What You Need to Know to Build a Motor

[TWOptSL0W]

What You Need to Know to Build a Motor:

@Raider can I get a sticky?

So lately I have been wanting to build a motor for my car. I know I only want to do it once and do it right (and for the right price obviously). After a nice long conversation with Gerry (@NJSPEED3) last night until 3am, I realized something. The whole conversation culminated with me saying, “Gerry, I honestly don’t know what I want”. With this humbling little epiphany, I decided there is still much to be learned and I want to share with the community what I find.

This thread is to serve as the ultimate resource for building engines. There are plenty of other build threads to read up on first, @StreetUnitMark (http://www.mazdaspeedforum.org/forum/foru...s-build-22217/ ) , @BlueStreak (How To: Assemble A Forged MZR DISI Motor | SpeedForums.org ), and @djuosnteisn ( Should i do a "how to" build a motor ) to name a few with tons of informative build pictures and information.

There are tons of different combinations of parts and set-ups to use and I would like to get everyone’s opinion of which works, which doesn’t when it comes to different topics as rod/piston design, compression, to bore or not to bore, etc.

I am going to use a list of parts that needs to be bought along with some recommended parts, and all other options and notes. I would like to give credit to much of my list of parts to this thread: Checklist of parts for forged engine rebuild and also my knowledge and knowledge that I have gained from conversations with many other members. I will also be using pictures that I find throughout the forums and giving credit as I do. If I use one of your pictures and don’t want me to, let me know and I will change it.

This should be a group effort that I would like to spearhead and organize into a thread, so please as I go through the different parts, give your input on how they work, how they are designed, other places to buy, and any other information you can add. Credit will be given where deserved.

I also would like to include which members are running what parts (if you feel comfortable giving that information to the community. I understand some people like to keep their builds somewhat secret). All I ask is that if you can, please contribute to the information in this thread (and correct me if I am wrong) to help me, others who are planning to build, and others who have already built a motor to further this community and platform as a whole.

Now onto the good part:


BUILDING THE BOTTOM END

There are a bunch of parts that you will need to buy no matter what your other options are. Those are as follows:

The Block



(Pic taken from @BlueStreak from How To: Assemble A Forged MZR DISI Motor | SpeedForums.org)

To my knowledge, all years of Mazdaspeed3’s, Mazdaspeed6’s, and CX-7’s use the same exact block. Either will work and as long as there is no damage to the block, it will work. The blocks are made out of aluminum which is lightweight and will also dissipate heat pretty well. Being that they are aluminum, our blocks come sleeved with (****WHAT MATERIAL ARE THEY MADE OUT OF). These sleeves can be bored over to up to 0.040 (****NEED CONFIRMATION) and are appropriate to handle most applications or boost.

Where to buy:

You can purchase these from other members, dealerships, junk yards, and other places as well. Prices should range from about $300-$600 depending on where you buy.

The Oil Pan



(Pic taken from @whoosh@Realtune from http://www.mazdaspeedforum.org/forum/foru...nstalled-1449/ )

The oil pan is also made out of aluminum. To my knowledge, I don’t believe there are any aftermarket options to the stock oil pan.

Where to buy:

You can purchase these from other members, dealerships, junk yards, and other places as well. I have no idea how much they would cost, probably within the range of $50-$150 depending on where you buy.


Oil Pan Windage Tray / Oil Pan Baffle

Now the stock oil pan comes with a 2 piece baffle in the oil pan to help with oil sloshing around too much. There is a huge space in the middle where there is no baffle because of the balance shaft that is normally on the car. If this is removed (commonly called a bsd for balance shaft delete), there is a huge space where there is no baffling.

Just to go over the difference between a baffle and a windage tray, the baffle (vertical portion) is meant to keep the oil near the oil pick-up during a hard turn where a windage tray (horizontal portion) is meant to keep the oil from splashing everywhere.

Options:

GP-WERKS

Where to buy:

GP-WERKS

https://www.gp-werks.com/products/Du...peed-3%29.html



Price: $65.00 + $5.00(shipping) = $70.00

(There is also a combo with baffle and BSD for $90.00 shipped https://www.gp-werks.com/products/Du...peed-3%29.html )

Balance Shaft / Delete (BSD)



(Pic taken from @danesti from How to - Balance shaft delete )

The balance shaft is a 17 pound piece of equipment located under the crankshaft under cylinder 3 that is spun by a gear on the crankshaft. That does not mean that if you delete it then you have 17 less pounds of rotating mass, but it does free up some friction against the crank as it spins. (Remember from science that friction is any force that works against motion.) Removal of this can get rid of the extra drag, but remember, it was put there for a reason. Remove at your own risk. With removal, you may notice increased vibrations at certain resonance rpm’s.

Where to buy:


SURE

SURE Motorsports Balance Shaft Delete



Price: $35.00 +$0 (free shipping) = $35.00

GP-WERKS

https://www.gp-werks.com/products/GP...elete-Kit.html



Price: $27.50 + $0(free shipping) = $27.50

(There is also a combo with baffle and BSD for $90.00 shipped https://www.gp-werks.com/products/Du...peed-3%29.html )

COSWORTH

Duratec balance shaft delete - Cosworth USA



Price: $39.00

MASSIVE

Massive Speed Balance Shaft Delete Kit - Massive Hardcore Racing Performance Parts - Massive Speed System - Ford Focus Specialists



Price: $34.99

CFM

CFM Balance Shaft Delete BSD for '03-07 2.3L Duratec Focus



Price: $29.95

(I just found this one and I do not know who is running this if anyone)

Crankshaft



(Pic taken from @StreetUnitMark from http://www.mazdaspeedforum.org/forum/foru...s-build-22217/ )

If you don’t know what a crankshaft is by now then you need to learn how a car works.

I have heard talk about using a crankshaft from a regular mazdas3 which will destroke the engine to a 2.0L. (****SOMEONE PLEASE SHED SOME LIGHT ON THIS.)

Where to buy:

STREETUNIT

Crankshaft: MAZDASPEED 3, MAZDASPEED 6, CX-7



Price: $1096.00 + $0 (free shipping) = $1096.00

You can also buy from a dealership or other members and junkyards.

Crankshaft Cradle/Girdle



(Pic taken from @StreetUnitMark from http://www.mazdaspeedforum.org/forum/foru...s-build-22217/ )

To my knowledge, there are no upgrades to this part of the engine. It holds the crankshaft to the engine block itself.

Where to buy:

You can purchase these from other members, dealerships, junk yards, and other places as well. I have no idea how much they would cost, probably within the range of $0-$1000 (aka I have no idea) depending on where you buy.

Oil Pump



(Pic taken from @BlueStreak from How To: Assemble A Forged MZR DISI Motor | SpeedForums.org)

To my knowledge, there are no upgrades to the stock oil pump. It pumps oil through your engine.

Where to buy:

STREETUNIT

Oil Pump




Price: $215.00 + $0 (free shipping) = $215.00

You can also buy from a dealership or other members and junkyards.

Oil Pick Up Tube



(Pic taken from @StreetUnitMark from http://www.mazdaspeedforum.org/forum/foru...s-build-22217/ )

Where to buy:

STREETUNIT

Oil Pan Strainer Tube



Price: $34.99 + $0 (free shipping) = $34.99

Oil Squirters



(Pic taken from @BlueStreak from How To: Assemble A Forged MZR DISI Motor | SpeedForums.org)

These are basically little tubes that direct some oil flow to the underside of the pistons. You will need 4 of these, one for each cylinder. For certain rod/piston setups, these must be bent slightly to increase clearance (****WHAT SETUPS AND HOW TO BEND)

Where to buy:

You can purchase these from other members, dealerships, junk yards, and other places as well. I have no idea how much they would cost, probably within the range of $0-$500 (aka I have no idea) depending on where you buy.

Main Bearings



(Pic taken from @BlueStreak from How To: Assemble A Forged MZR DISI Motor | SpeedForums.org)

These are each half circles that hold the crankshaft and go between it and the block and cradle/girdle. There are 5 sets each having a half with oil passages (for block side) and just half circles (for cradle/girdle side).

Where to buy:

STREET UNIT

Mazda OEM Main Bearings 2.3 MZR: Mazdaspeed6, Mazdaspeed3, CX7



Price: $110.00 + 0(free shipping) = $110.00

You can also buy from a dealership or other members and junkyards.

Main Studs

These studs hold the crank cradle/girdle to the rest of the block.

Options:

ARP

Where to buy:

STREET UNIT

ARP Main Studs



Price: $128.14 + $0(free shipping) = $128.14

EDGE AUTOSPORT

ARP Main Stud Kit MS3 MS6 MZR



Price $126.14 + Shipping

Head Studs



(Pic taken from @BlueStreak from How To: Assemble A Forged MZR DISI Motor | SpeedForums.org)

These studs hold the head to the block.

Options:

ARP

Where to buy:

EDGE AUTOSPORT

ARP Head Stud Kit MS3 MS6 MZR



Price: $179.82 + Shipping

MAPERFORMANCE

ARP Head Stud Kit 2007 - 2009 Mazdaspeed3 - Modern Automotive Performance



Price: $143.99 + Shipping

JSCSPEED

07-10 Mazdaspeed3 ARP Head Studs: JSC Speed



Price: $151.05 + Shipping


Engine Internals: Rods/Pistons

Ok, now it gets confusing. This is the part where you have TONS of options. There are an overwhelming variety of different possible setups for this and I will attempt to explain them in an organized manner. That being said, this is the area where I know the least as of now. I will be doing a bunch of research, but this is where I need the community’s help the most. As I put up information, please add if I am missing something. If you have a built motor, please let me know what you have and if you have anything you can share about the product(s) you have.

Background information you need to know about Pistons

Introduction to piston design for forced induction engines | HorsepowerCalculators.net

Bore

Wikipedia (Links)

Engine_displacement

The bore is basically what the diameter of the cylinder is. Our stock bore is 87.5mm/3.445in. When you have an engine “bored and honed”, the cylinder is basically cut wider (boring) and then polished inside (honing). When the diameter of the cylinder is increased, the displacement of the engine increases as well. Bigger displacement means more can fit into the engine and it will also increase engine compression (thanks @Jonnyquest ). "There is one massive con when it comes to overboring. If you overbore you increase the chance of overheating your engine. Your cylinder walls act like a heat-sink to spread the heat around evenly to all the coolant passages. If you overbore there is less material to spread the heat so hot spots occur and boils the coolant. Another thing is when you overbore the heat generated during the power cycle is greater which acts as a multiplier to the above." (thanks @MS6_Newb ) (*****CAN SOMEONE PLEASE ELABORATE ON PROS AND CONS)

Wrist Pin (Gudgeon Pin)

Wikipedia (Links)

Gudgeon_pin

The wrist pin (Gudgeon Pin) is basically what holds the piston to the rod. There are a couple different types depending on your setup, but most of these piston/rod assemblies need to be put together by a machine shop as the average person does not have the correct equipment. The stock wrist pin is 22.5mm, but other pistons/rods can use either the 22.5mm or 22mm wrist pins so you need to make sure it matches up.

Compression

Wikipedia (Links)

Compression_ratio

The compression ratio, in a nutshell, is the ratio of volume in the cylinder from its largest capacity to its smallest. From what I have found through a little research is that the higher the compression, the more thermal efficiency and power you get, but the more prone you are to knocking. I really know very little about the effects of changing compression on these motors and have heard that it did not work well in the past, but now that we have more tuning controls, more and more are experimenting with changing compression. The stock compression is 9:5:1, but lower compression ratios are available for different pistons. I have also heard that compression changes as you drive the car for longer, such as at highway speeds, but I do not know how, why, and with what effects. (*****CAN SOMEONE PLEASE SHED SOME LIGHT)

Piston Domes

Different pistons obviously will be made differently and one important factor when choosing a piston is the design of the dome. The tops of the pistons aren’t just flat and depending on their design, they will perform differently. I believe valve reliefs are cut into all of the pistons available, including stock, so that the piston doesn’t smack into an open valve on its way up. The stock pistons are flat with valve reliefs, but other aftermarket pistons will have different designs which will all effect the distribution of fuel in the combustion chamber.


Background information you need to know about Rods

Wikipedia (Links)

Connecting_rod

Rod Tech

Rod Design

This is one of the most important characteristics of the connecting rod that you will have to look at. There are many different designs, the most prominent being I-Beam, A-Beam, H-Beam, and X-Beam design.

I-Beam



These rods are common to most stock engines (including our own) and feature a non-tapered “hole” along the connecting rod.

A-Beam



These rods are stronger than stock and are very light-weight. They have a tapered “hole” along the connecting rod which gives it its name “A”. These come in different designs, including the regular A and the Super-A (The super being stronger).


H-Beam



These rods are much stronger than the I-Beam and A-Beam. This is the choice for many high power engine builds.

X-Beam



This design is made mostly by Pauter and have a single rib going down the middle giving it one strong point rather than two. It is light-weight because of this design, but might not support the same power that an H-Beam will.


Options:

***When choosing a rod, you need to pay close attention to the wrist pin size. This MUST match to the piston. Stock wrist pin is 22.5mm, but some rods/pistons come in 22mm. The smaller wrist pin can be machined the extra 0.5mm to work with 22.5mm pistons, but I honestly wouldn't recommend it if you have the option not to.***

***I am also not putting prices in this section because there are so many different options that including prices here would be confusing***


A-Beam


Carrillo

**Available in 22mm and 22.5mm wrist pins***

Where to buy:

EDGE AUTOSPORT

Carrillo Super A Beam Connecting Rods Mazdaspeed 3 6 MS3 MS6

Carrillo Super A Beam Connecting Rods Mazdaspeed 3 6 MS3 MS6




STREETUNIT

Carrillo Forged Connecting Rods



H-Beam


Carrillo

**Available in 22mm and 22.5mm wrist pins***

Where to buy:

EDGE AUTOSPORT

http://www.edgeautosport.com/carrill...t-pin-mzr-disi

http://www.edgeautosport.com/carrill...-pin-mzr-disi/

http://www.edgeautosport.com/carrill...-pin-mzr-disi/

http://www.edgeautosport.com/carrill...-pin-mzr-disi/



Molnar Technologies

*** 22.5mm wrist pins***

Where to buy:

STREET UNIT

http://www.streetunit.com/Molnar_Tec...zh5927mgb4.htm



K1

**Available in 22mm and 22.5mm wrist pins***

Where to buy:


EDGE AUTOSPORT

http://www.edgeautosport.com/k1-conn...mzr-disi-2-3l/





CP-E

http://www.cp-e.com/products/mazdasp...r-23-disi-rods


X-Beam


Pauter

**Available in 22.5mm wrist pins***

Where to buy:

STREET UNIT

http://www.streetunit.com/Pauter_For...-550-1505f.htm



To Be Continued...

[Raider]

Why you no VIP? I has monies

[TWOptSL0W]

Originally Posted by Raider Why you no VIP? I has monies

that also came up in my long convo last night. i'd rather not get into any discussions or arguments with anyone about vip membership and all, maybe i will renew my subscription eventually, but for right now, $25 is a bit much in my eyes.

as for the msf bucks, i did this to help the community, not for bucks


thread will be updated periodically, i just spent a few hours so far on it and im tired lol

[Raider]

I only asked to give msf bucks. Personal issues, no worries. Hell of a thread.

[TWOptSL0W]

updated

[MS6_Newb]

This post is very useful and full of info. However, you asked if there are any more pros and cons on overboring an engine. There is one massive con when it comes to overboring. If you overbore you increase the chance of overheating your engine. Your cylinder walls act like a heatsink to spread the heat around evenly to all the coolant passages. If you overbore the is less material to spread the heat so hot spots occur and boils the coolant. Another thing is when you overbore the heat generated during the power cycle is greater which acts as a multiplier to the above. If your wondering why I say/know this, well, I talk from experience. I overbored a honda .020 over and ever since then the car ran hotter than normal. It over heated a few times until I upgraded the cooling system. I don't want to discourage anybody but let this be a fair warning to not go to big.

[TWOptSL0W]

Originally Posted by MS6_Newb This post is very useful and full of info. However, you asked if there are any more pros and cons on overboring an engine. There is one massive con when it comes to overboring. If you overbore you increase the chance of overheating your engine. Your cylinder walls act like a heatsink to spread the heat around evenly to all the coolant passages. If you overbore the is less material to spread the heat so hot spots occur and boils the coolant. Another thing is when you overbore the heat generated during the power cycle is greater which acts as a multiplier to the above. If your wondering why I say/know this, well, I talk from experience. I overbored a honda .020 over and ever since then the car ran hotter than normal. It over heated a few times until I upgraded the cooling system. I don't want to discourage anybody but let this be a fair warning to not go to big.

thanks, op updated

[SPEED6 KILLAH]

Miss out the oil pump ..

[TWOptSL0W]

Originally Posted by SPEED6 KILLAH Miss out the oil pump ..

good looks, i almost forgot that part ill have to add it in my next update

[TWOptSL0W]

updated

[aviator79]

Thrust bearing?
Also not to discourage buying OEM parts from sponsors, but they are all less from parkmazda.com.
Thanks thou as I have been making a spreadsheet to figure out costs and this helped. I had not accounted for certain things such as bearings and oil pump. I also need to add seals, and junk, Head gasket...also i have a DCR VVT on my list for 230, or OEM for 120ish. I was thinking of going with just the revised OEM pistons for 280. Have not decided on rods. Also want to know what machine costs would be, but I have it estimated at $1000. I highly doubt my block needs to be machined so I wish I just had the bore gauge to do it myself.

[TWOptSL0W]

updated with rod options

[predapio]

Originally Posted by TWOptSL0W updated with rod options

I'll give you a rod.





With pharmaceutical help, mind you.

[CWP_MS3]

Discuss Here: http://www.mazdaspeedforum.org/forum/foru...-motor-106962/

[NJSPEED3]

nice job so far Mike. Its time you explain the building & upgrades process for our cylinder heads. Since you are doing pretty extensive work to your it will make for a great example.

k thx avon 4 life!