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Old 12-02-06, 03:52 PM
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The Cause of Death

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My TII build

***Copied from Major Projects Thread**11/13/06

Do Not read unless you want to follow the build, this is not a question or anything. This is so it can be linked in the major projects thread, per the instructions, so I figured the link should be kept in the tech section. If it's wrong, please move it and let me know.

Props to Aaron Cake for starting what will hopefully wind up being a pretty cool thread. Anyway...

WHO: spot_skater (James, for those who know/have met me)
Summary: Turbo II Swap into an 88 SE + Haltech E8 and supporting mods to safely run lots of boost.
WHY: Blew the NA motor in August, spent a few months looking for the right parts, and I got the deal of a life time on it in late October.
[bHOW[/b]: Uh...by hand, with the help of some buddies if they wanna swing through and drink some beer and get to work.
WHEN: In the process. Project began last week (Nov. 7, 2006) A few hours each day, I'm taking my time, keeping everything in decent order. Most work done during winter months of 2006-2007
Engine: Stock port J-spec motor and tranny.
[/b]WHERE:: Poughkeepsie, NY. In my garage.

Mods immediately going in: stage 2 competition clutch kit and pressure plate, fidanza 8 lb aluminum flywheel, FD pump, rb 2.5" dp and presilencer, corksport 3" catback, HKS SSQV BOV, bigger injectors (need to purchase), SS braided oil cooler lines, unorthodox lightweight crank pulley, Haltech E8 ECU (need harness + programming cable), mazdatrix tii tranny to NA rear driveshaft (need to purchase) and of course TII hood, and maybe some S5 tails.

Work is being done in the garage at my house... Polishing of manifolds and porting will be done in my basement...

Status so far... most parts acquired (see above), blown NA motor removed. Here's a few pics...

First pic is from two days ago.
Second and third pics are from yesterday.

Today I plan on removing the turbo, putting some oil in the housings, rotating it a bit, and spraying some pblaster on all of the apex seals. I also plan on doing this to check the condition of the apex seals, so that if a rebuild is in order, I will know before attempting to start the motor/droppoing it in. The motor was said to have been sitting for about a year, and the oil has been drained. It turns freely, and seems/sounds like it has good compression. A full emissions removal will also be included in the process.

Semi-Longrun plans: I am planning on using the Haltech E8 to control the electronic OMP of the S5, so I won't have to pre-mix. Stock TII TMIC will be used, and I hope to run either 10 or 12 psi of boost through the stock turbo. Although I have a spare, I'd rather save the spare for a later date to send it out to BNR for a hybrid set up.

Also, to aid in the tuning, I will use HALWIN's autotune to help get a decent idle (will be using a stock s4/s5 base map (thanks Claudio!!) ) and hopefully get a tune some time this winter (DYNO) from a reputable tuner.

Goal is to have the car idling/driven around my block before Christmas. How realistic is this? We'll soon find out.

That's all for now. /End First Post.

James

PS: Recently the PSU on my computer took a ****, will upload more pics at a later date when that is back up and running.
Old 12-02-06, 04:35 PM
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The Cause of Death

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For the last few weeks I've been doing small, minor things. Polishing my manifolds + some brackets +oil fill tube, ported my waste gate, and acquired a bunch of parts I've needed. Pulled out the old NA engine harness and ECU, spliced out the wiper motor harness from it so I can have wipers. Also lightly cleaned my engine bay... I use lightly very loosely, considering I'm still in my garage...don't want anything to flood up.

I ordered all new intake manifold gaskets, counterweight hardware to bolt my flywheel on, a new pilot bearing (and seal) and throwout bearing. Ray Crowe at Malloy Mazda (1-703-490-8170, ask for Ray, say you are from the club) hooked me up with the stock Mazda parts, which got here in about 2-3 days.

Also ordered solid motor mounts, auto meter boost and water temp gauges, got an FD fuel pump and a TII starter off the forum. Not to mention block off plates from 2751engineering.com ($40)... which I'm still waiting on.

Took all emissions and un-necessary **** off the J-Spec block. Decided NOT to run the electronic OMP (connector was broken, didn't feel like repairing it). Will run synthetic mobil-1 and pre-mix in the fuel. Picked up all necessary fluids from Wal-mart/ Sam's club.

A little bit of an update:

Finished polishing my manifolds a week or two ago. They came out ok, considering I only sanded to 320 grit. Also ported my wastegate. I over-ported a little, so I will see if there is going to be any boost creep...

Today I put my turbo back together. Kind of difficult getting it back together, the compression fittings were, at least. After actually thinking about it, it wasn't so bad. Tightened all bolts down, gave the wheel a spin, she still turned freely with no binding anywhere... still didn't touch the housings or make any noise.

Spent two days with some pilot bearing problems. The puller I borrowed from Autozone didn't fit in the bearing, so I tried to fill it with grease/paper and use the hydraulic grease out method. That failed as well. At some point I wound up destroying the inner race of the pilot bearing, so I removed it. That helped the puller I had borrowed fit in. A few whacks later with the slide hammer/puller and it came right out. Installed the new pilot bearing and seal and moved on.

Today I olted my Fidanza 8 LB flywheel to the counterweight. Used some red Loctite on the threads, just in case. Installed the competition clutch and pressure plate, as well. Put the new throwout bearing in the TII tranny. Swapped shifters from my NA to the TII transmission, made sure it went into gear, bolted it down.

Installed the clutch against the flywheel, keeping the alignment tool in the pilot bearing (damper springs facing the transmission!) and then bolted the pressure plate on. The pressure plate was kind of a bitch. The 3 guide holes used needed to be honed out a little bit (paint, I guess). Instead of getting a drill I just bolted one side in, only a few threads, then the opposite side, and kept criss-crossing. Some didn't reach with the washers on, so I took the washers off to make them reach. After they all were in a few threads, I took them out one by one, and put the washers in, one by one. Then I torqued it down to ~25 ft/lbs per FSM. Pre 89 said like 18-23, and 90-91 said 20-26 IIRC. All I know about my parts is they are S5, so I picked somewhat of a medium of 25 ft lbs.

Tomorrow I am going to bolt the turbo and manifold back on, as well as bolt the transmission to the engine. Then she will go in the car.

Parts still needed include: Haltech E8 wiring harness + connectors/sensor pack. Driveshaft to mate NA rear to TII transmission (Mazdatrix) TII throttle cable and some random bolts and washers and the like. Will also be doing Oil Thermo Bypass Pellet mod, as per Ted's site @ http://fc3spro.com/TECH/HOWTO/OTB/otb.html

My computer is still down, so no pics right now. They will be uploaded in the future.

James
Old 12-02-06, 06:48 PM
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Boost in..Apex seals out.

 
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Awesome build, James :-P


Hopefully mine will go somewhat smoothly >.>
Old 12-02-06, 10:25 PM
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In for the pics
Old 12-02-06, 10:46 PM
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Where in NY did you say you were from again? I think I remember the Albany area right? Once I'm done with Final Exams a week from Wednesday, I'd love to come out and give you a hand. It would be wicked cool to check out the build and take some pics. I could even post them while I was there on my laptop if you don't mind a Geneseo guy hangin out for a few hours. Let me know. Sound killer so far.
Old 12-03-06, 01:24 AM
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Eats, Sleeps, Dreams Rotary

 
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SOUNDING good james, sorry i cant come thru tomorrow, seems i have a similar issue like 1990RX..finals are just around the corner

GOod luck kid

Jason NYC
NYRA President
www.nyrotary.com
Old 12-03-06, 12:59 PM
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Maybe we should wait until after finals, rocket, when spot has dropped his engine and bring him a case of beer. We'll celebrate rotary style. Smoke some cigars, rev the engine, and get sh!tty. What do you think?
Old 12-03-06, 01:57 PM
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The Cause of Death

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Guys, gotta remember I'm only 20. -insert teal- I don't drink -end teal-



Some time in the summer I'm looking to have an NYRA get together at my house. Kegs, pool, sunshine, crack, bbq, roast a pig, etc.

As for an update... Turbo is back on the motor. Decided NOT to use the unorthodox racing pulley, after reading a horror story about someone installing one, and even professional shops having trouble with them on occasion. IMO, the gains are not worth it at this time...maybe at a later date will I use it.

Another choice I made is NOT to use the elctronic OMP, and to go pre-mix. I don't remember if I wrote that in any of my last posts.

Also, the other day I installed my flywheel, pressure plate and clutch, so today I bolted the transmission to the block. They are both sitting in my garage/driveway, going to be dropped in a little later today. ALNY93R1 may come by to give me a hand dropping it in a little later today. MMR-Direct engine mounts are in place, as well. They have an aluminum core encased in UHMW... whatever that means. They feel basically solid to me.

What else... I still need to get my haltech harness and the sensor pack. I'm going to give Speed Machine a call tomorrow when I get home from work, then I'm going to give Mazdatrix a call and get the driveshaft I need.

My apologies once again for the lack of photos. I'm still waiting for my power supply for my other computer to come. I have snapped a few pictures so far, though. So this is definitely happening.

Like I said in my first post, my goal is to have the car idling/driving around my block at or before Christmas. I've still got a little over three weeks. That would be a nice Christmas gift for myself. What would be even nicer is if none of the seals on this J-Spec are shot...

James
Old 12-03-06, 05:00 PM
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Boost in..Apex seals out.

 
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And if they are...yay! More learning! :-D
Old 12-03-06, 09:05 PM
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Eats, Sleeps, Dreams Rotary

 
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Originally Posted by 1990RXHeaven
Maybe we should wait until after finals, rocket, when spot has dropped his engine and bring him a case of beer. We'll celebrate rotary style. Smoke some cigars, rev the engine, and get sh!tty. What do you think?
yo sounds like a plan and james is def ready to hang out, hes been trying to get me to his new hood for a minute. Well see whats up, we can get **** faced, work on our cars then sleep in the garage together lol like without a paddle!

Jason NYC
Old 12-03-06, 09:22 PM
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coming along well bro, it's good to see people taking initiative.
Old 12-04-06, 12:53 AM
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what rebuild kit are you using? apex seals? springs? o ring kit?, im going to take apart my jspec 13b this week. it has bad compression on rear rotor...
Old 12-04-06, 12:23 PM
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The Cause of Death

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None. It seems to have good compression.

If it does wind up needing a rebuild I will go with all Mazda OEM seals, along with an aggressive port.
Old 12-04-06, 02:43 PM
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Go with Rotary Aviations big a$$ seals. They will never blow and you can turn your car into an airplane someday. I believe they are 3mm seals, or maybe 3mm is stock, I can't remember which. Either way, call up Tracy Crook and he'll set you straight. Great guy all around and you'll never meet anybody more knowledgeable on Rotary than him.
Old 12-04-06, 07:33 PM
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Boost in..Apex seals out.

 
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Why would he go with 3mm seals?

RX7's come with 2mm stock.

They will never blow? Are you saying, that it will run FOREVER? OMG?!

FAIL.
Old 12-04-06, 08:26 PM
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The Cause of Death

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Thanks for the advice and stuff like that guys. But I want to try to keep this somewhat designated for this project, and not clutter the thread with opinions on what's best for stuff that might not even pertain to the car. IE a rebuild on an engine whose condition is overall, unknown.

If it does wind up needing a rebuild, or I have any other questions, you can be sure I will do my reading and ask some questions to the forum.

For what it's worth... regarding apex seals, the seals in the J-spec seem to be in good shape. One may be slightly stuck, but I feel after being run for a bit should loosen up. If it does wind up needing a rebuild, I would go with the OEM 2mm apex seals, and like I said, a large aggressive port and all other necessary internal oil/coolant mods.

Thanks,
James
Old 12-04-06, 11:49 PM
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Sorry about that then. I'l keep the suggestions for other threads, although I don't exactly appreciate the "FAIL" comment from adrock. I was only trying to be helpful.
Old 12-09-06, 10:48 PM
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Well James computer went kaboom. So i wanted to post a lil update on his behalf. Today me , james and alex (ALNY93R1) put in the Engine and tranny into the car. After james finds the harness and the other necessary items he needs, he will begin putting everything together slowly but surely.

We had a suprise guest Peter (hellisholds77), he copped a fender from me.

So here are a few pics of todays events.

This is the NA engine that went Kaboom.





The new home for the Jspec t2 engine



Engine on the hoist



Taking off the main pulley. James wanted to put the washers on the thermo pellet, but they were to big in diameter and wouldnt clear, so he decided to do it another day.



Engine Close up



New MMR motormounts (There threaded all the way thru WTF lol)



James and Peter (doing nothing lol)



Oil Metering pump blocked off



Thats me!



I love pics lol

Jason NYC
Old 12-09-06, 10:57 PM
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Alex wiggling the engine into the bay, while james is under the car guiding it. I handled the Floor jack for the tranny and the engine hoist ( so i did nothing) For the most part james held the tranny by himself (MAN UP!)







Time to get out!

Watch ure nuts




Finally in



Good food!



Cant forget the illest rotary FAN!!!!!!!!!



Jason NYC

Last edited by ROTARYROCKET7; 12-09-06 at 11:10 PM.
Old 12-09-06, 11:20 PM
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In rotaries we trust...

 
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damn jay, dont kid yourself, you know i did half that ****, haha.

but on a serious note...one hell of a project there, james. good job and good luck for the long run.

it was nice finally meeting you also

and thanks for the fender jay, although it wont go on till xmas...lol
Old 12-09-06, 11:25 PM
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Hey peter thanks for all your HELP, your assistance will be needed again soon!.

We are all a big happy NYRA (www.nyrotary.com) family.

James will document the build very well, and hopefully will be saved for others such as yourselves can use.

Jason NYC

Last edited by ROTARYROCKET7; 12-09-06 at 11:39 PM.
Old 12-10-06, 09:27 AM
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The Cause of Death

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****, I came back to this thread to throw in an update, but Jason beat me to it. With pics and all. Thanks.

It really wasn't too bad, just one thing kind of fucked us for about a half an hour. I didn't realize the threaded part (rod?) of the MMR mounts could be moved up and down/in and out of the mounts themselves. So we tried to squeeze them in to the mount brackets, with no room to spare, with the rod ends being dragged all across the front subframe and ****. After a bit I realized they could be moved, and the engine fell in pretty nicely.

I still need to tighten up the transmission mounts, and the hardware on the upper part of the engine mounts... the tranny is still being somewhat held up by the floor jack. I'll take care of that today. Then start putting the manifolds on, maybe bolt on the downpipe and presilencer. Can't put the CS catback on yet, cause I think I'm gonna need one more gasket... but I need to see if I have one, I might.

Also...need to connect the oil and water lines for the turbo, and plug unnecessary vacuum lines that I won't be using... like the ones for the OMP on the LIM. Maybe block off the BAC, too, and consider ripping out the rest of the wiring in the engine bay... but I think I might save that for a different project.

Ah, almost forgot, I'm gonna need to install my FD fuel pump, and the other SS braided oil cooler line I have sitting in my hatch. Gotta take the steel hood off the roof, though.

****. I need to swap power steering pumps, too. Forgot about that. Whoever took this motor out of the othe car cut the hardlines going to the PS pump... and I really don't feel like making new lines, or going without power steering. I like it.

That's it for now.

A big thanks to Al (ALNY93R1) with the high 400+hp gt35r FD, and Jason with his low mileage S4 FC. Peter (hellisholds7), it was nice to meet you.

James
Old 12-10-06, 10:44 AM
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Eats, Sleeps, Dreams Rotary

 
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It was my pleasure james. Drove 160+ miles yesterday round trip from NYC, was a very Long *** ride, next time i come up ill stay for the weekend (if thats okay), so we can maximize our work time on the car.

So once you get all the necessary items you need, let me know. I got finals coming up so im going to be awol for a minute. I got all of january off, so let me whats up so i can help you kid.

It would off been a much better ride if i couldve taken the fc up there.....

See ya laters ( I couldnt wait mani had to post the pics, ya know me!)

Jason NYC
NYRA President
www.nyrotary.com
Old 12-10-06, 10:25 PM
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will a fd fuel pump fit into a fc gas tank, and if so do u have to mod it at all to adapt
Old 12-11-06, 08:15 AM
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The Cause of Death

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Should be a direct drop-in replacement. At least that's what I've read. I'll find out soon enough.


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