My way-over-budget...budget build thread - 99 Turbo
 

Well, after a year and a half of wrenching, my 1999 Miata build is nearly done. In an attempt to give back to the forum, here's a rundown of the build and a brief pictorial.

The project was NOT intended to be a big dollar/big HP build and ended up being much more costly than expected (doesn't it always); had i known where it was all headed, I would have chosen a few things differently. For example, higher comp pistons, better flowing turbo/exhaust setup, etc. That said, and all things consider, I'm please with the current results and the things I've learned throughout the process. There's more tuning to be done for sure, but I'm still learning that as well.

Enjoy!


Engine Internals / Accessories:
- Manley 14011-4 H-Beam Connecting Rod Set
- Weisco Pistons K553M835 (0.02 over / 8.4 comp ratio)
- ARP Main Stud Kit (218-5401) and Head Studs (2184701)
- Boundary Engineering Oil Pump Stage 1
- SuperMiata Harmonic Damper

Head:
- Sealed Power VS855 Valve Springs
- Supertech Valve Seals Miata

Engine Control / Spark:
- LS2 Coil-On-Plug
- Supermiata Trigger Wheel 36-2
- MegaSquirtPNP G2
- BKR7EIX
- Speed Density setup

Fuel:
- Injector Dynamics Fuel 1050X injectors
- Deatschwerks dw300 (hard wired)

Turbo/Exhaust:
- ebay GT35R (Stage III Ceramic Ball Bearing T04E GT35 Spec T3 5 Bolt .70 .63 AR)
- ebay T3 log Manifold
- Precision Turbo PTE PW39 39MM External Wastegate (dumps directly next to trans)
- Customer turbo elbow
- Flyin Miata Turbo Downpipe (Lower Section) w/ 2.5 boost actuated dump
- Flyin Miata 2.5" Resonated Turbo MidPipe with Milspec 3" 100 cell Catalytic Converter
- 2.5" 63mm Exhaust Control Valve Set boost Actuator CLOSED Style Stainless Steel

Intercooler/Cooling:
- KOYO V-Core Radiator
- ebay 29x9X3.0 intercooler
- ebay universal 2.5inch intercooler tubing kit
- ebay universal SQV Blow Off Valve
- Rival Autosport Type 1 Universal Aluminum Hood Louver

Transmission/Clutch:
- 6 Speed Swap
- Shifter Rebuild Kit (5xRacing)
- Flyin Miata Happy Meal Clutch (Level 1)
- Flyin Miata 10.3 lb flywheel
- Stainless Steel Braided Clutch line

Drivetrain / Body:
- 3.9 Torsen Swap
- FC RX7 Rear end Housing
- Delrin Rear Differential Bushing
- Delrin Door Bushing
- Mazda Competition Motor Mount

Suspension/Wheels:
- Flyin Miata V-MAXX Classic Coilover
- Flyin Miata Front and rear sway bars (1.0" front and 0.625" rear)
- Flyin Miata Frame Rails Reinforcement Kit
- 15x8 Jongbloed w/ Toyo 225 R1Rs

Other:
- Jeggs oil catch
- Innovate LC-2 Digital Wideband
- 5X Racing Miata Oil Pressure and Water Temp Gauge Kits
- huge amount of OEM seals, gaskets, nuts, bolts, bla bla bla

And thanks to everyone who's posted helpful content on the forum. Without it, this project would not have been possible.
Special thanks, in no particular order:
- Reverant
- Braineack
- 18psi
- Savington
- stefanst
- patsmx5
- thecarpassionchannel (youtube)


----------------------------------------

June 2016 - With just under 98k miles, the car arrives home. It was intended as a casual toy to putts around in on the weekends.
https://cimg6.ibsrv.net/gimg/www.mia...134496c725.jpg

In under a week of ownership, wheels and roll bar arrived. A month or so later, I started ordering the FM suspension parts mentioned above.

https://cimg7.ibsrv.net/gimg/www.mia...e50fe881fd.jpg
https://cimg8.ibsrv.net/gimg/www.mia...f28199bc79.jpg



November 2015 - After driving the car for about 5 months, I noticed the oil pressure gauge flutter. Long story short, I apparently had a small oil leak that i didn't catch in time. The somewhat noisy rod bearings only became worse at this point. Since the winter was about to set in, i decided to pull the motor. This being my first deep dive into an engine of any sort, it was nerve racking.


https://cimg9.ibsrv.net/gimg/www.mia...2aaf1b358a.jpg
https://cimg0.ibsrv.net/gimg/www.mia...2970edc1a1.jpg


Gross
https://cimg1.ibsrv.net/gimg/www.mia...f85f0ef079.jpg

Here's a comical attempt at trying to hold the crank bolt in place with some extra metal i had in the garage.


https://cimg2.ibsrv.net/gimg/www.mia...54bbd068a0.jpg


FAIL

https://cimg5.ibsrv.net/gimg/www.mia...217d23508c.jpg

January 2016 - Picked up the block from the machine shop.

https://cimg7.ibsrv.net/gimg/www.mia...376a7ec723.jpg

Engine parts also began arriving

https://cimg6.ibsrv.net/gimg/www.mia...3f3289746c.jpg

February 2016

https://cimg8.ibsrv.net/gimg/www.mia...b912d974d8.jpg

March 2016 - disassembling the head on the living room floor.

https://cimg9.ibsrv.net/gimg/www.mia...923839467a.jpg

May 2016 - The engine is slowly coming together.

https://cimg0.ibsrv.net/gimg/www.mia...db67d559cb.jpg

June 2016 - Head back on the block. Turbo mounted

https://cimg1.ibsrv.net/gimg/www.mia...3788703eed.jpg

Additional Items on (please ignore that stupid turbo head shield)

https://cimg2.ibsrv.net/gimg/www.mia...6b212828b7.jpg

Cat helping

https://cimg3.ibsrv.net/gimg/www.mia...12d666e9e5.jpg

July 2016 - It's back in the car!

https://cimg4.ibsrv.net/gimg/www.mia...6fdce0cc82.jpg

My cat providing direction on intercooler piping routing

https://cimg5.ibsrv.net/gimg/www.mia...a241b2e407.jpg

August 2016 - Finishing up the interior wiring (with additional guidance)

https://cimg6.ibsrv.net/gimg/www.mia...38b6823ff4.jpg

September 2016 - It runs! For the next few months I worked on getting the tune "correct" and adding other parts. Most of the time the car just sat in the garage due to crappy weather.

https://cimg7.ibsrv.net/gimg/www.mia...fd6203952f.jpg

May 2017 - Swapped the rear end to a 3.9. The 6 speed combined with the stock 4.3 open rear was a nightmare.

https://cimg8.ibsrv.net/gimg/www.mia...080ff2c6dd.jpg

May 2016 - The final product (for now):
https://cimg9.ibsrv.net/gimg/www.mia...2dc0909a82.jpg



Edit: Removed VD dyno graph and log. I suspect the hp numbers were a bit inflated.

Thanks!

Oh. That's what my car would actually look like if the paint wasn't shiet and it didn't have dings everywhere...

Awesome build. Hopefully I get to see it in person while I'm around town.

I'm guessing you bought stefanst's kosei's?

Congrats on getting everything running. Are you planning on doing the coolant reroute soon?

Just for lolz, you spool about as well as a s2000 making 800whp.

Best of luck with your build mate :likecat:

Thanks! I got the kosei's from tire rack. Probably won't do the reroute unless the car sees sustained track time.

Lol. Right? It recently dawned on me that I haven't touched the waste gate preload. I'll be messing with that today. I have a strong inclination it's set way too soft. Fingers crossed it helps!

You may want to reconsider the reroute.

The track time line of thinking is more for NA cars. FI introduces a whole new level of heat/hurt.

Especially if you still have AC installed, the condenser has an impact on airflow. One data point (of many) in a recent build thread: https://www.miataturbo.net/build-thr...t-90646/page2/ No track work, just interstate cruise.

Interesting. I'll strongly reconsider it. Let me do some reading.

Side note: shortening the wastegate arm actually hurt spool/power :vash: :facepalm:

A vendor here sells them. I really need to install mine. I've been lucky so far with driving temps. I'm still running lulz power (170ish rwhp) so it's a wash, but it'll need to go on rull soon since I have AC as well.

Here's the link: https://www.miataturbo.net/miata-par...r-mount-88962/

With your hot side the spool doesn't surprise me.

Don't listen to RTC, he makes less power = less superior. But I VD at 84whp so don't listen to me either.

Your cat is adorable

:(

When did you start making more power!?

I am sorry RTC. It was the binge rum drinking after finals talking.

Haha, thanks. He's an odd ball and friendly nearly to a fault lol

Attachment 180842

Update:
I ordered a new (better fitting internal wastegate actuator). It includes a few springs including a 1.5 bar that I plan on installing.

That said, i don't think it's going help. I found that:

• When completely CLOSING my boost controller, the wastegate still opens at ~22psi (intake pressure). That's with standard preload on a 14psi spring that came with the current actuator.
• This means back pressure in my turbo/exhaust must be so high that it's overcoming the spring, opening the flapper, and bleeding off boost - even without boost pressure assisting to press on the spring down.
• Thus, I think one of my biggest issues at the moment is too restrictive of a post-turbo exhaust (the ebay turbo elbow, the 2.5 inch piping, and the inclusion of a catalytic converter).

I plan to see if the new wastegate and stiffer spring has any effect. Otherwise I may be looking into other exhaust options. Outside of Begi and Flyin miata, any reasonably priced turbo elbows out there?

Update:

• The new wastegate (with a 1.5bar/22psi spring) did nothing for spool or power.
• I found an exhaust leak (pre-turbo) that I'll be fixing this weekend.
• I orded a Flyin' Miata cast log manifold to replace my current eBay one.

Bonus: Anyone want to guess why my tunerstudio logs won't capture a psi reading greater than 22.9psi? I'm pretty sure my map sensor is the standard 2.5bar mpx4250.

Because 14.7 barometric pressure + 22.9 psi boost == 37.6 psi absolute, which is 259 kpa. You're probably a thousand feet above sea level to get it that high. :)

--Ian

I'm at about 250ft :-/

https://cimg3.ibsrv.net/gimg/www.mia...509d59b349.jpg
Came across this on the underside of the intake manifold. Certainly not helping spool. :vash:

I'll be interested to see how much difference a single unplugged intake port makes with performance (though remedying the exhaust leak should also help).

Ohhh hayyyyyy.

Looking forward to the next VD pull result!

IIRC that's the one that feeds the VICS port -- if so, then it'll make a much bigger difference than just the vacuum leak.

--Ian