AFGMOTO1978 Build Thread
12-20-12, 07:34 PM
#126
6/14/08
Alright, finished exhaust porting, porting coolant passages and adding my custom external cooling system on my Cermet B rear rotor housing. I opened up the exhaust porting and coolant passages on my front rotor housing as well.
Will be cleaning and prepping parts for the motor buildup tomorrow.
Alright, finished exhaust porting, porting coolant passages and adding my custom external cooling system on my Cermet B rear rotor housing. I opened up the exhaust porting and coolant passages on my front rotor housing as well.
Will be cleaning and prepping parts for the motor buildup tomorrow.
12-20-12, 07:57 PM
#127
6/14/08
Eccentric shaft oil galleys are tear dropped now.
6/18/08
I'm going to make some additional cooling mods now, after discussing with Barry Bordes on the forum about cooling in another thread. Already did some porting of the front housing cooling ports. The leading spark plug coolant port has rather restrictive architecture due to a dowel pin boss being in the way. Did some porting, but was limited in what I could do due to the tight space afforded. It should help though.
Eccentric shaft oil galleys are tear dropped now.
6/18/08
I'm going to make some additional cooling mods now, after discussing with Barry Bordes on the forum about cooling in another thread. Already did some porting of the front housing cooling ports. The leading spark plug coolant port has rather restrictive architecture due to a dowel pin boss being in the way. Did some porting, but was limited in what I could do due to the tight space afforded. It should help though.
12-20-12, 08:01 PM
#128
Also, for those who are wondering here's a visual comparison to a stock rotor bearing and competition one. Also the stationary gear bearing with some oil mods done by Pineapple.
6/22/08
Well had a snafu yesterday, the corner seals were a little too tight. So I made a series of dies to remove material to get the clearance needed. Also waiting for the RTV to dry on the bolts that will be used as dual purpose coolant passages.
I also got my rebuilt turbo back. Thank you A-Spec Tuning. Did some porting and polishing on the compressor. The porting kit I got from Baxter's rocks, it just makes a mess.
[img][/img]
6/22/08
Well had a snafu yesterday, the corner seals were a little too tight. So I made a series of dies to remove material to get the clearance needed. Also waiting for the RTV to dry on the bolts that will be used as dual purpose coolant passages.
I also got my rebuilt turbo back. Thank you A-Spec Tuning. Did some porting and polishing on the compressor. The porting kit I got from Baxter's rocks, it just makes a mess.
[img][/img]
12-20-12, 08:15 PM
#129
6/29/08
The motor is finally in. Had a few hang ups, but they're squared away.
7/4/08
Alright, I got my gaskets in and I broke down and made a water inlet fitting. I took Barry Bordes advise and lapped the mounting face of the turbine as well. Tomorrow I will be going to oil filter supply and see if I can get a oil inlet fitting. Also, oil catch tank version 2.0 is made, just need to relocate the breather filter tomorrow and it will be done.
The motor is finally in. Had a few hang ups, but they're squared away.
7/4/08
Alright, I got my gaskets in and I broke down and made a water inlet fitting. I took Barry Bordes advise and lapped the mounting face of the turbine as well. Tomorrow I will be going to oil filter supply and see if I can get a oil inlet fitting. Also, oil catch tank version 2.0 is made, just need to relocate the breather filter tomorrow and it will be done.
12-20-12, 08:32 PM
#131
7/5/08
Well oil filter supply wasn't open, so maybe Monday for the oil inlet fitting.
Anyways, IC end tanks version 2.0 made. Just need to grind, port AND POLISH before welding them on to the IC. The oil catch tank is done.
Started adding fluids. I used the good shyte.
7/8/08
IC end tanks were ported and polished(internally), welded on IC core and found I needed to tweak a few things . TB elbow next.
Anybody want to ride shoot gun a mileage run to Medford Friday/Saturday? I may have access to an eddy current dyno Sunday to tune. So I need break in mileage.
7/9/08
Almost done with the TB elbow, just need to make triangular plates to fill the holes. Then porting and polishing of the insides and wrapping it with gold foil.
In anticipation of putting a 3 bar GM MAP sensor in place I built myself a little calibration tool. The gauge is huge, but it was the only one that had the accuracy I wanted and not cost $100+, the one I really wanted was $860.
Well oil filter supply wasn't open, so maybe Monday for the oil inlet fitting.
Anyways, IC end tanks version 2.0 made. Just need to grind, port AND POLISH before welding them on to the IC. The oil catch tank is done.
Started adding fluids. I used the good shyte.
7/8/08
IC end tanks were ported and polished(internally), welded on IC core and found I needed to tweak a few things . TB elbow next.
Anybody want to ride shoot gun a mileage run to Medford Friday/Saturday? I may have access to an eddy current dyno Sunday to tune. So I need break in mileage.
7/9/08
Almost done with the TB elbow, just need to make triangular plates to fill the holes. Then porting and polishing of the insides and wrapping it with gold foil.
In anticipation of putting a 3 bar GM MAP sensor in place I built myself a little calibration tool. The gauge is huge, but it was the only one that had the accuracy I wanted and not cost $100+, the one I really wanted was $860.
12-20-12, 08:44 PM
#132
7/10/08
IT LIVES!
I got my oil inlet fitting, best $63 dollars I've spent in awhile.
So I drove it home last night, had a small localized fire inside the heat shielding of the Headers, no big D. Maybe debris or the fiberglass strands caught on fire. Drove it to work today with no issues.
Just have one small leak at one of the earl fittings on the steering system. Too tight of a bend for the steel braided line maybe....
Registration, 3 Bar MAP and a few other things today.
7/13/08
720+ break in miles achieved. Went on the Medford track twice, not issues, will need to make ducting for sure to aid cooling for autocross style events. Highest temps seen were 207 water and 225 oil.
Will be at IPD today after 3-4pm, will be at the dyno for sometime. Wish me luck.
7/14/08
Well, it was a productive dyno session, but ran out of time to finish the initial tuning. Most of the time was spent playing with the Synapse WG settings to get it to achieve the desired boost. We got it, but I still need to play around some more. Wasn't able to touch any of the Chuck Westbrook's base timing maps. Once I start playing with the timing I should get a lot more power, as it is the timing is super conservative, which isn't a bad thing. Was able to achieve 373whp and 268 ft-lbs torgue at 15 psi. Had a few hiccups while on the dyno; I melted one of the straps and melted the paint off the bumper. Fortunately Haithem caught the strap before we did another run, which would have been really bad. And the melted bumper was from the exhaust tube that was put on. The bumper and the exhaust tube melted. Will fix the bumper later, right now I have some heat shielding on to prevent further damage. I will post video later.
And it wasn't IPD, it was another shop IPD contracts work out to, that has a Mustang Dyno. I will get the full details on these guys later. Haithem is going to Cali this week so the next dyno session will be Monday/Tuesday of next week. This current tune should be good for Packwood this weekend.
FD3S RX-7 GT35R - First Dyno Session - Car Videos on StreetFire
IT LIVES!
I got my oil inlet fitting, best $63 dollars I've spent in awhile.
So I drove it home last night, had a small localized fire inside the heat shielding of the Headers, no big D. Maybe debris or the fiberglass strands caught on fire. Drove it to work today with no issues.
Just have one small leak at one of the earl fittings on the steering system. Too tight of a bend for the steel braided line maybe....
Registration, 3 Bar MAP and a few other things today.
7/13/08
720+ break in miles achieved. Went on the Medford track twice, not issues, will need to make ducting for sure to aid cooling for autocross style events. Highest temps seen were 207 water and 225 oil.
Will be at IPD today after 3-4pm, will be at the dyno for sometime. Wish me luck.
7/14/08
Well, it was a productive dyno session, but ran out of time to finish the initial tuning. Most of the time was spent playing with the Synapse WG settings to get it to achieve the desired boost. We got it, but I still need to play around some more. Wasn't able to touch any of the Chuck Westbrook's base timing maps. Once I start playing with the timing I should get a lot more power, as it is the timing is super conservative, which isn't a bad thing. Was able to achieve 373whp and 268 ft-lbs torgue at 15 psi. Had a few hiccups while on the dyno; I melted one of the straps and melted the paint off the bumper. Fortunately Haithem caught the strap before we did another run, which would have been really bad. And the melted bumper was from the exhaust tube that was put on. The bumper and the exhaust tube melted. Will fix the bumper later, right now I have some heat shielding on to prevent further damage. I will post video later.
And it wasn't IPD, it was another shop IPD contracts work out to, that has a Mustang Dyno. I will get the full details on these guys later. Haithem is going to Cali this week so the next dyno session will be Monday/Tuesday of next week. This current tune should be good for Packwood this weekend.
FD3S RX-7 GT35R - First Dyno Session - Car Videos on StreetFire
12-20-12, 08:46 PM
#133
jeeezuz, never seen the additional cooling to the housings before thats a freaking great idea........... i like how this build thread actually has pictures! =)
HOPING hoodies will be in stock next week so i can fire up the press and have them sent out asap!
HOPING hoodies will be in stock next week so i can fire up the press and have them sent out asap!
12-20-12, 08:59 PM
#134
7/17/08
Well, finding a few little things that need fixing. The big one is one of the -10AN oil fittings on the drive oil cooler is leaking. Will need to replace that. I was able to get an air filter on the TB BOV and fixed a few little issue with vacuum lines. I have now offically killed two EGT probes with less than a thousand miles on them.
7/19/08
Found my oil leak, my Mocal oil cooler sprung a leak at the fitting. These things are rather fragile, that's two oil coolers now that started leaking at the attachment fitting. Anyways, got them fixed and also made the seat brackets. Tonight is going to be a late one for tomorrows AutoX.
7/20/08
Well first AutoX went without a hitch. Temps never got hotter than 199F oil and 193F water. No oil leaks!
Now prep for the Mazda GP Time Attack.
7/22/08
Was working on the driver side Sparco seat mount. I was trying to integrate the stock rails, but the seat height was too high, which defeated the main purpose of getting the seat. So I am now in process of making a sold mount setup.
Plus I gotta find my break in power to my EDFC unit.....
And tonight I will be going on the dyno again.
Well, finding a few little things that need fixing. The big one is one of the -10AN oil fittings on the drive oil cooler is leaking. Will need to replace that. I was able to get an air filter on the TB BOV and fixed a few little issue with vacuum lines. I have now offically killed two EGT probes with less than a thousand miles on them.
7/19/08
Found my oil leak, my Mocal oil cooler sprung a leak at the fitting. These things are rather fragile, that's two oil coolers now that started leaking at the attachment fitting. Anyways, got them fixed and also made the seat brackets. Tonight is going to be a late one for tomorrows AutoX.
7/20/08
Well first AutoX went without a hitch. Temps never got hotter than 199F oil and 193F water. No oil leaks!
Now prep for the Mazda GP Time Attack.
7/22/08
Was working on the driver side Sparco seat mount. I was trying to integrate the stock rails, but the seat height was too high, which defeated the main purpose of getting the seat. So I am now in process of making a sold mount setup.
Plus I gotta find my break in power to my EDFC unit.....
And tonight I will be going on the dyno again.
12-20-12, 09:05 PM
#136
https://www.rx7club.com/rotary-car-p...hlight=Cooling
Couple other good discussions:
https://www.rx7club.com/rotary-car-p...hlight=Cooling
https://www.rx7club.com/single-turbo...hlight=Cooling
Awesome! Going to sport it at DGRR 13, you going?
01-11-13, 07:40 PM
#138
7/28/08
SO I was able to finish the Sparco seat mount and assembly at 11:30 am Friday. 4 hours before the start of the Mazda GP Time Attack practice. All in all it turned out perfect as far as seating position and what not.
7/28/08
I won my class overall!
https://www.rx7club.com/nw-rx-7-foru...-758167/page2/
SO I was able to finish the Sparco seat mount and assembly at 11:30 am Friday. 4 hours before the start of the Mazda GP Time Attack practice. All in all it turned out perfect as far as seating position and what not.
7/28/08
I won my class overall!
https://www.rx7club.com/nw-rx-7-foru...-758167/page2/
01-11-13, 07:48 PM
#139
12/15/08
Rebuild!
Got a "brand new" motor from Jason via Jesse's moolla. Thanks Jesse, your alright.
We seperated it and have started working on building up this motor. Few changes will be done to improve the mods I done in the last motor. Should be good.
Oh, my engine bay is on page 57 of the Jan. 09 Super Street along with all the other sweet cars that were at Seven Stock this year.
Some funky build up in the coolant passages from storage, but other than that this motor is brand effin new.
Made a press die today to press out stockers and in comp bearings.
Rebuild!
Got a "brand new" motor from Jason via Jesse's moolla. Thanks Jesse, your alright.
We seperated it and have started working on building up this motor. Few changes will be done to improve the mods I done in the last motor. Should be good.
Oh, my engine bay is on page 57 of the Jan. 09 Super Street along with all the other sweet cars that were at Seven Stock this year.
Some funky build up in the coolant passages from storage, but other than that this motor is brand effin new.
Made a press die today to press out stockers and in comp bearings.
01-11-13, 08:11 PM
#140
1/10/09
Should be putting the motor back in the car tomorrow.
Also been working on a few things.
Gen 3 oil catch tank and a custom power steering tank. The PST filler neck is in the way of everything so a custom tank is in order. And doing a GB on the oil catch tanks.
Also did some baffling and trap doors for the oil pan. As well as adding a spacer the oil pickup to utilize for of the 7 quarts of oil in the oil pan.
1/22/09
Okay, well slowly getting everything back together. Currently working on a few side projects and starting on the beginning plans of a custom from splitter/diffuser.
I was lucky enough to have a professional automotive modeler work in the same building as I do. He's worked for the likes of Lotus, Jaguar, and few race teams back in the UK doing modeling for custom bodywork on racecars. Him and his son will be doing a clay model of the splitter I envision and will be making molds off of it. See attached photos for visual reference of the direction I'm going. IT requires some imagination.
REALLY REALLY WANT THIS BUMPER
[img][/img]
[img][/img]
Should be putting the motor back in the car tomorrow.
Also been working on a few things.
Gen 3 oil catch tank and a custom power steering tank. The PST filler neck is in the way of everything so a custom tank is in order. And doing a GB on the oil catch tanks.
Also did some baffling and trap doors for the oil pan. As well as adding a spacer the oil pickup to utilize for of the 7 quarts of oil in the oil pan.
1/22/09
Okay, well slowly getting everything back together. Currently working on a few side projects and starting on the beginning plans of a custom from splitter/diffuser.
I was lucky enough to have a professional automotive modeler work in the same building as I do. He's worked for the likes of Lotus, Jaguar, and few race teams back in the UK doing modeling for custom bodywork on racecars. Him and his son will be doing a clay model of the splitter I envision and will be making molds off of it. See attached photos for visual reference of the direction I'm going. IT requires some imagination.
REALLY REALLY WANT THIS BUMPER
[img][/img]
[img][/img]
01-11-13, 08:26 PM
#142
1/26/09
Alright, the modeler has the template and has already done some work on the top portion of the splitter and it looks good even in rough form. I'll take some photos when a finalized form is done.
Currently working on a catch tank GB, but beyond that also working on my custom power steering tank, front tow hook and Wide Foot sway bar mount reinforcement crossbar.
2/3/09
Power steering tank done, just need to sand blast it and ceramic clear coat it. Also working on my rear tow hook attached to my trailer hitch, lol.
Alright, the modeler has the template and has already done some work on the top portion of the splitter and it looks good even in rough form. I'll take some photos when a finalized form is done.
Currently working on a catch tank GB, but beyond that also working on my custom power steering tank, front tow hook and Wide Foot sway bar mount reinforcement crossbar.
2/3/09
Power steering tank done, just need to sand blast it and ceramic clear coat it. Also working on my rear tow hook attached to my trailer hitch, lol.
01-11-13, 08:27 PM
#143
2/15/09
Alright finally started back on working on the FD. Got the oil cooler cores in Saturday. 11" X 10" X 2.25", basically 85% of the surface area of the radiator. Will be making custom end tanks and adaptor block similar to the Mazdaspeed/Trust units. It's going to be a tight fit, but once these babies are in I should never want for more cooling for some time.
Also got the cross brace and front sway bar assembly together and I ordered 12kg springs for when I add aero to the equation. Will be putting the 12kgs in the front and moving the 10kgs to the rear.
Just finished the power steering tank, will be repainting the UIM and re-ceramic coating the headers.
Alright finally started back on working on the FD. Got the oil cooler cores in Saturday. 11" X 10" X 2.25", basically 85% of the surface area of the radiator. Will be making custom end tanks and adaptor block similar to the Mazdaspeed/Trust units. It's going to be a tight fit, but once these babies are in I should never want for more cooling for some time.
Also got the cross brace and front sway bar assembly together and I ordered 12kg springs for when I add aero to the equation. Will be putting the 12kgs in the front and moving the 10kgs to the rear.
Just finished the power steering tank, will be repainting the UIM and re-ceramic coating the headers.
01-11-13, 08:54 PM
#144
2/15/09
UIM Painted - Candy Winefire, looks sick. And painted the catch tank and my header is Ceramic coated.
[imghttps://www.rx7club.com/attachments/nw-rx-7-forum-33/331790d1234759848-fd-restoration-%24%24%24%24-damnit-img_1172-jpg][/img]
UIM Painted - Candy Winefire, looks sick. And painted the catch tank and my header is Ceramic coated.
[imghttps://www.rx7club.com/attachments/nw-rx-7-forum-33/331790d1234759848-fd-restoration-%24%24%24%24-damnit-img_1172-jpg][/img]
01-11-13, 08:57 PM
#146
2/21/09
Alright, working on the oil cooler concept design, now I need to make the individual pieces. Hope to be done with the main assembly by tomorrow evening. It's going to be a tight fit.
One oil cooler mostly done. Need to weld in the mounting taps, ducting tabs and fan taps. Changed up the design to give it a smaller foot print and minimize excessively sized oil galleys. Beyond having to deal with the silver braze on the core and changing my mind in the middle of making the adapter block it was pretty straight forward. Need to make the passenger side now.
Alright, working on the oil cooler concept design, now I need to make the individual pieces. Hope to be done with the main assembly by tomorrow evening. It's going to be a tight fit.
One oil cooler mostly done. Need to weld in the mounting taps, ducting tabs and fan taps. Changed up the design to give it a smaller foot print and minimize excessively sized oil galleys. Beyond having to deal with the silver braze on the core and changing my mind in the middle of making the adapter block it was pretty straight forward. Need to make the passenger side now.
01-11-13, 09:06 PM
#149
3/9/09
Well, ran into a snag with one of the oil cooler's. Was chasing a leak that wouldn't go away so I made another unit. This one doesn't leak.
Anyways should be starting this biatch up tonight.
Support tab for the sleek light lens cover. These suckers move at high speed, hence I added this little feature
Photo of pressure tester if your wondering how I tested the cores.
It runs! Got a small pin hole leak on the pump housing where I welded in different adapter, but runs! Sound mean with larger ports.
[img][/img]
[img][/img]
Well, ran into a snag with one of the oil cooler's. Was chasing a leak that wouldn't go away so I made another unit. This one doesn't leak.
Anyways should be starting this biatch up tonight.
Support tab for the sleek light lens cover. These suckers move at high speed, hence I added this little feature
Photo of pressure tester if your wondering how I tested the cores.
It runs! Got a small pin hole leak on the pump housing where I welded in different adapter, but runs! Sound mean with larger ports.
[img][/img]
[img][/img]
01-11-13, 09:21 PM
#150
3/11/09
Not quite done, fixed the pin hole leak, it's amazing how cast aluminum finds way to spoil all your fun.
The car should be on the road today.
3/24/09
I want to first say the power feels like a lot more than the last setup. But on the dyno at Forged which I really appreciate that they were willing to let me rent their dyno after hours (4hours). Their dyno said I only make 340 rwhp and 265 ft-lbs at 15 psi. The torque band is broad though, over 200 fts from 3500 rpm all the way to redline.
Finishing up the last minute details. Will be picking up my tow rig this evening and having Fred (formerly Race Dezigns) finish the vinyl work on the car this evening. Just have to do the dash unit and get the tires rotated.
3/25/09
I just purchased a new wideband and sure enough I'm pig rich everywhere. ~10.9 afrs at 6 psi and up.
4/3/09
Alright registered for the 18th PCA track day at Oregon Raceway Park. Will be taking onboard video
5/28/09
Did a video interview and car shot with Chris at Drivingsports.com on Skyline RD this last Sunday. Apparently they are in process of kicking off a Mazda specific webazine and my car will be the first featured car. Once I get a call that it's up I will post a link.
Not quite done, fixed the pin hole leak, it's amazing how cast aluminum finds way to spoil all your fun.
The car should be on the road today.
3/24/09
I want to first say the power feels like a lot more than the last setup. But on the dyno at Forged which I really appreciate that they were willing to let me rent their dyno after hours (4hours). Their dyno said I only make 340 rwhp and 265 ft-lbs at 15 psi. The torque band is broad though, over 200 fts from 3500 rpm all the way to redline.
Finishing up the last minute details. Will be picking up my tow rig this evening and having Fred (formerly Race Dezigns) finish the vinyl work on the car this evening. Just have to do the dash unit and get the tires rotated.
3/25/09
I just purchased a new wideband and sure enough I'm pig rich everywhere. ~10.9 afrs at 6 psi and up.
4/3/09
Alright registered for the 18th PCA track day at Oregon Raceway Park. Will be taking onboard video
5/28/09
Did a video interview and car shot with Chris at Drivingsports.com on Skyline RD this last Sunday. Apparently they are in process of kicking off a Mazda specific webazine and my car will be the first featured car. Once I get a call that it's up I will post a link.