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duck91 04-26-14 11:43 AM

My 93 Montego single turbo build
 
I decided its time to post my build. I have had this car since 2007 and it has gone through 1 build already. I bought the car while down in California, drove it for a few weeks and sped up my build plan when I noticed a pretty bad oil leak. I tore down the motor, to street port the motor. More bad news, the housings where grooved and a chip in one of the rotor corner. Needless to say I was pretty disappointed with the last owners maintenance program.
Ordered a JDM motor and started my motor build with that.
List of changes made from memory include:
Street port
Ported intake and double throttle delete
Apexi intake
Front mount intercooler
Koyo Rad
Power FC
Act clutch
Exedy flywheel
Apexi N1 exhaust
probably a few more goodies to throw in but my memory isn't helping.

Had it nearly complete then went racing in Europe so sent it to a shop to finish up the vacuum setup and get it running. Well they got it running however it was not holding boost.

Started to investigate, and decided hey may as well check the whole motor.
Got the sequential's off and noticed the cracking manifold. Time to go single!
I am now nearly complete and almost have the car fired.
Talked with Force Fed Performance about tuning and Marco recommended going with a microtech EMS so over the last few days my buddy and I have been planning our attack on rewiring the car. He had helped me build my single turbo wiring harness, now over the next few weeks we plan on rewiring a big portion of the car, using his knowledge as an emergency vehicle wiring specialist.

I will do my best to fill in a bit of the story and let you know all of the learning experiences/mistakes I have had over the past few years as well as post all of the current changes being made.
List of build 2.0 that has been added:
GT4088R turbo
FFE fuel rails
ID 725cc primary injectors
Bosch 1700cc injector secondary (to be switched to ID 1000cc per tuner request)
resonator mid pipe
Proflex bushings all around
Fikse Profil 13 wrapped in Michelin
Apexi N1 coilovers
AEM aux injector kit

What to look forward too.
Lots and lots of wiring including a Microtech EMS
Paint
Interior
slight chassis reinforcement

I will post some pics shortly.

tt7hvn 04-26-14 12:10 PM

:ttiwwp:

duck91 04-26-14 12:36 PM

tt7hvn I agree! Tried to upload but I don't have flickr and my picture size is to large. I will be sorting this out as I have several hundred photos on my computer.
http://s64.photobucket.com/user/Tyle...a29db.jpg.html
http://s64.photobucket.com/user/Tyle...tml?sort=3&o=5
http://s64.photobucket.com/user/Tyle...l?sort=3&o=113
http://s64.photobucket.com/user/Tyle...l?sort=3&o=122

TonySeagle 04-26-14 12:45 PM

4 Attachment(s)

Originally Posted by duck91 (Post 11725611)
tt7hvn I agree! Tried to upload but I don't have flickr and my picture size is to large. I will be sorting this out as I have several hundred photos on my computer.
http://s64.photobucket.com/user/Tyle...a29db.jpg.html
http://s64.photobucket.com/user/Tyle...tml?sort=3&o=5
http://s64.photobucket.com/user/Tyle...l?sort=3&o=113
http://s64.photobucket.com/user/Tyle...l?sort=3&o=122

Fixed.


Attachment 646557

Attachment 646558

Attachment 646559

Attachment 646560

duck91 04-26-14 01:12 PM

Thanks for fixing the pictures. Is there something I did wrong?

TonySeagle 04-26-14 01:29 PM


Originally Posted by duck91 (Post 11725626)
Thanks for fixing the pictures. Is there something I did wrong?

Nothing a quick fix didn't solve. When posting pics from photobucket, select/copy the direct link code in the code menu on the right hand side. Then post the pictures here using the img code button (looks like a mountain). Works every time.

ZE Power MX6 04-26-14 01:35 PM

You just need to put your link in between [IMG] and [/IMG], that will show the picture instead of the link.

I know your tuner suggested ID1000s for secondary, but I would take the opportunity and just upgrade to ID2000s so you have room to spare. I would shorten that oil drain, the more straight down the better.

Looks good so far, can't wait to see more picture :)

tt7hvn 04-26-14 02:34 PM

I like your shop. Jealous.....

duck91 04-26-14 09:40 PM

2 Attachment(s)
Thanks tt7hvn. Unfortunately not my own work space. The shop used to assemble the motor and rebuild the brakes is my dad's dream garage He has a 3 car up front then it rolls through to the shop pictured here... Attachment 646424
It also has a floor below for motorcycles. Permission to be really jealous.
The shop where I was building the car has been upgraded to a 1300sqft shop we share at the office.

Ze Power, I have actually run the turbo drain straight down since that photo was taken. As for the injectors I completely agree with you in my personal opinion. I have the 1700cc's in now not ID but the tuner likes to keep the primary and secondary injectors close to the same size. If it where up to me I would go to a more traditional set up found in many on the forums. But Marco at Force Fed has a good reputation up here and I rather let him do what he does. He says one of the shop cars is running 1000cc's all around is good for 600hp. The duty cycle must be quite high I would assume.
Thanks for the kind words and keep the good advice coming.
Attachment 646425
Best way to pay helpers, free beer and burgers.

duck91 05-01-14 06:36 PM

3 Attachment(s)
Because its Thursday here is the throwback to when the car was first purchased in 2007.
Attachment 646153
Attachment 646154
Attachment 646155

duck91 05-01-14 06:49 PM

5 Attachment(s)
On to what has happened in the last year or so.
A set of Fikse Profil 13 donated by Fikse Wheels who have been very patient to see these on the road.
Attachment 646148

Engine in again. Don't mind the vacuum lines and fuel lines they got axed.
Attachment 646149

New bushings installed.
Attachment 646150

Apexi coil overs added.
Attachment 646151

A little help getting the engine bay painted.
Attachment 646152

duck91 05-07-14 04:09 PM

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Had a little bit of time yesterday to kill in the shop last night before a meeting. Started stripping a few more interior pieces to make way for a black carpet and cleaner wiring.
Attachment 645654
Got a little hung up with the dash. I assume I need to take out the rest of the air circulation and drain the coolant before going any further.

I also got under the car to tackle an oil leak, I suspect is coming from the turbo drain line. Replaced the gasket with a brand new mazda gasket and some silicone. I will have to wait to turn the motor over to confirm I got it.

jacobcartmill 05-07-14 04:34 PM

2 Attachment(s)
careful pressing in your bushings like that... it's easier to break those control arms than you may think :)


also, one more thing: it appears that your turbo oil drain is not making a constant downward slope, so the oil will puddle at your 90* fitting coming off the CHRA
you may be aware that these are gravity drain only, and if you have a blocked (or effectively "blocked" by a puddle) oil will get pushed out of the CHRA seals and into your compressor housing or turbine housing.

1 straight and 1 45* (and hose shortening) would be more ideal here, i would think.

Attachment 645585

Attachment 645586

great thread! looking forward to some updates.

duck91 05-07-14 04:39 PM

I figured someone may call me out on that picture. they new bushings slid in pretty easy but I would never do that taking the old ones out. Next time I will invest in the proper bearing press kit.

duck91 05-07-14 04:52 PM

I somehow missed the second part of your post. I have since changed the design of the turbo drain. It now follows the original shape of stock turbos using the original straight pipe off the engine, then has a 90* bend and then straight up to the turbo. It is the shortest path and I would assume the 90 straight up should be much better. One thing is there is not much room for flex and I don't know if it will put stress on the hose. I plan on making a support from the engine to the turbo to prevent vibration which will make this less of a concern.

Samito Built 05-07-14 05:58 PM

Bump looks good nice to see another microtech FD out there! My setup is pretty alike...

duck91 05-07-14 08:18 PM

5 Attachment(s)
Samito Built, Im excited to try out the microtech. How do you like it? Your not to far from me just a bit of a boarder jump away.
I took a picture to show the new turbo drain plumbing.
Attachment 645573

I spent a little time deconstructing the car again.
More interior bits out, and out with the engine wiring harness.
Attachment 645574
I think I need to pull the steering wheel, I will have to pick up the correct puller tomorrow.
Attachment 645575
Out with the ugly test harness.
Attachment 645576
Bits and pieces of what remains of engine harnesses before we create the microtech harness.
Attachment 645577

Looks like I'm going backwards again. The plan is now to finish pulling the carpet out, clean up the wiring, and install the microtech next.

Samito Built 05-09-14 07:43 AM

You have people that say there outdated and better ecu's out there. But from experience the microtech is simple to tune and is extremely reliable. I'm actually using a lt8 which is plug and play to the stock FD harness very rare. Instead of cleaning up the stock engine harness. I just went ahead and bought a rywire single turbo harness. I also installed (4) 1000cc ID to help with staging and ease on tuning.

duck91 05-09-14 01:53 PM

When I still had the PFC I was thinking about going with the rywire harness. I ended up creating my own for the experience. I am trying to do everything in house and learn a bit of everything. Going to attempt the bodywork myself soon too. I have a friend who have considerable skill in wiring so he will be the mentor.
The 1000cc injector setup is what the tuner wants to use too. I may have to go that route but I will talk to him first to see what he thinks. I will be using the LT10C.

Mitchocalypse 05-09-14 02:02 PM

Someone already mentioned it but that oil drain off your turbo is just asking for problems.

Really nice looking build though, super clean.

duck91 05-09-14 02:09 PM

Mitchocalypse, if you look at the first pic in post #17 the problem was fixed. I just didn't take a photo of it until the other day.

Mitchocalypse 05-09-14 02:35 PM

Right on, that looks much better
Guess I missed it

duck91 05-09-14 02:45 PM

No worries and thanks for the kind words and the advice anyways. Good advice redundant or not is welcome.

jacobcartmill 05-09-14 03:41 PM

wow, microtech. i didnt notice that before. are they still in business?

duck91 05-09-14 05:14 PM

I think they are still well received in Australia, Porto Rico, and my tuner out here swears by them. I was thinking the Adaptronic looks pretty attractive but I will go with what he knows. I think he's pushing over 1000hp on his 13B drag car so it must be ok.


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