Voodoo`s S4v2 build

[VoodooJef]

Just gonna do the quick and dirty as this is already chronicled on another site. Happy to answer questions as they come up.

Got the car nearly stock. All it had on it was an intake (and one from a brand I am not at all fond of at that). Within a month I had the magnaflow exhaust, test pipe, a different and bigger intake (3" JBR aluminum), CPe TMIC, and of course hpfp internals and the AP, and got a map from Lex, tuned to an E85 blend. It was quick and gave up 330whp and 375ish torque. It was fun and quick and sounded great.

But it wasn`t enough. Been hotrodding cars for almost three decades and I`ve had some cars much faster than this little FWD scooter could ever hope to be, but I knew it had more potential. And so the lust for a new, bigger turbo started.

I searched high and low for what would get me where I wanted to be. I wanted solid, reliable 425whp. It really looked like the GTX2971 would be the one but it was expensive and no one really had any info on it. Right about that time the S4v2 came along and I learned that it was for the most part a 3076. Not a fancy 3076, but it would blow enough air to get what I wanted. Done. Bought it and a catless DP and a methanol kit. The build took on a whole new attitude. I wanted to break 400whp on parts many people said couldn`t do it.

Got the whole thing installed in a few hours and it ran great but was overboosting like a mf`er. As we`ve come to find out, the S4 wastegate actuator has a wicked strong spring in it. 22psi at spring pressure was more than we were looking for. A very simple swap and we`re back in business.

Tuned it up, dialed in the meth, tuned some more. Put it on the rollers and got 406whp with the top mount. Goal #1 accomplished. About that time I got a killer deal on a front mount intercooler so forward I went. The FMIC flowed much more than the TMIC and was putting me over load targets, so back into the tune we went. Got that squared away, 424whp now, and pretty much out of fuel with 12gph of methanol. Upped the methanol to 20gph and pushed the tune ever further. The last clean log I got resulted in a vdyno of 462whp. I will never claim vdyno as gospel but it was a clean pull so I suspect it was at least close. Two days later I turned a connecting rod into a boomerang. Got VERY lucky. I was 25 miles from home. Did not ventilate the block, in fact babied it home and it didn`t so much as get hot.

When we tore the motor down it was really nothing but the best news in a bad situation kind of deal. Block was fine, crank was fine, bearings and cylinder head all fine. Not a spec of metal shavings in the oil. Machine shop confirmed the block was in perfect condition and would require minimal machining. Took the block out to 88mm. Manley rods, Mahle 4032 pistons, XS V3 exhaust mani, a clutch to handle it all, and an ST intake mani going on it soon. Haven`t even picked it up from the shop yet, but I did opt for them to beak it in on the dyno (a three hour process and the car comes off the dyno ready for whatever you can throw at it) so I can get to tuning it again as soon as I get it back (they did in fact give me the option of dyno tuning after the break in so it would be completely done when I pick it up but for a few reasons I declined).

I`m not going for huge numbers. The S4 will do 460 pretty comfortably and if you`ve seen any of the dyno charts I`ve posted in different places you`ll know it responds remarkably well. We`ll tune it up a little more aggressively and bring on the torque a little earlier but honestly, at 460whp/420tq these cars haul ASS. There won`t be many cars out there I`ll worry about in the occasional Stop Light Grand Prix or trips through Mexico, and at that point the cars I`ll lose to would beat me even with another 100hp. I don`t street race very often, and I`ve done all the drag racing a lifetime needs. Got into track racing so we`ll see where that leads.

I`ll put up a dyno chart once it`s all tuned up with the new motor. If I left interesting or pertinent info out, just ask.

[tmillner]

Wait you did 460whp with out auxiliary fueling and just meth? Glad to hear no additional damage to block too

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[VoodooJef]

Originally Posted by tmillner Wait you did 460whp with out auxiliary fueling and just meth? Glad to hear no additional damage to block too Sent from my SM-T587P using Tapatalk

20gph of methanol is more than considered aux fuel. It`s just not delivered by mechanical fuel injectors. In fact, 20gph can be officially considered "a shitload" LOL. To be technical, at full pump pressure it delivers about 21.8gph, which is nearly identical to running a 1300cc 5th port injector.

I debated adding a full PI setup but for my power goals it isn`t the overwhelming advantage it would be at >500whp. **IF** I jump to a bigger turbo next year I`ll do it because I`m running 130hp worth of methanol as it is, and that`s about as fringe as I want to get with it. The setup now would survive a methanol failure (unless I was just a jackass and stayed in the loud pedal with the afr too lean) but if I were making another 100hp and relying on methanol for it I suspect it would be a bad time if it failed.

[ProChargedLS2]

That looks like a really solid setup, subbing! Don't forget to post pictures once you complete it all

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[NJsean0]

Can't wait to see the finished product and pics!


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[manu]

Interested in this setup myself, my goals would be very similar
Sounds like ure rods handled way more than well at over 400hp

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[VoodooJef]

Just a few "before" pics. Not much will change other than the blue couplers going away for black and all of the IC piping will be the same flat black as the turbo outlet pipe. Oh, and a different intake and exhaust manifold. Couple of random pics from along the way as well:

http://www.mazdaspeedforum.org/forum/foru...1&d=1503270169

http://www.mazdaspeedforum.org/forum/foru...1&d=1503270169

http://www.mazdaspeedforum.org/forum/foru...1&d=1503270169

http://www.mazdaspeedforum.org/forum/foru...1&d=1503270169

http://www.mazdaspeedforum.org/forum/foru...1&d=1503270169

http://www.mazdaspeedforum.org/forum/foru...1&d=1503270169

http://www.mazdaspeedforum.org/forum/foru...1&d=1503270169

http://www.mazdaspeedforum.org/forum/foru...1&d=1503270169

[JakeMS3]

Nice build! Can't wait to see final results. Post up some footage of pulls when it's done. Would love to see what this machine traps in the 60'.

[VoodooJef]

Originally Posted by JakeMS3 Nice build! Can't wait to see final results. Post up some footage of pulls when it's done. Would love to see what this machine traps in the 60'.

I have been keeping an eye out for some sticky tires. The PSS are a great tire, probably the best street tire I`ve ever used but they`re not a drag tire and even before the new motor I could break them loose in 3rd if I wanted to. I just don`t drag race much so it hasn`t been a priority. We`ll see if I can turn up a set of cheapie 16" wheels and real race tires.

[manu]

What about upgraded brakes now ,having or reaching double the stock factory power?

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[VoodooJef]

Originally Posted by manu What about upgraded brakes now ,having or reaching double the stock factory power? Sent from my SM-G955U using Tapatalk

Definitely next on the list. The suspension is done, the motor is done. Just gotta figure out where I want to go with them.

[manu]

I saw some no upgraded brakes systems made by KSport, not cheap tho..this was from jmautosports.com ,they 've got a range from13mm to 16.5mm pretty insane with 8piston calipers

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[VoodooJef]

I`ve seen talks of a CTSV kit in the works, so that may be an option if the price comes in at a reasonable point. I can do "better" brakes without going to "bigger" for a very reasonable price. I`ll start shopping around once I figure out what I want, there`s bound to be a good deal out there.

[manu]

Oh yeah the are so many reasonable deals the "better " while the "bigger"
"are like quadruple $$

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[JakeMS3]

I upgraded a few months ago to a BBK by wilwood for $1100. Lightweight 6 pots, 2 piece rotors, brake pads, and stainless lines were all included. It was bolt that on with their supplied brackets. Great improvement over stock and they look amazing!

[2008mazdaspeed3!]

Are you still running the E85 blend with the big turbo and methanol?

[drive_sideways]

That much power on a speed3 haha must get some wheel spin lol


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[VoodooJef]

Originally Posted by 2008mazdaspeed3! Are you still running the E85 blend with the big turbo and methanol?

Yeah. Been on the fence about going back to just 93 in the tank for fuel headroom and letting the methanol handle octane but with E85 in the tank it buys me a little bit of buffer if the methanol fails. I`d rather it just go lean for a second than to have it go lean AND go into detonation.

Originally Posted by drive_sideways That much power on a speed3 haha must get some wheel spin lol Sent from my iPhone using Tapatalk

Wheelspin was a problem WAY before now LOL. I run a good tire in a pretty meaty size and first gear is there just for comic relief but it hooks well enough through the rest. The advantage of a BT is that the torque doesn`t come on like you were rear ended by a bus, so it`s a little easier to manage traction.

[andale927]

It's good to see what's in my future lol. Is a 4032 piston enough for a reliable 460whp?

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[VoodooJef]

Originally Posted by andale927 It's good to see what's in my future lol. Is a 4032 piston enough for a reliable 460whp? Sent from my Nexus 6P using Tapatalk

Absolutely. 4032`s will support nearly any HP you can thrown at them (good for 500+, straight from the folks at Mahle who make them). 4032`s are a better choice for a daily driver, their "weakness" is they are less resistant to detonation. You can drive a 2618 into knock and detonation and it`ll hardly whimper but 4032s are a harder alloy and don`t absorb the forces of detonation as well. I run a shitload of alcohol so detonation and knock aren`t really an issue so they will do me just fine. I`m more interested in the 100K+ miles life expectancy. It`s not like they are any cheaper than 2618`s.

[andale927]

Originally Posted by VoodooJef Absolutely. 4032`s will support nearly any HP you can thrown at them (good for 500+, straight from the folks at Mahle who make them). 4032`s are a better choice for a daily driver, their "weakness" is they are less resistant to detonation. You can drive a 2618 into knock and detonation and it`ll hardly whimper but 4032s are a harder alloy and don`t absorb the forces of detonation as well. I run a shitload of alcohol so detonation and knock aren`t really an issue so they will do me just fine. I`m more interested in the 100K+ miles life expectancy. It`s not like they are any cheaper than 2618`s.

Gotcha. I read a lot of conflicting information online about the 4032 alloy and I guess that made me overthink it. Can't go wrong if Mahle themselves say they can handle that much!

Looking forward to seeing more from you lol. The s4 has the perfect spool, it definitely makes sense to push it to the limit and not go any bigger.

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[VoodooJef]

There are a few of us on here running the 4032s. I believe Goosey has them in Florida maybe, and hasn`t had an issue. I`ve got some friends at my house because of the flooding down in Houston so I haven`t even gone to pick my own car up yet but I`ll get it wednesday. I suspect it`ll do just fine. The S4, like I`ve said, is just BNR`s version of a 3076 and does the 450-460 range pretty easily and that`s plenty for a DD FWD car.

[VoodooJef]

Drove her today. Didn`t go far, just a quick test drive. I`ll pick it up tomorrow. A few little detail thing will change ie; the blue couplers go away in favor of the black/red and all of the intercooler piping will be the same flat black. I`ve got the Focus ST mani going on in a few weeks but for now I`m good with just having it running again. http://www.mazdaspeedforum.org/forum/foru...1&d=1504214389

[tmillner]

Is that the ecu between the intake and battery box?

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[andale927]

Nice, I bet that felt good! That seems like pretty quick turnaround, when did you take your car off the road?

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[VoodooJef]

Originally Posted by tmillner Is that the ecu between the intake and battery box? Sent from my SM-N930P using Tapatalk

No, it's just sitting where it is for the moment. It's been on top of the fuse box but I'm fabbing up a panel to mount it to.

Originally Posted by andale927 Nice, I bet that felt good! That seems like pretty quick turnaround, when did you take your car off the road? Sent from my Nexus 6P using Tapatalk

Quick? Hahaha it's been down for three months.

[andale927]

Oh damn, still not too bad compared to a lot of other motor builds haha.

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[tmillner]

Took me 6+ months

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[VoodooJef]

Originally Posted by tmillner Took me 6+ months Sent from my SM-N930P using Tapatalk

Yeah that would have made for a bad time. My only car, and it was scheduled to be done in 4 weeks. As soon as I recover from the build I will most definitely pick up a cheap beater LOL.

[tmillner]

Wife and I shared a car and I had a work Truck I could use so not that bad. Bought a RUNNING Toyota sequoia for $200

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[Fstrnyou]

Screaming deal on the 'yota. I paid $500 for my running Taco. 350k+ miles.

[voodoo2crue]

Anybody down to line up the beaters, high 19 second car here

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[tmillner]

I'll put up the price of the yota! Bad head gasket and all

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[Fstrnyou]

I have no doubts that you all have me beat.

[tmillner]

Definition of a beater

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[5doorsoffury]

I HAVE TO TURN THE AC OFF TO PASS PEOPLE BEAT THAT!

The other side of bumper is duct taped. The rear bumper is falling off there is no carpet in the car. No fender liners and an exhaust leak. I hit a orange highway barrel that blew onto the road doing 60 so since the bags didn't blow i kept on going like a boss.
Other then the leak it's rock auto top to bottom. Great commuter car.

[Fstrnyou]

I have to leave extra early to get to work because it's not fast enough to pull out into rush hour traffic.
Also an exhaust leak
Primary O2 is dead
Tires rotten and about to blow
Crap alignment which is currently eating up one of my front tires
Shocks are blown
Radio was stolen which busted up most of the dash
Rear window IS busted from the radio theft. Now filled with a foamboard window, lol.
Drivers rear quarter window latch is missing
Drivers door from a donor vehicle. I only have 1 key, and it's for the passenger door/ignition
Ebay/ricer tail lights that function improperly
Ebay/ricer intake pipe with holes in it...after the MAF!
There's no fuel tank fill cap
The rear exhaust is held up with metal coat hanger.
Rear seat and belt hardware is missing.
Front seat headrest inner framework is poking thru the padding.

Shall I continue?

[voodoo2crue]

Originally Posted by Fstrnyou I have to leave extra early to get to work because it's not fast enough to pull out into rush hour traffic. Also an exhaust leak Primary O2 is dead Tires rotten and about to blow Crap alignment which is currently eating up one of my front tires Shocks are blown Radio was stolen which busted up most of the dash Rear window IS busted from the radio theft. Now filled with a foamboard window, lol. Drivers rear quarter window latch is missing Drivers door from a donor vehicle. I only have 1 key, and it's for the passenger door/ignition Ebay/ricer tail lights that function improperly Ebay/ricer intake pipe with holes in it...after the MAF! There's no fuel tank fill cap The rear exhaust is held up with metal coat hanger. Rear seat and belt hardware is missing. Front seat headrest inner framework is poking thru the padding. Shall I continue?

Pics or this doesn't exist :-) Sorry voodoojef, we'll get back on topic soon brother.

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[Fstrnyou]

Originally Posted by voodoo2crue Pics or this doesn't exist :-) Sorry voodoojef, we'll get back on topic soon.

If you insist.
Check engine light was on when I bought it, but it drove, so that was enough. Had to jump it off because the battery wouldn't take a charge. Drove it like that for a few days and finally got a new battery. Expected a lengthy list of codes, but it was just the Bank 1 Sensor 1 code for O2. It's a wideband.
The sad part is, I bought PlastiDip before I bought the O2 (which I've had sitting on my kitchen counter for the last week or so)
Didn't realize the front tires were quite that bad, so getting 2 new ones today. Putting rear tires on front and new tires out back, yadda yadda.
The last pic is how the exhaust sat before the coat hanger mod. Resting on the rear axle.

I will say though, the A/C blows cold and it's currently faster than my 6. Can't complain.

[VoodooJef]

Originally Posted by voodoo2crue Pics or this doesn't exist :-) Sorry voodoojef, we'll get back on topic soon brother. Sent from my SAMSUNG-SM-G890A using Tapatalk

No, no...please....turn my build thread into a junkyard find thread. LOL.