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Old 10-21-2009, 01:17 AM   #1
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Default Norm's Build Thread

I have been gathering parts and information for the last couple of months and decided to start my build thread because I will have some questions to ask the more experienced Miata turbo members very soon. I have turbo'd three other engines in open framed off-road cars, but this is the first production car I have turbocharged. It is much more involved than the off-road cars because everything is so tight and hard to get to, and this is the first aftermarket EMS I have touched .

My Build Plan:

1. Research this forum and other sources of info, read Maximum Boost, etc. (done)
2. Buy/build all the parts to do the project at once (done)
3. Install HD clutch (done)
4. Install EMS on stock engine to work out issues before installing turbo hardware (partly done, screwed up, removed, starting over)
5. Install 600 cc injectors (same as 4)
6. Install turbo kit
7. Build 3" exhaust system
8. Tune EMS for completed system
9. Enjoy some boost!

Parts I Have In Hand:

1. FM Level 1 clutch/pressure plate (installed)
2. Adaptronic ecu w/3 bar MAP sensor (installed, removed, installed, removed)
3. Deatschwerks 600cc injectors (installed, removed)
4. BEGI S3 turbo kit w/GT2560, S5 mani w/EWG option, rev. SGDP for EWG, #1 IC
5. TiAL 38mm EWG
6. LC-1 WBO2 w/gauge (installed)
7. DIY Autotune GM IAT
8. Boost gauge
9. Dual pod A-pillar gauge mount
10. 3" aluminized steel exh. tubing and bends from Columbia River
11. 3" Dynomax resonator
12. 3" Magnaflow muffler

I recently installed the WBO2, MAP sensor, and mounted the Adaptronic ecu under the dash successfully (per the very helpful write-ups by other members). Then I ran into some serious issues. The Adaptronic ecu would not work. First I had a bad serial cable, then the unit would not power up. After a couple of days of trying everything I could think of, Travis pulled his Adaptronic ecu from his personal car and sent it to me, which solved the problem. Then, while trying to get the initial ecu set-up done, I decided that I might as well install the 600cc injectors and set the ecu up one time. I was leaving a few days later for a pleasure drive in the Arkansas mountains with two other cars so I wanted to at least get the ecu up and running to take advantage of autotune in a hilly environment. Installed injectors, tried to tune, had many settings problems, consulted w/Travis, car would idle, then wouldn't idle, could drive it but idle not acceptable, worked on it until I ran out of time, then reinstalled the stock injectors & switched back to MAF and drove it on the trip bone stock. Just got back today from Arkansas. Great highways to drive on for three days without repeating any roads. I was highly disappointed to not have the
Adaptronic working, though.

At this point I have a number of questions about Adaptronic settings/maps and Deatschwerks injector length issues I need to ask, but to avoid creating a super-long first post in this thread I will address those in future posts. Here is one appeal though: could anyone with a good Adaptronic 600cc map suitable for 2001-2005 cars send me their map? I have the ones from Travis' website, but they were not up-to-date and I may have goobered them up while floundering around trying everything I could think of.

I will post pictures as soon as I learn how.

Noob question: Now that I have started this thread, should I post all my questions and cries for help here or post them in the various topic subforums (eg., Adaptronic problems in Adaptronic forum) or tag onto other threads (eg., Deatschwerks injector length thread)?
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Old 10-21-2009, 10:44 PM   #2
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Default Photos (hopefully)

I am attempting to attach some photos of my project. The preview shows the pictures too large, but I don't really know how to manipulate them yet so I apologize for that. Also, they uploaded out of order.

The pics show my car, my roll bar installed, my turbo parts bolted together to check fitment, my EMS, my 600cc Deatschwerks injectors (there is some problem with length by 1/8th inch I'll address later), various piping and intercooler parts, exhaust system parts, a couple of pics of my turbo offroad car, and my Harley just for good measure.

I'll try to polish my photo skills and post more pics as I can.
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Old 10-21-2009, 10:45 PM   #3
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WOW you are off to a great start and parts list. Absolutely beautiful
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Old 10-21-2009, 10:52 PM   #4
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Who cares about your miata, I want your garage!
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Old 10-22-2009, 12:42 PM   #5
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LOL. Yeah, I am fortunate to have a large shop to work in. I do everything with cost in mind. The only way I could afford a 60' X 60' shop was to build it myself. I lkive in a semi-rural town. I only had a stick welder at the time, but I fabbed and erected the entire building myself, by myself, one-man job. It was a nightmare summer project, but I can now house a bunch of projects.
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Old 10-22-2009, 04:19 PM   #6
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Deatschwerks had a few issues with shipping an incorrectly labeled injector that was too short for Miatas. A few others had that problem that I read about. A short injector will make vacuum leaks that will make idling well impossible. Just a shot in the dark...
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Old 10-22-2009, 06:43 PM   #7
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Wow...that's going to be an awesome build.

Should make for a REALLY fun car.
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Old 10-22-2009, 10:11 PM   #8
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jesus ****, why am I the only person with a begi kit who got the choked-down 2" compressor inlet?
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Old 10-22-2009, 10:16 PM   #9
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btw, you need an oil restrictor.
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Old 10-22-2009, 11:25 PM   #10
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With regard to the size of the compressor inlet, I originally asked BEGI if I could have a turbo with a 2" inlet. They asked me if I was gay. I said "no", and they said, "You get a 3" inlet."

With regard to needing an oil restrictor, I'm glad you mentioned it. I planned to add one to a fitting at one end of the braided oil line, but I hadn't thought about it in a while, and BEGI didn't mention it. In the past I have tapped the oil fitting and screwed in a brass set screw with a 0.055" to 0.060" orifice drilled in it. That was for a T4 turbo with journal bearings. Would that size orifice be good for the GT2560?

(Sorry for the first reply above. I couldn't help myself after reading about you in the sticky about the new search features)
(Hey, I'm pretty proud I learned how to use the smiles feature)

Norm
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Old 10-23-2009, 12:21 AM   #11
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.035 works for savington. I still had smoke at .060.
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