New '95 Montego on the Block
 

Sup guys! My name's Zak. I've been a long time lurker and newbie poster around here for a bit. I put up a post about my car/plans in the meet & greet section on here a while ago but figured I should start an actual build thread to stay more active around here (and maybe keep track of my progress for my own benefit). Some of this is copy and pasted from my other thread but here's a rundown of what I've done on the car so far

My Miata's a 1995 Montego blue with 191k on the clock. I've had the car for 9 months and have made some decent progress on my build, mostly handling upgrades so far. The story of how I came across this car is kind of an odd one. My coworker inherited the car a little over a year ago and had it towed to our dealership as it was in no condition to be driven on the road. His family member was the original owner of the car but had left it sitting on the side of their house for 3 years after it was in a fender bender in a parking lot. I performed the smog check for the car last May when he brought it in and then parked it in a corner where it sat untouched for several months. One day, it was slow at work and decided to look up how much it would cost to turn a Miata into a track car. Game over. A couple hours later, I was fully down the rabbit hole on the Miata forums. I bought the car off of him a couple days later.

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Bone stock and sitting pretty(?) around New Year's time.

Fast forward 9 months and I've made some decent strides with the build. My goal for the immediate future is to turbo the car on pump gas and the stock block and get it running around 200whp as a reliable track car. Then get a second motor to build with forged internals and make a little more power later on. As of right now, I'm leaning toward going with an MKturbo kit but am still having thoughts about building a kit piece by piece around a GT2560r.

I'm going to leave out all the maintenance items I've replaced because there's too many to list, but here's the main parts of the build spec as of now:
BC coilovers, Advanti Storm S1 15x7 wheels, 205/50/15 Nitto NT05 tires (Falken RT660's next), MS3x ECU, DW200 fuel pump, MAF delete, Racing Beat Tubular Race front sway, extended lower ball joints, braided stainless steel brake and clutch lines, EBC Yellowstuff Brake pads, Hard Dog M1 roll bar, SuperMiata coolant reroute and crossflow radiator, Supermiata "Hybrid" motor mount setup, Poly diff bushings, ACT 9lb flywheel & replacement clutch, Sparco R383 steering wheel and Sprint seat, rear bumper trim, ABS front airdam, 1/2" birch underbody tray and some homebrewed radiator ducting, NRG 59" ricer wing that I got off a buddy and some mounting plates to stiffen up the trunk, AC deleted and lots of peripherals removed from the engine bay, probably a couple other minor things I'm forgetting...

Here's the car as it sits today.

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A few shots of the car at Streets of Willow last weekend. First time running with the new aero bits. Car seemed to be running the fastest with the wing set at a 3* AOA based on lap times. Best time was a 1:34.11 running CCW. I know there's a little more time I could shave if I change up my line into the toilet bowl and cut inside at the corner entry.
Also one pic of the car looking ridiculous with the hardtop off. :rofl:

Next upgrades are going to be Flowforce 640 injectors and poly suspension bushings on all corners. Both on their way in the mail as we speak. Also considering doing a proper steering rack depower next. Had the PS belt hop off a couple times in the last month and I can't say I minded the extra steering resistance on track. I'm just curious how much harder it'll make hand-over-hand oversteer corrections if I get into a pickle on track. I'll post up what I decide to do...

Thanks again to everyone here for all the help so far! Hopefully I'll have this thing turned into a Corvette-eating track monster in the next half-year or so!
-Zak

Nice car. I removed my power steering (just looped the lines) earlier this year and have really enjoyed it. The improved feel is worth the more difficult low speed maneuverability in my opinion. I haven't had any issues with keeping up with it on the track, I even did a rallycross in the dirt and didn't have any issues with correcting the oversteer.

Thanks dude!

I appreciate the input. I’m thinking I’ll do the same thing. Start by looping the lines then remove the rack and cut off the main internal piston and get the pinion welded once I get some time. Glad to hear oversteer hasn’t been a problem on your end. My car’s set up pretty balanced as far as handling goes right now so I guess I don’t have too much to worry about.

Progress is slowly being made in all sectors! Got a few more upgrades/mods completed in the last couple weeks and I'm pretty close to having the car ready for the turbo install. Fuel injectors are installed and ready to go and I made a couple solid improvements in the handling department as well.

Started last week off by swapping out all the worn out 27 year-old rubber control arm bushings with Energy Suspension polyurethane ones. Found out Energy Suspension is based in San Clemente just down the road from me which is pretty cool. Always nice to support a local brand. I did the bushings one control arm at a time whenever I had a little extra time at work. Every one of my bushings were frozen tight in their sockets. I thought I'd be able to get them out with an air hammer like I did with the diff bushings. No dice. In the end, I wound up heating them up with a torch and tapping them out with a couple large sockets.

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Hard to see in the picture, but I wrapped every bushing and insert in a layer of PTFE pipe thread tape. Hopefully this keeps them quiet a little longer.

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Front LCA bushings installed. Between the melted rubber and pre-lube, my hands were dirty for three days. I don't normally like to wear gloves while wrenching but this would've been a good time to change my stance on that :rofl:

Also, ever since I removed the AC last month, the car had been periodically ejecting the power steering belt. I was able to retrieve the belt after losing it on track once (shoutout to the flagger that grabbed it for me) but lost the belt on the road a couple weeks after. I knew this was certainly due to an easily fixable pulley alignment issue. However, with all the other projects I had going on, I put it on the back burner. Wound up driving the car without power steering and stopped noticing after a couple days. After installing the poly bushings, and knowing I was going to do an alignment anyways, I said screw it and pulled out the PS pump, reservoir and hoses. During teardown, I found the big bolt that goes all the way through the PS pump and mounting bracket had backed out about half an inch. If slid forward, it could almost make contact with the PS pulley. Oops, haha. I guess that's where my pulley alignment issue was. I looped the PS lines and called it a day for the time being. I'll find time later on to tear the rack down and do a proper depower with a welded pinion. Got the car on the alignment rack to find that the minimum caster actually increased after the bushing install. I could now only lower caster to 4.7*, up from a previous 3.9*. Oh well, no going back now! Set the caster to 4.7*, camber to 3.5* front, 2.8* rear, zeroed out toe on all corners, and headed to our local mini-track to see if all the work I had done would amount to a noticeable improvement.

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Sitting pretty in between sessions. The camera angle makes the wing look like its set further forward and steeper than it really is...

The shakedown went well! I should've dished out the $250 for a bushing kit long time ago! The car reacted to steering inputs notably quicker but what I noticed most was the increased braking response. I'm assuming with the lowered control arm deflection, the brakes actually start slowing the car down more instantaneously and the suspension doesn't toe out as much under heavy braking. It's instantly noticeable, and it feels really good.

Next up, injectors! I got my FlowForce 640s in from 5X racing (thanks for the included candy, guys) last Wednesday and got them installed and up and running that night. It's a surprise the OEM injectors were still even sealing. Three of the four injectors literally fell out of the head when I removed the fuel rail :rofl:

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Crusty little bastards.

I plugged in the required fuel and deadtime settings for my car and it started right up. The entire fuel table was a little lean but after a 20 minutes of autotuning and a little hand massaging of the VE table, AFRs were mostly acceptable across the board. Got the fuel table more dialed in over the next couple days and the car's running strong now.

Some miscellaneous pics of the car this weekend:

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Was never huge into NC's but this guy's track toy was pretty sick.

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One of these cars is faster than the other (for now).

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That's all for now! Next up is a SuperMiata organic clutch, oil pressure/temp gauge, and boost gauge then it's turbo time! Hopefully I'll have that update on here in a couple weeks.

Cool thread man. Love me a track car, even better if you are going turbo!

Why did you choose to mount your undertray flush like that instead of building a splitter? For ground clearance? Just curios because I was looking at going with the same bumper for next track season.

I see you mentioned rt660's next. They are grippy and come up to temp quick, but they get tortured by my turbo track car and end up super greasy only a few laps into the session. Next season I'm definitely going to check out something that holds up to the heat better.

Hey thanks man! I’m glad somebody finds the thread worth reading haha.

Well the undertray/front air dam combo is a bit of a long story. My buddy initially built it for his NB1 before handing it down to me. His car was a dedicated track car but he never had any intention of turbo-ing it so he decided on a balanced mild aero setup consisting of the air dam/undertray and a lexan spoiler. Now that it’s mine, I’m thinking maybe I’ll tear the undertray off at some point and build a splitter to replace it. My car’s ride height is sitting at 4.0” front/ 4.25” rear measured from the pinch welds and I actually don’t have any clearance issues with the air dam as it sits. It clears pretty much all speed bumps no problem without having to do the ricer sideways crawl maneuver over them lol.

I appreciate the feedback on the 660s as well! You might be the first person I’ve heard to give them solid critique. I actually just put a new set of NT05s on my car again (they’re easy to get and fairly cheap through my work) and was thinking maybe I’d just get really well acquainted with these for the time being. The grip they provide doesn’t seem to degrade very much with heat either. What else have you run as far as tires that you liked over the 660s?

The 660's have great peak grip, it just falls off far too fast for my taste. So much that I'll set my fastest lap in the first 3 hotlaps, then can't quite match that lap again until the tires fully cool. Usually around my fifth lap they are super greasy and generally sliding everywhere. I use them in time attack so they are OK (and like I said fast before they overheat), it just means I have to be on point and set a fast lap first thing in the morning.

I've had 615's, and they hold up better to heat, but don't put down as good of lap times. I've had Federal 595-rsrr's as well, and those got me lots of track time, and were consistent(ly slow). I'm looking into the new Conti 200tw for next season, as some people I track with that have high horsepower cars on 200tw seem to love them and say they don't fall off like the 660s.

I think the 660 is a great auto-x tire but I'm going to try something else for track abuse next year.

Good info, man. Maybe one day when I'm rich and famous I'll get another set of wheels with RT660s for autocross/mini track duty. I'm usually not fully pushing it on track until my second session a few laps in. That fall-off in grip after lap 3 would probably be detrimental to my top times haha.

I've heard good things about the Contis from my friends who usually religiously run RT660s. Maybe I'll give them a shot next.

Update time once more! Took a bit of a detour from the clutch replacement I was planning to do this month and finished up some other projects on the car I wanted to take care of before installing the turbo.

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Waiting for the gates at Apple Valley Speedway to open.

Started out two weekends ago by legitimately depowering the steering rack. I was working a Saturday and it was slow as hell so I had some time to get the car in a lift and tear the rack down. Chopped the main piston seal out and reassembled with a bunch of fresh grease. I still need to get the pinion welded, replace the boots, and install some r-package tie rod ends. That being said, I'm super happy with how the rack feels for now. Steering inputs are much easier than with the line-loop method!

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Moisture in the rack after degreasing and spraying it down. Yeah that looks... good

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All torn apart. My old clutch and flywheel even showed up to hang out. And a banana that I had put off eating in favor of a Wendy's 5-dollar biggie bag.

Next up, oil cooler and oil pressure and temperature gauges. I bought TrackDogRacing's oil cooler kit with the thermostat sandwich plate option and modified the mounts to install the heat exchanger to the backside of my radiator where the AC fan used to be. I really should have installed and capped the sandwich plate first and monitored the before and after oil temps with the oil cooler installed. Oh well, oil temps didn't get above 215-220*F doing ~1min autocross runs in ~75*f ambient temps on Saturday. I'll have to wait until the car's next big track day to see where they top out at. On a related note, does anyone have input on ideal oil temps at cruising speed? Ambient temps all weekend were 60-80*F. My oil temp never got above 195*F on the freeway and got up to 210 max in stop and go traffic.

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Oil cooler tucked away

$6.99 Amazon special gauge holders to get the oil temp/pressure and boost gauges as close within peripheral vision as possible. Might look just as ricer as A-pillar gauges but at least they don't obstruct any of the windshield like the A-pillar mounts do. The Glowshift gauges I got are... about as cheap as I expected them to look, but they seem to read accurate and they light up pretty colors so they'll do. Also, running a boost gauge while still naturally aspirated feels super duper rice-y :bigtu:

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I have all my non-wideband gauges wired up to their own switch so I can turn them off if I'm driving leisurely at night. Not that any of my electrical jobs have been the world's cleanest but damn if it isn't satisfying wiring these suckers in...

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5:30AM on the way to AVS. The car's interior is starting to look like something out of a Fast and Furious movie but I don't mind it too much.

Alright, now THIS paycheck I'm going to get my upgraded clutch to finish up the framework needed for the turbo install. The light at the end of the tunnel is finally visible. Wish me luck. Or berate me if there are things I could do better. Onward!

Bonus video: quick shot of me trying to go fast at Apple Valley last Saturday.

Anyone got advice on how to embed videos on this forum? Never mind, that was easy.

Wow, doing it right!
Getting all the support upgrades done BEFORE turbo is the way to go...

Being familiar with your ECU and tuning software before turbo is another hurdle that most folks deal with under boost.
You are far less likely to hurt parts knowing what to do before going to the dark side (boost).

I'd read lots of the "boost on track" threads to get ideas. Boost on track requires LOTS more cooling upgrades than boost on street but you have done many of them at this point.

I'd run either race gas or E85 on track. These fuels are more stable, burn cooler, and are a lot less likely to create detonation in a track environment.
I would NOT use pump gas on track...
E85 is the ticket for me.

I didn't see which ECU you are using but if you can change injector settings you're not stock.
Which ECU?
Add knock sensor if you haven't already. I'm going to change to the Bosch version on my MSM.

Looks like you are taking the proper path and the car is coming along nicely.

Your job looks like a Ford dealership. Am I right?

Yo dude, thank you! I'm trying my best haha. It's been quite the learning curve figuring out what goes into making these cars work right under heavy abuse.

I've been scouring this site getting an idea of what needs to be done to keep these cars reliable on track once the turbo goes on. Savington's list in the "Turbo Reliability on Track" sticky'd post really opened my eyes as to how inadequate the stock cooling system on these cars is. Along with the clutch in a week or two, I'm thinking I'll order the Singular Motorsports hood vent kit and a radiator support cover panel, just to make sure I'm covered on the cooling system.

I installed an MS3x in the car back in June and have been familiarizing myself and experimenting with it quite a bit. I'm definitely still a novice "tuner" but I'm comfortable playing with most of the basic settings in TunerStudio and am aware of how most of the settings I play with will affect the car. The info on this site (Curly's advice especially) has helped me immensely. That being said, although I'm comfortable making adjustments to my MS as far as fueling goes, I'll definitely be getting the car professionally tuned once the turbo is on.

I was planning on running 91 octane for the foreseeable future but you bring up a good point and my fuel system does have the components to run E85. What would be the best way to go about running E85 for the track? I'm assuming the optimal setup for my use would be to install a flex fuel sensor and then have my tuner develop an E85 fuel/ignition table that would interpolate with a 91 octane tune depending on the flex fuel reading? There aren't any E85 stations close to where I live so I'd probably only run it for track days. Maybe I oughtta educate myself a bit more on that subject. Same goes for the knock sensor. I've had that on my to-do list but haven't done much actual research on that project yet. Man, we gotta add all sorts of stuff to these cars to turbo them reliably. When I first bought the car, I just assumed they were equipped with knock sensors from the factory :rofl:

Yeah, I'm a drivability tech (air/fuel/spark/emissions) at a Ford Dealership in SoCal. It's great because modifying a Miata has so much in common with what I do at work. That being said, we don't deal with anything like ECU tuning. My coworkers are all blown away when they see what I'm messing around with in Tunerstudio. The closest thing I've ever done to tuning a Megasquirt is hooking up a scan tool into a Mustang to update the ECU with some pre-programmed software from Ford Performance haha.

Singular hood vents and Supermiata 4-puck sport clutch installed.

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When I put the lightweight flywheel in 4-ish months ago, I told myself that it would temporarily satisfy the desire for straight line acceleration. How naive I was haha. I tossed in a new OEM clutch with the flywheel at the time and called it a day. Should’ve just put in the Supermiata one at that time. Oh well, it’s in now and all the matching Orange attached to the back of my engine is definitely making the car faster.

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First impressions after commuting home with the clutch: The bite point is pretty narrow and there’s a very finite sweet spot to get the car moving smoothly from a stop. It definitely demands more attention in stop and go traffic but I think I’ll get used to it and stop noticing it after a few more drives. Interested to see how much this aspect changes once the clutch is properly broken in too. Once moving, it’s a dream. The quicker bite and slightly stiffer pedal give the clutch a much more precise feel than the OEM one. No remorse from purchasing the puck clutch over the organic yet.

It's been a while since I've posted so I figured I'd keep this thread alive. I've only done couple tweaks to the car this month but have been putting it through its paces and driving the piss out of it as much as I can. Mainly waiting on the turbo kit to show up at this point before moving onto any other projects.

I ordered my turbo kit from Kraken at the beginning of this month. Top mount manifold, GT2560r, intercooler, and full 3" exhaust into a dual tip muffler. Michael at Kraken told me the GT2560 showed up on Friday and that my kit should ship midweek this week. Extremely amped to get this thing on and start ironing out the kinks so I can actually keep up with muscle cars on the straightaways.

I've also been kicking around the idea of trying to race some NASA time trials next year, and possibly Global Time Attack finals in Buttonwillow in November if I can get the car dialed in and get my van set up with a towing package. Having only 8-9 days of track experience, I'm going to need to get some more seat time in too. I think I'm going to sign up for VARA's racing school in January so I can learn to maximize my skill-building with the time I get on track.

On the coattails of that thought, I took the car out to Big Willow this weekend and had an absolute fucking blast. I always assumed a stock-engine Miata would be underwhelming on this course but I was extremely wrong. The same principles apply as anywhere else in this car, do everything you can to keep your momentum up and the car will hold its own.


Quick clip chasing my new buddy Jonathan in his STI. Forgot I left my pit music on this session because it was inaudible over the wind noise :rofl: Wound up posting a best lap of 1:39.95. The spec Miata guys are running 2-3 seconds faster in qualifying which makes me curious how much more time I can squeeze out of this car in its current configuration. I definitely have a little time I could make up in turn 4 if I start to turn in later.

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She got her workout in for the day :beer:

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I also installed a Status racing 5-point camlock harness in the car last week. This is another upgrade I should have done much sooner. So much more comfortable having actual restraints rather than the stock 3-point harness. HANS device coming soon...

DHL decided to tease me by delivering my turbo kit packages on different days. Kraken manifold and elbow, 2560, and oil/coolant fittings and lines came in last night. Intercooler and exhaust bits are supposed to arrive today. The suspense is killing me

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It's a good conversation piece on the garage workbench though.

Other updates...

Locked up my brakes (twice) at Auto Club Speedway last weekend and flat-spotted the sh*t out of my front tires. Luckily they were already smoked and I had a new set waiting for me at work. Still had a good day out there. The car topped out at 114mph on the oval portion of the course, up from 110mph last time I was here without the aero and Megasquirt. Managed to shave two seconds off my previous best and get down to a 2:09.3.

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Carnage.

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That Z in the background had a WWII-style crosshair mounted to the driver side of his hood. Awesome :rofl:

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Safety in numbers.

Hoping to get the intercooler piping mocked up this week after work and then spend Saturday getting the rest of the turbo stuff installed. Hopefully I'll have an update on here Sunday if all goes well.

Well, against all odds, the install went smoothly and I finished it up on Friday. Holy hell this thing scoots now! It’s got more punch than what I was expecting running 8psi without a boost controller and a conservative spark map. The whole setup is in, just need to iron out a couple things like making permanent intercooler mounts. Next step is to get it dyno-tuned and work on some heat-shielding for the brake lines/heater hoses/etc so it’s ready for the track.


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Donated some blood to the boost gods. Hopefully that brings some good karma.

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Installed the intercooler and slapped an air filter on the end of the intake pipe to drive around for a couple days.

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Enough gold? Might almost be enough gold. Might need more gold…

Better/more pics of the car coming soon hopefully. It’s pissing rain out right now.

Thanks again to everyone on here who’s helped out and answered my questions! I never would’ve made it this far without this damn forum haha.

Got the car dyno tuned at Advanced Engine Dynamix yesterday, as per many buddies' recommendations. Toby, the guy running the operation, is the man. Got the car tuned and all my car's running quirks ironed out, and I learned a couple things. Ended up making 212whp @ 10.5psi, right at my power goal. Decent torque curve too for just running off the wastegate spring. Amped on it.

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Cool to see the car here after watching so many YouTube videos filmed in the same shop.
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A little canyon run fun today. Car's as fast as I need it to be for the time being. Still just getting used to how damn fast it accelerates in low gears. Can't wait for the next track day.

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Nicely done! 200whp is plenty for the track, but on the streets you'll definitely be hungry for more once you get used to it. Sweet build!

Thanks man! Yeah, I'm perfectly happy with the power on tap (for now) and am gonna try not to rush for more. Next up is proper intercooler/radiator ducting and getting the car to some track days after the new year.

The car survived its first turbo'd track day this weekend! Took it to Big Willow for the shakedown and holy hell this thing MOVES now. So much goddamn fun.

I took it pretty easy my first session just to make sure the car was holding together (and also because I was a little bit afraid the power would be hard to handle). Second session and onward, I gained the courage to start pushing it more and more. To my pleasant surprise, the car wasn’t hard to handle at all with the extra power! All of this time, the NA purists and turbo nay-sayers had me convinced that the turbo setup would be quirkier and require more finesse to handle on track. Such was not the case at all.

By session three. I was comfortable pushing the car and passing 350s, EVOs and Bimmers on corner exits and straights where I never would have been able to before. Even with only 210whp, the feeling was otherworldly. I was able to reach and hold 127mph through turn 8 and on the front straight, and dropped my PB down to a 1:35.4.

More detailed write up and videos to come later…

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Zoom zoom
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Tent camped the night before in 35 degree weather. Dedication… or stupidity.
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Wandered around the facility for a few hours Friday night. 11pm track walk. The bumps & cracks in the pavement on Big Willow are way bigger than you realize while driving over them.