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Old 07-17-2010, 11:35 PM   #21
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Day 12: July 17: Spent all morning running around trying to fing that Oil Jet Bolt, and no luck. Finally broke down and call the dealership...$25 for a ******* bolt!!! It'll be here on thursday.

Was only able to work on the car for 3 hours

- Remove entire front suspension system
- Remove wheel hubs
- Repalce Bolt joints (lower) and Boots (upper)
- Remove and replace inner and outer tie rods

Waiting on bushings to complete the job, should be here on tuesday. Tomorrow I am going after the rear subframe and differential.

DIYPNP is here, lets see if I can do this thing.
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Old 07-19-2010, 04:44 AM   #22
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Day 13: July 18

Many bolts seize and frozen in the rear suspension system, had to cut a few of them. I will spend the next two days fabricating new bolts, cleaning and replacing the bushings.

Still reading the DIYPNP documentation.

My supplier failed me, I went to pick it up today and the "Garret 2560" turned out to be a turbo for a diesel application...that thing was huge!!! I am glad I did my reading here and save myself the embarrasment and $250. So **** it, I am going Churbo for the initial set up, will upgrade when I get to Germany.

This project is turning into a real nightmare...and the clock is ticking.

Last edited by Maluk; 08-02-2010 at 03:29 AM.
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Old 07-19-2010, 11:45 AM   #23
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Nice so far. It looks like your making some good progress despite the setbacks. I really like what you did with the pistons and lifters.Don't cook them for too long they'll be dry and not very tender. I'm anxious to find out how they work for you.

I would be suspicious about the 30 psi on stock pistons. At 16-17 psi mine decided it didn't need the ring land on the #2 piston anymore. This was of course before my stupid *** had an intercooler.

The high silicon content makes them brittle. The Wiseco is kind of the best of both worlds. It's a very low silicon forging which allows one to run a tighter piston to wall clearance as opposed to one carved out of an aluminum billet like the JEs. In any event, at 12 psi the stock ones should be fine. With proper intercooling and good fuel, you should be able to squeeze more out of them.

Like Curly said, there will be plenty of other things that get pushed past their limit anyhow. My poor diff feels like it has about an 1/8" of backlash in it from running 20 psi on it. I just love stress testing my parts.

Looks like your on your way to a fun ride. Best of luck with it!
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Old 07-19-2010, 02:13 PM   #24
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Quote:
Originally Posted by lordrigamus View Post
Nice so far. It looks like your making some good progress despite the setbacks. I really like what you did with the pistons and lifters.Don't cook them for too long they'll be dry and not very tender. I'm anxious to find out how they work for you.

I would be suspicious about the 30 psi on stock pistons.

Looks like your on your way to a fun ride. Best of luck with it!
I've done the ceramic coating before. My brother had an MR2 and after 2 years we change the head gasket and the piston crowns were almost perfectly clean. The ceramic coating prevents the formation of gunk on the pistons (seen this first hand). The teflon (dry lubricant) keeps the skirts nice and moist .

I dont thrust the 30PSI thing either. I beleive in substracting 40% off manufacturer limits just to be safe.

Thanks, this Forum its whats keeping me motivated.
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Old 07-22-2010, 05:24 AM   #25
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Day 14 July 21 Had some good progress today:

- Installed new Radiator
- Made Brakets and installed IC (not the pipes)
- Replaced Fuel pump
- Installed crankshfat and bearings
- Replaced steering wheel

Wasted some time helping the guys next to me. Their engine stand took a nose-dive with the engine on it. They are building sleeper trucks (old Ford F-100 and F-150 with a 454s in it).

I am hoping to have the engine in the car by Saturday evening.

Still waiting for Diff, manifold, and bushings.

I got 1 month till completion. Then I fly to the land of *****, Beer and Bratwurst!!!
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Old 07-22-2010, 05:55 AM   #26
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News flash. 7.5 liter engined are heavy. Glad Youre chipping away at progress. What wheel did you go with?
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Old 07-26-2010, 04:22 AM   #27
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News flash. 7.5 liter engined are heavy. Glad Youre chipping away at progress. What wheel did you go with?
I just got a cheap ($20) wheel from a local swap meet market here in Tacoma.

Day 15 & 16 July 24-25

Saturday- Spend all day wiring Gauges (Oil Temp, Bost, AFM). My big monkey hands dont help much when it comes to small tight places.

Sunday - The engine is completly put tougether, but I was unable to put it in the car since I still missing the bolt for the oil jet.

MAZMART failed me; my diff is not here yet!!!
Mazda parts center screw me; they forgot to order the bolt twice the same week.

Thanks Travis, I got the injectors right on time.

Wednesday and Thrusday are going to be knockle buster. Complete suspension goes back in the car.

The way this is going I am going to have to put this car on a boat the way it is and finish this project in Germany.
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Old 07-26-2010, 03:24 PM   #28
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Which "oil jet" bolt are you missing? Is this the oil squirter bold in under the cylinder bores? I have tons of these if you need them.
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Old 07-26-2010, 06:13 PM   #29
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Which "oil jet" bolt are you missing? Is this the oil squirter bold in under the cylinder bores? I have tons of these if you need them.
Yeah thats the one...PM sent
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Old 08-02-2010, 03:12 AM   #30
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Day 17: Jul 28 Started changing the bushings on thge front end. I wasnt able to finish. This things were attached for dear life.

Day 18: 29 July Completed the front bushings. Started the rear end and my tools had enough, they busted up halfway thru the job. I was too fustrated and tired to continue.

Day 19: July 30 My hands are in pain from all them bushings (I'll finish them up next week)
Ran around got some more tools.
Mounted the intake Mani and Injectors
Drilled Hole in Oil Pan
Pretty much a wasted Day

Day 20 : July 31 Got the Bolts From Wayne_Curr (thanks Brother)
Re-checked all of my torques
Installed Oil Pan
Installed Flywheel & Clutch Kit
Installed Transmission

Day 21: Aug 1 Put engine in Car!!! That took me 3 hrs since I had to do it alone.
Started Cutting pipes for the DP

This was a terrible week to get anything done. I spent a lot of time working and at the end of each day I felt that I got nothing done. I am starting to run short on patience, time and money.


So here I am going to use my freebe stupid question.

Below is a picture of the vaccum diagram. Yes I have read, and done my research, But I am still confuse.

I want to connect these thing the right way the first time.

Can someone please conect the dots?

I will be very Greatfull
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Old 08-03-2010, 07:18 AM   #31
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I got the DIYPNP completed. I was able to flash the firmware , but it will not connect to Tuner Studio (Comp Port issue). The Mega Tune program does recognize it. I have not loaded anything to it other than the firmware using a 12v 500ma plug at the house.

I have tried everything that I know on the computer side with no luck. I will not be able to test it in the car for a few days. I followed the instructions to the letter from the DIYPNP site. I have checked all connections and jumpers on the boards and everything is soldered right. I have also search this site, and Google for answers with no luck.

Any Ideas?


BTW I got the vaccuum thing figured out from my previous post
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Old 08-03-2010, 09:07 AM   #32
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Give Mannheim a nod for me if you pass by... some good memories from there... and some drunken-hazy-not-so-good ones too - I think
In for seeing how this plays out, keep it coming.

If you had to buy a usb to serial adapter to connect to the PNP, you'll have to install software for it before your laptop and PNP talk. Thought I'd mention it just in case...
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Old 08-24-2010, 05:31 AM   #33
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Hey everyone,

Just in case anyone thought that I failed, here is the latest update.

The last two weeks have been hell on me. Trying to clear the post (Army thing), work on the car, and illnesses, I have some progress and set backs.

After putting the engine back in the car and attempting to build oil pressure, I came to find out I had bought the wrong oil pump. Since the last one was still in good shape engine came out of the car and oil pump was swapped.

Then came the fuel pressure nightmare. After many hours of trouble shooting it came to be a bad ground (actually a lose cable)

After all that corrected and done (fuel pressurize, and oil pressure started) I hooked up all electrical, and vacuum hoses and gave her a crank.

SHE IS ALIVE!!!...ALIVE on the very first crank. I almost had a tear come out of my eyes (maybe because I rubbed my eyes after bleeding the brakes)

She is far from being completed (still got to do all the body work and fine tuning), but I am out of time. By the end of this week she will be taken to the ports and shipped to Germany. So far I have spend well over $4k on the car, and she is still not even halfway done.

Here are some pics, but please take it easy...like I said she is far from being completed.

Thanks to those who kept up and gave me some motivation. Although this threat might die for a while. I will resurrected once I feel it is necessary to post something entertaining.

Good Luck to everyone. Catch you all later!

P.S WAYNE_CURR, don't think I have forgotten about you! Once I get to Germany I will payback that favor.
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