fd3s7007

Finally rebuilding. Problem started when i was on a long trip back home over the holidays. Radiator fan hits fuse box holder and dies on me. I was crusing pretty much 110-120kmh so my aftermarket gauge did not reveal much but as i slow down i steadily see the needle rise to approximately 90c which is where i've set it to warn. Everything is fine and dandy till i hit a strecth which jammed with holiday makers. Upon coming to a complete stop, needle goes up to 115c and i shut her down. AFter waiting for ages for the traffic to clear i managed to drive home slowly. Next morning i've got the add coolant buzzer on. Did the infamous champagne test and yup we've got bubbles.

To cut the story short i'm rebuilding with RA 2pc seal kit. converting to single gt35/40. here are some pics of the teardown. I'll be running RE Upper Intake and Lower manifolds.

http://i45.photobucket.com/albums/f7...icture2394.jpg
http://i45.photobucket.com/albums/f7...icture2392.jpg
http://i45.photobucket.com/albums/f7...icture2391.jpg
http://i45.photobucket.com/albums/f7...icture2031.jpg
http://i45.photobucket.com/albums/f7...icture2029.jpg

more pics to follow

papsmagu

iTrader: (19)

good luck with the re-build. love the color of your FD. what its that?

willjs7

iTrader: (1)

thats one nasty looking throwout bearing...

looks like fun though, good luck

dubulup

copy the [IMG]PHOTOBUCKET PICTURE[/IMG]

fd3s7007

Thanks dubulup for the tip. here goes nothing...

fd3s7007

thank you for the word of encouragement. Couple of good firends specialize in rebuilds and i'll pretty much be the beer supplier for those long nights spent cleaning parts etc.

i've sent out the following parts for polishing

1.RE Upper and lower intakes
2.alternator
3.water pump housing
4.greddy elbow
5.turbo housing

and a couple of other things which i cant seem to remember. tomorrow hopefully i'll post up pic of intakes and turbo housing.

papsmagu- thanks mate. the colour is metallic copper

fd3s7007

SOme parts have arrived. I plan to run RE cosmo UIM and LIM. Will be building a custom plate to mate FD throttle body to UIM. At the same time i will also be posting more pictures of the porting process involved to mate Cosmo LIM to FD iron housings. Should anybody need specific pictures please pm me and i'll do my best to help.

Cosmo TB

Cosmo UIM

Cosmo UIM Underside

Cosmo LIM

R-magic

I've done this...but i used a 20B throttle body

Mr rx-7 tt

iTrader: (5)

I would suggest STOCK MAZDA apex seals. Do a search.

charlies7

iTrader: (4)

I have RA seals there working fine for me

efini_fd3s

Nice color, good luck with the rebuild, I plan on tearing down and rebuilding my spare long block too.

Turbo II-FB

waht about the tear down mwan ,so use the damage

fd3s7007

we've used RA seals with great success here. i was slightly paranoid after the whole radiator fan incident and decided to rebuild. coincidentelly the the idea of going single turbine was already in the pipeline.

teardown pics coming soon. good news is,

1: housings are in excellent shape
2: rotors are good albeit carbon build up

Mods to go with the rebuild are:

GT3540 from Garrett
Spearco Custom IC
Tial WG
Greddy Type R B/O valve
Bosch 1600 Sec. Inj
Apexi Turbo Manifold
High Flow Fuel Pump
Street Port

fd3s7007

Had some time today to get started with cleaning. Was hoping to get everything pieced back together before chinese new year but parts sent out for polishing will only make their way back here late feb so here are some updates thus far.

Very Very Dirty Rotors. Once cleaned will be "spec'ed" and reuse if good


Street Port


Me trying to get rotor housing cleaned

13Joe

woah... lookee the handsome dude...

R-magic : i understand that the 13b TB flows the same as the 20b TB. Why did you go with the 20b TB?

fd3s7007

cleaning parts has to be the most difficult part of the rebuilding process. Degreasing --> Industrial Cleaner--> Wet Wash. Man i'm pooped. Will resume work on thursday and hopefully get started to checking tolenrances.

Some input form you guys would help. any good tips during rebuilding?

joe13- where were you when the cleaning started!! lol

fd3s7007

Updates:

Upon cleaning the rotors we found one to be slightly damaged. Lucky for me we had a couple of good, low mile units around the house. Everything has been cleaned throughly as per bruce turrentine's (sp?) video.

Whilst in there also decided to port down echaust ports on the rotor housings.

pics:

eccentric shaft and the good stuff to keep man going at this mad thing we call rebuilding!!



exhaust ports on rotor housing. notice markings made for port job


Difference between RE Cosmo Exhaust Sleeve and FD unit


Cleaned rotors and Iron housings


Damaged rotor. Notice top left side.


Internal Parts cleaned and ready for installation



Again, should anyone require specific pictures whilst i'm under the hood please ask.

chopstix

Hope it goes back together as easy as it came apart. Good luck.

Driving a FD in Malaysia? Would be fun, you have some nice open highways there along with interesting lane splitting driving habits.

Ottoman

how is part availability in Malaysia?

I live in teh middle east and have no support..

always ordering from USA.... even for spark plugs...

good luck with the rebuild.. i'll be starting mine soon as well

13Joe

haha... you know it... not funny when you have to live with it daily, though...



i was *conveniently* busy with work. heh heh... btw, you really should post the trying-to-get-flywheel-nut-off picture...

fd3s7007

chopstix - driving the fd in Malaysia is super fun as the inefficient cops are always to lazy to bother when you do a 240kmh ++ run on the highway with other rotary cars in tow. lol

ottoman - we have plenty of parts considering the front clips arrive here from japan before being despatched to other countries.

joe- no comment.

fd3s7007

Ported Intakes to match RE LIM


Prep before going blue


Ford Blue


Taking a breather.


RA Super Apex Seals


First Rotor in!!

fd3s7007

Rotormaster Glen and Portablasta Kace doing their magic

fd3s7007

Finally finished putting the engine together. The colour looks funky. Its gonna be a color coded engine bay. Polished metal and blue coupling etc.

mdpalmer

iTrader: (24)

Damn, one day I would absolutely love to do what you guys are doing. Props. Kinda funny how you haev the engine stand in the kitchen One question: how many miles on the engine when you pulled it?