FourtyOunce

iTrader: (15)

Not sure where to start .... I am terrible at build threads.

I've had my red FD since 1999 when it had 54k miles and bone stock. Over the years, It's gone through the typical evolution of bolt on mods all the way to its current state. This will be my attempt at documenting my (re)build of the car.

As of this post, the car has 85k miles. The motor is a stock, unopened shortblock which was purchased new back in 2004. Since 2004, the motor had a GT3540 single. I recently switched up to a BW EFR 8374 EWG set up accompanied with all the typical trimmings (ID injectors, Excessive LIM, AEM water injection, SBG ignition coils, etc). Last Friday, during a dyno session at IRP, the motor lost compression on the front rotor at a modest 12psi of boost. That evening, I uninstalled the turbo to inspect the expected carnage on the turbine wheel. To my surprise the turbo escaped unscathed! New OEM motor has been ordered, and am contemplating on do what I have always done (install stock motor) or go with a wilder build.

FourtyOunce

iTrader: (15)

Some exterior shots of the car, courtesy of local semi-pro, Michael Mauro aka ZoomZoom.

FourtyOunce

iTrader: (15)

Engine bay before the tear down.

FourtyOunce

iTrader: (15)

Assessing turbo damage post dyno. I am not sure if there was an apex seal that got ejected, but turbine seems OK. Once I tear down the old motor, I will post pictures of the process and internal damage. I have a few ideas as so why the motor lost the front rotor compression.

ZoomZoom

iTrader: (2)

FourtyOunce

iTrader: (15)

Here is the dyno plot from a 10psi run, boost control off, water injection not yet on. Boost control was solid, AFRs were steady.

FourtyOunce

iTrader: (15)

Picked up these OEM Recaro seats a few weeks ago. The covers are black alcantara with red stitching. The seat shells were re-cleared to get a better glossy finish.

FourtyOunce

iTrader: (15)

Had new rubber installed as well. Hankook Ventus TD in 285/30/18 on old school SSR Comp H wheels 18x10.5 +43 square fitment.

Cozmos

Love the simple black clean engine bay. And those Recaros...

What are the power goals for the new motor? Sticking with the GT3540?

FourtyOunce

iTrader: (15)

My old setup was the GT3540. The current turbo is an EFR 8374. Power goals are modest at 400-450RWHP.

Molotovman

iTrader: (49)

Those seats are WAY better than R1 seats. Glad to hear you bought a 100% new engine to start with!

Spalato

iTrader: (33)

So basically what you're telling us is that you had to blow your engine to start a build thread?

FourtyOunce

iTrader: (15)

Haha! Thanks, Ian. The Recaros are a nice upgrade. I bought them as it was one of the only ways to get a set of ESH covers. I have the other set of recaros with tilt rails sitting in the basement now. New engine should be in this week. I am still pondering the thought of just dropping it in as is versus opening it and having it built up.

FourtyOunce

iTrader: (15)

Well, I never had a build thread which documented my progress through the years. This is more like a re-build thread.

IRPerformance

iTrader: (41)

That motor had a long 14 year run. I believe it still had the original 3 piece seals too. I remember when you bought it. Looking forward to giving you a hand with this.

BLUE TII

iTrader: (9)

I really love how the Black aftermarket engine bay bits work with the stock engine bay bits and Black painted stock engine bay bits and make it all come together visually.

I hope you consider me biting your style on my FD as the highest form of flattery.

ZoomZoom

iTrader: (2)

FourtyOunce

iTrader: (15)

Thanks! I had a a bunch of stuff polished in a previous iteration. The upkeep and lack of time resulted in the wrinkle black powdercoated theme. With the new coating, cleaning is much easier - a damp microfiber cloth does the trick.

FourtyOunce

iTrader: (15)

Was informed that the new OEM Mazda shortblock is arriving on Thursday. I'm still contemplating installing the motor as is versus opening it up and upgrading (studs, dowels, apex seals, porting, cooling mods).

cloud9

iTrader: (4)

lol I had to read that a couple times but I get what you mean. Have always loved this car.

BLUE TII

iTrader: (9)

Yeah, what I mean is usually when you put cool aftermarket parts into the FD engine bay it really makes the crap looking/positioned stock FD wiring, relay, fuse, etc really stand out.

Stock FD engine bays look OK to me because; well, that is how they came.

Really cleaned up, tucked FD engine bays with aftermarket parts look good to me because they actually look good.

This Black aftermarket parts engine bay look looks good to me because nothing really stands out.

FourtyOunce

iTrader: (15)

Thanks cloud. She's an oldie. I've owned her for almost 20 years now.

FourtyOunce

iTrader: (15)

New motor is in hand and mounted on the stand

Got a new thermal pellet and will replace the oem pellet tonight.

FourtyOunce

iTrader: (15)

I forgot how much of a dream it is to work with a new motor. Was able to get the eshaft bolt out with a breaker bar. Cleaned off the oil from the bolt, and hub then got to work by placing the Atkins thermal pellet in. Then I applied some Toyota FIPG on the bolt and a little bit of locktite. Proceeded to torque down the bolt as per the FSM. Endplay in check.

I have to get my engine hoist from ZoomZoom's house once I'm ready to pull the old motor.

MOBEONER

iTrader: (18)

awesome will be tuned in...... my car has gone through so many changes over the years and i never had a build thread my self so i feel you on that..