Rebuilds Project!
 

Hello Everyone,

Well being on this forum since its inception, I have gained quite a bit of knowledge (and drivel) about the rotary. I thought I would contribute more than just the usual, so I am going to chronicle my project with pics, info and hopefully help someone else that is on the fence about rebuilding their own engine. Helpful comments are welcome! And at least when I blow my own engine(s), I will know that I built it to spec and have no one else to blame!

My current engine still runs great, though it’s pressurizing the cooling system; I have 107K on my original engine and turbos.

So, here’s my project goals:

Build a "stock" engine and a single turbo engine. I have been debating on if I should just buy all the parts and just bolt them on or I should just try to make the stuff. I really like to build things so I am going to try to do everything myself. If I can't, then I will get some help!

"stock" engine setup
very mild porting - my own port job
new or modified stock sequential twin turbos
(to have a spare setup, but mainly for smogging)


single turbo engine setup
street port - my own port job
GT40R Single Turbo - I will try to build a manifold / DP; (yes, with a welder, and if that turns out f*'ed up, then I will buy the A-Spec kit)
720cc Primaries, 1600cc Secondaries
Resonated Mid-Pipe

Components that will be common to both setups:

PowerFC, Datalogit, & WB O2
Blitz Frount Mount IC - possibly turn it into a V-Mount Setup
Fuel Pressure Regulator
Lightened Flywheel and StreetStrip Clutch
HKS Twin Ignition
Modified Engine Mounts
no AC, no Power Steering (my wife hates the no AC thing)
Jim Lab's bushings (the ones that have been in the box for two years :p:)
And other expensive stuff.

The car is going to remain looking stock from the outside. No fancy stickers :D, no Space Shuttle wing, and as little *bling* as possible).

I have two cores, one's still in the car :D, and the other I am tearing apart now. I plan on finishing the stock rebuild first, so I can drive it while I build the single turbo engine.

*PS. Thanks to my wife for signing off on the blank check :bigthumb: !

http://www.atihun.com/pictures/Rebuild/IMGP0554.JPG

Here's the core; I don't yet know the internals stat, probably tonight.

http://www.atihun.com/pictures/rebuild/IMGP0558.JPG

Easiest way to remove the Eccentric Shaft Hub bolt:

Physics 101:

(if you ain't got lb's you can use some extra ft's ;) )


http://www.atihun.com/pictures/rebuild/IMGP0569.JPG

Here's the "key":

http://www.atihun.com/pictures/rebuild/IMGP0570.JPG

The bolt loosened with minimal effort, and probably at about 450 ft/lb's of torque.

This bolt gets seized in even though the spec torque to tighten it in is only about 65 ft/lb's.

wait, what did you use to get the flywheel off?

Nice Picks, and keep up the good work.

pretty cool, I assume it's you on the picture (see slippers) ;-)

Nice Attila. Want to come over and help me organize my garage?:D

SurgeMonster:
There was no flywheel on the core, so I borrowed one from Rotary Reliability and Racing. BUT, I use the same bar bolted to the flywheel and a big ass (I think its a 2 1/4 inch) 3/4 socket and the long black bar (the bar that you get with any heavy duty 3 ton jack; it fits right over the 18 inch Craftsman breaker bar).

Fatman0203:
Thanks!

Speedworks:
Ya thats me; I was so excited to get home with the flywheel that I forgot to put on my work boots. Safety first! :D

dclin:
Heya man! You like the shelving I built? I do custom work; just fly me out there ;).

Your garage is cleaner than my kitchen! :eek:

Nice writeup though, I can't wait to see more progress. That has to be the cleanest 107k engine bay I've ever seen. I'm jealous...

Only guy I know that does heavy mechanical work in SANDALS... lol Must be nice living in Cali..

Also your car is very clean for 107k. Other than that, good luck and keep us updated as to how that manifold comes out.

thats cool man. you should just buy another car for your single turbo car. This way you can enjoy both at the same time and you can keep the AC in the twins car for the wifey and possibly let her drive it (I wouldnt but its up to you). Your garage sure is big enough for another FD. Hey i was just wondering since your from Orange county, is it anything like the TV show, lol. I love that show! I bet your rolling in the dollars.

911GT2:
Thanks! I am a bit meticulous (anal as my wife calls it) about my gear :)

black99:
LOL! Yea most of the time you can find me working in the garage or yard with the sandals. I (my dad) have an industrial welder, but my wife thinks I am going to weld my hand to the manifold! :D

fastcarfreak:
I wish I could, but then I would be living in the garage! Actually she does drive it, and loves it! We are going to buy her a '95 993 when I am done with my project. Rolling in the $$; yea don't I wish :p: . Actually I have been patiently waiting years to do this project!

is it just the picture or is that UIM REALLY REALLY polished to hell!!

SurgeMonster:
Yes it is polished all to hell...(btw. that is the most bling I will have ;) )

The person I purchased the core from had that thing ground down to remove the seams from casting and then polished. The reason I bought the UIM is because it has the double throttle already removed.

http://www.atihun.com/pictures/rebuild/IMGP0556.JPG

nice...
Keep us well-informed on your progress.

You gonna get some upgraded wheels too?

good luck attilla and pretty soon i will be buying one of your mazdaspeed replica hoods....soo dont forget to keep making those awesome carbon fiber and aluminum products...thanks and peace out

really cool write up , keep the pics coming
and dude......love the sandals , and garage seems spotless

First off, my wife kicks ass; she helped me pull apart the core motor. :bowdown:

Now for the really good and really bad news.

The good:

I have the Blitz FMIC, and all I have to say is it’s a quality piece and has an excellent design. The kit includes all mounting hardware, brackets, etc. One bad thing is I don’t read Japanese, so it’s going to be pictures and just plain figuring it out for the install. I am also debating on whether or not to try and turn it into a V-mount setup. (It seems too pretty to hack it up.)

http://www.atihun.com/pictures/rebuild/IMGP0605.jpg

I also have a new set of 99 turbos on their way. I considered the BNRs, and rebuilding my own, but since I am building a “stock” engine setup and from the numbers I’ve seen, the stock twins will be more than adequate for a reliable 13 psi setup.

http://www.atihun.com/pictures/rebui...ins/09_1_s.jpg

Lastly, I found a source for the GT40R turbo by itself so I probably will build my own setup.

The bad:

The core turned out to be complete junk. Both rotor housings, the iron plates, and rotors are unusable :mad: . The engine looks like it was over-boosted or excessive detonation occurred. I have never seen such a poorly maintained engine. Most coolant passageways were blocked with what feels like a thick mud, and the remaining oil had the consistency of crude.

http://www.atihun.com/pictures/rebui...e/IMGP0579.jpg

http://www.atihun.com/pictures/rebui...e/IMGP0581.jpg

http://www.atihun.com/pictures/rebui...e/IMGP0592.jpg

http://www.atihun.com/pictures/rebui...e/IMGP0604.jpg

So the plan will change to building the “stock” engine setup from a reman engine.

I will use my current rotors and E-shaft for building the single turbo engine. I already have a set of new irons that will be streetported. I will need to get new rotor housings.

Here’s some additional pictures:

http://www.atihun.com/pictures/rebuild/core/index.html

The person that sold me the engine is taking care of it and honoring our agreement. :D

Can I watch and/or help with your project? I have plans for the same setup. I'm still debating keeping the twins for a smog swap every few years to. The GT40R also sounds good since I can't afford the T04Z. I wish I had a dig cam to show my Mazdatrix ports. You can check it out since your close by.

UPDATE!!!
 

http://www.atihun.com/pictures/m3/m3forum.jpg

Where's the update? Oh yeah, it's on his laptop. Man I wish my garage was as organized and clean as his but then my house isn't as organized and clean either. ...but I don't wear beach sandals when working on the engine "lol". :eek: Thanks for the motivation to rebuild mine! :bigthumb:

Does this mean you sold the RX7 and got an M3?

Edit: Upon closer examination, I see a silver Rx7 next to the M3. So it must mean that you have added an M3 to your stable?!?

Atihun,
what do you prefer, M3 or your Rx7.

Talk about old threads coming back.. this is like 3rd one I read today.

PHIL

Man Attila...that looks like Butt Mudd!!:ret: