The Mazzder MX FIVE Build
 

Thanks to Lars we got this thing idling like normal. Glad to be part of this community. Next up: fine tuning Idle and intercooler install.

We got it idling ok. I would not say it is like normal. Now it just needs lots of fine tuning, but the car is driveable.

The Mazzder MX FIVE Build
 

That part I'll get sorted out. Good stuff nonetheless though. And then it will be mk turbo time. First 1.6 with an mk setup??

The Mazzder MX FIVE Build
 

So made some progress and mounted the recommended intercooler in preparation for the mk turbo setup this weekend. Please note that I did not have 2" t bolt clamps so I need to get those and I ran out of aluminum piping 90s so I had to improvise. I could use two reducers as well but everything fits. The undertray is sitting back a smidge so it will be held by 4 bolts for now. Will need to make a sheet metal plate for IC yo channel air to it and connect bumper to it as I'm getting rid of that plastic piece that originally connected to the bumper.

Attachment 234223

Front view

Attachment 234224
Top view- have a turbosmart bov and will run recirculation just because I want to use that particular turbosmart. Note: tentative top view until turbo gets installed.

Attachment 234225

Passenger's side view

Attachment 234226

Driver's side

Attachment 234227

And down thru the center.

The Mazzder MX FIVE Build
 

Well just dropped her off with Lars to get some mk turbo greatness. This will be the first model 1.6. Stay tuned for awesomeness.

The Mazzder MX FIVE Build
 

Test fit done today. You may have seen this in the mk turbo thread but I'm putting it here for build thread completeness.

Attachment 234221

Manifold fitment

Attachment 234222

Turbo fitment

The Mazzder MX FIVE Build
 

So I has da boost! Very cool! Here is a picture of the setup. I will get more and upload. Please note the zip ties add 5 hp each and this was just setup to get me home from shuiend's garage.

I will post trip home and shenanigans after that tonight.

Attachment 234219

Attachment 234220

So I was able to drive it again today, looks like a boost leak as I am not feeling boost haha. Here is a log of me just driving it now.

https://www.dropbox.com/s/03o1m80ied...01.40.msl?dl=0

The Mazzder MX FIVE Build
 

Drove the miata yesterday and still have a boost leak! Today I bought a leak tester from silicon intakes and took off the undertray to inspect my intercooler piping. I managed to tighten a few t bolts and realized I had some were that were a bit too large so I ordered the right size today as wrll.
I found a fitting that was leaking oil so I tightened that up. Leak averted.

I then decided to take off the exhaust as I need to grind off a Nipple that keeps hitting my brand new exhaust and drives me bonkers while driving. I then decided to clean some of the welds up and I am starting to give them a couple coats of your typical rustoleom(spelling?) High temp paint so that it prevents surface rust at the welds.

Plan is to fix my leaking axle seals on rear diff this weekend so I don't have to worry about that any more.

Pic for fun.
Attachment 234218

congrats sir
a lot of those couplers look like they're too big so I bet that's where you're leaking

The Mazzder MX FIVE Build
 

Thanks! I had ordered a 2.5" ebay kit and then got 2" pipe for the hot side because 2.5" didn't fit (shoyld have listened to Lars) soooooo yeah I definitely need to use 2" t bolts as a starting point so I can get everything super snug.

One day I will use a Garrett.

Got a lot work work done today. Cleaned and painted welds for maximum life. Heat wrapped downpipe and sealed it. Made the most hideous heat shield for brake lines and coolant hoses. I won't scar your memories with this chunk of horribly made metal. ;)
Attachment 234217

Well I think I still have a little leak but not much. I think I know where it is tho. I am concerned the the chra is hitting either the compressor or turbine housing so I'll try to pull it tomorrow. Here is a screen shot of max boost acheived today.
Attachment 234216

Mk turbo on my car at idle.

that looks like a huge leak, not a little one
it is really bad for the turbo to boost it with a leak, I suggest you properly fix it once and for all asap

The Mazzder MX FIVE Build
 

Good looking out. Will do.

Additionally the parts for leak testing should be here today or tomorrow. :)

So here is a screen shot of the miata boosting on the MK turbo. Note this one was one of the better pulls, but I had to slow down because I was speeding pretty good as it is.

https://www.miataturbo.net/attachmen...ine=1442962322

Did some porting. Before and after shown below.

Attachment 234213

Attachment 234214

Attachment 234215

Going to memphis for a week for work so I'll put it all back together Friday or Saturday as time allows.

I finished up the porting show in the previous post by taking out some space behind the flapper and actually on it a bit so it would allow a smaller volume (I think of it as a pie shape more) of air to pass through. Below is a side by side comparison of before porting and then after. You can see that I did not hit my max boost numbers on the second graph as I shifted before that to enjoy the car more. It did produce a more linear trend as well as slowly get to the overboost protection of 170 kPa.


https://www.miataturbo.net/attachmen...ine=1443972412
9/23/2015
3rd: 3802 rpm @119kPa to 4483 rpm @173.9 kPa with a delta t(time) of 2.145 s
2nd: 2250 rpm @95.9 kPa to 5021 rpm @161.7 kPa with a delta t(time) of 4 s
https://www.miataturbo.net/attachmen...ine=1443972412
10/3/2015
3rd: 3529 rpm @119kPa to 4554 rpm @162.2 kPa with a delta t(time) of 2.674 s
2nd: 2632 rpm @98 kPa to 4867 rpm @154.7 kPa with a delta t(time) of 3.472 s