going hard on the hours,

42 hrs this weekend on car alone and 17 hr days with work and car.

Finished up the water to air intercooler lines and fire sleeved the lines, finished all the oil cooler and return / feed line, oil pedestal. Tapped all the 1/8npt to 4an fittings on manifold for vacuum sources and air temp pre-post intercooler. Installed fuel press fittings, oil press fittings pre-post engine, oil temp sensor and water temp sensors. Measuring lines for 16an water pump lines to and from radiator tomorrow. Cleaned out the intake manifold w/ acetone, water, and air to ensure all shavings/dust is eliminated. Setting up for final install of intake manifold to Pport runners with the clamp-shells. Waiting on clips for fuel injectors to connect hats solidly to the injectors for final fuel system setup. Cut and and fitted and fire sleeved fuel lines to and from regulator. Fabbed a remote high-point filler neck over the ABS area for the water-to-air system to bleed/fill.

Left to do list: (using this thread to keep thoughts straight)
1. remove ppre studs from block and install mazda OEM inconel studs with anti-seize
2. clean stud threads w/ m10 1.5 die for exhaust manifold to turbo
3. final polishing of turbo
4. install exhaust manifold and gaskets and copper lock nuts
5. install turbo, reconnect return line
6. connect oil feed line
7. install dust covers over transmission/rear iron
8. permanently install the intake manifold clamshells, lube o-rings first
9. install rubber washer between aluminum mount and rear iron for intake manifold support to minimize wear/vibration on mount
10. mark all oil lines w/ white paint pen for tightening verification
11. install tps to throttle body, install throttle body to intake manifold
12. swap to 5psi wastegate springs, install wastegates
13. install 1/8npt to 3an fittings to wastegates
14. measure lengths to and from boost controller, and order pre-made ptfe lines and y splitters
15. mount boost controller permanently
16. reinstall fuel rails and injectors with clips permanently
17. install fuel lines, firesleeve before final install
18. check for tightness verify w/ white pen
19. re-tap sensor bungs for 1/4npt on filler neck, install EWP feedback 1/4npt sensor, install 1/4npt to 1/8npt adapter and engine temp sensor for ECU
20. install gasket, and water pump neck permanently, mark white paint
21. assess and order angled 16an fittings, using 16an line to dictate routing for water system to and from radiator to EWP and returning to block
22. route oil vent line to rear subframe 8an line, mount catch can to subframe
23. install 45* silicon hose and t-bolt clamps to radiator inlet and mount EWP
24. assemble and install radiator lines
25. install pre-ordered 2/0 gauge starter wire to 2kw starter already installed from battery
26. install 1/0 gauge wire from starter to alternator post and insulator
27. route alternator sensor wire 10ga to battery and loom
28. route fuel pump speed controller sensor wiring to fuel pump from fuel regulator
29. check all fuel fittings mark w/ white pen
30. check interior water lines mark w/ white pen
31. connect fuel level sensor to fuel level gauge, verify operation
32. calibrate fuel level sensor
33. install MAP sensor and mount firewall area
34. assess vacuum line lengths, make 4an lines and order fittings to each unit
35. install vaccuum T and route to mechanical boost gauge in cabin
36. install wiring harness in engine bay
37. lengthen fuel pressure sensor wire from harness to new location
38. lengthen oil temp sensor wire to new location
39. assemble 6an line and fittings with check valve to brake booster
40. bleed brakes/clutch
41. assess clutch operation through inspection plate and replace plate
42. adjust pedal height
43. tighten PPF nuts and torque to spec
44. fill trans with fluid and rear differential
45. have u-joints serviced at drive-shaft shop and install driveshaft
46. fill gasoline test fuel system for leaks, set pressure
47. spin CAS test for spark
48. remove plugs, set timing on CAS, crank to prime oil pressure, check oil pickups and system for leaks
49. fill radiator system and check leaks power on EWP
50. install EWP unit and controller
51. install ordered wastegate lines
52. wrap and install downpipe
53. timing light on engine w/ cranking verify spark on each plug while plugs in engine on cranking
54. check basemap, lock timing, start engine
55. measure and order throttle cable
56. make america brap again

 

I see the white pen marks everywhere, but have you ever heard of this stuff?


We use it in the aviation world, but its so cheap that Ive started to do it whenever possible.

 

.54 on the list is my favorite so far...my proposed list add ons
.55 xxxxxx
.56xxxxxxx
.57 tune
.58 decimate all nearby pavement
.
.
.
.
.
.
.
brap.

 

Putting in the hours.

#1-10 completed last night.

Test fitted the 2/0 gauge alternator wiring and battery wiring. Superb. Hopefully zero voltage drop issues so the most can be extracted from the alternator and starter will always get full amperage from the battery!

Getting closer.

 

This thread is full of awesome! Good work!

 

Thank you!


Ok so today:

-clutch slave installed and bled (made a dumbf*ck mistake, forgot to snap in the throw-out bearing to the pplate, went to bleed clutch and overextended the slave cylinder dumping brake fluid all inside the bell housing. SO lucky it didn't hit the clutch disks. Spent 20 mins cleaning the bell housing through the inspection plate. O what lack of sleep does)
-alternator wired to starter terminal
-fuel rails repolished and reinstalled and injectors and mounts
-exhaust manifold permanently installed with gaskets
-brakes bled and e-brakes adjusted
-short shifter installed
-turbo oil feed / return connected and verified
-oil lines to coolers connected/verified
-routing for 16an radiator lines marked, waiting on 2 fittings for install, test fitted EWP to radiator outlet

Getting very close now, home stretch.

For plumbing to be finished we have one line to complete for the w2a system remote filler neck, 1 lines for the oil breather line from the block, and 2 radiator lines

This weekend will be wastegate springs, wastegates installed, marking/measurement for PTFE 3an lines and T fittings, and install boost controller, order all fittings for install next week. Wrap downpipe. Reconnect fuel lines. Wire up EWP and install/assemble 16an radiator hoses.

By mid next week all plumbing and hard parts, and systems should be 90% complete. Then time for 7 days of review, few wires here and there, and testing systems/playing w/ basemap, verifying sensory input etc

On a side note, fired up the interior again for fun, been a few weeks. All the custom wiring works perfect, blinkers, lights, switches etc. Can't wait to drive this thing. I used to love fighter jets and flight simulators when I was little. Always wanted to be a figher pilot. This is as close as it gets for me with the dash setup. so worth the many hours

 

Just make sure you can control it :p

For some reason I picture that lambo video when the dude is at a stop light and shows off and then gets sandwiched between cars.

Looking good though.

I probably forgot, but are you running an exhaust larger than 4"?

 

full 6.5"

 

6.5" long straight out the hood?

Maybe I missed the joke.

 

yes, through the windshield and out the passenger window

Lol no i was just trollin' broke-a-baller in return

So, anyway that actually would be incredibly fun for a few runs at a show etc, can't imagine the flame show inside the car if DP was routed directly out of the hood straight up

 

Any reason why you're not going to ceramic coat all the hot side and down pipe stuff? Just curious.

 

I'll be in Birmingham next week for work Tuesday-Friday. Let me know if you are open to me stopping by one evening to check this out. I'd love to see this in person!

Thanks,
Robin

 

It doesn't last very long and adds a good bit of cost/shipping/risk, having to send it off or hand these parts to someone. The only method I've seen that can handle the heat of rotary, for extended time, is the Swain-Tech coating, which would require shipping to NYC. I just went ahead and wrapped everything and use heat blanket on turbine.

 

of course,

ill PM you my contact info, and we can see about working that out

 

Looking good David! Keep up the good work, can't wait to hear the monster!

 

January 23, and September 16th. <br/><br/>This is what 2,000hrs of love into an FD3S looks like

 

Train is rolling full speed ahead. so pumped!

Starter wired up, 3/0 gauge wire! Bi*ch spins so hard. Blew the 200A main fuse! Had to bump up to a 300A. With the trailing plugs removed you can't even hear tick-tick-tick of compression, the firing angle/interval of the 90* crank order sounds like an absolute machine gun at full auto. So incredible! Thing is going to sound like a high strung pissed of orchestra of satan's hornets. Cannot wait !

Primed the oil system tonight with a drill on the peterson pump. NO LEAKS!!

She's pulling 40psi on cranking, and up to 90psi with a drill. Took nearly 7 liters of oil to fill her up.

Fuel pump speed controller wired up, starter and alternator charging wire finished. All we have left to do is pressure test fuel system (hopefully secondaries don't leak, theres a little play in the rail due to the way its setup/machined but it could be normal), bleed the radiator and wire up the EWP controller. We've got the 16an lines completed and tapping out the coolant temp sensors now for both the EWP and the ECU engine temp. I've installed all the sensors on the engine. Just need to mount the map sensor and boost controller, swap wastegates springs and install wastegates/dump tubes and measure out the lengths for the 3an ptfe assemblies to order!

List is getting shorter. So happy to be at this point. This is where the fun truly begins. Just hearing this thing crank over is a dream come true.

Glad to share it with you.

 

Man, your determination is inspiring. Great job on your build keep it up, you might be able to start a shop after all this :-) by the way what EWP are you planning on using and how many GPM do you think you need to keep this monster cool?

 

Any plan to run some sort of heat shield between your secondary injectors and turbo/exhaust piping? Sure would hate to have a fuel leak ruin your day. Just a thought.

 

I'm jumping on the "get a better camera" bandwagon, now. The car is looking great, but the pictures are holding it back.

Impressive oil pressure when cranking. Getting close to brap day.

 

EWP finished, worked 38 hrs this weekend. Slacking on last weekend's 42 hrs. Time to step it up.

Engine bay side of EWP harness and sensor finished and loomed. Test run performed pump, bled system, again ZERO leaks. Flows beautifully. Love the EWP. No need to start engine with loud exhaust, heat, leaks, waiting on t-stat to open...just simple run the e-pump and bleed

Getting close now. Thanks for following.

dzmazzei@gmail.com is my paypal, feel free to send whatever you'd like towards that camera

in the mean time, you can count on continual updates










Next is to finish the pump controller wiring, finish wiring up the fuel level sensor to the aftermarket gauge, fill the tank and test-run the fuel system to ensure no leaks. Then literally all that's left is wastegate plumbing, wrap the dumptubes/downpipe, install downpipe, and run the overflow tank line, and 3an PTFE lines for vaccum hoses, mounts the Map sensor and install the wiring harness.

I'm gonna say 60hrs 'till it makes fire.

Coming up to well over 2,000hrs in total into this build. Can't believe its been so much time into this project. It's become spiritual.

Whether it runs or not, or blows up transmission or whatever, is besides the point of this build at this point as funny as it may seem. I've now come to realize that this is all for a lesson of patience and sacrifice. Something that can only be earned with time. That no one, not even the fastest car, or space shuttle in the world can diminish. There will always someone else in the world who can outspend us and outperform us, but as long as we make our biggest competition our own selves, we can always win by outworking ourselves, striving for higher self-actualization.

Pushing through the seasons in thee confines makes me feel more motivated then ever at this point. It feels like this car is an extension of myself. Terrified of starting it to be honest, because then it means it will have to be driven. Which is great, but sad in that it will never remain perfect as it hits the streets. Though, its as if, once it starts, I'm released from this prison of labor/worry. And assuming it actually works, it will be an amazing relief. But I know I'll be left itching for more. In the storage unit there's no outside world to interrupt, to tell you how you're supposed to be, its just a place where you can escape the world. So in a sense its freedom by confinement. Very paradoxical. Anyhow, hope to see her run soon. love this rotary.

 

In your last photo, I see the radiator bottom mount is not isolated with rubber. You may want to do that.

 

 

she'll have a turbo blanket and wrapped downpipe but that's about it for it now, will look into it in the future when it's driving,thanks