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CHR NC EFR Turbo Build

I like to document my builds so here is the latest. I can't go long with out a car or build.

I sold my PTD car early in January 2016 and the next day I picked up this low mile doctor owned 2006 Mazda Mx5. It lasted about 16hrs before it was a shell.....

Details:
2017 ST4 NASA West then East Championships
Toyo RRs 255 or 275 depending on what it needs.
EFR 6258
Stock Gearbox
Samsonas 6spd Sequential after ST4
Teves ABS after ST4
Life Racing F88 Ecu (Adaptive knock control, DI, and TC options)
Motec C125
Front and rear aero
TC Design Cage
Brennan Autosport Damper Support
Charlie Hayes Racing building and development

https://cimg6.ibsrv.net/gimg/www.mia...6bf116164e.jpg
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Tony and I had a discussion on whether to acid dip or blast the chassis. We decided on blasting it, so I went with a local referral. Ended up with Max at American Canyon Stripping and he did a great job.

https://cimg2.ibsrv.net/gimg/www.mia...39280bcdeb.jpg

Car now back in the shop after a week with Max due to rain. Time to start getting some work done.

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The seam welding is just about done and I have received a few new parts to try out. I got a custom wing made. It is built to SCCA STU/STL specifications (6in below the roof line) Carbon uprights, foil and endplates)

https://cimg9.ibsrv.net/gimg/www.mia...948a8d0fc4.jpg

Car is now at TC Design getting the monkey bars installed. I have been working with Tony and Joe since I first started racing. This is now my 7th chassis with a cage from Tony. He is the man when it comes to doing it right and in a timely fashion. :) We decided to go more of a FIA route with the design and he also did the firewall mount for the Tilton pedal assembly.

https://cimg1.ibsrv.net/gimg/www.mia...e48f273b3f.jpg
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Car is now back in my hands for me to try and screw things up. Going with 17x10 et38 Enkei RPF1s. These are on the large side for this NC chassis and I wanted to see how much work it would take to get it under stock fenders. It wasn't possible if you include any bump travel. Flares it is.....

https://cimg4.ibsrv.net/gimg/www.mia...578051bd82.jpg
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While waiting for the flares I worked a little more on the interior. Dash was trimmed and mounted. Also welded up the hard top brackets.

https://cimg0.ibsrv.net/gimg/www.mia...fc6fe0aae6.jpg

Time to do some work on the rear fender wells. I cut and made them flat to the highest point. This allowed me to about 2in of pinch weld to ground clearance with 40psi and no tire deflection accounted for.

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Taaaaa-DAAAAAAAA

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RR done also with less drama and build up.

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Started toying around with the front end ideas. I already scrapped this, luckily I didn't waste my foam core and carbon. Went with a 2009-2013 spec front bumper. I like this type better because it doesn't have as much of a "nose" shape to it. The radiator opening is almost perpendicular with the sound acting like more of a air dam.

https://cimg7.ibsrv.net/gimg/www.mia...0e92394337.jpg

Boxed the firewall for some accessories and covered a few holes up there too.

https://cimg8.ibsrv.net/gimg/www.mia...3f4213fc9d.jpg
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I built a custom Ron Davis Radiator with a internal oil cooler. I went as big as I could while fitting inside the stock frame rails and fitting inside the stock from crash bar.

https://cimg9.ibsrv.net/gimg/www.mia...6e6142812f.jpg

Also had a custom set of JRZ Series 12 3-way Dampers made. I have all the options for it with the DA-50 shaft and adjustable FA3030 pistons. Going to be fun dialing myself out with these. :D

https://cimg0.ibsrv.net/gimg/www.mia...2ee4ca3220.jpg

I will post more as it comes. Been crazy busy with work, so this is on the ultimate back burner. I have a few more brackets and welding to do before I send the chassis off to powder coating. Then the final assembly and setup can start!

Why an SCCA STU/STL rear wing if you're running NASA?

I imagine your leaving a lot on the table running to SCCA's silly rules.

Who built the wing? It looks pretty serious bizness compared to some other STU/L wings I've seen.

Sweet build...love the flares and meaty tires.

Quote:

Originally Posted by Efini~FC3S (Post 1419977)

There is a bigger/deeper puddle to jump into for 2018 running SCCA, and thats where I would like to be. Keeping options open and I will try multiple setups. For NASA I will run the wing pictured raise up a few inches.

Keeping tabs on this one :)

Awesome. I just bought a 2009 a few weeks ago and I've been drooling over your build on Instagram.

You built the custom radiator or you supplied dimensions to Ron Davis and they made it?

I love the simplicity of integrated oil coolers and I wish companies made them for Miatas...

Quote:

Originally Posted by charliehayes22 (Post 1419954)

Teves ABS

When I google Teves

Quote:

Originally Posted by Chilicharger665 (Post 1420251)

You built the custom radiator or you supplied dimensions to Ron Davis and they made it?

I love the simplicity of integrated oil coolers and I wish companies made them for Miatas...

PWR does

So they do. I can't find any installed pics or any real details on it, though.

Quote:

Originally Posted by Chilicharger665 (Post 1420251)

You built the custom radiator or you supplied dimensions to Ron Davis and they made it?

I love the simplicity of integrated oil coolers and I wish companies made them for Miatas...

Yes I contracted Ron Davis to build the cooler for me. It was not cheap.

Quote:

Originally Posted by aidandj (Post 1420254)

When I google Teves

Its the ABS unit from a e46 M3. Bomb proof, easy install, and the mapping is actually really good for a readily available "stock" unit.

I'm sure it is. I just got a chuckle when that was the first video in the results.

Very cool Charlie. Look forward to seeing it in action.

ABS in SCCA road racing? I thought those old men had banned that new fangled technology stuff.

Quote:

Originally Posted by Leafy (Post 1420459)

ABS in SCCA road racing? I thought those old men had banned that new fangled technology stuff.

This comment is ignorant and pointless.

ABS is allowed in most SCCA Club Racing classes.

It certainly is allowed in "ST" classes (STU/STL), however, I'm under the impression the rules only allow the OEM ABS systems. I'm not sure of the legality of CHR's proposed E46 system.

Quote:

Originally Posted by Efini~FC3S (Post 1420491)

OEM in a production car? Or OEM in the car being raced.

Rules for STL/U are OEM ABS from that model line, similar to NASA ST4. However there are a lot of no goes in this build to end up in STU for right now. Can bring it back down if it doesn't have enough for the class I desire.

Well it fits. Using the Fab9 manifold for this setup. https://cimg9.ibsrv.net/gimg/www.mia...b405ea61fc.jpg

Man, that Fab9 is tight. Are there any other manifolds available for the NC that supports a TS EFR by any chance??

What pulley is that on the bottom exhaust side? Some tensioner? It looks like you have the mazda 3 alternator but made it work with the NC PS pump instead of doing a trunk mounted PS and just using the mazda 3 accessories?

Very interesting ecu choice. Never heard of it. Just did some quick googling. How much do they cost? can't see a price anywhere

Quote:

Originally Posted by Leafy (Post 1468542)

The pulley is a stock 2.0 mx5 tensioner. I have a 60amp alternator I got from a company in the UK. It was a basic kit and cheaper than making it myself. As for power steering I will use the stock mx5 power steering unless it turns out to be a problem. Electric is an option as I have a couple take off pumps from some GT3 cars. Just don’t think it’s needed.

Quote:

Originally Posted by 18psi (Post 1468546)

Very interesting ecu choice. Never heard of it. Just did some quick googling. How much do they cost? can't see a price anywhere

This will be my second car with the Life Ecu. The software is great and you can do just about anything you can think of. To run the direct injection there was no hesitation to stick with it. The base ecu which will run a port injected turbo engine would be a little north of 2 grand. It’s comparable in price to the current motec ecus with more configuration available in my opinion.

They use use them as a spec ecu in the Indy lights.

Lyfe motorsports GTR uses (the Life ECU) for time attack and hill climbs.

Quote:

Originally Posted by 18psi (Post 1468546)

Very interesting ecu choice. Never heard of it. Just did some quick googling. How much do they cost? can't see a price anywhere

Life Racing ? Danzio Performance

Fahkkkk

They are not the cheapest but the F88Rxx will do anything a BP engine needs for a reasonable price.

I made my appointment for mapping the engine on this upcoming Monday. I hope to get my inlet restrictor back from machining this weekend. It will be interesting to see what the engine will make with a little 37mm restrictor in the compressor housing.

The next few days will have a good amount of updates for the car.

https://cimg3.ibsrv.net/gimg/www.mia...a9c79a8a2.jpeg https://cimg9.ibsrv.net/gimg/www.mia...46366a952.jpeg
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Continued buttoning stuff up and made the intake pipe off of a prototype restrictor. Working on RE making the cold side charge piping. I originally made it out of 2.5 but would like to see it 2.75 to match the TB.

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Worst thing I have ever made. Came out cool but still sadface.

car runs to the dyno on Monday or Tuesday...

Build is looking GREAT Charlie! How did the tuning session go? Look forward to seeing you out on track!

Had some issues with the HPFP. The spill valve spring was too soft with the aftermarket internals. Would loose control at about 4300rpm and go from 30 bar to 130 bar. Ended up mapping the car with a stock HPFP then eventually found the limit of the intank regulator. Made decent power off the wastegate and low timing. Cut out was around 6000rpm. Planning on getting it sorted when I get back next week.

What did it make with the issues??

If it’s worth mentioning he would have. With the fuel problems it’s likely not good.

Love the direct injection! Can’t wait to see final numbers!

260/260 with the issues and the 37mm inlet restrictor.

What which DI motor uses the normal NC miata intake manifold? The DISI and Ecoboost heads both use totally different intake manifold flanges.

Quote:

Originally Posted by Leafy (Post 1471559)

What which DI motor uses the normal NC miata intake manifold? The DISI and Ecoboost heads both use totally different intake manifold flanges.

It is a DISI 2.3 long block with a adapter flange. ;)

Ah, you want the high flow ford performance manifold that faces the throttle body forward? Its for a 2.0/2.3 ecoboost but IIRC it fits the DISI as well, does not fit the normal MZR, hence why I dont need it.

Quote:

Originally Posted by Leafy (Post 1471586)

I want/have/need the 2.0 mx5 mzr one because it’s legal for the rules and fits. Otherwise I’d make a custom plenum.

Ah so its like scca IT where you have to use the intake manifold that came in the chassis but you can make an adapter plate. Gotcha.

Well we got the car all mapped yesterday. I will say that I did not pull the restrictor out because I will be worried about keeping the rest of the car together. With the 37mm restrictor we made more WHP and more WTQ than wanted and expected. Peak torque at 4000rpm it falls on the restrictor at 4750rpm. Makes over 300whp from 4000rpm to 7000rpm. Boost by gear and traction control are going to be utilized for sure....

This is a worthless post so far but I wanted to bump so I can find the thread for the updates during the week. Finally have a nice open week where the race cars are in route from Long Beach to Virginia.

Oh man, I really wonder what it's capable of without that restrictor!

Quote:

Originally Posted by RalliartRsX (Post 1477672)

Coming to VIR??

I will be there next week for the PWC race. I work with Kpax on the Bentley’s.

Since pictures are needed. One of the most important things done this week was tinting the tail lights. Here is a compare shot.
https://cimg6.ibsrv.net/gimg/www.mia...6a8522408.jpeg

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Only got got a few hours in today.

Installed the RB 14108 front ARB
Mocked up the Stoptech front brakes and ordered some spacers to clear the wheels. The brakes look big for the car but are smaller than all GT rears.
Started working on the rad ducting. Going to finish it up in the morning then start on the inlet duct with the splitter. Also ran out of argon so it’s a good stoping point.

MoTeC dash mounted with a carbon panel.

https://cimg5.ibsrv.net/gimg/www.mia...7af70a1e3.jpeg

Awesome build! Looking at the engine bay reminds me of how much I hate NC engine bays there is so little room.

Quote:

Originally Posted by ridethecliche (Post 1477643)

Oh man, I really wonder what it's capable of without that restrictor!

My guess is about 425whp based on the torque numbers it produced with the restrictor.

Quote:

Originally Posted by miataman04 (Post 1478459)

Awesome build! Looking at the engine bay reminds me of how much I hate NC engine bays there is so little room.

The engine is actually very serviceable, nothing is very hard. The worse thing so far is removing the intake cam. I did not clearance the firewall enough without some more steps than normal. Oh well, things you get when you complicate it...

Quote:

Originally Posted by charliehayes22 (Post 1477692)

Since pictures are needed. One of the most important things done this week was tinting the tail lights. Here is a compare shot.

That looks so good!

Well finally got around to test fitting the gearbox. Came across a deal I could not pass up.

brand new 15G sequential. Everything seems to be really close. I need to get a hydraulic release bearing and make a modification to the bell housing. The drive shaft needs to be made but all in all smooth so far.
https://cimg3.ibsrv.net/gimg/www.mia...8dc6f97c3.jpeg

Sick build man, really impressive all around.

Past week has been very good for progress.

Fixed the intake pipe and cold side charge pipe. (not pictured)
Modified the bell housing to make the gearbox sit straight in the car.
Made the carbon exit duct and added the track spec hood vents
Had a custom driveshaft made for the gearbox
Re vamped the power steering (not pictured)
Got a couple parts to get water jetted.
Figured out the rear suspension and ordered some parts for that.
Next up is the ABS install, body work, some numbers, a lot of testing, and a big trophy.

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Work has been taking a lot away from the project. I have been put on the back burner with some manufacturing of parts. I still need my clutch release bearing adapter, hope to get that this week or early next...

I calibrated the gear pot and the load cell for the sequential. We will have flat foot upshifting and blipped downshifts with the drive-by-wire.

I have finished the Teves Mk60 wiring harness. Need to do the wheel speed sensors and the brake lines to finish it up. I had to do some goofy things to make the wheel speed sensors work.

Got the rear SPL bump steer adjustable toe links and the lower link. I then added bearings to the other 3 links. Rear suspension is all rod ends at the subframe. Waiting on some bearing inserts for the front upper and lower control arms.

I added the transmission brace to the stock forward crossmember and made some ghetto differential braces for the RX8 differential housing. Doing this I had to redo the exhaust. Only thing not pictured is the saddle for the exhaust.

Got bigger flares for the Hoosier 275 A7s. May try 295s if the grip is needed. The rear flares are a little bigger than I would like. (makes me want more tire..) The car is extremely light. About 2200lbs currently. Going to have to add a ton of weight to the car. I have a few places in mind to get the car closer to 50% front.

Still have a few days left of work. Depending on this clutch situation will determine when it hits the track....
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Clutch release bearing adapter got machined today. Installed and bled the clutch tonight. Going to work on the alignment tomorrow and planning on a shake down Friday.

https://cimg7.ibsrv.net/gimg/www.mia...a5ac9f759.jpeg

will having the hoses like that make it hard to bleed the clutch?

You know what I love about this? How clean the build looks. Only the functional things are in, everything else is out or minimized and cleaned up.

Awesome job and great write up.

Love the wet layup carbon duct.

Quote:

Originally Posted by shlammed (Post 1503699)

will having the hoses like that make it hard to bleed the clutch?

I was thinking the same thing? You would think a couple of 60*-90* fittings would be a cleaner install?

Quote:

Originally Posted by shlammed (Post 1503699)

will having the hoses like that make it hard to bleed the clutch?

And its just more hose in the hot bell housing for heat to transfer into the fluid. I'm sure it doesnt matter, but it bothers me.

Quote:

Originally Posted by shlammed (Post 1503699)

will having the hoses like that make it hard to bleed the clutch?

The top line is actually the bleed line so it pushes the air out. No issues for bleeding, had a clutch within the first few pumps.

Quote:

Originally Posted by Blkbrd69 (Post 1503765)

Awesome job and great write up.

Love the wet layup carbon duct.

I was thinking the same thing? You would think a couple of 60*-90* fittings would be a cleaner install?

The space is a little tighter than it looks. Tried some other fittings, I didn’t like that it wasn’t a straight shot out of the holes for chafing the lines. The crimps for these lines were longer than I wanted.

Quote:

Originally Posted by Leafy (Post 1503769)

And its just more hose in the hot bell housing for heat to transfer into the fluid. I'm sure it doesnt matter, but it bothers me.

Yea, not worried about that with good fluid. When you have a hydraulic release bearing sitting on the clutch and in the bell housing, the fluid will be warm regardless. If the fluid boils you just have a lazy clutch pedal. I won’t be using the pedal besides leaving the pits and getting back into neutral.

Charlie, Why do you gotta build stuff like this? You really ruin it for those of us with less talents and resources.