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Old 10-19-2014, 06:16 PM   #141
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2560! damn man, that's sick!

Get us some videos, virtual dynos, and moar pics asap!

Edit: also, what downpipe/exhaust are you currently running?
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Old 10-20-2014, 02:44 AM   #142
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Thanks Nate! Will post more stuff once it is fully retuned and good to go. So far with only a few touchups to the fuel map VD says I'm up about 40hp and 40tq at the same pressure I had the GReddy running (17psi peak tapering to 14). However, peak boost is happening at the same RPM as the GReddy, so I think I need a bigger exhaust now lol. I'm still making more power earlier, but I feel like this setup ought to be spooling quicker, maybe it will once I dick around with timing on the low end.

Downpipe is the FM two piece, but only the upper half. The lower half was angled all weird to meet my existing exhaust so I welded up a short section to work with it. I got a decent price on all this stuff and it's known good, so I went for it. Would have loved to pick up the ARTech mani/separated dp the turbo seller had but it was too much coin.
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Old 10-28-2014, 10:01 PM   #143
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Nice! I can't wait to see this in action! Have you run it at the track (not 1/4mile) with the Greddy setup?
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Old 10-29-2014, 06:35 PM   #144
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Nope, last time I was there on the road course was with my first setup (16g). I'm excited to get back out there!
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Old 11-01-2014, 04:03 PM   #145
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Good meeting up, hope you had a blast like I did at the roadcourse. How'd you do at afterwards at the drags?

I really need to rethink my car. I drove a bunch, and I like Andrew's FM miata as well as the S2K.

I am basically limiting myself because I like to autox in STR also. I also have this goal to keep up w/SpecMiata drivers (not beat them) in STR trim. They run PMP between 1:47- 1:52.

I dunno though, i'll continue to have fun until I figure it out. lol. See you out there again.
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Old 11-02-2014, 04:27 PM   #146
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Good to meet you guys, too. Drags were a bust, too cold and no track prep...I spun all the way down the track. The only person who I knew that hooked at all was driving an AWD Talon on slicks, everyone else was skating around like me haha.

Lapping was a blast though! I got a new personal best on the road course at 1:51.75 with a bunch of 1:52-54 laps mixed in. And the new turbo setup ran flawlessly, really happy with how well it is working.
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Old 01-26-2015, 08:43 PM   #147
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Trans finally started munching itself today. Something on the countershaft has been whining loudly for months, and during some highway tuning today 3rd finally got too pissed off for life and is done. Will post pics once it's apart (not for a rebuild but for giggles). I have a 5spd that is getting some mods, and a 6spd that is stock, so one of those will go in. Looks like the perfect time to get my 1.8 swap underway, might as well go ***** deep if I'm fooling around in there.

Here's a sound clip I made after I got back to my neighborhood shifting through 1st and 2nd, then comes 3rd lol. I shift up past it into 4th then back down. Due to the tapping sound I thought it was the bottom end of the motor at first, thankfully it is not because this motor is going in another car after it comes out.
https://dl.dropboxusercontent.com/u/...oice%20003.m4a

Here's a VD graph of the pull that killed it. I was dialing in more timing haha.


Data points for posterity: 15K+ miles at about 240WTQ (until the last month or two), abused regularly in the mountains, a couple times on track (2 full days); Mitsu Diaqueen EVO MR fluid; after my last track day 3rd was harder to engage and now it's the dead gear.
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Old 02-15-2015, 12:30 AM   #148
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Picked up a 97K mile BP out of a '96M.

Two weeks ago



Today



Walls all look like this, pretty good I think, but I'm installing rods so I may hone it anyway.

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Old 03-08-2015, 09:40 PM   #149
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Finally warmed up enough to spend some time in the garage today, got the last few things off the block so I can take it to work and pull the guts out to clean up.



Also been collecting some new parts for it. Not gonna do anything crazy with the build, just rods/bearings, headstuds, Cometic MLS gasket, timing/wp/seals, and a head refresh. Debating having the rotating assembly balanced, but the motor is not going to live at high RPMs so that my not matter as much; at the very least I'm going to weight match the piston/pin/rod combos. Also going to check/resize the big ends if necessary, because Chinarod.

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Old 03-10-2015, 05:59 PM   #150
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inb4 you build your 1.8 before me.

These updates are super awesome, glad to see you are still doin work! I'm pretty surprised your 1.6 is still kicking, to be honest. stout little motor.
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Old 03-10-2015, 11:58 PM   #151
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Thanks man.

I credit the motor life to decent tuning and a forgiving fuel The 1.6 is getting a headgasket and going in a '90 that I bought to flip, so we'll see how good and forgiving it actually was when the head comes off.
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Old 03-11-2015, 12:27 PM   #152
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Quote:
Originally Posted by matthewdesigns View Post
Thanks man.

I credit the motor life to decent tuning and a forgiving fuel The 1.6 is getting a headgasket and going in a '90 that I bought to flip, so we'll see how good and forgiving it actually was when the head comes off.
Nice, make sure to post up pics here! Curious to see how she looks.
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Old 02-14-2016, 10:39 PM   #153
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Eleven months later...

I'm finally back on the road with a 1.8 and 6spd swap. Last January I broke a tooth off of 3rd in my 5spd, and decided to build a 1.8 and install my 6spd when the engine was done. Well, I didn't think it would take this long, but I did resurrect a '90 with a broken crank in the meantime by swapping in the de-boosted 1.6 from this car so I got my Miata fix that way.

Anywhoo, here are some pics and all that went into it. I did everything except the balance job, sent that off to the machine shop we use at work. Worked in a reroute with a Skou spacer as well, but changed it up a little by using an inline t-stat housing under the TB, under which I gained space via an FIAV delete. Adapted my DSM TPS to the 1.8 TB by cutting new keyways in the shaft and trigger plate (was 90* out otherwise). Gasket matched the head on both sides, and the IM. Lapped the valves. Picked up some 15x8 Kosei K4R wheels and in the downtime I borrowed a roller and flattened the inner fender lips, and installed a Wilwood prop valve while the bay was empty. Also put some heat shielding in the trans tunnel.

'96 1.8 donor, 97K miles in good condition
Eagle rods with ARP 2000 hardware
ACL Race rod and main bearings
ACL thrust bearings
Rotating assembly balanced; crank polished
Head ports gasket matched, mild port in runners
Valves lapped
Head and block decked
Cometic MLS head gasket
ARP head studs
New rings
Intake manifold gasket matched
Coolant reroute with Skou billet spacer, Kia waterneck, and inline t-stat housing; long section of typical GM reroute hose runs up to the TB area, then the inline housing sits under the TB, finished off with a Dayco 71950 from the housing to radiator inlet (goes around the driver side of the TB inlet)
Front water neck deleted; freeze plug and blockoff plate fabbed/installed
Fan control moved to FPS output at ECU
EGR delete; blockoff plates fabbed/installed
TPS from 1g DSM adapted to the BP throttle body
FIAV deleted
Turbo oil feed from sandwich plate, OEM oil cooler retained; coolant outlet on oil cooler feeds turbo
New crank seals front and rear
New water pump/timing belt/pulleys
New valve stem seals
New cam seals
New intake and exhaust manifold gaskets
New valve cover gasket
New knock sensor
New O2 sensor
-10 AN bung welded to pan; 5/8” drain from turbo
Comp ceramic 6-puck sprung clutch disc (“Stage 4”) with FM Level 1 pressure plate
New pilot bearing
6spd from '01 Miata, new output seal installed
Motorcraft synthetic fluid
Braided long line to replace the rubber and curly clutch lines
FM throttle cable and coilpack relocation parts
Cleaned up/repaired a lot of brittle wiring
Heat shielding added to trans tunnel
Wilwood prop valve just for kicks

Retained from previous build: 1.6 CAS; 1g DSM coils, TPS, engine harness, ECU; all fuel related items; FM Level 1 pressure plate, lightened stock flywheel, 2.5” exhaust

Still needs a touch-up on the clutch adjustment and break-in miles on the disc itself before I bump the boost up. Shooting for 300wtq/350whp. Rough tune at 12psi is netting about 210wtq/230whp per VD, so I'm thinking 22-24psi ought to do it.




'96M 1.8 donor





Block looked good, crosshatch still visible.





Nothing burned up here.





Nice and clean for all the mileage.








Nervous about mixing caps up so I got a little an4l with the head disassembly.











Lapping the valves. Our head guy at work always makes a nice, wide edge in turbo applications, so that's the way I went with it.





Gasket matching.





Ground out, and then finished with scotchbrite wheels.





Granite sanding block to flatten the head. Was only out a couple of thousands so nothing major needed to happen.





Waterneck blockoff with a freeze plug, then knocked out a plate to cover it.





Block all smoothed out on the granite, too.











Polished and balanced.











Adapting a 1g DSM TPS to a Miata 1.8 TB. Trigger plate is 90* out, so the shaft and plate are modified to work together.





Adapting a 1g DSM TPS to a Miata 1.8 TB. Vees cut into the plate and shaft so it will be held in place.





Adapting a 1g DSM TPS to a Miata 1.8 TB. All wrapped up with locktite.





Ultrasonically cleaned TB.





FIAV blockoff plate.








A ******* mess under the intake manifold. Knock sensor hidden up top, OEM oil pressure sender on a 20mm steel extension (to clear the knock sensor), aux oil pressure sender (since eliminated), oil temp sender, OEM oil cooler, sandwich plate, turbo oil and water feeds. My biggest fear is that there would be leaks under here. There were two!





Competition Clutch ceramic 6 puck. Sticking with the lightened OEM flywheel and the FM Level 1 pressure plate.





Balanced bottom end, with assembly marks on the clutch.





Six speed going in as well.





A little clean up before the stabbing.





Hopefully my feet wont melt any more.








Supervision kitty approves.





Coolant reroute using Skou spacer/Kia neck, typical GM long hose, but with an inline t-stat housing and a short S-shaped hose from a GM V6. Dayco 71950 is the part number.





FIAV delete makes room for the inline housing.





Another view of the GM V6 hose.





All wrapped up.








Fender rolling while the weather cooperated.
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Old 02-15-2016, 09:24 AM   #154
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Looks good, but why no epoxy on the throttle body shaft?
I would cry if my built engine got wrecked from an ingested TB screw.
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Old 02-15-2016, 11:00 AM   #155
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I have not read about screws backing out of OEM throttle body shafts, is this something I don't know about? I know Skunk2 TBs have a nasty habit of shedding them.
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Old 02-15-2016, 11:26 AM   #156
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Ian's 99 post-TB screw re-rebuild.

Epoxy is good, I've also seen somewhere where they tac welded the screws.

They back out from the vibrations of the motor & high rpm.

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Old 02-15-2016, 12:24 PM   #157
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Ouch. Epoxy it is!
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Old 02-15-2016, 12:48 PM   #158
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Quote:
Originally Posted by matthewdesigns View Post
I have not read about screws backing out of OEM throttle body shafts, is this something I don't know about? I know Skunk2 TBs have a nasty habit of shedding them.
waitwut?
isn't that the whole reason everyone here switches to junk2?
supposedly junk2 never loses screws so many here upgrade to them vs stock
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Old 02-16-2016, 02:20 AM   #159
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The throttle body shaft breaks too. Which is why epoxy isn't a full solution.
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Old 02-16-2016, 10:53 AM   #160
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Quote:
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The throttle body shaft breaks too. Which is why epoxy isn't a full solution.
You are talking about the stock throttle body correct?
I'm with Vlad in thinking that the Skunk2 was the appropriate fix.
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