The PG6KGJ build...slowly

[fastnfurious7]

I knew that would get some attention. The thoughts are "WTF is a PG6KGJ????". Well, I've been reading all of these badass builds on here & I'm like, I would like to show my progress as it goes with my car even though it will be SLOW and PAINFUL compared to the cool cars on here with good financial backing. So PG6KGJ actually stands for Poor Guy with 6 Kids and a Government Job build. :lol: I have some pics of the car as I received it a couple of years ago. So, it started out like this:

http://i902.photobucket.com/albums/ac226/Gregoryga7/34f359b9bae0-1.jpg

Probably a little different than most...but, really...I traded that to someone on CL for this:

http://i902.photobucket.com/albums/ac226/Gregoryga7/f30d695acaa1-2.jpg

Not a bad start...but the car didn't run correctly. The Miata Link Engine Management System was not properly tuned & the car wouldn't run if pushed after 4000 RPM...so...off to Balanced Performance to see Ed Senf.

http://i902.photobucket.com/albums/ac226/Gregoryga7/ddcd2f770c47-1.jpg

Not as impressive as I had hoped but Ed commented on two things that I remember.

"Wow...that's a tiny little turbo" & "What can you say...it all works together"

http://i902.photobucket.com/albums/ac226/Gregoryga7/3b91c82efcef-1.jpg

Well, it wouldn't surprise me if the manifold was cracked when we tuned because it got bad enough to actually KNOW that it was cracked & then we took it apart & welded it back together, adding some bracing to hopefully avoid future cracking. Now, the tune is off again.

[fastnfurious7]

I know that my phone pics suck but that is all this poor fella has to take pics with. The blurry dyno sheet reads something like 155whp & 154 torque or something like that. Heck, I can't even read it & the sheet is in the car which is apart @ home. Next is why the car is apart.

http://i902.photobucket.com/albums/ac226/Gregoryga7/68bd082d5662.jpg

Pic is blurry as all get out...but you get the point. The woodruff key is smashed & was causing the pulley to wobble. It got bad enough that when the car was in neutral & the clutch was out, the pulley would scrape the engine making a subtle but frightening noise that caused me to freak out & think my whole engine was toast. Hopefully not.

http://i902.photobucket.com/albums/ac226/Gregoryga7/aa1c8ee482d9.jpg

That would be a pic of the offending woodruff key next to the new one from Mazda.

[fastnfurious7]

Now...along with tearing out the front of the motor...I went a little crazy spending some cash I really don't have and bought some stuff. Items include:

'99 six speed transmission
EVO 8 intercooler
R Package front & rear lip
Track Dog Racing Air Splitter for R Package front lip
New aftermarket (stock look) front nose
Torsen LSD
Haste 3 row aluminum radiator
ACT xtreme 6 puck clutch
8lb Fidanza flywheel

The not so fun items I had to buy:

New water pump
New timing belt
New timing belt tensioner & idler
New pulley boss for the crank pulley
New woodruff key for crank gear
New crank gear

Things I may still need for interim build

Different IC
IC piping

http://i902.photobucket.com/albums/ac226/Gregoryga7/904174fc687d.jpg

That is the lovely front of the car as I received it. Complete with a non symetrical hack job. If you look closely, the two cuts are @ two different angles. Looks like poo.

http://i902.photobucket.com/albums/ac226/Gregoryga7/2f248cd62634.jpg

Wow...that is a vast improvement. Side shot:

http://i902.photobucket.com/albums/ac226/Gregoryga7/b8532e87accd.jpg

Please don't poke too much fun @ my completely disgusting garage. It is an abomination & it's all my fault. I honestly have too many projects & too little time.

[fastnfurious7]

Now it's time for the "how old are you?" portion of our show. Yes, I'm too old to be so caught up in car stereos but it is an obsession. I went WAY overboard on the system in this car & I didn't mean to do it. I was JUST going to add an amplifier and some 6x9's in the parcel deck. Yeah...right. Ended up with this.

http://i902.photobucket.com/albums/ac226/Gregoryga7/5830e50c0526-1.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/60cc24a06078-1.jpg

So, the sound system went through about 4 completely different set ups before I came down to this & it STILL isn't completely done.

PO had a crappy Panasonic HU & some pretty good Boston Acoustics components in the doors. So, I added the MB Quart 6x9's to the parcel deck & amped with a crappy Boss Audio 4 way. That didn't work for me so I added a MTX sub amp & 10" sub. Still wasn't working so I went with an old school xtant 4 way & the MTX sub amp. No dice...put in Clarion drz seven hundred & something HU with plans to add a sound processor but I got the mighty fine Clarion DRX 9255 you see in the pic because I'm obsessed...like I said. By this time I was out of control & bought all old school Audio Art amps. A six way for the front stage & a bridged 2 way for the Image Dynamics 10" sub. Another, smaller bridged 2 channel runs a JL Audio 6" sub in the cabin currently on the parcel deck. One of the 6x9's started buzzing so now I'm changing the front door speakers to Image dynamics components, putting the Boston Acoustics on the parcel deck with the JL Audio 6" sub in the middle of the parcel deck. Tweeters up front will be run active from the six channel Audio Art & the Mid signal will be split & run to the Boston Acoustics & the Image Dynamics in the parcel deck & in the doors.

[miatasaint]

Dude. You are going a good direction it seems.....wish i had the money. I still want a torsen. Cheers man.

[fastnfurious7]

Enough of all of that crap & on to more important things...like the turbo set up & some problems I have encountered & some...I made for myself.

With the install of the new nose & R Lip, the current placement of whatever wierd intercooler that came on this car is not going to work. Now, eventually, I would like to build a stouter 1.6L engine, add a bigger turbo & a decent intercooler (possibly that EVO 8) and some proper piping. For right now I would like to just run what I have and acquire the other components over time...slowly & painfully as I said. I want to go ahead & put in the 6 spd & the Torsen & find a way to route the pipes to the current intercooler. Problem is that I still may need to modify the IC. Is that possible or will it mess up the IC functionality? I may have to flip it upside down & then invert the tube on side. Pics would help (especially some decent ones that weren't from my crappy phone)

Second problem (I'll try to get pics of all of this stuff when I am home on Sat)...my impatience may have cost me an oil pump. In my effort to get the timing gear off the crank nose I may have fouled my oil pump housing. Only way I will know for sure is to run it & see if it holds pressure & doesn't leak. Bummer is that I already have the front of the engine torn down &, as we all know, oil pumps are a PITA to change. I keep thinking I should do one of two things & can't decide which way to go. 1) Put it all back together & leave the 5 spd in & see if the pump works. If so, change to 6 spd tranny when I have time. If not, go ahead with 6 spd swap & also drop subframe to change oil pump. 2) go ahead & not take chances, front of engine is already torn down & out of the way, do the 6 spd now & drop the subframe & put in an oil pump.

Also, the oil pump for the 1.6L is a tricky little number to find for some reason. The parts places like Rock Auto don't list one for a 1993 at all. They have one for a 1.6L Kia Sephia which I thought used the same engine (must be wrong on that). Travis from Boundry Engineering in a thread on another site said the pumps were all the same from '91.5 when they went to the long nose crank all the way up to '99. I don't know if I should continue to try to find a new pump or just score a used one and be done with it. Probably get a BE oil pump when I build the engine...as if I can afford that.

[fastnfurious7]

Thanks pony...I don't have the money...I'm in WAY over my head...LOL! I call putting these nice bits in without the built motor & larger turbo my "interim" build. So, just really trying to get the thing back together & paint the front and roll while I gather the funds & other pieces I need over time. Interim build also needs:

Polyurethane bushing kit (before I put in the LSD)...might as well get all of 'em...right?
Shifter rebuild kit for the 6 spd. Need both boots and all of the washers & bushings except the bottom one because I have a nice one coming from Rev9 for that.
Seal for one of the axles that is coming with the Torsen
May need slim fans to fit the new radiator in
Still need to get cam shaft seals
Prob more stuff!

[miatasaint]

Yeah i hear ya. I could pull out loans but i just dont have the effort or good credit. lol

[Shortround]

Looks like it is going to have a lot of potential nice build so far can't wait to see how it turns out

[Jack-MX5ATLanta.com]

Good luck man, don't give up.

[oldgrayfrog]

1.6 motors are plentiful and cheap, so lots of folks just pull theirs when things like internals or woodruff keys go bad. Remember that the protege had the same 1.6 and 1.8 motors, and are REALLY cheap at the pull a parts. If you decide to stick with the 1.6, and I gotta say, I love the free rev character of that motor, look to BEGI to grab a more durable turbo mani. It's hard to beat FM's silicone premade intercooler pipes, although at about $250 each they aren't cheap. That said, there is nothing wrong with Ebay intercoolers, you should be able to find an apropriate sized FMIC for around $100. I'm guessing that's a 2554 turbo, or is it even smaller? Anyways, you can locate the 2560 turbos that FM sells with it's standard kits, through some Nissan supply sources on Ebay as cheap as $500 New in Box. They were standard on JDM S13/S14 Silvias (240sx). Of course, if you want you could always haunt Miataturbo.net, and scrounge up used parts like most of us do:)

[nickt93]

Poor guy with 6 kids and a government job :lol: I love it!

You are off to a great start. I agree with OGF's recommendation on a new manifold. You are in luck! Flyin' Miata is blowing out some "not pretty" 1.6 manifolds right now for crazy prices. I picked up one for $100. The $100 ones are gone, but they have some left for $150 (scroll down to 10/11/11). http://flyinmiata.com/dealoftheday/older.php

If you want some help tuning the Link, I'd be more than happy to do what I can. I run on on my '95 and have gotten fairly fluent with it over the past few years. With a wideband it should be able to tune itself to about 90% of it's potential power and keep everything nice and safe.

I think I remember the previous owner posting about this car. Didn't he pick it up at an auction for an insane price?

[Bob_Bobber0]

Looks better than when I saw it last at the waffle house man! Got rid of that hideous bumper!!! Good luck with the build!

[oldgrayfrog]

Nick, I have a spare wideband at my house,it's a standalone deal, you can certainly use kit to help tune that Link. Also fast and furious, I have a lot of spare red body panels hanging in my garage,lmk if you need anything specific.

[fastnfurious7]

Awesome stuff, guys. Wouldn't surprise me if PO picked it up for a song. He got my truck & a good amount of $$ on top but I'm still happy with my purchase. PO never got it running right & it's been a joy to drive since Ed did his majic. Nick, I'm sure you could have it tuned right up from where it is because it isn't too far off. Since you know what you are doing it should be a snap...me...not so much. I still have to order my WBo2...I have a boost gauge & an EGT gauge right now...might take OGF up on borrowing that WBo2 to tune until I can afford to get one.

OGF...the turbo is a Mitsubishi TDO4. Greddy used to sell a low PSI turbo kit with these W/O an IC. The person who built this added unidentified IC to be able to up the PSI. Original kit was set to run @ 5 to 6 psi...I'm running @ 10psi right now & it does okay. Original kit was good for 35HP & I guess I'm getting around 50hp w/ the 10 psi so...not great but an improvement for sure.

I will definitely hit you guys up for some help!

[fastnfurious7]

So, after 8 24 hour shifts in a row, I finally found my way to the house & to the car. UPS left me some love:

http://i902.photobucket.com/albums/ac226/Gregoryga7/f1af68c02587.jpg

That's a 3 row aluminum radiator & the Gates timing belt kit that comes with the tensioner & idler pulleys. Bad news is that there was so much oil spit all around the timing area that the marks I made on the old timing belt & the ones on the cam gears are mostly gone. My fault for working in the dark when I began this project. :( I may need some assistance from the folks here to make sure I get the new one on right.

http://i902.photobucket.com/albums/ac226/Gregoryga7/0354a05325cc.jpg

Too excited not to at least do a test fit. Of course, it'll come out again until I finish the timing belt...and possibly that oil pump. :(

http://i902.photobucket.com/albums/ac226/Gregoryga7/9b363dff7d90.jpg

Put the stock fans on to see if it'll all clear. Not too bad on this side.

http://i902.photobucket.com/albums/ac226/Gregoryga7/d3a854d7661b.jpg

Not so lucky here. Can't tell from pic but the fan doesn't even fit on the radiator in the spots provided. When put in the grooves on the bottom it is about a 1/4" from being able to be attached in the top spots. BOV won't clear in the current position. I'll mod the bottom attachment points on the fan to drop it down enough to fit the top attachment points & then the BOV should clear.

Probably shouldn't have even worked on the car this little bit since it was the wife's birthday & I hadn't been home in forever but, you know, I just couldn't resist. Hopefully UPS will be showning me some more love by the time I get back home on Tuesday & I can also visit Auto Zone & Moss Robertson Mazda & pick up the other parts I ordered to keep this build rolling.

[JEMERY]

I have a PDF factory service manual detailing the install of your timing belt if you're unsure of the specifics. I might could help, wife permitting. Looking great otherwise!!

[fastnfurious7]

Well, I need to come see you, John, for obvious reasons. I better get you this coin for the Torsen before I blow it on other stuff. You're assistance with the timing belt would be GREATLY appreciated because I really would like to get that right the first time.

I might could help, wife permitting.

My wife said it would be fine if you helped...OH...you meant yours! :p

May have scored a used oil pump from one of the fine folks here...I'm almost positive I cracked the housing on mine...THANKS PAT! Boy is that going to be a royal pain in back side to put on. MY FAULT! :(

[JEMERY]

Just found this out but, you might want to look into boundary engineering oil pumps.

Lol, as long as one of them ok'd it.

[fastnfurious7]

Just found this out but, you might want to look into boundary engineering oil pumps
Because of you, sir...I have long had my eye on their product. Expensive as all crap but may be worth it. I already fired off an email earlier today to see if I can get away with just rebuilding the housing I'm getting with their gears (still expensive as crap) and that'll be all good or if I should come off the hip & get the street/strip model. If I decide to buy the plug & play model...project will be put on hold until I can score some more jack to fund this ridiculously expensive adventure...sheesh...all I thought I was going to do was fix a knocking noise...dang mx5atlanta and all of your temptation! :lol:

[fastnfurious7]

Moving right along...got these yesterday.

http://i902.photobucket.com/albums/ac226/Gregoryga7/a90ad5c1d0a5.jpg

Timing gear, pulley boss (STUPID expensive), cam seals.

http://i902.photobucket.com/albums/ac226/Gregoryga7/86aec59c2f0e.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/b74779b70a7c.jpg

Those two pics explain why I paid 80+ for a pulley boss. The keyway is widened on the end & the back is embossed with the imprint of the timing gear. While I realize some of that is to be expected...this seemed a little too severe. Widened keyway sealed the deal...bought a new one.

[fastnfurious7]

I don't have a pic but I did assemble the pulley boss to the pulley...and overtighted the bolts. Oh well, it's DEFINITELY on there. I went to about 30ft-lbs...looked afterward (I know...it would have been a little smarter to look beforehand...my impatience getting the best of me again)...supposed to be 140 INCH lbs. Whatever...nothing broke & it's together with locktite 242 in the the threads.

I did take the opportunity to work on getting the new aluminum radiator to fit with the stock fans.

http://i902.photobucket.com/albums/ac226/Gregoryga7/d3a854d7661b.jpg

Remember...problem number one was that the BOV wouldn't clear.

http://i902.photobucket.com/albums/ac226/Gregoryga7/2f777bba8b62.jpg

Modified (read: cut with the Rotozip) the fan to allow the BOV to clear. This is my "interim" set up so the "REAL" setup will probably include the slim fans & a fan shroud so I really don't care that I had to cut this one.



Also had to cut a bit & drill to get the fan to mount properly on the new radiator. I suppose the folks that made this radiator put the spots where the fan is supposed to attach in the wrong spot. Not too far off to be a deal breaker. Easy fix.

http://i902.photobucket.com/albums/ac226/Gregoryga7/c0ed9b7a95df.jpg

Blurry pic...sorry. It's only off a little bit. I was able to drill a new hole here & make the slot in the bottom attachment point on the fan longer so the fan would drop down. Seems to have worked out okay.

[fastnfurious7]

Now, my other problem is that the original builder of this car's placement of the IC sucked. I removed the front end (has to go to be painted anyway...plus makes it easier to work) & mocked up where I would like the IC to go.

http://i902.photobucket.com/albums/ac226/Gregoryga7/cb60b573ad79.jpg

This places it back & up from where it was, gaining ground clearance & allowing it to clear the brake cooling channels on the R lip.

http://i902.photobucket.com/albums/ac226/Gregoryga7/cd7d281c34a4.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/edffdc58d0e0.jpg

The IC piping will have to be modified on both sides. Looks like a section on each can be cut out & welded back together to meet the proper spot on both sides. Anyone a good welder that can help? :lol: My nephew or my buddy may be able to make this happen. I am going to try to make some brackets that will work to put the IC in the right place & then when I get the car together I will hook it up as is (without the front) & drive it to wherever I need to go to get the welding & cutting done. I'll just bring the brackets with me that put the IC where I want it & then have the expert make the piping fit. Sound like a good plan?

Anyone see any problems having the IC here? It isn't going to interfere with cooling or anything I hope. I can only surmise that the original builder thought the original placement was a good idea because it kept it well away from the AC & Radiator...I don't know if me placing it in front of them will be too much of an issue...car didn't run hot AT ALL with OEM radiator so my thoughts are that the new aluminum 3 row radiator should keep things nice and cool & placing IC here won't affect too much. Right or wrong?

I can't put the timing belt or gears or anything on until I R&R that oil pump so that's on hold until I can get the part from Travis @ Boundary Engineering. The storm smacked the place he has them made so it'll take a little longer than I had planned. Next up:
1) Drop subframe & Tranny
2) Drop rear end
3) Put bushing kit in 6 spd
4) R&R oil pump
5) Install polyurethane suspension bushings (set is en route)
6) Reinstall Subframe
7) Install 6 spd
8) Install Torsen
9) FINALLY put the timing belt & crap back on the motor

Again, I ORIGINALLY planned on only doing number 9 when I started. Things got out of hand quickly. :lol:

[miatasaint]

You sir, are a bawss.

[Bob_Bobber0]

Work Work Work!

Looking good Greg.

[Shortround]

Looks like you have your work cut out for you.

[Jack-MX5ATLanta.com]

Coming along nicely!

[fastnfurious7]

Thanks everyone! Working every third day on this makes it go SLOW...but hopefully my truck will be done today so I'll have something to drive instead of taking the motorcycle to work. Thank GOD for heated gear. :lol:

Coming along nicely!

Could be coming along nicer. ;) I completely understand, sir.

Some UPS love (actually USPS):

http://i902.photobucket.com/albums/ac226/Gregoryga7/3aebe9b4904b-1.jpg

And I already have this:

http://i902.photobucket.com/albums/ac226/Gregoryga7/da2637de62b9.jpg

To clean up this:

http://i902.photobucket.com/albums/ac226/Gregoryga7/60cc24a06078-1.jpg

Should all match up nicely & give me the info I need. Link pod or whatever you call it will be hidden away. Don't really need it front & center like that. Then I just have to get some of the eyeball vents.

[fastnfurious7]

Didn't get as much done yesterday as I had hoped. When I took the boost gauge out there was a kink in the tube. I'm an idiot & can't leave well enough alone because the gauge worked fine...I just HAD to cut the kink out. Little adapter that goes on the end of the tube is a double PITA to get back on. I'm embarrassed to say how freaking long I worked on just that. Finally got it. Anyway...here's my transmission boots:

http://i902.photobucket.com/albums/ac226/Gregoryga7/89cda0ef62fb.jpg

Do you think I could use some new one's? :lol: I was already aware of this situation & already ordered a shifter rebuild kit that includes these boots...but they are on backorder. No biggie, not ready to install 6 speed yet anyway. Next pic I was NOT anticipating:

http://i902.photobucket.com/albums/ac226/Gregoryga7/207289f5aa6e.jpg

Picture of shift levers (from left to right), stock 6 speed, stock 5 speed, short shift 5 speed. Does the 6 speed one look bent to you? Yep, it's bent...Fudge. I've been looking for a short throw 6 speed lever & the decent ones are STUPID expensive. Can anyone point me in a better direction on this? I was just going to stick with the stocker due to price but now since I'll have to get one anyway...might as well try to get what I want.

Took the piece that the keypad for the LINK was attached to off & when I compared it to the 3 gauge plate:

http://i902.photobucket.com/albums/ac226/Gregoryga7/e62107c4d03a.jpg

Another pooville. :( No big deal to fix but I wasn't planning on having to modify the darn thing.

Got it all done though...like I said...not as much accomplished as I had hoped...all day for this & the gauges aren't even hooked up. :(

http://i902.photobucket.com/albums/ac226/Gregoryga7/17741c52fd11.jpg

Hopefully a better update on Monday.

[fastnfurious7]

Good God...this is getting out of hand. Well, I thought I had planned my mild build before I got started but cracking the oil pump has thrown a monkey wrench in the plans because it is a huge MFer to change...and you know the old addage..."if I'm doing all that I might as well..." burn money I don't have is the answer. Well here's where we start:
http://i902.photobucket.com/albums/ac226/Gregoryga7/50035e3014df.jpg
Fidanza 8lb Flywheel & Act 6 puck clutch & pressure plate

http://i902.photobucket.com/albums/ac226/Gregoryga7/8c8c03a2554a.jpg

Full Prothane Urethane Bushing Kit for the suspension on the whole car.

http://i902.photobucket.com/albums/ac226/Gregoryga7/238f5a65227c.jpg

Shift boots and shifter bushings for the new 6 spd. Also a fancy schmanzy bushing for the end ball that mates up to the tranny.

http://i902.photobucket.com/albums/ac226/Gregoryga7/59f79d588511.jpg

Vishnu dual feed fuel rail & Rx8 540 injectors...THANKS JOHN! Folks...if John had kids...I'm puttin 'em through college. :lol: He doesn't have kids...just a new puppy.

[fastnfurious7]

Oh no...we're not done yet. I'm not gonna be able to put my own kids through college but check it...more miata parts. :lol:
http://i902.photobucket.com/albums/ac226/Gregoryga7/0ffd665676a8.jpg

Got those eyeball vents I needed. Gotta seal the whole engine so I got the rear main seal. Got a Intake Air Temp gauge that I have no idea where I'm gonna put. Guess I'll be a super ricer like my gay screen name & put it on the A post. :lol:

http://i902.photobucket.com/albums/ac226/Gregoryga7/3df0c15c1c35.jpg

Oil pump...I hate these with a passion at this point for obvious reasons. :cry: However...it's all my own fault for brutalizing the poor thing getting that dang timing gear off.

http://i902.photobucket.com/albums/ac226/Gregoryga7/3cfb382c62e6.jpg

New pilot & throw out bearings for my new clutch.

http://i902.photobucket.com/albums/ac226/Gregoryga7/ab73f010381b.jpg

Please tell me what build is complete without a valve cover from a Capri that shows off those sexy cam gears? :banana: Not so fast, my friend...the douc-hebag that sold this to me must have painted it with testors model paint silver or something because while it looks nice in the pictures...everytime it is touched it leaves silver all over your hands. That ought to hold up really well in an engine bay. Guess I get to spend more dough I don't have fixing that crap. :(

[fastnfurious7]

And if you thought that I was just running around the internet purchasing parts I don't really have the money for and not getting any work done on the car...you would be WRONG!:p
http://i902.photobucket.com/albums/ac226/Gregoryga7/dfcc9756dfcc.jpg


http://i902.photobucket.com/albums/ac226/Gregoryga7/aaade10ddafb.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/04bae805fceb.jpg

Yep...that's right...abandoned the subframe drop & just pulled the dang engine. It'll work out better this way. Scored another engine...THANKS PAT!! I'm gonna build that engine with some go fast parts as money allows & put it in the car. This project will take one of three paths depending on some other factors & people. Once those variables are decided I will know if I am going to reinstall this engine I just took out in my car after sealing it up with the new seals & mating it with the 6spd & the Torsen & then build the other engine as money permits or if I'm gonna build the other engine a little more quickly & the car will just be out of comission until I finish. Meanwhile...

http://i902.photobucket.com/albums/ac226/Gregoryga7/aea702fc3bc7.jpg

The engine I took out is resting peacefully on the engine stand. Man...that sucker was spitting oil outta every seal. The tranny was full of oil so the rear main seal was toast, the CAS seal was toast, the crank seal was most certainly toast...what a mess. Crazy thing is...the engine ran great...so I have no doubts that it will be an even better engine once I seal it all up.

Well...I just did pull that engine a few hours ago so now I'm enjoying some Samuel Adams Octoberfest that I was lucky enough to still find...DANG that's a good beer! :banana:

[JEMERY]

My god I wish I had your energy. It's looking great.

[Bob_Bobber0]

Scored another engine...THANKS PAT!! I'm gonna build that engine with some go fast parts as money allows & put it in the car.

Dude you are very welcome, you'll sure as hell put it to better use than I would!!! Hopefully it'll save you a little money, but I bet with all those performance internal parts its just gunna cost more for you!!! Haha.

This build is coming along rather quickly I'd say. Looking awesome.

[fastnfurious7]

Christmas is certainly kicking my tail but I got some work in today so here's an update. I picked up a whole car with some parts on it that I I'm going to use...thanks again, John! So, it's sitting in the driveway after I towed it over. It has no engine or trans. It does have:

http://i902.photobucket.com/albums/ac226/Gregoryga7/878ae47bf413.jpg
That's the Walbro 255lph fuel pump
http://i902.photobucket.com/albums/ac226/Gregoryga7/9b99f50b11fa.jpg
Torsen LSD
http://i902.photobucket.com/albums/ac226/Gregoryga7/1bac400cc674.jpg
Trunk lid with R package spoiler. Pic is with it already on my car. It'll get painted red with all of the other parts, of course.
http://i902.photobucket.com/albums/ac226/Gregoryga7/31b602b29b0b.jpg
The axles for the Torsen. Suckers WILL NOT come out of the hub. Ruined a puller that I had. It stripped the threads on the puller & didn't budge these things at all. Anyone with helpful suggestions on how to get them out, I'm listening.

I didn't have time to get the manual steering rack out of the parts car & into mine. That'll be next along with getting these parts on my car & the cooresponding ones off my car & back on the parts car.

I did also pull the radio & a boost gauge out of the parts car that will probably be sold. Now I have to get these parts on my car. Seems like it may be a good while before I get to drive it again.

[iamdallas]

Awesome progress!

I need your wallet, good sir. ;)

Sent from my PG86100 using Tapatalk

[fastnfurious7]

Thanks! Unfortunately, due to my progress & Christmas my wallet is FLAT. :lol:

http://i902.photobucket.com/albums/ac226/Gregoryga7/80e240dc6e0a.jpg

Got this apart @ the fire station this morning. I just need it for a core return as this one's threads are toast. We clamped it in a vice & rested one sledge hammer on the axle tip & beat the stew out of it with another sledge. :lol: As was expected it mushroomed the tip but no matter since it's just a core. The other one is another story. I've tried everything I can think of (including an elaborate set up with the hydraulic ram which is part of the group of tools we have that include the jaws of life :lol:) to no avail. Guess it'll go to a shop & get removed with the proper tools before I ruin it.

[Jack-MX5ATLanta.com]

That is ridiculous how stuck in place that is/was. It blows my mind how difficult some of these parts can be to remove, especially when all the guides you follow typically say "simply remove xxxxx"

[fastnfurious7]

Yeah. I read that if these aren't installed with anti seize they are a complete PITA to get apart. Obviously no anti seize here. :( On my car, same problem with the regular O2 sensor. We were getting ready to shred the exhaust in two with a big breaker bar on that thing...then we gave up.

[nickt93]

Usually I've found that lots of penetrating oil and an air hammer will do the trick. Have you tried that? I'm guessing so :) Seems like it would be harder with the assembly off the car, as you would want to have the spindle braced so that it is fixed in place when the air hammer shocks it loose. Not sure if heat would help - sometimes the thermal expansion is enough to help break it free. Good luck man!

[jzilla]

http://image.trucktrend.com/f/32156032/star-tourers-back-to-the-future-pickup-truck.jpg

[fastnfurious7]

Oh...the Toyota 'Dream' Truck from Back to the Future. I would love to have some of that goodness but my 2WD with a reg cab & crappy paint will have to do for now.

http://i902.photobucket.com/albums/ac226/Gregoryga7/1cc891e8fdde.jpg

Car is taking a field trip. Going to my buddy's house where the engine also resides & a spiffy car lift in a detached garage. Much easier to work on.

http://i902.photobucket.com/albums/ac226/Gregoryga7/7369491fa053.jpg

Inverted engine on stand being worked on. So far mostly just cleaned the GOBS of oil and crud caked on it.

http://i902.photobucket.com/albums/ac226/Gregoryga7/f42ff5b223bf.jpg

Okay, so my buddy is helping me with this engine & he takes the parts off to clean them. I'm the guy that would have each set of bolts in labeled ziploc bags not because I am Mr. Superorganized because I'm not but because I would definitely be frustrated trying to remember where they all go. He's done a bunch of full builds on drag cars and such & told me that he knows where they all go. They are nice and clean now which was definitely not the case before. I should've gotten a pic of the engine bay & the tranny because oil is everywhere. Can't wait to get the mess cleaned up & looking good.

[Bob_Bobber0]

Love this thread. Super shiny oil pan cover thing. lol

[fastnfurious7]

Please remember in keeping with the PG6KGJ theme (Poor Guy w/ 6 Kids & Gov't Job)...my camera is my cell phone which is also a POS & I'm pretty close to being the world's worst photographer. I feel like I have to keep apologizing for the pics here bc they are super bad but they get the point across, I hope.

http://i902.photobucket.com/albums/ac226/Gregoryga7/0f33b33cad62.jpg

Offending oil pump is on (not in pic) & the oil pan is freshly painted.

http://i902.photobucket.com/albums/ac226/Gregoryga7/a88585dad2c7.jpg

The AC & the power steering are history. No need to depower the rack because the parts car came complete with this yummy manual steering rack. I love it when a plan comes together.

[fastnfurious7]

More pics w/ my buddy's camera = better quality.

http://i902.photobucket.com/albums/ac226/Gregoryga7/IC5.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/IC3.jpg

Shows spacing for IC & radiator.

http://i902.photobucket.com/albums/ac226/Gregoryga7/IC4.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/IC1.jpg

Spacing as shown from top of engine bay.

http://i902.photobucket.com/albums/ac226/Gregoryga7/IC2.jpg

Front view with nose on. Centered up nice. Seems we may be rearranging the IC inlet & outlet. Maybe have some more pics on that upcoming.

[iamdallas]

I bet it's soooo nice to have that lift. I work in the dirt. :(

[nickt93]

Loving the progress - your car is coming out really nice. Looks like you are taking your time and doing it right. I haven't heard of Haste radiators but that one looks exceptional. Keep the pics/updates coming!

[fastnfurious7]

How about some coolant reroute action?

http://i902.photobucket.com/albums/ac226/Gregoryga7/RTPERFMX-5H2ORE-ROUTE1-1.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/RTH2O2-1.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/RTH2O4.jpg

Below we have a pointer for the timing because we got rid of all of the front plastic junk.

http://i902.photobucket.com/albums/ac226/Gregoryga7/timingpointer.jpg

[fastnfurious7]

And now....WHAZZZZUP! Getting this stuff done, yo!

http://i902.photobucket.com/albums/ac226/Gregoryga7/motorcomp.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/installed.jpg

Yeah...my buddy fixed the Capri valve cover with a pretty nice paint job and cleaned up the oil soaked engine bay. :banana:

[Bob_Bobber0]

DUDE! NICE! I was wondering where the hell you've been! lol Looks fantastic!

[fastnfurious7]

Wish I could say that I was doing all of this work but my buddy is knocking most of it out because I have been in a Rope Rescue Tech class for that past two weeks & it has eaten up all of my time. Even worse than my normal ridiculous work schedule. Apparently the timing pointer in the pics is no bueno & he spent all day today redoing it. I wish I could get out there & assist but probably won't happen until week after next.

[fastnfurious7]

Need some help here...what exactly is this tube for?

http://i902.photobucket.com/albums/ac226/Gregoryga7/Evactubepic.jpg

Also, would there be any adverse effects from disconnecting the coolant going to the throttle body other than some cold starts being a bit more of a challenge?

Thanks in advance.

[fastnfurious7]

Don't all answer those questions @ once! :lol: J/K...I actually posted a different thread with those questions & Pat answered them quite quickly. I appreciate it.

So, what is in the middle of the pulley boss here?
http://i902.photobucket.com/albums/ac226/Gregoryga7/bushingfromthebackside.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/cbcloseup.jpg

Well, it's probably this.
http://i902.photobucket.com/albums/ac226/Gregoryga7/crankbushing1.jpg

We had a bushing made that takes up the space left in front of the crank nose & it's held on by the crank bolt after you slide it into the pulley boss like this.

http://i902.photobucket.com/albums/ac226/Gregoryga7/crankbushing3.jpg

Has a keyway cut & everything so we will make our own longer key to tie it all together. What do ya think of that?

[fastnfurious7]

Also, have a new adjustable fuel pressure regulator and all of the piping for the IC on the way. We are still working on a suitable way to hold the new COPs down. The Capri valve cover makes that a slightly more interesting affair. Wiring in the engine bay is being cleaned up at the same time. Should have a shot of the new 540cc injectors installed with the Vishnu fuel rail and all of the other goodies soon.

[fastnfurious7]

Wow, I guess no one really cared for the one off bushing we made for the crank. I thought it was a good idea.

Anyway, more pics of the progress.

http://i902.photobucket.com/albums/ac226/Gregoryga7/POharness3.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/POharness2.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/POharness1.jpg

Please don't think we did that! That is the hack job the previous owner did on the injector harness. Under cover all this time, we had no idea it was butchered like this. My buddy is good with this stuff & is in the process of cleaning it up properly.

http://i902.photobucket.com/albums/ac226/Gregoryga7/copsmainharness.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/mainandindividuals.jpg

This is how my buddy likes the wiring to look. This is the wiring for the COPs. Should be nice & clean when installed.

http://i902.photobucket.com/albums/ac226/Gregoryga7/waterreroute3.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/lowerradhose.jpg

This shows the other side of the coolant reroute. Goes through heater core in first pic & then shows how we did the lower radiator hose in the second.

http://i902.photobucket.com/albums/ac226/Gregoryga7/oilline2.jpg

Routing of oil line for the turbo.

The new fuel pressure regulator is due in tomorrow but it looks like this wiring mess is going to hold us up for a few days. Much like when I was remodeling houses, one can make an estimate of how long it'll take to do a job but until you actually tear into it & see what's actually there, you never really know.

[nickt93]

Cool stuff - I'd missed the past few updates. Any estimate on when you'll get to drive the car?

[Jack-MX5ATLanta.com]

Seeing that coolant reroute kit really doesn't make me look forward to doing that on the car!

Excellent progress.

[fastnfurious7]

Any estimate on when you'll get to drive the car?

We thought we were going to be able to "start" it this week. Now with the wiring it appears we may be out on the initial "start" until late next week. Probably won't be actually driving it until the end of Feb if I'm being realistic with myself.

Seeing that coolant reroute kit really doesn't make me look forward to doing that on the car!

Excellent progress.

Thanks! My buddy has been doing a ton of work on it as I've been mostly busy with, well, work. :lol: That & working on my other cars every day I have had off. :(

Coolant reroute wasn't too bad while the engine was out. I would imagine it to be nearly impossible the way we did it with the engine installed. We saved some money doing it ourselves rather than a kit. How much we saved, I'm not exactly sure but other than the approx $55 t-stat housing, everything else was just hoses.

[fastnfurious7]

Now with the wiring it appears we may be out on the initial "start" until late next week. Probably won't be actually driving it until the end of Feb if I'm being realistic with myself

NOT realistic! :lol: We'll be lucky if we get it started by March...driving it isn't even in the cards right now. Must...have...patience!

Anyway, we are making progress and that is good. Getting the wiring right has been a bit of a challenge. Not only are we sorting out a mess of butt connectors & stuff the original builder of this car did, we are also removing the LINK & returning the wiring to stock. Why return car to stock wiring? MSPNP2...that is why. :) Not ready for it yet but we are getting close.

http://i902.photobucket.com/albums/ac226/Gregoryga7/SENSORANDHARNESS.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/MOTORFRONTVIEW.jpg

These pics show a few different things. The Vishnu dual feed fuel rail is in. The COPs are in place but not completely finished. Our fuel pressure gauge is ready to go. The block off plate now also has a sensor installed for coolant temp.

http://i902.photobucket.com/albums/ac226/Gregoryga7/INJECTORHARNESS.jpg

Better pic of fuel rail also shows injector harness that is cleaned up a bit. Obviously still not done as it'll all get sleeved.

http://i902.photobucket.com/albums/ac226/Gregoryga7/UPPERRADHOSE.jpg

Had to move some things around on the coolant reroute as they wouldn't fit with the installation of some of the other parts. This is the upper radiator hose now.

So, we still have to get some of the IC piping that we ordered incorrectly swapped for the proper parts & then deal with the rest of the fuel lines. Proving to be a little more of a job than previously thought. Anyway...we'll keep plugging away!

[fastnfurious7]

More pics of the progress:

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120217_084923-1.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120217_084902-1.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120217_084846-1-1.jpg
New Torsen LSD is now installed as are the Prothane bushings on the rear. To say that the bushing installation is a royal pain in the posterior is an understatement. One of the control arm bolts was so stuck in position that it actually twisted in the middle while we were trying to remove it. All stock bushings were burned out & then the new ones were pressed in. Still have the front to do...oh joy.

[fastnfurious7]

You can barely see it in the last pic but the diff got the Prothane bushings as well. I even ordered extra ones that the set didn't include for the tie rod ends & the ball joints so the whole thing will have new, sexy red bushings. :lol: The pic does show the nice Supermiata adjustable sway bar end links installed. Have them on the front as well. Man, I can't wait to drive this freaking car!

[iamdallas]

I envy this build. At this rate, I'll never get to do my bushings!

Sent from my HTC Evo 3D using Tapatalk

[fastnfurious7]

I envy this build

Thanks! I hope it turns out the way I want after all of this time...and MONEY!

At this rate, I'll never get to do my bushings!

I'm lucky my buddy helps me with all of this. If I had to tackle this whole project with my crazy schedule it would be literally years before I ever got to drive the car again. Those bushings are a PITA!

[fastnfurious7]

So, check out the IC set up. Short a few clamps but it's almost ready to go and much better than what was there.

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_085853.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_085838.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_080820.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_080756.jpg

[Stealth97]

looks good! Nice IC pipe routing

[fastnfurious7]

Back view:

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_080336.jpg

[fastnfurious7]

Front side:

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_080733.jpg

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_083110.jpg

[fastnfurious7]

Ole one eye:

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_090338.jpg

[fastnfurious7]

Front:

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120226_080720.jpg

[nickt93]

Yeah dude - looks great! Smart that you are doing all of the stuff now that you'd eventually want to do anyway - coolant reroute, etc. When will she be back on the road again?

[cxmoney]

where did you get that aftermarket stock looking front bumper? how much did it run you, and is it the same materioal as stokc, or is it fiberglass?

good build so far! i cant wait until i can have alot of cash to throw at my car. =p

[fastnfurious7]

Thanks for the replies guys. Working diligently trying to get it all done before the great weather comes around.

Smart that you are doing all of the stuff now that you'd eventually want to do anyway

We made sure we did everything this go around so the next upgrade will be to work a little bit at a time on the crazy built engine. Add big turbo, swap long blocks & go. Many of the things we are doing now are overkill. It's all with the idea of not doing it twice.

When will she be back on the road again?

I don't even know. We are so close but the "punch out" list of small things seems to continuously grow. Big things left are to finish the fuel system & add the MegaSquirt & tune.

where did you get that aftermarket stock looking front bumper? how much did it run you, and is it the same materioal as stokc, or is it fiberglass?

I got that in the beginning of my build because the stocker was butchered. I got if from a forum member that works for Mazmart & I believe that is actually from whence it hails. Not same as stock material but not fiberglass. It's rubbery & actually looks quite like the stocker once the structural pieces are put on it & it's affixed to the car. I think I got it for $100. I had to heat it with a heat gun a little but I like the way it turned out.

[cxmoney]

damn i need to get me one. those dimples from front the license plate annoy the shiz out of me.

[Jack-MX5ATLanta.com]

I love your build. It's so well thought out, keep it up buddy!

[JEMERY]

Ol one eye is looking good. I love those R lip/spoilers.

[fastnfurious7]

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120502_165144.jpg

Remember me? :lol: Finally back home in my garage...but still not running. :(

[fastnfurious7]

Let's get to the meat of the issue:

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120502_165241.jpg

Yummy engine with COPs installed...leaving the wiring raw for now until ECU goes in just in case we need to make any changes (none planned...that's for sure)

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120502_165302.jpg

Holy mother of HUGE fuel lines! Yes, overkill to say the least...remember this is all with PHASE 2 in mind. ;) I'll update you on all of the fuel crazyness once I get the car up in the air & can get some pics.

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120502_165312.jpg

Wee little TD04H. That is NOT the way I planned to hook up the air intake but I had to work with what I had on hand. Yes, there are solid parts under those clamps. :lol: I have some stuff to isolate the intake from the hot engine bay as well but it has to be modified & will take some time to get done.

[fastnfurious7]

So, last night I got a few things accomplished.

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120502_225127.jpg

Return fuel line hooked up.

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120502_225402.jpg

2 white molex clips I made for the upstream O2 sensor. Upgraded to a heated 4 wire sensor.

http://i902.photobucket.com/albums/ac226/Gregoryga7/20120502_225135.jpg

What's this pic for you ask? It's to show you the absence of T clamps on the cold side IC. Why? Because Summit sent me the wrong ones! :banghead: :banghead: :banghead: :banghead: :sadbanana:

[nickt93]

Getting closer! Got an ETA on the first drive? I want to see a picture of the smile that will plastered on your face once you get to drive it!

[fastnfurious7]

Going to DIYAutoTune on Tues morning. Fingers crossed that we set it all up correctly. God knows we've taken our time to try to make sure it's right the first time.

[mazdakart]

Good luck!!!