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Old 03-06-2013, 11:00 PM   #1
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Default 1999 build #3, wire tuck, and a few custom made parts

So I boosted my 1999 about a year and a half ago...maybe longer, and I did a build thread that failed miserably and the main guys on the site ripped me a new one when I chose certain parts that weren't worth a **** when I was convinced they would be decent....everyone was right. But anyways, I am now on my third build and figured I would try again. I put my car into a ditch a couple of months ago and that's what kicked off the idea to tear the motor apart and add a couple of upgrades.

The first build was really just slapping a turbo on, but this is what it consisted of:
-Garrett T3 internal gate .42 cold side, .48 hot side
-BEGi cast manifold
-A really shitty scrap tubing manifold
-DIY PNP built by me and street tuned
-No cat, factory mid pipe, 2.25" mid pipe back with Flowmaster 44
-eBay intercooler kit with 2.5" aluminum tubing
-All stock motor

I ran 8psi on this setup and I thought it was fast as hell...it wasn't. The turbo was used and lasted about 2 months before an oil seal blew when I was 20 miles from home...after pulling over and realizing how much oil I was losing I decided hell with it I'm going to rebuild the motor. I made it home smoking all the way and lost a bearing in the turbo about 3 miles from home which sent turbo fins through the motor. Real build #1 begins!

I decided not to be a cheap *** this time and take advice from people on this site. Build #1 consisted of:
-BEGi cast manifold
-DIY PNP built by me and street tuned
-eBay intercooler kit with 2.5" aluminum tubing
-Injector Dynamics 750cc injectors
-BEGi fuel rail
-HKS SSQV4 blow off
-M-Tuned H beam rods
-Supertech 8.6:1 84mm pistons
-Had the block hot dipped and bored to 84mm
-Supertech 1mm oversized intake and exhaust valves
-TIG welded my own 3" down pipe
-Enthuza 3" midpipe and midpipe back
-New Turbonetics T3 50 trim ceramic ball bearing turbo
-Turbonetics evolution 2 external gate
-Turbonetics manual boost controller
-FM valve springs with titanium retainers
-New factor bearings (very bad idea)

I ran this setup on 18psi with no problems for about 8 months until one day I was showing off my car to a buddy when I melted my boost line to my gate at full boost and about 6k rpm....by the time I heard the turbo flutter it was too late. I maxed out my 30psi boost gauge and was engulfed in a huge cloud of smoke. Pulled over and pushed the car home, only about an eighth of a mile. The cold side bearing came apart and ate my turbo. Pulled the motor that night, pulled the head, and to my surprise no internal damage! On to build #2!

I didn’t have much cash at the time so I did the bare bones with a little upgrading:
-new head gasket
-added water meth injection
-New Turbonetics T3/T4 super 60 ceramic ball bearing turbo
-Synapse Engineering Gate
-Added a second Blow off (Synapse Engineering)

Ran this setup at 26psi with no problems at all! Had to run 225 RS3 tires and they still wouldn’t hook up which kinda sucked but it was fun while it lasted. Put the car in a ditch, got 6 staples in my head, but worst of all I did it right in front of an off duty cops house...Build #3 begins!

I will post pics by the weekend and give an updated list of what is being done this time around.
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Old 03-06-2013, 11:17 PM   #2
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Sorry to hear about the ditch and the staples.
Hopefully it wasn't from doing idiotic things...because in that case I'm not that sorry.

Sounds like you had a powerful/nice setup, can't wait to see the new stuff!
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Old 03-07-2013, 09:38 PM   #3
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@miatacross: well I was coming home from dinner when I wrecked, it was a road I wasn't used to and a 90 degree turn came up way to quick...started sliding so I hammered the gas and made it through the turn but didn't let off in time and started spinning till the ditch stopped me. So I guess it wasn't too idiotic lol

My first order came in with a few motor and suspension parts:
-Supertech 9.5:1 84mm pistons
-Supertech shim under bucket lifters
-Gates water pump
-Gates racing timing belt
-ARP main and head studs
-ACL race series main, rod, and thrust bearings
-Energy suspension bushings
-All new Mazda alignment cam bolts (the ditch bent a couple)

Now for a couple of pics:


9.5:1 pistons mounted to the rods:


ARP everything in the bottom end! I just remembered I also have the chromoly billet oil pump


Ready for the head
Attached Thumbnails
1999 build #3, wire tuck, and a few custom made parts-8537317145_9da5d2ea9b_z.jpg   1999 build #3, wire tuck, and a few custom made parts-8538427928_3a433e0e33_z.jpg   1999 build #3, wire tuck, and a few custom made parts-8538426014_554e11d794_z.jpg   1999 build #3, wire tuck, and a few custom made parts-8538423280_ea093cd58e_z.jpg  
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Old 03-19-2013, 11:01 PM   #4
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Update time!

A couple of boxes arrived today so I figured I would share the contents of them. I had two $25 off $150 or more at summit racing so I ordered some stuff last night and got it in today. Summit racing is the ****!

I had a problem with my coolant lines breaking on the last build so I went with -6AN braided stainless lines this time with AN fittings on the ends.



Drilled and tapped the piece off the water pump to take a 90 degree elbow (-6AN to 1-4"NPT). Turned out pretty decent. I used Summit racing fittings and SS lines for all this.



Also got an AEM water/meth progressive controller and an Innovate Motorsports EGT gauge kit.






I was using the Devils Own water/meth kit but the controller kept getting fried so I'm going to try the AEM controller.

I have the wire tuck about half way done, need the motor in to do the rest. Moved the fuse box inside the cabin, cut all the emissions **** out the harness and the diagnostic connector since I have MegaSquirt. I ran all the wires in the fenders, mainly just de-pinned the connectors and re-routed the wires, but I had to cut and extend a few. here is the progress:








I haven't got to any of the custom parts yet, but I am going to make a water/meth tank, coolant overflow tank, power steering reservoir, and intercooler tubing all out of stainless steel. I know I know the intercooler tubing is going to be double the weight of aluminum but I'm not that worried about weight, and I like my **** to be consistent so everything is going SS!
Attached Thumbnails
1999 build #3, wire tuck, and a few custom made parts-8573763794_399b1f1ca4_z.jpg   1999 build #3, wire tuck, and a few custom made parts-8573774094_b82802112c_z.jpg   1999 build #3, wire tuck, and a few custom made parts-8572677521_bba70cc11e_z.jpg   1999 build #3, wire tuck, and a few custom made parts-8572673141_a1bbab5b70_z.jpg   1999 build #3, wire tuck, and a few custom made parts-8572666971_27dd68f858_z.jpg  

1999 build #3, wire tuck, and a few custom made parts-8572690487_5c407c012a_z.jpg   1999 build #3, wire tuck, and a few custom made parts-8573780892_b17754729e_z.jpg  
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Old 03-20-2013, 01:07 AM   #5
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You know we have a section specifically for build threads right?
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