Progress report

[djuosnteisn]

So, i know i haven't posted any pics or anything lately, so i figured it was time to post a few more up. Things are finally starting to come together.


Let me also just say that i do have a forged motor currently being built, but my machinist is slow and i'm impatient. So i just started slapping and fabbing everything onto the stock block in the car. I've also been putting alot of thought into our bottom ends, the reasons the motors let go, and how much power the bottom end can actually take realistically with a good tune and lots of attention to avoiding detonation.

I really have no answers, but i'm willing to find out i guess. If anything it'll at least give me a chance to set the stock block record lol.



So, on to the hardware. I switched to a T3 .82 a/r hotside on my 3071 (same setup as Sean). I had Mark Gongloff (old fabricator for DCR) build me a custom manifold (basically saving my ass when DCR disappeared). I knew this new setup would require some tweaking, but it was quite a bit more than i had expected. The t3 hotside moved the turbo quite a bit closer to the head, which in turn threw off the down pipe, etc etc. But i'm happy with how it's all turned out.


Here's the manifold:



I welded the EWG like that cause it was gonna crash into the o2 sensor, and cause it looks plain dope.



I started from an ATP downpipe, which was originally v-band to a mazda specific adapter flange. Unfortunately the V-band diameter wasn't right for the new t3 turbine, so i had to adapt it over to the right one. I just used a small section of 3" ss pipe welded to the old v-band flange:



You can see how much farther forward the down pipe now sits. It's very very very close to the alternator heat shield, but not quite touching (pubic hair width). I'm not sure if this is going to be any issue, so i'll probably heat wrap the down pipe at some point.



This also made the downpipe move away from the mid pipe, so i had to extend it a bit. I just used a stainless slip section off a 3" resonator that's been in my garage for ever. Looks a bit silly, but form over function on this one. And welding critics go easy on me. If you knew how many times i had to cut / tack / fit / cut / tack / fit / cut / tack ....... you'd understand why they look like they do:



I also had to tweak the hell out of the down pipe to clear the drive shaft, cause now all the angles were off. This was another iterative process, and you should all have pity for me hahaha. Also, just a note, the atp downpipe used to hit the driveshaft on my stock turbo anyway, and had left quite a nasty lil dent in it. It's a much better fit now, and even better than this pic once the exhaust hangers were hooked up:



So at this point, the down pipe was finished, and i got to fab up a dump tube today. Literally took like 2 hours tops, and that's with a decent hangover:



There was alot of room with the new downpipe configuration, so with the right angle it was just a straight shot down and out:



Here's a shot looking up from the bottom:



And i put a nice lil chopper flare on the end of it. This pic kinda makes it look like its aimed at the driveshaft, but it's well below it:




Thats about it. Here's a teaser shot of the the new engine bay. Hot pipe still needs a tad bit of work and all the intercooler piping will be powder coated soon (i just bought an oven off craigslist a couple weeks ago ).



Teaser shot of the fmic:



And some teasers of the piping. I'll update my fmic thread once they are finished:






All i have to do now is fab up the cold pipe, install ecu, SB, wotbox, move wmi pump, re-do all the plumbing and electrical for it, and buy a 2 - 2.5" coupler for the hot pipe. Oh and buy a bov.

[skeeter149]

dustin thank you for all the time you put into this car. if you know what your doing cheers, and if you figure out some new shit double cheers. but either way your stuff is stuff to be watched. i am in debt.

[djuosnteisn]

Originally Posted by skeeter149 dustin thank you for all the time you put into this car. if you know what your doing cheers, and if you figure out some new shit double cheers. but either way your stuff is stuff to be watched. i am in debt.

Not sure i know what i'm doing, but i do say cheers alot when i drink

Thanks for watching though! I'm so damn excited to wrap it up and actually enjoy the car for a bit before swapping motors out. This is ALOT of work haha.

[Jarods7920]

Looks awesome my only bitch is recic the dump tube!

[gsrtype1]

looking good bro!

[madvillain]

I have a massive woody right now. Beautifully done. I wish I had a welder in my garage =(

That WG placement is SO sick, by the way.


Oh, and I have a ~15" piece of 3" ID SS #304 never used if you ever want it. I paid like $50 for it.

[djuosnteisn]

Yea, i'll probably recirc it in the not too distant future. Tons of room to do it too. Would just need to order an 1.5" flex section. But it's definitely on my to-do list!

[PaPaSpeed]

Looks like you're making a lot of progress. Keep up the good work, I know you've put a lot of time a effort in this project. I can't wait to see the end result.
Good luck.

[djuosnteisn]

Originally Posted by madvillain I have a massive woody right now. Beautifully done. I wish I had a welder in my garage =( That WG placement is SO sick, by the way. Oh, and I have a ~15" piece of 3" ID SS #304 never used if you ever want it. I paid like $50 for it.

Thanks mad!

I think i'm good for now though, but i appreciate the offer. I'm gonna be upgrading my welding setup real soon to a full TIG so i can do aluminum all day long. Deciding between these two welders:
Hobart Welders - Products - TIG - TIGMATE

Hobart Welders - Products - TIG - EZ-TIG 165i

The hobarts are knock off Millers as my buddy pointed out to me (just painted a different color, but oem'd by miller). Great quality, and you can have them for way under msrp. I think ebay has some for like 1200 or so.

Originally Posted by PaPaSpeed Looks like you're making a lot of progress. Keep up the good work, I know you've put a lot of time a effort in this project. I can't wait to see the end result. Good luck.

Me either. Knowing my luck i'll just instantly blow the motor and ruin all the shit i just spent 2 weeks building hahahaha. I'll keep my fingers crossed though.

[m4tic]

will the parts to me when you die.... dont want you to die.... you know at least make some more significant discoveries first

[Fagwagon]

Awesome! I like seeing all the custom work!

[madvillain]

I vote to not recirc the dump pipe. Drive it first and you'll fall in love with the sound of the wastegate VTA and you won't turn back.

[djuosnteisn]

Yeah, I do like it. Sounds cool, like a switch flips and your car goes from mild mannered sedan to holy shit i'm gonna eat your kids.

If it becomes too loud, i may experiment with some baffling or a mini resonator or something before i go full recirc.

[rigor]

LOOKING GREAT!!! your giving me the bug damn it

[SneakyP86]

DJ its really looking good man......if the noise is too much you could try a muffler off a ATV or something, pretty sure you can find one to fit.

[cageyvet]

looking mighty proper dustin

[superskaterxes]

cant wait to ride in this beast!

[djuosnteisn]

Originally Posted by cageyvet looking mighty proper dustin

Thanks man! Glad to finally be wrapping it up.

Originally Posted by superskaterxes cant wait to ride in this beast!

Oh, you'll be riding me in it... trust me. Gas, cash or ass... and i already have plenty of gas and cash...

[spnkr21]

Nice job man! I also found out the hard way that the T3 moves the turbo closer to the block.

[SilverDemon]

I can't believe I missed this thread until now!! Nice work DJ!!! Keep up the great work!!

[turd burglar]

fooooooook me, i want that manifold even more now! looks tasty maing

[Overkill]

Nice build man! Leave the wg as is and frighten some honda's or unknowing old people on the side walk.

[djuosnteisn]

Will do.


I promise... mark my words... my first video will involve frightened old people. I'll put one in the pass seat, and drive-by-scream all his friend's, and fill everyone's diapers. It will be magic.


My car is 99.99999% done. all electrical finished. new wmi bracket made, ecu in, pnp in, i re-wired all my taps for injection pw timing and tucked em off to the side, pretty much just waiting on my bov now, cause i don't have a recirc tube for all the new shit.



It will all be happening very soon, i'm so excited. I'm gonna make so damn many videos.

[Haltech]

Tat car is gonna be a lot of fun man! Keep us posted! Also, about the alternator, you will def need some good shielding as they are very sensitive to heat that close.

[spnkr21]

What are you gonna run for boost with the stock block?

[djuosnteisn]

Originally Posted by Haltech Tat car is gonna be a lot of fun man! Keep us posted! Also, about the alternator, you will def need some good shielding as they are very sensitive to heat that close.

Thx, and i <3 you Hal. I'll look at it tomorrow.

Originally Posted by spnkr21 What are you gonna run for boost with the stock block?

As much as I can without detonation issues. Detonation is the killer. I'll do a mild street tune first to about 20 psi or so, whatever feels comfortable, and keep things super safe above 5700rpm. Then i'll strap up to a dyno and dial in the rest, followed by one more street session.

I feel like if detonation is properly addressed, the stock block can handle a fair amount. But who konws, I could be completely wrong. We'll see i guess

[holeinmypocket]

hopefully 20-24 psi ...

[djuosnteisn]

24 minimum IMO. If knock isn't an issue, i'll run this 3071 like i used to run the k04.

[spnkr21]

Well I'm doing 22 with NO meth and get zero knock. I bet you can do better than 24 . But that's a stock block so maybe you'll hit some knock. GL!

[Docnox]

Great looking build. Hope you don't hit any snags so you can get this puppy on the road soon. Hot damn 6s are sexy.

[djuosnteisn]

Originally Posted by spnkr21 Well I'm doing 22 with NO meth and get zero knock. I bet you can do better than 24 . But that's a stock block so maybe you'll hit some knock. GL!

Did you lower the compression? If not, our cars will likely behave quite similar.

[Lex]

Looking forward to some videos D - in regards to the alternator, Hal's right, build some sort of sheet metal heatshield or it may not last too long.

I should add - hope that WG pipe isn't too close to anything or it may rattle against/hit it since it's fairly long.

[djuosnteisn]

Originally Posted by Lex Looking forward to some videos D - in regards to the alternator, Hal's right, build some sort of sheet metal heatshield or it may not last too long.

Thanks. I'll wrap that section of dp maybe. The alternator has the stock heat shield there, and there's a decent amount of space between the alternator and it, but still, would rather not have to deal with an issue down the road.

[Dano]

nice work and love the EWG placement!!

are you going to get it started today?

[djuosnteisn]

Originally Posted by Dano2010 nice work and love the EWG placement!! are you going to get it started today?

Great question lol. I think i could, with some hackery. I'd have to use the stock bpv and kludge together a recirc tube out of something laying around. But i think that's it. I'm gonna shit shower shave here in a bit, and go stare at the car while i drink my coffee. Make sure i didn't forget anything. I ordered a new bov last week so it should be here soon, and i don't have to worry about recirc'ing.


Hmmm. would be cool to at least drive it around today... i think i will (pending any fail).


I'll take a vid if i do!

[Dano]

Originally Posted by SneakyP86 DJ its really looking good man......if the noise is too much you could try a muffler off a ATV or something, pretty sure you can find one to fit.

BTW...a buddy of mine has an LGT with EWG and put an ATV muffler on the dump pipe and it was too restrictive on a VF39 turbo [basically a stock STI snal clocked]. He would get lots of creep in 4 gear up so I don't think that route will work.


Edit: he was running a 38MM Tial so maybe a 44 with a bigger muffler to match would do the trick...
just .02 here

[Lex]

O yeah - you guys get today off in the US!

Waiting for vids

[Dano]

Originally Posted by djuosnteisn Hmmm. would be cool to at least drive it around today... i think i will (pending any fail).

doooo eeeetttt!!!

[spnkr21]

I kept stock compression. You should def try it out today.

[PaPaSpeed]

Yeah, take it for a little test ride. Can't wait to see the video.
Good luck.