And my engine project begins
 

Well, for those that don't know I recently got a free s5 that "burned oil" when it was parked. I've been parting that out, and I'm keeping the motor for myself. The motor will be my next project, s5 n/a with some goodies that you will see in due time. Excuse the fact that some of (like half) the pics are a tad blurry. With dirty hands and bad lighting, some of the pics didn't turn out the best. Even though they looked PERFECT on the little viewer on my camera, they came out not so great for some of them.

First the engine was brought home and placed on the stand.

http://home.comcast.net/~rx7projects...-03-2005/1.jpg

http://home.comcast.net/~rx7projects...-03-2005/2.jpg


The next day I began taking the engine apart. Here is the large socket/adapter needed for the flywheel nut.

http://home.comcast.net/~rx7projects...teardown/1.jpg

http://home.comcast.net/~rx7projects...teardown/2.jpg

I'm using an IR impact gun rated to ~350 ft/lbs in reverse at 120psi (I think), however I overdrove it at 145-150psi for a little extra oomph.

http://home.comcast.net/~rx7projects...teardown/3.jpg

Flywheel nut came off without a single problem, I was very happy about that.

http://home.comcast.net/~rx7projects...teardown/4.jpg

http://home.comcast.net/~rx7projects...teardown/5.jpg

However, that god damn 19mm front e-shaft/hub bolt would not BUDGE. I got a torch and proceeded to heating it up for about 30 seconds and it spun right off, luckily.

http://home.comcast.net/~rx7projects...teardown/6.jpg

http://home.comcast.net/~rx7projects...teardown/7.jpg

Front cover off.

http://home.comcast.net/~rx7projects...teardown/8.jpg

Everything detached from under the front cover.

http://home.comcast.net/~rx7projects...teardown/9.jpg

Tension bolts out.

http://home.comcast.net/~rx7projects...eardown/10.jpg

http://home.comcast.net/~rx7projects...eardown/11.jpg

And I begin disassembling.

http://home.comcast.net/~rx7projects...eardown/12.jpg

http://home.comcast.net/~rx7projects...eardown/13.jpg

Hmmm, burning oil.... Think maybe this contributed to it?

http://home.comcast.net/~rx7projects...eardown/14.jpg

Half of the oil control rings just FELL out during disassembling like they were barely even in there, and then this o-ring is... well... effed pretty bad.

More disassembling.

http://home.comcast.net/~rx7projects...eardown/15.jpg

http://home.comcast.net/~rx7projects...eardown/16.jpg

http://home.comcast.net/~rx7projects...eardown/17.jpg

http://home.comcast.net/~rx7projects...eardown/18.jpg

http://home.comcast.net/~rx7projects...eardown/19.jpg

And this is where I gave up for the night.

http://home.comcast.net/~rx7projects...eardown/20.jpg

I ran into a bit of a problem. I couldnt seem to get the last 2 dowel pins out! Now I don't have a dowel pin puller, but on my last build I was still able to get them out without a problem. This time, no dice.

The next mid-day, when I woke up, I started at the engine again. Still couldn't get those damn dowl pins out without a puller. I didn't want to have to buy a dowel pin puller or find one, so I started thinking to myself. All a dowel pin puller is really is just something that threads into them and makes them easy to pull out, right? So I figured a bolt might work just fine. I was going to come on here and ask if anyone know the thread of the down pins, but just for the hell of it I took the bolt I was using the keep the engine stand from rotating out and tried it. Sure enough it worked! I guess I lucked out, but it thread right in and made it very simple to pull them out.

http://home.comcast.net/~rx7projects...eardown/21.jpg

More disassembling.

http://home.comcast.net/~rx7projects...eardown/22.jpg

http://home.comcast.net/~rx7projects...eardown/23.jpg

Mmmm yummy, oil seal failure.

http://home.comcast.net/~rx7projects...eardown/24.jpg

http://home.comcast.net/~rx7projects...eardown/25.jpg

http://home.comcast.net/~rx7projects...eardown/26.jpg

http://home.comcast.net/~rx7projects...eardown/27.jpg

And I'm spent.... That was the end of pulling the engine apart, barely took any time after those dowels finally came out. And here is the mess I left myself.

http://home.comcast.net/~rx7projects...eardown/28.jpg

Organized engine parts.

http://home.comcast.net/~rx7projects...eardown/29.jpg

And everything is all cleaned up and my RX8 can finally have his spot back after spending a couple days outside :)

http://home.comcast.net/~rx7projects...eardown/30.jpg

http://home.comcast.net/~rx7projects...eardown/31.jpg



That's it for now. This is just the beginning, the tear down process. I'll be updating this thread as I go through everything I'm doing. Next will be some porting to the irons, cleaning the housings and inspecting their condition (though they look too worn for the use I want), cleaning the rotors, putting new rotor bearings in, some oil mods, bla bla bla. You'll see as I do them :)

looking good mannnnn,

cool beans, i gotta get ahold of that damn turbo motor

How were the housings and such? You didn't say a damned word about the shape you ass!

That's because they are still dirty and haven't been inspected closely :)

All irons look super! Rear housing looks like too much wear for my liking, front housing is questionable but needs to be cleaned fully to make sure.

Sounds good. A new engine project is always fun. Keep us updated.

nice. whats the other car in the garage?

looks like a porshe maybe?

You are correct. That would be my moms 2001 Boxster, her pride and joy.

^looks like a porsche
EDIT: Damn, too slow typing :(

Anyways, looks cool. Always wanted to do a rotary engine tear down and build up (no, stock is not in my vocabulary for an engine build...) since all i've seen is pictures thus far and still am mesmerised by it. Come to think of it, that's why I got the 7 in the first place...

how do you match your rear port up to the front port when cutting away material? do they have to match? im rebuilding my turbo engine, im doing it cheap but alot of power i hope.

Most people use a template to make sure the the ports are the same. For those that "free hand" their ports (those that are more experienced) I'm not sure exactly what they'd do. If it were me I'd just copy the port onto paper to make sure it is the same front/back.

You're pwning that engine this time. Its hawt.

Yep, this build is going to be better, much better... And much more attention to detail :)

I haven't seen stock ports in a while, they look so tiny!

Haha, I know don't they? They wont be getting too much bigger, though. Just some simple work to them, and possibly a bridge :)

^ :D

TII exhaust sleeves came in the mail just now! All thanks to razorback :D

http://home.comcast.net/~rx7projects...05/sleeves.jpg

What is that yellow guck on the housing? If its oil, what makes it turn into that?

Looks good man! Thanks for the pictures:)

James

Yellow? Which pic are you referring to?

nice teardown, doesnt look too used up. anyways FWIW the 3 bolts that hold the motor mount bracket(oil pan) can be used to remove the dowel pins, they thread right in.

Ah that's good to know.

Update I suppose. Today was a day for cleaning. During the process I discovered that I will NOT be using either of my housings, this means I need 1 more s5 n/a low mileage/good condition housing since I already have one. I will also be lapping my irons because of wear, but I had already planned on doing that anyways so no biggie.

I cleaned up my rotors all nice. Here's some pics.

This is what I used for cleaning them
http://home.comcast.net/~rx7projects...cleaning/1.jpg

How they looked to begin with
http://home.comcast.net/~rx7projects...cleaning/2.jpg

Submerged in the solution
http://home.comcast.net/~rx7projects...cleaning/3.jpg

After about an hour
http://home.comcast.net/~rx7projects...cleaning/4.jpg

Another 30-45 min later this is how they looked after coming out
http://home.comcast.net/~rx7projects...cleaning/5.jpg

Bling Bling!
http://home.comcast.net/~rx7projects...cleaning/6.jpg

http://home.comcast.net/~rx7projects...cleaning/7.jpg



My product review of Zep Purple Industrial Cleaner/Degreaser is a thumbs up!

In addition to cleaning I finalized my shopping list. I think this is it, but I may be changing/adding things later, not sure yet. I have some of the parts already, but nowhere near all. Looks like I need to get another job as my funds are too low to pay for all of this :(

Mazdatrix:
- Competition rotor bearings
- O-ring gasket set
- Apex seal springs
- Side seal springs
- Oil seal springs (front/rear outer ones will be competition springs)
- E-shaft plug
- MFR oil pressure regulator
- Thermostat/gasket
- Pulley bolt spring
- Front cover gasket
- Oil pan gasket

Atkins:
- 2mm solid corner seals
- FD corner seal springs
- Viton oil rings
- Front main seal
- Rear main seal
- Pilot bearing and seal

Racing Beat:
- Type I stationary gears

Rotary Aviation:
- Apex seals

Mazda Dealership:
- Oil cooler spring
- Front regulator spring

Forum/other:
- Oil pan baffle
- Aluminum radiator panel
- S5 n/a housing, low mileage/good condition
- Lapped irons
- Webber #200 jets for e-shaft oil mod
- TII oil pump (or FD if I can get one)
- S5 rear counterweight
- TII exhaust sleeves

You pwnt those rotors Mr. Clean. And I can't wait to see how the engine turns out ;o!

Nice job...

http://home.comcast.net/~rx7projects...eardown/24.jpg

check that seal land for any cracks, looks much like a failure in that area but sometimes sludge just deposits in the housings..

And the Purple stuff is safe for teh bearings?

Generally no it's not, but I'm replacing the bearings with new MFR ones, so I didn't care ;)

Oh and Karack, I already checked and there are no cracks so no worries.

looking good man and bling bling is rite. Hope this project goes well for you.

Thanks man. Yah I can't believe how nice the rotors came out, they look awesome :D

Anyways, my RA apex seals and weber 200 jets came in today

http://home.comcast.net/~rx7projects...-10-2005/1.jpg


Might be tackling the e-shaft tonight for the jets if I get bored. Oh and I wont be using the RA springs for this build, OEM all the way, so anyone in the market for some cheap apex seal springs PM me :p:

i LOVE THE WAY THE ROTORS CAME OUT. Did you have to scrape anything off, or you just wiped the rest of the gunk up?

The way they came out in the pics they were pretty clean. Most of it just whiped off, but a few spots I had to scrub with some scotch brite, with some scrubbing the spots all came off fairly easily though!

E-Shaft oil modifying
 

Here's what I did tonight, some e-shaft oil modifying with some weber 200 jets.

Here's what needs to be removed, there are 2 jets on the e-shaft. They are usually very hard to get out and sometimes will need a torch taken to them to loosen up the loctite.

http://home.comcast.net/~rx7projects.../e-shaft/1.jpg

Removed jet

http://home.comcast.net/~rx7projects.../e-shaft/2.jpg

This is what comes out. The jet/screw and a ball/spring.

http://home.comcast.net/~rx7projects.../e-shaft/3.jpg

JB weld was mixed up and then a very thin layer was added to the weber jets before being put into the e-shaft. After putting the jb weld on and putting the weber jets in, make sure there's none on the threads of the screw and none blocking the passage of the weber jets. Let sit at least 24 hours before using.

Also, before applying the jb weld and putting the weber jets into the e-shaft jet, make sure it is very clean and nothing is gunked up or in the way.

http://home.comcast.net/~rx7projects.../e-shaft/4.jpg

A q-tip with removed cotten works very well for mixing up the jb weld and applying it to the weber jets ;)

http://home.comcast.net/~rx7projects.../e-shaft/5.jpg

http://home.comcast.net/~rx7projects.../e-shaft/6.jpg

That rebuild is looking excellent man, those rotors cleaned right up, where'd you pick up the degreaser again?

Home Depot in the cleaner section :)

The bucket I got was 29 bucks, they sell other smaller containers for less, though, but I just went ahead and got the biggest bucket I could.

More work tonight... I'm bored.

Checked my side seals to be within spec.

http://home.comcast.net/~rx7projects.../sideseals.jpg

Got to use my new digital caliper, and yes I even made an "In" spec and "Out" of spec chart because I'm cool like that. All of them were well within spec so that's good news. No use in checking the corner seals because I'll be going with brand new solid ones :)

how much was the caliper?

$15.99 from harborfreight, pretty good deal http://www.harborfreight.com/cpi/cta...emnumber=47257

Also picked up a dial indicator from harborfreight while I was at it, and some feeler gauges.

I guess they went up $24.00 but its pretty much a must have if you are rebuilding an engine and reusing some parts.

You would be surprised how much more you will uses that caliper for besides your engine rebuild....

It is a great tool to have !

James

Oh, the sale must have ended, but yah it was on sale for 15.99 guess I ordered at the right time.

I agree, it's going to come in very handy.

By the way, guys... you can still get a 4" caliper for $15.99
http://www.harborfreight.com/cpi/cta...emnumber=47256

It's just the 6" one that costs $39.99...
Not really sure why such a big difference for 2", but whatever.

The 4" one should be large enough for checking everything inside of the engine correct ? Im tearing my engine apart next week so I need something to measure everything with and this seems like the best deal.