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-   -   Zellers' 03KSE (https://www.miataturbo.net/build-threads-57/zellers-03kse-92109/)

zellers88 12-21-2018 05:31 PM

Close, but I'll take my donut shipped to 46234. No reason to get a K20 head when a ported TSX head will flow very similarly.

zellers88 01-20-2019 08:44 PM

Finally got the head back on Thursday. Getting close to buttoning everything back up. Ran into a hiccup removing the VTC gear though. Guessing I may have loctited it on before? Will not budge with anything I have here. Going to try drilling out the bolt.

Also bought a Radium FPR and fuel filter because I think the stock one is being overpowered by the 255 at idle. Need to hurry up and finalize the mounting so I can order hoses for it.

Padlock 01-22-2019 10:09 AM

Hopefully can see this at Gingerman (whether I have my car there or if I'll be spectating is TBD)

zellers88 01-22-2019 10:20 AM

Unfortunately won't be at the Kmiata meetup. Somehow managed to schedule vacation for the same weekend. I'm still planning on getting to Gingerman this year though sometime.

zellers88 02-01-2019 04:46 PM

Getting everything back together now. Hopefully done playing the "wait on parts" game for a little while. Added a 40* VTC limiter to the cam gear just in case as well.



https://cimg9.ibsrv.net/gimg/www.mia...55f66977e9.jpg

Pconlon 02-02-2019 12:53 PM

It’s hard to visualize the true beauty of K24a2 when it’s all buttoned up, but this picture brings it home.

Look at those intake ports. Look at the size.

Remind me, why it’s better for me to invest thousands of my hard earned dollars in building a BP engine for output and durability.

golfandcars 02-03-2019 09:41 PM


Originally Posted by Pconlon (Post 1521399)
It’s hard to visualize the true beauty of K24a2 when it’s all buttoned up, but this picture brings it home.

Look at those intake ports. Look at the size.

Remind me, why it’s better for me to invest thousands of my hard earned dollars in building a BP engine for output and durability.

Truer words have never been spoken.

stock bottom end K24's are known to make ~240 at the wheels without much fuss. From what i have gathered from lurking on this site for a couple years, you gotta work decently hard on a BP to get to that number, especially without a built motor. Then reliability is an issue, overheating, it's just a domino effect. Hondas are known to take some serious abuse, hell my K20 has 165k miles on it and its been to the track twice in the past 3 weeks with no issues. Yes the initial investment is pretty high but in the long run i think you save and your car spends more time on the road instead of on jack stands.

KMiata 02-04-2019 10:39 AM

So pretty! I'm itching to do the same port on my head and push my setup to 300-310whp.

I'm bummed you won't be able to join us on 5/11. Let me know when you take the car out to Gingerman though, maybe we'll be there.

zellers88 02-06-2019 10:01 AM


Originally Posted by KMiata (Post 1521570)
So pretty! I'm itching to do the same port on my head and push my setup to 300-310whp.

That'll be pretty wicked better hurry up, they have white the lead time now!

I've been thinking about adding an ethanol sensor. I'm curious how much of a difference E85 would make on a stock bottom end. Likely not as much as your high compression build.

zellers88 02-24-2019 08:55 PM

Got the car started and cams broke in the other weekend. Oil looked clean and metal-free so that's good. Next project is fuel system. Worked with Nigel to get a Flow Force setup for the K series tested. The 640cc injectors should give me plenty of headroom. I ended up buying these connectors to make for a cleaner install. Also bought an RDX fuel rail which includes a damper since I don't have any other one in the system.


https://cimg2.ibsrv.net/gimg/www.mia...a83ce5801e.jpg




Finished mounting my Radium fuel filter and FPR as well. Now I need to order the lines for it and I'll hopefully be good to go.

https://cimg1.ibsrv.net/gimg/www.mia...c7500dc15f.jpg

Pconlon 02-27-2019 03:37 AM

Great to see an update! Thanks...Couple of Q’s...Any significant tweaks needed in tuning from adding the new cams and headwork?
After break in, any plans on a visit to the rollers?
Guesstimate ~260 ish?

zellers88 02-27-2019 08:17 AM

I'm sure it'll need tuning between that and the new injectors. It hasn't left jackstands yet though, hopefully within the next week I'll start putting miles on it again.
Planning on dynoing but we'll see what I have time for. Still have a big list of things I want to do before track day on April 13th. I would estimate somewhere in the 260-270 range, yeah.

slammed200 02-28-2019 09:30 AM

What's your track schedule looking like this season? My wife built up a stock learning Miata and we'll be at Putnam frequently along with a good mix of NCM, GIngerman and Mid-Ohio this season.

zellers88 02-28-2019 02:36 PM

Haven't really decided much past the April 13th at Putnam. Looks like AutoInterests has a Memorial Day weekend at Gingerman that looks tempting. Might wait to see how this first one pans out before booking another.

slammed200 03-01-2019 08:01 AM

Is that with 1010ths? If you wait until the 26th there is a 3-Day Central Region PCA event, go whoop up on some Porsches!

zellers88 03-01-2019 09:50 AM

Yeah with 1010ths. How is PCA for track days? I've went with 1010ths, SCCA, and Gator Motorsports. 1010ths has by far been the best and most organized.

slammed200 03-02-2019 11:18 AM


Originally Posted by zellers88 (Post 1524955)
Yeah with 1010ths. How is PCA for track days? I've went with 1010ths, SCCA, and Gator Motorsports. 1010ths has by far been the best and most organized.

1010ths is still the best but I've not tried this PCA group yet. They sound low key - hopefully not unorganized but relaxed. The 3 day part is most intriguing to me, Instructors and Advanced get all day Friday to play for the same price!

zellers88 03-29-2019 10:04 PM

Starting to get everything dialed in. Car is running pretty strong but has a slight hiccup/knock around 3500rpm low load that I can't seem to get rid of.

Finally switched over to LiFePO4 batteries. Played around with carbon fiber for the first time and made a little battery tray. Anderson Powerpole connectors used to tie in.

https://cimg9.ibsrv.net/gimg/www.mia...81ae470e92.jpg


https://cimg0.ibsrv.net/gimg/www.mia...e43373a6f5.jpg




Installed a S2 intake manifold spacer. Space is starting to get a little tight on the driver's side.

https://cimg1.ibsrv.net/gimg/www.mia...d0fee782bf.jpg

zellers88 04-10-2020 03:39 PM

Updates while waiting for parts.
Decided to finally take the plunge on an idea I've had for a while now. Main idea was switching the intake from the a filter in the front bumper fog light area to a headlight intake. Used a spare headlight to finally give it a go. Used a die grinder and dremel to bore out the high beam to 3.5".

https://cimg0.ibsrv.net/gimg/www.mia...76ade92db8.jpg

Found a nice carbon fiber tube to use as the through-headlight pipe. Dremeling out the actual lens is a pain. Didn't bother to take the light apart since it didn't seem necessary. I did 3d print some tapered guides which helped a lot.

https://cimg2.ibsrv.net/gimg/www.mia...0507fbf3c4.jpg

Finally got it all put together and used a K&N 54-5000 for the filter box.


https://cimg0.ibsrv.net/gimg/www.mia...2eb40a8c25.jpg

Which meant that the upper radiator inlet was exactly in the wrong place. After looking through a ton of different options, I found that the S2000 radiator is similar width as Miata, only two inches taller, and has both inlet and outlet on the driver's side. Made up new upper and lower brackets for it and it fit right in with Gates 22909 hose for the lower. Also in this picture is the new alternator setup. Water pump housing from a 2011 Accord 2.4 gives mounting for a radial mount alternator. Through more fun research, I found 06-14 Yaris has a nice little 80 amp radial mount alternator that plugs right into the K harness. Just need to shave the bottom mount on the alt a bit to allow it to be inline with the belt.

https://cimg9.ibsrv.net/gimg/www.mia...bc14e0dcd8.jpg


zellers88 04-10-2020 03:46 PM

Couple more projects. 3d printed some brake ducts inlets for NB2 bumper fog light holes. Can be found here.

https://cimg0.ibsrv.net/gimg/www.mia...25cfa12ac0.jpg
https://cimg2.ibsrv.net/gimg/www.mia...66252ecd8d.jpg



Finally decided to work on radiator ducting as well. Installed Mat Russell's front rad support bar to free up a some extra room. It was a little difficult to make the bumper mouth seal up with the radiator on all 4 sides but I'm pretty happy with the results. The two side panels are removable so I can access splitter mounting.

https://cimg7.ibsrv.net/gimg/www.mia...94aea0ade3.jpg


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