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Old 01-25-2013, 06:24 PM   #21
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So as I wait for the rest of my intercooler piping to arrive, I've had time to touch up some of the new components. Since the GT2871R is internally wastegated, AND because my buddy states that even his 2560R likes to spike and creep, I figured it might be worth a short to do slight porting in the wastegate region.

ChrisCar shared this article written by Corky which I used as a rough guide:

BEGi - - Corky's Comments - turbo_porting

The one thing I'm not too keen on is causing additional turbulence in the exhaust housing right before entering the nozzle/turbine wheel, so I was pretty conservative with the channel towards the wastegate. Also, for the rest of the exhaust side I didn't try to achieve anything other than removing casting roughness. Amateur 2-hour job with some air tools, vice, carbide bit, some grinding stones, and 150-250 grit sandpaper. I don't care what it looks like, it's smoother to the touch than it was and I don't have the goddamn patience or desire to make it bling.

I also noticed that the BEGI cast manifold was pretty badly aligned with the turbine housing, so I did some basic gasket port matching.

Before port and gasket match



Showing grooved channel



After porting/semi-polish



Then I proceeded to give the wastegate a SLIGHT port. I would say there was only 1mm-1.5mm material removed around the circumfrence of the port. I left the region at the top alone, as requested by Corky's instructions.



After Wastgate



And here's a final pic of my old turbo setup before removal



With the new manifold and turbo mocked up. Note that I did have to cut a small chunk out of the frame to clearence the compressor housing. Sawzall, sanding disks, then it was quickly sprayed with primer.

Attached Thumbnails
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Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130124233649.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130124224628.jpg  
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Old 01-26-2013, 08:23 PM   #22
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Since I picked up low impedance RC injectors (measured 1.9-2.0 ohms) I needed to modify the injector harness appropriately. Since I'm also using Toyota COPS, it was a good time to omit the coil plugs and clean up ignition harness.


Here's the stock Mazda harness:



And you Honda guys might recognize these gems. I had an old OBD0 (88-91 MPFI) Civic Si harness lying around complete with resistor box. The injector clips are compatible with the RC's with minimal modification, and the resistor box has a factory-ish look when spliced in.



Here are the necessary connections spliced between the two harnesses. They go as follows:

Power: White/Red from Mazda factory harness goes to Red from Honda Resistor Box
Yellow/Black from Honda plugs goes to Black outputs from Honda Resistor Box

----Honda Color-----Mazda Color
Inj1-----Yellow------Yellow
Inj2-----Cyan-------Yellow/black
Inj3-----Red--------Green/White
Inj4-----Brown------Green




Finished result.
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Old 02-18-2013, 11:37 PM   #23
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Couple of quick photo updates since I had time.

Finished bolting together the new setup and currently daily driving it. Pic of engine compartment during first startup:


Exhaust to replace the 2.5" straw. Begi SS divorced downpipe 2.5" to 3" mandrel bent SS exhaust, 12579 Magnaflow muffler (dual 2.5"?), vibrant resonator. Welded with MIG 308LSI wire.


Managed 3" pipe with 6" radius bend in it for the tail section, for those that saw the 4" radius recommendation. I think this will be slightly less turbulent on flow - don't ask me to prove it.


Slant-cut exhaust tip. Nothing fancy.


HardDog HardCore HardTop Double Diagonal awaiting install.


And a video taken last night. I drove like a whale vagina because there was black ice everywhere.
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Project: Turbo Me-Otter! Frugal 1.8 daily driver build-79379110200089307648690.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-86096010200184131019215.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-85775610200184131099217.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-86023810200190915388820.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-86072910200159850692222.jpg  

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Old 02-19-2013, 08:59 AM   #24
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lol @ compression ratio.
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Old 02-19-2013, 10:19 AM   #25
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Quote:
Originally Posted by hustler View Post
lol @ compression ratio.
Stock piston compression no bueno?
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Old 04-04-2013, 09:21 PM   #26
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Been putting this update off for a while since I've been insanely busy. Instead of elaborating in great detail on everything that's been done, I'll just share the pics and my build notes. Feel free to ask any questions or post criticism


FIRST:

My current tuned MSQ file for anyone interested.
http://www.symtechlabs.com/support/d...q.php?file=296

Intake cam retarded 7 degrees!
VE Table incorporated into tune under secondary load parameters

  • Injector Size: 750cc/min
  • Processor: MS2
  • Fuel Pressure: 38psi
  • Firmware: MS2/Extra DIYPNP 3.2.4
  • Temp. Sensors: Std. GM
  • Board: v3.57
  • Oxygen Sensor: Innovate WB
  • MAP: 255kPa






WiFi antenna and switch wired up to toggle between BT and DB9 serial


Re-used fuel pressure regulator solenoid and wiring for VICS activation.


Homemade PVC VICS vacuum manifold because I didn't feel like chasing leaky rubber lines in the insanely difficult to reach factory spots.


Roll bar install. Robbins streamline one-piece just barely clears


Flyin' Miata frame rail reinforcements. Really stiffened the wobbly chassis up in addition to the roll bar.


Clearwater fiberglass subwoofer rear deck install and finishing roll bar trim.


Compression testing in the snow before my tuning appointment


Tuning at Xenocron by Matt Ivan and Chris Harris


*** Cam gear proved to be a great investment. Picked up 26WHP by just retarding intake came 5 degrees!


Mainline dyno = heartbreak dyno since it reads very low. Tuner estimates Mustang dyno will show 300whp+, either way I'm extremely happy with how the car feels. Note the dip at 6k is likely from the 2.5" downpipe.



Before her first auto-x event



Back to daily driver status. Averaging 21MPG city, 27MPG with 75% highway usage.




And a video I compiled together from GoPro footage taken from NYR SCCA test/tune last weekend:

Vimeo - PROJECT MEOTTER




BUILD NOTES:

General Output Relay 2 - VICS (PT6 Output, Pin 2R factory harness, 4R DIYPNP)

3/13/2013 - New fuel filter, bled brakes with Valvoline DOT4 Synthentic, fixed valve cover leak, disconnected LC-1 calibration switch due to short, wired in 4 2700uF capacitors for COPS, compression test: ALL cylinders 188-190psi


3/14/2013 - Dyno tune at Xenocron. End result 247.3whp / 215.8wtq @ 20psi Mainline dyno (closer to 300whp dynojet). Intake cam retarded 7 degrees (14 crank), BKR8E-11's swapped in place of BKR7E-11 plugs.

3/16/2013 - Initial tune of AE complete, enabled EGO closed loop and closed loop idle. Hot restarts still common - created VE Table 3 (table-switching) with 15% more fuel across map to run manually if needed during hot-restart. Replumbed power steering hose. Annoying interior rattle found to be rear-view mirror.

3/17/2013 - Violent high-load low-rpm bucking found to be launch control. Assumed to be involving grounding issue on account of cruise control module. Regrounded throttle body ground in effort to clean up TPS signal - still see spikes 100%/s so increased AE threshold to 110%. Small oil leak off back of block was loose cam sensor caps. (left loose to adjust timing and forgot to tighten back down).

3/24/2013 - Installed HardDog HardCore HardTop M2 and FM frame rail reinforcements. Fixed Clearwater rear deck woofers (wiring issue). Replaced COP boots and springs with BECK ARNLEY 175-1068

3/29/2013 - Had alignment done by Foster tire care as per Flyin' Miata recommendations:

Front
Caster: 5.0 degrees
Camber: 1.0 degrees negative
Toe-in: 1/16", 0.15

Rear
Camber: 1.5 degrees negative
Toe-in: 1/16", 0.15

Camber on front was left at 1.5" due to passenger lower control arm wear - should replace and realign.

Plugged in neutral safety switch - need to wire up launch control. Moved COPS ground away from main grounding point and cleaned up sensor signals.

3/30/2013 - First Auto-X test of 2013. Need launch control wired, AE adjustment, TPS shielded wiring, interior plastic screws for top, spring for two piece downpipe

May 31, 2013 - 155602
Mobil 1 synthetic 5w30, k&n oil filter. Installed fire extinguisher.

Lookout for 205/50/15 15x7

4/4/2013
Revised launch control use MAF blk/ltgrn wire. Blk/Ltgrn ground source clipped behind master cylinder. Leg from 2F (4F on DIYPNP) ran to neutral safety switch. Grounds when pushed.
Attached Thumbnails
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Project: Turbo Me-Otter! Frugal 1.8 daily driver build-30589749667729704611413.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-67026102003527624748962.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-69810200360358824800168.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-89335810200407731889097.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-88331110200407731169079.jpg  

Project: Turbo Me-Otter! Frugal 1.8 daily driver build-90385810200427691148066.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-442013afrtable.jpg  

Last edited by JustinOMGWTF; 04-04-2013 at 09:51 PM.
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Old 04-28-2013, 08:07 PM   #27
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Old 10-05-2013, 01:52 AM   #28
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So at this point I should really rename the thread title to something that better reflects the actual amount of money I've put into this project.

Anyway...been a long time since the last update and I had time so I figured I'd toss in some details for the curious.

4/20/2013
Replaced both lower ball joints front

5/5/2013
Mtuned big brake kit, VW corrado 11" rotors, hawk hp+ pads, flyin' Miata stainless lines, ATE racing fluid, fully rebuilt all four calipers, Kosei K1 15x7 rims, Nitto NT Neo Gen 205/50. Installed dual hood lift kit, rollbar padding and cover, gas pedal extender, outer tie rod ends, repacked and sealed front upper ball joints. Foster care auto 4 wheel re-alignment.

5/10/2013
Racing Beat Tubular adjustable sway bars, front and rear.

6/19/2013
Catastrophic engine failure due to severe detonation. Suspected rise in IAT from heat-soaked intercooler, bad gas, and aggressive timing. Engine mis-firing due to physical damage to spark plugs.

10/4/2013
Rebuilt engine with Wiseco 8.5-8.8:1 pistons, Hondata intake manifold gasket, Fab9 Vibrant (similar to 12810) 550HP intercooler, TurboXS KnockLite with Bosch knock sensor.




So picked up some 15x7 Kosei K1 track-rat wheels for $150 for the entire set with Hoosier drag slicks. They were pretty badly scratched and marked up, so I performed my usual TLC to restore them. One had to be completely stripped and painted - the others were touched up and polished.





At the same time I installed the big brake kit I got a great deal on since now the larger corrado rotors would be able to fit. The calipers were rebuilt, and I took a picture of what I had to do to get to the bottom snap-ring in the rear caliper assembly. (snap ring removal adapter with 90 deg needle nose).













And some meaty Racing Beat tubulars:



This car was fun as hell to daily drive at 22PSI, but as the build notes and picture below reveal the aggressive tuning eventually took it's toll.

My first indication that something was awry after limping the car home...a crushed electrode:



And after inspecting the bottom end:








Solution: Bigger intercooler, toned down tune, knocklite, and Wiseco 8.5-8.8:1











Now breaking in the new rings. Back to looking pretty and boosting around.



Attached Thumbnails
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Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130502_181902.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130505_202839.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130621_155506.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130727_113239.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130731_202719.jpg  

Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130501_184158.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130506_192005.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130921_135900.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130927_171419.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130927_195916.jpg  

Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130928_195021.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130526_171414.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20130506_192026.jpg  
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Old 10-08-2013, 03:11 PM   #29
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Cool car!
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Old 10-08-2013, 03:36 PM   #30
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Looks like a lot of det on those stock pistons.

Awesome build!
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Old 10-10-2013, 06:47 AM   #31
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Awesome build. Enjoyed it. Keep up the good work
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Old 10-24-2013, 05:49 PM   #32
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Thanks for the compliments

Some new updates with pics.

10/09/2013
Installed Knock-Lite
Red -> +12V accessory power behind radio
Black -> knock sensor and ground on Intake Manifold
White -> knock sensor
Orange -> Black/wht tachometer input from COP harness

10/13/2013, 157,872 miles

AKEBONO Part # ACT636
AKEBONO Part # ACT635

Akebono's were used to replace the horribly dusty and noisy Hawk HP+ pads. Track pads make for an embarrassing daily driver.

10/21/2013
Installed Fab9 550HP Vibrant core intercooler
Had 750cc RC injectors cleaned by SouthBay. Flow rate is within 1% of each other, and max flow was 810cc


Intercooler install - Comparison of the Fab9 Vibrant core (essentially a 12810 with different end tanks) versus my old Mishimoto z-line.



The intecooler required a lot more cutting and trimming of the bumper support than I had originally anticipated, and to get the pre-drilled holes in the brackets to line up I would have had to do even more cutting which I wasn't too fond of. Instead, I used the brackets as a template and drilled my own holes about 3/4" back from the factory tow hook bolt the brackets were meant to utilize. This allowed more room in front, anyway, so I didn't mind. The bolts to hold the intercooler in place were regular 8mm x 1.25 bolts with washers and used eccentric bolt washers welded to them so they wouldn't require a box wrench on top when bolting up. Hard to explain, I suppose. Horrible night-time pics here:





And the end result. Factory bumper fit perfectly - although I need to become creative with an aftermarket power steering cooler. Ground clearance is about 2".




Attached Thumbnails
Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20131020_090743.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20131022_203754.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20131022_203804.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-20131022_223028.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-1235352_10201717693037307_1710154257_n.jpg  


Last edited by JustinOMGWTF; 10-25-2013 at 11:58 AM.
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Old 11-20-2013, 11:17 AM   #33
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IC looks great fills that grill up nicely. - I'm a fan of the Wiseco ashtray too...
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Old 11-20-2013, 03:34 PM   #34
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Quote:
Originally Posted by FAB View Post
IC looks great fills that grill up nicely. - I'm a fan of the Wiseco ashtray too...
Yep - def recommend the Vibrant cores...beautiful construction and very cost effective.

I have plenty of blow-up pistons if you want your own ashtray
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Old 11-20-2013, 03:58 PM   #35
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SUB'D.
Beautiful build thread keep it up.
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Old 06-08-2015, 10:24 AM   #36
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Been a long time since updating this - understandably, my priorities shifted after the purchase of two houses.

In case anyone had remote interest in this thread in the past, here are the quick updates:

157,872 miles
Akebono brakes and pulled fuel injectors for cleaning by SouthBay Fuel Injectors (flowed 810cc)
AKEBONO Part # ACT636
AKEBONO Part # ACT635

11/02/13
158212, 614 miles on engine
Bled clutch
Rerouted oil catch can

11/05/2013
Compression test: 1-4- 170, 168, 168, 180

11/08/2013: 158500
Retuned by Xenocron
Leaking fuel injector seal abandoned tuning session
Oil change to 15w40
.025 gap on spark plugs

11/10/2013
Replaced injector seals, modified fuel rail for dual feed, performed boost leak test to 50PSI. Seafoamed engine and freed up rings, found timing off a degree. Retimed yellow mark to TDC and yellow mark to 10deg BTDC.


04/09/2014
Resoldered lc1 wire inside PNP due to intermittent wideband signal
Replaced Wide Band O2 Sensor 17014 -1yr warranty through Advance Auto

7/29/2014
Casual driving, 2nd gear exploded causing catastrophic failure of main shaft in 5spd transmission. Replaced transmission with another 5spd unit. Filled with Ford motorcraft full synthetic fluid. Painted driveshaft.

8/16/2014
162357
Pennzoil platinum 5w30 synthetic, ngk plugs .25 gap, New suede shift boot to replace torn vinyl unit.

9/23/2014
Casual driving, turbo bearings let loose and caused compressor wheel rubbing inside of compressor housing. Excessive CHRA play both axial and radial. Upon investigation, also noticed stock wastegate rivets broke loose causing overboost, which was likely culprit.
Turbos Direct: $500, warranty 1 year.

Turbos Direct LLC.
Attention: MIKE
3581 W Electra Lane Suite 100
Glendale, AZ 85310
623-376-2562

Complaint:
Ball bearing noise, and sudden loss of boost due to compressor wheel rubbing.

Application:
Mazda Miata 1.8, performance street with some track. 18psi full spool by around 4100RPMs. Looking into possible performance upgrades to assist spool or top-end. Not sure if exhaust housing swap to .82 would be recommended for street
.

11/08/2014
163197
Rebuilt GT2871r with new CHRA (Turbos Direct LLC.)
Installed Evo Turbosmart Internal Wastegate Actuator - had to make own wastegate actuator rod out of stainless threaded bolt.
Flushed rear differential with 75w90 Lucas synthetic
Cleaned and recirculated blow off valve to turbo inlet using silicone tubing
Replaced heater core due to leak

05/17/2015
Replaced two-piece downpipe exhaust spring with Akrapovic Rubber isolated stainless spring 80mm
Upgraded to and tuned MS2/Extra Release 3.3.3 Firmware
Replaced rear driver side caliper, bled brakes
Tightened frame rail stiffeners
Welded exhaust leak
Lubricated rear bushings

5/31/2015
Tires rotated and balanced at Midas

6/6/2015
166135 miles
Tightened all frame bolts, alignment bolts were a bit loose and causing creaking on accel/decel
Straightened out steering wheel
Oil change, Castrol Edge 10w40
Fresh plugs NGK R5671A-8 - Stock# 4554 (normally use BKR8E-11: Stock number 6587)
Retuned AE by dropping tpsDOT to threshold of 5 and reforming AE curve







GT2871R rebuilt by Turbos Direct LLC.





All back together again





Back in action at NY SCCA Solo
Attached Thumbnails
Project: Turbo Me-Otter! Frugal 1.8 daily driver build-80-10653683_10204259780107895_6466920551567232642_n_a0f35b7a07079435d8cff971b3b0df8d98afe346.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-80-10497474_10203382024044542_449036347292946607_o_88c0c74c2957dcfab5bbcd35eaa862887722cef5.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-80-11390084_10206014571336579_60410420392313376_n_c9782407d9b5b9cce48f57c7045f83e080756acb.jpg  
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Old 06-08-2015, 10:28 AM   #37
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Thanks for detailed update. Now get some vids for us
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Old 06-08-2015, 11:58 AM   #38
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Quote:
Originally Posted by 18psi View Post
Thanks for detailed update. Now get some vids for us
As you wish.

Cold startup video after finalizing Warmup Enrich and Closed-loop:




SCCA Solo auto-x from 6/7/2015:

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Old 06-19-2015, 04:13 PM   #39
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Trying out on of the eBay turbo blankets. A lot of back and forth on the turbo failures regarding insulating the heat in the turbo housing, but the CHRA is water cooled and I always have my turbo timer on. Time will tell.



Had to clean up all the temp 90 degree bends coming from the turbo outlet. Stepped up from 2" to 2.25" and then into 2.5" pre-intercooler. At the same time though it'd be a good idea to fabricate a sheet metal air filter isolator / cold-air box. Diverted the warm air from the radiator away from the air filter as well...will check IATs to see if there's a noticeable difference.

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Project: Turbo Me-Otter! Frugal 1.8 daily driver build-10915064_10206073001917307_66413239758263612_o.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-10520551_10206102930665507_8694537465826217637_n.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-142072d1434740402-project-turbo-me-otter-frugal-1-8-daily-driver-build-10915064_1020607300191730.jpg   Project: Turbo Me-Otter! Frugal 1.8 daily driver build-142073d1434740402-project-turbo-me-otter-frugal-1-8-daily-driver-build-10520551_1020610293066550.jpg  
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Old 06-19-2015, 10:14 PM   #40
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There should be a significant difference
at least there is on NB's that have a hole right behind the headlight
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