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Old 05-17-2017, 10:35 PM   #1
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Default 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:
- Trackspeed Engineering Coil-On-Plug Kit
- Supermiata Trigger Wheel 36-2
- DIYPNP (Reverant built)
- BKR7EIX (Pre-gapped)
- Speed Density setup

Fuel:
- Walbro Fuel Pump 190LPH-HP 89-05
- Flow Force NA/NB Miata 640cc Injectors with PNP Kit

Turbo/Exhaust:
- Garrett GTX2867R (w/ .86 A/R) Twisted Motion GT2871R (Glorified China charger?)
- Flyin Miata Cast Manifold ebay Cast Iron log manifold (seller: ilovetacotaco)
- Flyin Miata Cast Elbow ebayTurbo Outlet Elbow 2.5 inch (seller: cooper813)
- Flyin Miata Turbo Downpipe (Lower Section)
- Flyin Miata 2.5" Resonated Turbo MidPipe and Catalytic Converter

Intercooler/Cooling:
- KOYO V-Core Radiator
- ebay CX Racing Intercooler (28x7x2.5)
- ebay universal 2.5inch intercooler tubing kit
- ebay universal SQV Blow Off Valve

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

Drive train / Body:
- 3.9 Torsen Swap
- FC RX7 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
- 15X7 Kosei K1 Racing Silver

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.


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.






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.






Gross


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





FAIL



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



Engine parts also began arriving



February 2016



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



May 2016 - The engine is slowly coming together.



June 2016 - Head back on the block. Turbo mounted



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



Cat helping



July 2016 - It's back in the car!



My cat providing direction on intercooler piping routing



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



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.



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



May 2016 - The final product (for now):




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

Thanks!

Last edited by Carloverx; 08-19-2017 at 06:01 PM.
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Old 05-17-2017, 11:02 PM   #2
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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?
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Old 05-18-2017, 12:43 AM   #3
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Just for lolz, you spool about as well as a s2000 making 800whp.

Best of luck with your build mate
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Old 05-18-2017, 08:08 AM   #4
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Quote:
Originally Posted by ridethecliche View Post
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?
Thanks! I got the kosei's from tire rack. Probably won't do the reroute unless the car sees sustained track time.

Quote:
Originally Posted by Lexzar View Post
Just for lolz, you spool about as well as a s2000 making 800whp.

Best of luck with your build mate
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!
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Old 05-18-2017, 10:56 AM   #5
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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.
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Old 05-18-2017, 11:14 AM   #6
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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.
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Old 05-18-2017, 09:55 PM   #7
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Quote:
Originally Posted by ridethecliche View Post
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.
Quote:
Originally Posted by slowcarfast View Post
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
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Old 05-18-2017, 10:39 PM   #8
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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/
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Old 05-19-2017, 02:26 AM   #9
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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.
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Old 05-19-2017, 03:12 AM   #10
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Your cat is adorable
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Old 05-19-2017, 10:22 AM   #11
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Quote:
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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.
:(

When did you start making more power!?
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Old 05-19-2017, 03:41 PM   #12
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:(

When did you start making more power!?
I am sorry RTC. It was the binge rum drinking after finals talking.
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Old 05-20-2017, 02:20 PM   #13
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Your cat is adorable
Haha, thanks. He's an odd ball and friendly nearly to a fault lol

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Old 05-20-2017, 02:32 PM   #14
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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?
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Old 06-02-2017, 04:36 PM   #15
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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.
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Old 06-02-2017, 04:56 PM   #16
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Quote:
Originally Posted by Carloverx View Post
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
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Old 06-02-2017, 07:24 PM   #17
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I'm at about 250ft :-/
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Old 06-05-2017, 10:50 PM   #18
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Came across this on the underside of the intake manifold. Certainly not helping spool.

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).
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Old 06-06-2017, 01:12 AM   #19
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Ohhh hayyyyyy.

Looking forward to the next VD pull result!
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Old 06-06-2017, 01:27 AM   #20
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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
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