TonyV's
 

So I've been stockpiling parts for some time now, and figure it's about time I think about documenting my project. This thread is open to suggests, opinions, debate 9within in friggin reason).

I have a full time job, a 2yr old son, and my garage is 20+min away from my house, so it's not going to be a very fast paced build, but hopefully a great one.


Car is a 95, with 136k on the clock. Orig engine. Currently has an upgraded clutch, ss lines (brake & clutch), 3" straight exhaust, and a simple Begi/DIY setup (2560, cast log mani, sssgdp, 460cc inj, ms parallel, 18x12 IC, tial bov, godspeed rad, lotus elise seats, ebay wheel, boost/afr gauges.



Project consists of....

Engine is 1996 1.8l: (purchase used with a couple thousand miles)

-overbore 1mm Flyin Miata 9:1 Wiseco pistons and rings(skirts are coated)
-Carillo I beam rods
-knife edged and polished stock crank
-Calico coated bearings / ARP main and head studs
-block is fully blueprinted/torque plate honed/square decked/align honed/deburred
-new water/oil pumpshead

'00 head:
-ported
-+1mm stainless SI intake and exhaust valves
-94/95 valve springs
-Web Cams billet camshafts
-Fidanza adjustable cam gears
-mildly ported intake
-throttle body bored
-billet fuel rail
-new pressure regulator
-550cc RC low impedence injectors
-DIY oil catch can
-coolant reroute
-Mazda competition engine mounts
-NGK plugs
-new harmonic balancer

Additional:
-6ULS 15x7 (tires TBD)
-Corrorado BBK
-GC sleeves/Illuminas
-Rpkg lip
-Interior color change (tan to black)
-depower steering
-ac removal

F/I:
-some sort of begi tube replacement manifold
-3" downpipe
-ewg
-larger i/c (current 18x12)
-large turbo (current 2560, considering 2871/3071 chinas)
-v bands (if i can budget for them, I just have a "thing" or them)
-ms standalone (current ms parallel)
-750 injectors

Goal is to try and balance all around performer, with budget. I know the engine is capable of much more than my goal, and eventually I might catch up to it. But for now, this is a very big leap forward as is, and would like to savor the levels of power before trying to push the limits any further.

Plenty more little things I'll be tweaking, upgrading, have to fix as I go. I'll post in better details when it comes to it.

Engine Pulled
 

With the limited amount of time per visit to the garage, it took 3 visits to get it out. Mind you this is completely alone, no other eyes/hands to help...

Minor "moments" included forgetting to drain the tranny oil before pulling and plenty of "hope i didn;t just crack that connector".

Engine is healthy, good cleaning, new HG/belts and anything else you may want but it's ready to go. Was going to keep it as a spare, but now decided to sell it in order to extend my budget some.

Was babied by PO as he had a connection at Mazda. Service records to back it up. I had it boosted for 500+/- miles and then life took a course which put this car waaaaaaaaaaaaay on the back burner. Car has sat for nearly 2 years while we went thru some family issues, relocated, started new jobs, got a new place, etc... It was run regularly, taken for a drive occasionally, but really NO time to work on it. In the meantime, I struck when deals arose and pieced together this setup. Goal is 325-350whp fairly reliable, all around car. Understandable it won't be great at anything, but will be very fun in nearly everything with compromise. When the day comes, the car can be altered for a more specific purpose....

Omg I think I'm gonna cry. My boy is growin up.
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Nice seats. I'd love to get a set of those for my daily.

^thanks and glad to hear it cuz you'll get your chance shortly. Elise seats, w/ lumbar pump, great condition will be hitting the F/S section along with some other things.

if only i was rich, you would have a buyer right now for those seats right now.....


looks great so far, it sucks working on your car by yourself. at least it does for me cause i get discouraged easy with no moral support around....

This needs to be cheap, bro. I have a Jackson Hero kayak to buy.

^this ain't yo mamma, will cost more than $5 for a ride....oooooooooooo

All kidding aside they aren't cheap, and weren't for me. But I'm not looking to make anything on them, just recoop what I put out which was reasonable. If I intended rapage, I'd put them on CR with a JDM sticker on the back lol

Interior color change, Im liken the details.

Well sold the old motor this weekend, so that will help move things along and I needed the space. Also snapped some pics of things I'll be selling from current setup (almost everything).

Next up will be some attention to the grimey engine bay (see pics). Plan is to pull anything thats not necessary (ac/ps/egr), hopefully shed some weight from the harness (goign MS stand alone), reroute/tuck whatever I can of the harness, and then give it a much needed cleaning, and repaint. Prob go with black unless I can find another color that will show leaks better and I can live with.

Also on the agenda will be to prob start pulling the interior apart since I'll be in cleaning mode anyway. New stuff isn't going back in till the end though

I noticed the seats as well....so tempting. Just what I've wanted for some time now...

Not much on progress, due to LIFE...

However made use of some funds I got due to the sale of some items, and ordered:

-Chickety China 3076
-F1 Stage 3 clutch/pp
-Master/Slave cylinders
-Ground controls (500/300)
-Manifold/DP ala Anton (see Levnubhin's "I'm pussying out thread")

Need to gather some injectors, larger IC, EWG, Tial Housing, tires, and several other items....

Sorry for the delay guys, but this comes after Wife, Kid, Work, etc.... Wanting to document for myself, and glad to share while I'm at it. It'll be paced, but on topic comments/discussion/etc welcome

Lil something to get this thread going again...

Godspeed 3076 arrived/pics

Also F1/Stage 3 6puck arrived
Master/Slave cylinders
GC coilovers (500/300)
TSI's

WIN, now get that shit in!
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I'ma "dooooooooooooooo it"

i think i heard that line in a porn recently.

Update
 

Nothing fun, but def needed. Cleaned the engine bay very very well. Other than prepping for possible rattle can or mild wire tuck, this engine bay has not been even wiped down in it's 15years...and it showed, the before pics are after a hose down and still don't do it justice...the after pics look better in person but you get the idea.

Like I said not a big deal, but in my world it was huge. Now it's back in the garage, and I can continue chipping away at it on late nights as I usually do.

Lots more to come!

ps---see 5th pic, this was not setup. Just wanted to snap a final pic of the finished work, and it seems a beam of light was shining saying aaaaaaaaaaaaaaaah, :giggle:

Update
 

Started on suspension tonight.

Much easier than I thought, although I did get stuck for a minute on the fronts.

Rears super easy, 2 nuts up top, bolt through shock, sway/endlink, pry down while pulling out

Fronts also super easy, same as above, but need to free the an arm to get the shock out as the upper does a good job of making it impossible to just pry it out. I wasn't able to get the impact gun on the bolt under the shock (no swivel ftl), so then I went at the 1 huge bolt that holds the upper control arm to the car. Again no room for the gun, but gold old might and a 21mm socket did the trick, shock came out on its own. Gotta back up the 2 bolts that hold the sway bar as they stop the long ass control rm bolt form coming out all the way.(thanks to Levs for filling me in on this method which Brain mentioned at some point)

Total time: under 2 hours (taking my time). Next time around could easily get all 4 out in probably well under an hour.

Tools: impact gun, 14mm/17mm/21mm sockets, hammer/screwdriver(push bolts out), prybar/jack handle/etc...



Note: Need to order Corrado upgrade kit from M-tuned, rotors, pads and bumpstops. Waiting for Racing Beat front sway to arrive.

Awesome! Id come help but I have too may lawns to cut.
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Update
 

Still not into anything fun yet, but progress it is none the less...

Pulled out the interior tan carpets, and FM frame rails (purchased 2nd hand, and before the GB on the knockoffs)

Carpet not much to explain here, remove seats and go at it. Mine came out in pieces as it was nasty and going right to the trash. If anyone wants the parcel shelf pieces they should come out ok with a lil TLC, you pay shipping and can have. For the time being (and for the sake of time), I've opted to keep the 2 tone dash and door cards. Condition is pretty good, and I think might look pretty good with the black carpet. If not I'll swap during the winter when car won't be used anyway.

FM Rails are a BITCH, unless you either have a helper or abnormally long arms. I had neither. Luckily my original rails only required slight convincing to be straightened enough for the Fm pieces to go over. Temporarily put the jack stands at the seam, slipped the FM rail into place, then used the jack and gravity to squeeze them in place. Then carefully set jack stands back under the rails. Drilling is no issue, was patient enough to unbolt the factory ECU and MS as for me those 2 bolts/holes ended up an inch from the wall holding both ECU's and I was not: A) moving the rails after getting them in place, or B) risking putting a drill through either box/harness. Another BIG bitch was the last bolt (towards the rear) where the fuel lines have least play in them. I ended up just flipping it over and putting the bolt head UNDER the car so the lines weren't contacting. On the inside, yes I have about 3/4 of thread coming up, but shouldn't interfere with anything as the ECU stick out 1.5-2" off the wall anyway, I doubt the carpet in that area will be affected and in which case I could always cut the excess threads off if need be.


Calling 949 tomm to order a few things, at the very least will be front Corrado BBK/rotors...FM will be getting some money too for the prop valve kit. Rest I'll of the brake stuff I've already priced and will get local as shipping was more than taxes. Should be able to order my bump stops/dust boots tomm as well.

Depending on how soon this stuff arrives, hoping to be able to wrap up suspension and possibly brakes by the weekend which will leave me completing some cool misc details while I wait for the turbo goodness to get underway.

Again, details/non crucial updates are to document the build for myself-and you guys get the sheer honor of following along. I don't see pulling carpet as a real "build update" I'd be bragging about :giggle:

PS--the puppet show going on in the pics are what I rigged to keep my driveshaft, exhaust, and PPF off the ground for when the car needs to be moved.

No pics of frame rail install as I was in a rush to get home, but I'll snap some on my next visit to the dungeon





EDIT: f-it, just ordered: brake prop. valve, hellas, diff bushings, bumpstops, dust boots, and 800cc inj from our very own Deatschwerks...(OUCH says my wallet!!) Still plan on ordering the brake goodies in the morning.

I need shit to work on as I have lots to do and clock keeps ticking

Ordered Corrado BBK, all 4 rotors, and some misc odds and ends from 949

woohoo, page 2. lol
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Dear lord, just stick a screwdriver across the shifter hole and cut your yearly cost of twine down to 10%.

or a jackstand...

it was spur of the moment...saw a roll of twine sitting there, saw the rollbar, and saw no negatives.

jackstands were no good as I had to move car out of garage, and back in

Get back to work!
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^where are you logged in from again?

I'll report you to your owner.
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Update
 

Few things arrived: DW Inj, IC, rotors, hellas, and some other odds and ends...will post pics of my assortment laterz


edit: pics added :drool:


Waiting on bumpstops to arrive from FCM, then I can continue with next steps which will be getting the suspension and brakes on, move the car outta the way and get the engine unwrapped and on a stand to start completing the long block

Stay tuned

new pics^

Last 2 ordered items arrived, bumpstops/boots & pedals

If not tomm night, over the weekend suspension and brakes go on ;)

those pedals are sweet. Lookin good so far.

Update
 

Well took a blind look at the suspension stuff today, realized I have more things then I require and without having read up on it I was uncertain on assembly... I don't wanna wing it and have to reinstall.

Suspension:

Illuminas, GC sleeves/springs, NB tophats (set came with 2 metal washers, and 2 rubber bushings for each hat), and FCM bumpstops (comes with 1 metal washer, 2 plastic spacers per corner)

I took a pic of everything available to me for ONE CORNER, for me to reference as I search--but at the same time; should anyone have a definitive 100% sure answer on what's the proper way to assemble, (whats needed/discarded AND the order it goes in) I'd surely be grateful ;)

Pics below 1 is everything, 2 is closeup on all the hardware I'm confused about, 3 & 4 are the tophats (each side)

Shock-bumpstop-threaded collar-spring-boot-medium metal washer (should sit on base of shaft threads)-small rubber "washer"-top hat-big rubber "washer"-big metal washer-nut.

The plastic spacers are meant to limit shock travel if you hit the limit of the shock before you start sitting on the bump stop. This limits destruction of the shock internals. The small metal washer is for the FCM bump stop, and will only work if you use FCM's threaded nuts, which go through the big rubber pieces, eliminating the need for the big and medium cupped washers. The cupped washers should sit with the rubber part inside the cup.

Boot should be zip tied somewhere, not sure where. I've never ran them. Only time I've damaged the shock rod is during installation.

Hope this helps.

P.S. If the spring is smaller than stock size, you're going to need spring isolators from FCM, $11.50x4+$15 shipping. Otherwise it'll hunt around on the top hat.

^this helps alot, thanks. Maybe it was just looks, but seemed like all the NB stuff wouldn't fit. I'm actually gonna go to my garage and bring the stuff home so I can assemble 1 corner at home, and the repeat the other 3 at the garage (no internet access there)

I know once I have it in front of me, try this method, and read FCM's info I'll likely have more specific questions

are those shocks for NBs? if not you gotta do some ghetto rigging to utilize those mounts.

No, they are NA shocks--I understood as long as I had all the NB hardware I'd be ok?

Gonna attempt to try this in a bit..will post back

Pics bitch!
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Since my suspension wasn't happening yesterday, I took advantage and had a buddy go to town on my exterior. I would've waited till the motor was in, but he's going back to school and wouldn't be back in town for a bit.

The "before" pics don't do it justice. Aside from the usual 15yrs of wear and tear. It's been seriously neglected and in the elements for nearly the last 2+years, and was covered with oily handprints and whatnot, then caked on dust, dirt, etc etc. Tried conventional aggressive cleaning to no avail.

Treatment consisted of a wash, then claybar, cutting compound, wax, seal--1 coat of each, with some spots receiving more attention with cutting compound and claybar. Took him about 3 hours including bs-ing with me. These pics also don't do justice, but believe me when I say the car feels like glass when you run along any panel....and the paint is as sharp as it could be given the history.

Pics are in progress order, with the last being finished product
If you seen my car in last 2+yrs, you'd swear it's not the same, lol

Loooooooooooooookin goood man. 100 times better.
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Ok Scott....fill me in. I tried Curly's directions and although it seems right---I'm about 1.25 inches SHORT of being able to get the nut on...(go ahead, lots of jokes ot be had here)

Also in doing this, I misunderstood something when ordering my GC..I .ordered 300lb rear which = 7", whereas my fronts are 500lb = 6". Will be calling GC to swap the rears to 300lb = 6", very different part #'s(GC150.64.53)

(quietly begins to search: NB tophats problems, fitment, issues, etc--like I should have done earlier)

Ok, so I think i see what you mean now...

Shaft is 2 short to use all the NB tophat gear without a special long threaded bolt FM & FCM sell. Though what I haven't figured out yet is how the top mounted adjustment knobs fit in to the picture as they would have to be left off to use something like that.

Will continue to search for the answer...


By ghetto fabbin'--would not using the large bushing and large washer be an issue? The NA doesn't have the bushing/washer over the tophat....thoughts on worse case?

Some progress, finally decided on a setup and got the fronts mocked up-haven't torqued anything down as I'm waiting for my sway to arrive.

Some pics

Update
 

Well, finally some progress.

Suspension is done, say for my front sway which is still in transit...
Ended up using partial NB hardware. 1 rubber NB busing, 1 small metal NB washer,NB tophat, generic flat washer, and OE nut. For the fronts I was able to use the slightly thicker NB rubber bushings, but for the rears I had to use the slightly thinner ones, couldn't thread the nut otherwise...go figure.

My true feeling as that shortly after the snow starts and car is garaged, I'll be tearing this car down again and correcting a few things, this could easily be top of the list... we shall see


Corrado front BBK done, biggest PITA was cutting the dust shields with shitty dremel wheels :vash: Otherwise it's very simple. 2 bolts to attach the new bracket to the caliper bracket, 2 more to attached the caliper bracket back onto the car.

Day went sour when I found out both my rear calipers were seized badly, got replacements on their way and made sure to express my disapproval via a BFH.

Once the calipers come in, still need to install the brake prop valve, and the clutch master/slave cylinders-- then the car can be put back down and work can start on trying to get the motor back in and running.