Well I'm finally getting close to getting things together with my car and maybe before the end of the year I'll be driving it again. :glee: With that I have been collecting parts and getting things ready for a smooth start when its all back together. I've gathered info from a couple other posts here and from that I'm looking to see if I've left anything out from my build.

I am staying sequential, nothing will get me away from it as I love the twins, even if they are the little bastard children of Mazda. I've simplified my sequential system and am very happy with the results and in turn the reliability... even if it isnt on-par with singles.

Here is how things are looking.

:Shortblock:
-Mild streetport (Compliments to Spyder)
-RA hard seals
-Mazda OE apex springs
-viton softseals
-atkins thermopellet

:External:
-S.S. oil metering lines
-Ported wastegate on sequentials
-New Mazda OE FPD
-OE injectors cleaned/flowtested by Witchhunter
-Simplified sequential, all emissions removed/blocked off
-dbl throttle blades removed
-TB coolant line removed (block nipple used for air bleeding - waterpump nipple blocked off)
-FC3S thermoswitch (maybe)

:Bolt-ons:
-Downpipe
-Midpipe
-TurboTuf cat-back
-Pettit Intake
-M2/Bonez hardpipes
-Enfini Y-pipe
-Custom SMIC
-Alt/waterpump underdrive pullies
-ACT street/strip clutch
-Racing Beat 9lb lightweight flywheel

:Engine Management:
-Apexi PowerFC + Commander

:Misc:
-Koyo radiator (Damien-style ducting coming soon)
-Silicone(fiber reinforced) radiator lines
-Silicone vacuum lines (simp. seq.)
-Defi boost guage
-Defi temp gauge (connected at side of waterpump housing)
-Ceramic coated exhaust bits (turbo housings and manifold)
-NGK BERQ9 spark plugs (leading and trailing)

I'm concerned about the factory injectors and being able to feed this setup, I'm thinking that after being cleaned and flow matched they will be fine though. Any thoughts on this? Otherwise my list feels pretty complete, dont think I'm missing anything but if so, please feel free to suggest.

Thanks,
~Kris

 

I do have a few suggestions. The first and most important would be a new high flow fuel pump.
Number two If you are planning on keeping the stock boost levels everything is fine. If you plan on turning it up you will need at least 1200cc secondary injectors. RC engineering can bore your stock ones to get to that.
Number three, also if you increase your boost you will want a aftermarket intercooler the stock one is not ment for any level other than stock.
Hope this helps you a little you setup is similar to mine and Good Luck with your car!

 

I do have a custom SMIC that is similar in size to the Greddy, little more surface area though.

I forogt to mention that I'll be ordering a Walbro 255lph pump as well and of course my new Mazda fuel filter is in hand for installation.

I intend to run 12PSI but never beyond that.

You mentioned that RC engineering can bore the secondaries out, I heard that this can greatly change the spray pattern for the worse, any input on that?

Thanks,
~Kris

 

Bump.

Does anyone make larger wastegate flapper doors? I can open up the wastegate a little bit but I think if I had a larger door I could open it even more without having boost leak issues.

I'm also kind of afraid to port it myself, I can get the shape right but I'm worried metal shavings will get into the turbo itself.

~Kris

 

I think Garfinkle did this with his hybrid BNR turbos. You might give him a call and talk to him on the phone.

Just blow out everything with compressed air after you are done.

 

Okay, I'll try to find his contact info and see what he says.

I was afraid that wouldnt be good enough but I feel safer hearing it is from someone with first hand knowledge.

EDIT: What do you think about the injector issue Mahjik? Should I have my secondaries bored out or will they be okay for my setup?

~Kris

 

list looks fine to me, mahjik already posted in here so that pretty much ends any other info you can possibly fit in here..he is da man!!

hope you're liking that exhaust man

 

Well, that kind of depends on you.

Running 12-13 PSI will put the stock injectors into higher duty cycles. While there really is nothing wrong with that, as long as you are providing enough fuel for a good AFR, some people don't like to see those high cycles.

IMO, I don't see a problem with higher duty cycles. However, that just means you don't have a lot of room to grow. I'm not a power hungry guy so the stock injectors will provide enough performance for me.

 

But wouldn't power and performance go hand in hand... and I'm sure your goal is maximum performance.

 

Not to everyone. I want my car to be "quick". I don't care so much about "fast". Performance to me means all around, not just flat out speed.

Think of it as a sprinter: I'm looking for the 40 yard dash performance, not the 100 yard.

 

Yea, beyond the mods I have listed, I dont plan to go beyond it. The porting was a last minute decision my friend suggested and everything else I'm doing is just to support my 'bolt-ons' which are all I originally planned to do.

Alright, so Walbro 255lph pump, new filter and clean OE injectors should be sufficiant for my fuel system. Already replaced my FPD about 3k ago.

Thanks,
~Kris

 

David (Garfinkle) is currently going through my BNR Stage IIs (non sequential), welding up all the cracks/holes, porting everything (including the wastegate with an oversized, custom stainless steel door)....basically everything you can do with stock turbos, it's alot of work and I'm not sure he is eager to do it again....he already has 9 hours of labor into it

thanks David!

 

you're pushing your luck (hard)....any boost creep at all on a cold night and you're dead....that's how I popped my second engine

spend a little more and do it RIGHT (1200 cc injectors)....then you can run up to 15 psi without worrying

 

Anyone know off-hand how much RC engineering charges to bore the secondaries?

So then my fuel system would consist of 550cc primaries and 1200cc secondaries right? I'm still concerned about how this effects the spray pattern or for that matter reliability of the injectors being bored out.

The idea of the oversized wastegate port is to avoid any possible creep/spiking. I am also thinking of replacing the precontrol and bypass solenoids with manual boost controllers like Damian (I think?) did, to further control boost spiking/creep. A solid 12psi tune will make keep me more than content power-wise and also keep my stock sequentials from working too hard.

Thanks,
~Kris

 

Well, an oversized wastegate will do nothing to prevent fuel starvation... upgrade the injectors, better to be safe than sorry.

 

It doesn't matter what injectors he has, if it's not tuned for the "boost creep", he's in trouble period.

JaNusSolSumnus,

Larger injectors aren't going to magically save you from overboosting. Overboosting is a problem regardless of what injector sizes you are running because you are "overboosting" as to what you are tuned for... Think about it, if you are tuned for the overboost, then it's not "overboost".

 

Yea, thats the idea I'm going with. Prevent overboosting as much as I can (larger wastegate, better or more responsive BOV/CRV control, etc) and tune for any that may remain beyond my target pressure level of 12PSI.

However, if at 12PSI I'm at more than 90% injector duty than maybe larger injectors in the secondary rail are *needed*. I had just always thought that upgrading injectors wasnt neccesary until you upgraded the turbos or went with large porting. I am fine sticking to the stock injectors given that Mahjik is confident in its function but I'm also paranoid at this point after loosing my *young* motor due to my negligence in the past.

Thanks,
~Kris

 

Read through this thread and see what you think about higher duty cycles:
https://www.rx7club.com/3rd-generation-specific-1993-2002-16/what-situation-do-you-have-259912/

 

That was an interesting read for sure, thanks.

I guess what it comes down to is that I should stick with the stock injectors and get the car tuned. If things are looking hairy I can go from there. Now will a *good* tuner, tune with the idea of climate changes from super hot/humid days to the cold/dry ones to assure the car will safely run in those realms? What about boost above what you plan to run, I assume that if they see spike/creep above the boost you intend to run they compensate the fuel table for whatever amount of overboost the car is seeing.

Again I plan to elimenate as much of that as possible but safe and reliabile power is key here. I'd hope to see 320rwhp at the end of this but I'd gladly sacrifice 20hp to have peice of mind.

~Kris

 

Well, I'm sure there are little tricks and safety margines tuners use and do. Unfortunately, I'm not ECU tuner so I can't comment on what they can or can't do. I would suggest calling Gotham and talking with Steve Kan.

I'm sure he can give you much a better insight as to what can or can't be done when tuning.

 

Just for reference, on my old car my duty cycles were hitting around 87% on the stock fuel system running 10lbs of boost.

Mods were stock ports, K&N in stock air box (with adam_c mod), Blitz SMIC, DP, stock cat, RB cat back, PFC.

For convenience sake alone, I'd probably go with larger 1200cc injectors. You really don't want to have to go back in there after the whole thing is together. Especially running sequential.

As for tuning, Steve is the man

 

Yea, I'd love to get Steve to do my tuning but unless a group gets together in FL I dont think it'll happen. Will probably get my tuning done by Scott at MazSport in Tampa since he seems to be one of the better tuners in my area.

I'm still probably going to give Steve a call and see what he thinks of my setup and how tuning would be with it. Also gotta PM Garfinkle about the flapper door.

From what I've read it seems the injector duty isnt so much mod dependant but variant from car to car and depending upon tune. Alberto, your injector duty cycle seems higher, similar to what some running 12psi+ with full exhaust would see given some of the other posts I read so I think I'll give my 850's a chance before moving up to something bigger.

Would upping the primaries to some red top 850cc acheive similar goals without sacrificing the chance of a damaged injector or a affected spray pattern? I know that the primaries are more for lower RPM and the secondaries fill the voids up top but didnt know if the extra primary flow would compensate up top enough or not.

~Kris

 

You can achieve similar goals (ability to inject more fuel) by using 850s in the primaries. However, I have read that it is harder to tune for smooth operation especially at part throttle and low RPM. Not a good trade off in my opinion.

A competent local tuner is a great thing to have

Good luck.

 

Yep, just called Gotham, Steve will be in later today so I can speak with him more about it, one of the other guys there runs 4x850 in his car with a large port and 16psi of boost, he said he was pretty content with it after Steve worked his magic. He said I should be okay with stock injectors but reccomended 4x850's for insurance sake.

~Kris

 

Get your wastegate ported by Garfinkle.. Go ahead and get your UIM and LIM polished by Garfinkle too.