

Next was the gauge install. The previous owner put in the sony radio and cut the stock radio connector almost all the way off. I decided to reattach it to the harness and get an adapter for the radio. I then wired my gauge lights off of the radio and made a harness the signal wires for the gauges. I used the wiring connectors they sell at radio shack to make the harness. I also got all my gauges working 100% at this point. This was all over Easter weekend.

The miata had some roadster company
http://img517.imageshack.us/img517/644/mgandmiata1.jpg

Picture of the TDR gauge panel again
http://img266.imageshack.us/img266/5151/gaugepanel2.jpg

Wiring mess after day 1
http://img27.imageshack.us/img27/4803/wiringmess.jpg

Hood open to wire up sensors (note: actually had coolant reroute installed at this point, beauty of after the fact builds)
http://img576.imageshack.us/img576/7...geinstall7.jpg

Me staring very intently at something (I think I was messing with wiring connectors)
http://img820.imageshack.us/img820/2...einstall10.jpg

Here is a side view of the TDR gauge panel. I am not a fan of how thin it is, I was expecting a little more for the price. I still like the gauge panel and it would be my choice if I did it again too. The push button is the calibration for the LC-1. Takes me 5 seconds to pull out the gauge panel to calibrate if I want to.
http://img266.imageshack.us/img266/6...einstall14.jpg

Best picture I have of it installed (This was actually taken this weekend)
http://img517.imageshack.us/img517/8427/1005311f.jpg

Also removed baby teeth
http://img267.imageshack.us/img267/1256/babyteeth5.jpg
http://img266.imageshack.us/img266/9982/babyteeth1.jpg


Next update: A close-up of the completed gauge panel

Here is a close up of the gauge panel I took the other day

http://img64.imageshack.us/img64/5168/gaugepanel5.jpg


Next: The fun part...

So I guess it's turbo install time. I did this over Memorial Day weekend and it was hot as balls inside the garage.

Thursday:
Friend comes down from Columbus and we take the car and parts over to a co-workers garage. Put car on lift and spread parts out to make sure we have it all. Leave car over night to cool off. Here are pictures of the garage. It is 40'x70' with a lift.

Note: My friend takes shitty pictures so some of these are blurry

http://img25.imageshack.us/img25/7986/dscf1083nw.jpg
http://img413.imageshack.us/img413/9960/dscf1088r.jpg
http://img709.imageshack.us/img709/6089/dscf1086v.jpg
http://img217.imageshack.us/img217/3060/dscf1085m.jpg

Car on the lift
http://img97.imageshack.us/img97/9153/dscf1089a.jpg

I'm super strong!!
http://img94.imageshack.us/img94/301/strongfeller.jpg


Next update: Day 2 of turbo install

Pretty sweet garage... all my work gets done in the driveway :(. And I don't think 'day 1 of turbo install' should count. Seeing as day 1's pictures include the car being in the garage and up on the lift. Now show real build pics, with stuff taken apart, and then a big hunk of metal hanging off the block.

+1

Well you're lucky, because we took all the pictures on day 2 so no boring pictures of taking it apart. The rest of the days will be posted later today, just wanted to post a teaser, see if anyone was paying attention

Ok, so here is the actual turbo install. Will post cliffs in a couple minutes if you don't feel like reading all this

Day 2 - Friday
My 2 friends and I get an early start (8AM-ish) and go over to the garage (It was really more like 1 friend cuz the other never really did anything). The goal for day 1 was to get everything uninstalled. Tore apart everything and had no real surprises. Installed the injectors and the 323 pcv valve. Cut the access slot from the flyin' miata directions and went to install the turbo/manifold/elbow. We could not get the assembly on. The little slot was just not enough room for the turbo to fit in. We ended up pounding down the whole section next to the turbo to get it to fit. I think the slot might work if I was running the banjo bolts, but not with my AN fitting. We called it quits about 9:30PM and drank way too much Captain's.

Day 3 - Saturday
We got a late start (10-ish) because we were all hung over. We got everything installed this day and took all the pictures. Here are the things we struggled with. Because this kit has the upgraded intercooler, I had to bend a bunch of AC and PS lines (expected) and bend the horn bracket (unexpected). The intercooler was also a pain to install because we didn't pull the bumper off. The downpipe nuts are very hard to tighten. We ended up with a little exhaust leak and had to retighten a couple. The FM exhaust brace does not work with the roadster sport midpipe. It pushes the exhaust like 1" too far over to meet the downpipe. Anyone want a FM exhaust brace? The FM lower coolant hose is a pain in the ass. It leaked on me before I went turbo until I clamped it really tight on the block. It is very hard to get over the radiator inlet. We tried to press -6 lines onto the coolant outlets on the engine and could not get the bottom one on. We ended up using the stock hose to go up to the top of the PS pump and then a bung to the stainless line. We had the car on 4 wheels and put together by sunset. Hooked up the ECU and calibrated the sensors. Find out the 3-bar map sensor is toast (reading 3 bar all the time). Now I'm really frustrated, but we are done for the night. Drink, play pool, sleep.

Day 4 - Sunday
We search around for a 3-bar map and cannot find one locally. About to leave to get a 2-bar and Travis calls. He ends up bringing a new 3-bar over and gives it to me. Car cranks over and starts, but idles like complete crap. This is also where we find the exhaust leak. Travis spends a couple hours trying to get it to run right, but no go. We did put a suspension on my buddies STi though. So still no car :(

Day 5 - Memorial Day (Monday)
Get there in the morning, kinda depressed. Try to start it again, still idles like crap. I get looking through all the sensor readings in the computer and notice a weird trend in the injector test. 3 of the 4 injector voltage tests are over each other. Cylinder 1 has a flat line. Tear the intake manifold apart and pull the connector off. We managed to bend the electrical tab on the injector when we installed them. Plugged it in right, cranked her over and she runs purrs like a kitten. Button up the car, do a little tuning, and go play putt-putt!

Actually installed the heat shield and underbody during the week after the install.

Pictures (no particular order):

Tapping the pan. It is very tight in there, but not hard to drill at all
http://img404.imageshack.us/img404/4871/0528101524a.jpg
This is what she looked like after day 1
http://img413.imageshack.us/img413/793/dscf1013k.jpg
You can see the shelf we beat up
http://img15.imageshack.us/img15/5976/dscf1014h.jpg
http://img708.imageshack.us/img708/182/dscf1015v.jpg
Decent shot of oil sump for people who want to see the space we're working in
http://img156.imageshack.us/img156/176/dscf1022.jpg
Large intercooler really fills the mouth
http://img16.imageshack.us/img16/7942/dscf1029qv.jpg
Close-up of oil drain
http://img203.imageshack.us/img203/9669/dscf1032.jpg
Coldside pipe
http://img52.imageshack.us/img52/3561/dscf1036d.jpg
Hotside pipe
http://img215.imageshack.us/img215/2327/dscf1037r.jpg
http://img704.imageshack.us/img704/2194/dscf1038n.jpg
http://img269.imageshack.us/img269/2382/dscf1043n.jpg
http://img405.imageshack.us/img405/9509/dscf1044s.jpg
Stainless Coolant Lines
http://img85.imageshack.us/img85/884/dscf1045m.jpg
http://img291.imageshack.us/img291/5679/dscf1046l.jpg
http://img189.imageshack.us/img189/7215/dscf1049c.jpg
http://img686.imageshack.us/img686/9238/dscf1050r.jpg
http://img709.imageshack.us/img709/3261/dscf1051a.jpg
http://img25.imageshack.us/img25/3565/dscf1055v.jpg
http://img34.imageshack.us/img34/3848/dscf1056p.jpg
http://img268.imageshack.us/img268/9240/dscf1069w.jpg
http://img38.imageshack.us/img38/7568/dscf1079y.jpg
http://img718.imageshack.us/img718/7438/0602102029a.jpg

Cliffs
-Everything installed in 2 days, but would not run right
-Broke 3-bar map sensor by over-tightening
-Travis brought new one over but car would not run right
-Bent connector on injector 1, fixed and she ran
-FM exhaust brace does not fit with roadstersport midpipe, but is for sale
-Drilling and tapping the pan is very easy, despite the tight space
-FM's cut-out slot is too small, solved with BFH


Next update - The next 2500 miles after turbo

Not half bad. Just one question... why in the world did you drill and tap the oil pan with it on the car. It isn't that difficult to pull off, especially with your nice lift and would've made the process much easier.

Looking nice. In for videos.

It took maybe 15 minutes to drill and tap the pan. That included stepping up the drill size at least once. Looks like you would have to drop the subframe to take out the pan. Even if you don't, I bet it would take me longer to get the pan off and back on. It is not hard at all to drill the pan. You can almost get a straight shot at the pan with the drill.

Well there's an autox tomorrow so you might get one

Car was not running for the first time yesterday. Full update and results soon. Need to upload video first

Ok, finally updating this.

Issues since turbo (~3000 miles)

-Random erratic idling. Turned out to be adaptronic adapter board got scratched.
-Overheating on highway
-Broken map sensor


1) Random erratic idling.

It turns out the adapter board was rubbing on the clutch pedal switch for the cruise control. It was jumping the idle control and making it go all the way open. I "fixed" that by covering the back of the board in e-tape. Noticed some bad solder joints too. Now some of the wires are crossing and messing with the idle. This week Travis is bringing a new adapter board to me and we are switching mine out.
Pictures:
http://img514.imageshack.us/img514/6273/1005658h.jpg
http://img827.imageshack.us/img827/9032/1005659.jpg
http://img838.imageshack.us/img838/8963/1005660.jpg
http://img838.imageshack.us/img838/7426/1005661.jpg
http://img838.imageshack.us/img838/5579/1005662.jpg
http://img828.imageshack.us/img828/2295/1005667.jpg
http://img838.imageshack.us/img838/5586/1005668.jpg

2) Overheating

The car was overheating on the highway. It was 104*C-110*C on the highway. I made sure the system was bled and I put the underbody back on. Still ran pretty hot. The solution will be my next update.

3) Broken map sensor

I did my first autox since the turbo install on 7-11. I made it to corner 5 and it broke. I was at about 7000rpm and went hard onto the brakes. What I think happened is the engine torqued over and the map sensor hit the hood. There is a large scratch directly above the map sensor. As I said before, do NOT mount a map sensor to the throttle body like I did. Met the nicest guy with a locost that loaned me his truck to get home. Replaced the map sensor and moved it to the washer bottle and got the car running.

Dave's Locost ('93 miata based)
http://img638.imageshack.us/img638/7893/1005746.jpg

Tow Rig Home
http://img8.imageshack.us/img8/1117/1005753t.jpg

Original, bad location
http://img526.imageshack.us/img526/5415/mapsensor1.jpg

Relocated map sensor
http://img840.imageshack.us/img840/4964/1005848m.jpg
http://img833.imageshack.us/img833/7661/1005846g.jpg
http://img16.imageshack.us/img16/300/1005847w.jpg



Next Update: Radiator install

Since the car was overheating, I decided I needed a bigger radiator. I bought the Mishimoto because my friend had good luck with one in his RSX and it was cheaper than the Koyo. I read about the fitment issues and was expecting to fight it putting it in. It actually went in very easily. I think I spent more time taking pictures than actually installing it. I also put a 180* thermostat in.

Modifications I had to make to install it:
-Bent the AC condenser brackets forward maybe 1/4". Not hard to do; just unbolt condenser and shove forward by hand
-Installed radiator without fans attached
-Moved clamps on charge piping around so they would not hit the fans
-Cut the bottom corner of the drivers side fan shroud off because it hit the PS lines

Here is the radiator when I got it
http://a.imageshack.us/img832/5499/1005676.jpg
http://a.imageshack.us/img821/3696/1005677.jpg
http://a.imageshack.us/img412/286/1005678l.jpg
http://a.imageshack.us/img836/1701/1005679.jpg
http://a.imageshack.us/img821/435/1005681.jpg
Compared to stock radiator
http://a.imageshack.us/img405/830/1005692.jpg
Stock
http://a.imageshack.us/img836/2141/1005685.jpg
http://a.imageshack.us/img832/2631/1005686.jpg
Remove driver's side fan so I can get to the lower radiator hose from the top
http://a.imageshack.us/img836/1744/1005687.jpg
http://a.imageshack.us/img412/7782/1005688.jpg
Here is the back of the AC condenser. Unbolt and bend the top tabs forward
http://a.imageshack.us/img651/9720/1005689.jpg
Replace Thermostat
http://a.imageshack.us/img412/3931/1005690u.jpg
http://a.imageshack.us/img843/4163/1005691.jpg
Fans bolted up with 0 modifications
http://a.imageshack.us/img801/9153/1005693.jpg
Mishimoto sitting in place
http://a.imageshack.us/img651/2330/1005694.jpg
Driver's Side Fan Shroud Modification (I think I made the cut a little bigger than this)
http://a.imageshack.us/img405/1548/1005697u.jpg
Clearance to charge pipes (clamp rests against fan)
http://a.imageshack.us/img843/3227/1005696.jpg
Stock Swaybar clearance
http://a.imageshack.us/img843/4438/1005695.jpg
Finished
http://a.imageshack.us/img843/6845/1005698.jpg
http://a.imageshack.us/img801/375/1005699.jpg


Now this thread is caught up to current events. Who knows what the next update will be.

De-rats-nest-ify the wiring and vac hoses. How has that radiator been working out for you? Any over heating issues since?

I had leaking issues with their cap, ditch it.

Haven't ran the car for a long period with the computer hooked up, but the fans aren't on all the time anymore. So that is a pretty good sign it is not overheating anymore. If you are talking about the gauge wiring rats nest, it is actually better than the last picture. Everything is in a harness and is removable from the car and the panel disconnects from the harness


Yeah, I heard about that and I was planning on picking up a cap from AutoZone or something

Well, I did some more modifications. First, I did install the stock radiator cap onto the Mishimoto.

Next, I picked up some winter gear off of Craigslist. 5 - 15" Borbet wheels with winter tires and a hardtop. I might get it painted by winter time, we'll see.
http://a.imageshack.us/img32/8332/1005963j.jpg
http://a.imageshack.us/img231/1534/1005971.jpg
http://a.imageshack.us/img811/4048/1005972.jpg

I also decided that my FM turbo muffler was too quiet. After running no muffler for a little bit, I decided on an Enthuza Lightweight Turbo muffler. Arrived about a week later and it took me 15 minutes to install. I love the new sound. It is the perfect volume and not boomy on the highway. The FM muffler is for sale in the classifieds too.
Free beer coozie too!
http://a.imageshack.us/img841/1541/1005970.jpg
http://a.imageshack.us/img231/4826/1005962.jpg
http://a.imageshack.us/img32/2908/1005964k.jpg
http://a.imageshack.us/img199/2359/1005965.jpg
http://a.imageshack.us/img819/1051/1005967.jpg
http://a.imageshack.us/img198/6697/1005968t.jpg
http://a.imageshack.us/img197/2706/1005969.jpg

Next update: maybe a dyno tune....

Well it's official. I'm getting the car tuned on September 18th. Looks like I will be running 10psi which should give in the range of 250whp. I'm looking forward to it because I have been too lazy to put the time into cleaning up the tune after I got VVT working.

Here is a new autox pic too:
http://a.imageshack.us/img52/1180/pic2wb.jpg

Result of dyno is 220whp on a Dyno Dynamics at 10psi

http://img641.imageshack.us/img641/6224/10psidyno.jpg

Well I have been lazy and not updating this lately. Lots of stuff has happened. Let's start with the fact the the clutch was slipping from day 1 after the dyno (possibly on the dyno) but that is fixed, I no longer 1-wheel peel, black hardtops look a lot better than purple hardtops, my head no longer hits the roof of the car, and I am starting to prepare for autox season.

I'll put some pictures up soon