stage 1 to bnr s3 full support

[Doucems6]

Finally decided to pull the pin on the bnr s3, and got around to installing it last weekend. We clocked about 25 hours for the entire project. It included auto-tech hpfp, brake change, m2 catless dp, full custom fmic ( fit,fab,weld and painted piping), grimspeed ebcs, ets catback , and the bnr stage 3. (custom egr delete, ported im ,valve cleaning pre build).

Here's a few pics of the ordeal, didn't get into to much detail with the photos because of the weekend time crunch as this is my dd. I used a stg 2 cpe nano+tip+ic+93 oct. With abilors tuning and perms bt 101 intergated in the tune, it Fired up first couple of cranks ran perfect. idles perfect and low throttle conditions are spot on. wot im experiencing what i believe to be spark blow out around the higher rpms and got pretty lean on me. Waiting to install the new plugs at .026 gap. and go from there.

Still waiting on a few other pieces 3.5" wp, wmi, and the 3 bar map sensor, battery relocation and of course a proper tune from who better then the freek!

Here's a copy of my tune if anyone could spare their input it would be greatly appreciated!

[turboKart]

Nice pic layout - for your log, to find out why AFR is where it is, I'd think it would be good if you can log injector data too, but my only real input is that pic of the reflection of the babe in the pipe is way fucking cool.

http://www.mazdaspeedforum.org/forum/foru...-26-09_262.jpg

[Doucems6]

Originally Posted by turboKart Nice pic layout - for your log, to find out why AFR is where it is, I'd think it would be good if you can log injector data too, but my only real input is that pic of the reflection of the babe in the pipe is way fucking cool. http://www.mazdaspeedforum.org/forum/foru...-26-09_262.jpg

Thanks I'll take another log after i get the new plugs installed! And that is actually a 21mm socket its called socket art! lol

[mczimer]

Those are some good looking welds and cuts...share?!

[Doucems6]

Originally Posted by mczimer Those are some good looking welds and cuts...share?!

Thanks, my friend and I took our time making sure everything was going to be perfect fit and weld wise ( clearance for shifter weight, reuse of the stock windshield washer tank, fog light housing, horn). Both of us combined also have more than 20 years in oil field fabrication.

I'm a pressure vessel welder for the refinery's and hes a oil rig hydraulic fabricator. We had no choice but to do a good job! Were not about doing rework. The whole intercooler set up was designed to be 3 pieces (minimum connections to reduce boost leaks, but still fully removable). If you have any questions i'd be happy to answer and supply more pictures!

[mczimer]

Originally Posted by Doucems6 Thanks, my friend and I took our time making sure everything was going to be perfect fit and weld wise ( clearance for shifter weight, reuse of the stock windshield washer tank, fog light housing, horn). Both of us combined also have more than 20 years in oil field fabrication. I'm a pressure vessel welder for the refinery's and hes a oil rig hydraulic fabricator. We had no choice but to do a good job! Were not about doing rework. The whole intercooler set up was designed to be 3 pieces (minimum connections to reduce boost leaks, but still fully removable). If you have any questions i'd be happy to answer and supply more pictures!

You have this routing WITH the OEM washer tank in place?? PICS!

[AZSPEED3]

Very nice setup you got. Like the custom ic you made, very nicely made.

[Doucems6]

Originally Posted by mczimer You have this routing WITH the OEM washer tank in place?? PICS!

Hopefully by the end of the day! Were working on it right now, pics soon after. Oem tank in driver side fender well area. Might have to do some senor surgery, but tank should fit.

[mczimer]

Originally Posted by Doucems6 Hopefully by the end of the day! Were working on it right now, pics soon after. Oem tank in driver side fender well area. Might have to do some senor surgery, but tank should fit.

Can't wait to see how you will manage to get it to fit. I have a custom FMIC job next weekend, so this would be amazing

[Doucems6]

Originally Posted by mczimer Can't wait to see how you will manage to get it to fit. I have a custom FMIC job next weekend, so this would be amazing

It was a bit of a pain in the ass but we fabbed up three brackets that could be utilized, on the body. 2 of the bolts/nuts were from the tank itself (these were used on the 2 larger brackets made from 1/4 x 2" flatbar).

The 3rd small triangular bracket was made as a resting point on a factory bolt. We basically built a jumper harness for the pump, and low fluid level sensor. and just ran them in a new loom zip tied along the other larger loom across the rad. into its new location. We also notched out a small piece just under the intake so that the bottle would sit upright.

I know its kind of a vague how to but im hoping the pictures will help it make sense!
Keep in mind this is on a speed 6 and highly depends on the routing of the fmic cold piping, we didnt use the tradtional route under the intake we actually notched out some of the plastic rad support to keep the radious as tight as possible.

I take no responsibility on anybody else's out come! But i will be happy to help out and take more pics/explaining.

[mczimer]

Originally Posted by Doucems6 It was a bit of a pain in the ass but we fabbed up three brackets that could be utilized, on the body. 2 of the bolts/nuts were from the tank itself (these were used on the 2 larger brackets made from 1/4 x 2" flatbar). The 3rd small triangular bracket was made as a resting point on a factory bolt. We basically built a jumper harness for the pump, and low fluid level sensor. and just ran them in a new loom zip tied along the other larger loom across the rad. into its new location. We also notched out a small piece just under the intake so that the bottle would sit upright. I know its kind of a vague how to but im hoping the pictures will help it make sense! Keep in mind this is on a speed 6 and highly depends on the routing of the fmic cold piping, we didnt use the tradtional route under the intake we actually notched out some of the plastic rad support to keep the radious as tight as possible. I take no responsibility on anybody else's out come! But i will be happy to help out and take more pics/explaining.

Bad a**! I had no idea the OEm tank would fit there....

@TiGraySpeed6;

[Doucems6]

Originally Posted by mczimer Bad a**! I had no idea the OEm tank would fit there.... @TiGraySpeed6;

Thanks! Just depends on keeping that tight radius on the cold pipe! To save as much space as possible.
Let me know if you need anymore pics when you do yo
ur fmic!

[TiGraySpeed6]

That's a pretty nifty idea for the washer tank!

I've been debating what or how I was gonna mount something, and this should fit the bill rather nicely & the price is right too

[6Y MAZDA]

That's awesome. I never even thought of utilizing that big ass empty space over there to relocate the washerfluid tank. Great work.

[mczimer]

Originally Posted by Doucems6 Thanks! Just depends on keeping that tight radius on the cold pipe! To save as much space as possible. Let me know if you need anymore pics when you do yo ur fmic!

Did you "have to" modify the tank or the hoses/connector to get it into the driver side?
Are the bracket mounting points preexisting or did you make the holes there, just to verify what I see!

[Doucems6]

Originally Posted by mczimer Did you "have to" modify the tank or the hoses/connector to get it into the driver side? Are the bracket mounting points preexisting or did you make the holes there, just to verify what I see!

Hey sorry for not getting back to you sooner I know you have your install coming up the only part of the system we modified was the stock sensors for the pump, and low fluid level. Not sure if you can see from the photos but there's 4 connectors on the passenger side next to the orginal tank placement. One is for the foglights, one is side markers. There other two are pump and low level.

Cut those two run enough wire so they will reach the new location. Be sure to double check they are the right ones before cut. Splice the wires solder and shink wrap them.

All the fluid lines will work, just follow them under the winshield and reroute them.

Its not as complex as it may seem. Baseline is your just relocating.

You need shink wrap, wire 4 . Pos and ground for each sensor. Length may vary.

And 2 x 1/4 flat bar to fab you new brackets!

[mczimer]

Sweet, thank you. Got all my parts yesterday, so the weekend shall be fun!

[Doucems6]

Originally Posted by mczimer Sweet, thank you. Got all my parts yesterday, so the weekend shall be fun!

Awesome be sure to post some pics when its all complete! I'll be on the look out to see how it went!