Intake Part Deux
 

Having passed emissions, put back the PFC and went to work replacing the intake. First step was getting a JDM UIM (top pic) which does not have the AWS system (on the bottom)

https://cimg1.ibsrv.net/gimg/www.rx7...120e51b217.jpg

Then I removed the double throttle and honed the both the TB and UIM as best I could

https://cimg4.ibsrv.net/gimg/www.rx7...8a6aa3c882.jpg
How to Disable or Remove the Double Throttle

I left the EGR because it was a pain to get to. I also left the air pump because I have one more emissions test to get through.

Ic
 

Since one of my goals is to limit the Financial Disaster as much as possible, I sourced a used no name custom SMIC.

https://cimg8.ibsrv.net/gimg/www.rx7...da74309355.jpg

It's a fairly large IC and looks like an efficient design, but did not come with a duct :icon_tdow which means more fabrication

https://cimg0.ibsrv.net/gimg/www.rx7...f9be0529c6.jpg

https://cimg2.ibsrv.net/gimg/www.rx7...818a256042.jpg

I believe I mentioned I suck at fabrication (note the use of a fender liner and pieces from a window frame held tighter with racing tape). Will see how this does and probably will have to go the eventual V-mount route

The custom frame (came with the IC) and duct installed...

https://cimg9.ibsrv.net/gimg/www.rx7...9107c11b64.jpg

Looks like there's some gaps :blush:

C.a.i
 

Unfortunately, there's not a lot out there for a good cold air intake so I went ahead and tried to hobble something together starting with a used Pettit intake I got used for cheap. Problem with the Pettit (and M2) is the intake for the secondary turbo is right on top of the filter for the primary turbo.

https://cimg3.ibsrv.net/gimg/www.rx7...f00f13ac30.jpg

Since the fresh air is coming from the bottom, I'm not sure how effective the secondary filter placement is. If they could be staggered over the fresh air opening, that should improve air flow to the secondary turbo. I used CXRacing intakes to try to stagger the Pettit filters

https://cimg7.ibsrv.net/gimg/www.rx7...802b925f3b.jpg

Not super happy with the primary intake flange as it seems a little warped, but not enough that the gasket won't fix.

https://cimg2.ibsrv.net/gimg/www.rx7...808ea7868f.jpg

The CXRacing secondary intake was not long enough to extend the filter passed the primary filter, so I cut a stock intake to extend it and angle it down :icon_tup:

Hard to see, but here's how they line up

https://cimg7.ibsrv.net/gimg/www.rx7...d1ec799848.jpg

All complete with a Greddy compression elbow

https://cimg2.ibsrv.net/gimg/www.rx7...4a52a2fb13.jpg

Knowing the IC duct may not be the best, I added a fan to the IC

As well as adding a section with bungs for meth injection (don't really like the flex hose and will probably have a custom section fabricated). I also tapped the cold side of the IC for a second IAT sensor to measure the IC effectiveness before injection

https://cimg9.ibsrv.net/gimg/www.rx7...4fb22c6d70.jpg

Wideband
 

Went with a 14point7 wideband. They seemed to get good reviews and use a Bosch 4.9 sensor.

Sigma Lambda Controller Pure Plus 2.1 | 14Point7

It's also a rectangular gauge so I can put it in my DIN cubby vice needing to get another 52 mm gauge pod. Another benefit of the 14.7 unit is it has multiple sensor inputs. I ordered their IAT sensor so I can read intake temps before AI and also a fuel pressure sender.

Another fun electrical installation job :ugh2:

https://cimg0.ibsrv.net/gimg/www.rx7...b5e2aba8d1.jpg

And another spilled box of connectors :wallbash:

https://cimg5.ibsrv.net/gimg/www.rx7...a332d94b4c.jpg

Kind of a tight fit for the O2 sensor which I routed through the transmission tunnel. I used an AEM finned bung (Stainless Steel O2 Sensor Bung | AEM) that is supposed to dissipate heat which the 4.9 sensors are more sensitive to

https://cimg9.ibsrv.net/gimg/www.rx7...f0246de42c.jpg

https://cimg5.ibsrv.net/gimg/www.rx7...0636464bbe.jpg

And all installed. Must say I like the hideaway feature of the DIN cubby :icon_tup:

https://cimg8.ibsrv.net/gimg/www.rx7...dc6a39c25f.jpg

https://cimg1.ibsrv.net/gimg/www.rx7...d2f8ee255b.jpg

Have not yet figured out how to do logs or get it to work with the Datalogit.

Exterior
 

More into function over form so I went with '99 bumper to get bigger radiator and oil cooler openings.

An earlier shot fitting the bumper...

https://cimg7.ibsrv.net/gimg/www.rx7...74ba868918.jpg

And attached and painted. More fabrication was needed to get a USDM license plate to fit the JDM frame. Cut a piece of aluminum and tapped some holes for the license plate holes. I'll admit tho that I kind of like the form of the '99 bumper. :nod:

https://cimg5.ibsrv.net/gimg/www.rx7...f567d79c1f.jpg

Also went with a somewhat functional '99 spoiler

https://cimg6.ibsrv.net/gimg/www.rx7...e43cd2fa82.jpg

...and added the '99 taillights which are not functional, but what the hey :bigthumb:

https://cimg7.ibsrv.net/gimg/www.rx7...8a8fb52439.jpg

Welcome to the 99 spec club :icon_tup::icon_tup:

Can't say I'm a fan of those chrome turn signals though. Black ones are more low key :)

Looking good :)

Agree, but they came with the bumper :rolleyes:

Steering Wheel
 

Somewhat function over form, but the old wheel is truly hideous :icon_tdow

https://cimg8.ibsrv.net/gimg/www.rx7...17aa04d751.jpg

Went with a pre-drilled Miata/Nardi wheel with cruz control (just set it 100 and you don't have to worry about the accelerator :lol:)

Only minor problem was I had some problem getting the connectors to fit in the compartment. Something is keeping it from compressing the horn connection on the left side. Oh well, whenever I get around to taking it apart i'll deal with it then.

https://cimg9.ibsrv.net/gimg/www.rx7...807a8b1445.jpg

Instructions: https://www.rx7club.com/3rd-generati...-wheel-830139/

Looks good Tom. Glad you are enjoying the car.

Thanks. Getting somewhat ahead of the storyline, the car's been transformed into a monster (ok, not a 500 HP monster, but a monster none the less :nod:)

More on Ihor's handiwork later....

It's really cram under that airbag, you have to play with the connectors position a lot to find a spot where they don't interfere with the horn bracket. Switching to the 99 Spec airbag connector will free up some room, I can send you the connectors if you want to try that down the road.

Looking good. Looks like you're getting an irp engine?

Not a new one, but they heavily massaged my low mileage reman (see posts #2 & #50)

Got their stage 3 motor build with aggressive street porting and 2mm RX Parts apex seals and viton water seals and oil control rings. Also had them port the water and oil passages as well as the wastegate

Did not have the rotor balanced or lightened tho, nor did I get any engine bolts/studs

Think that should work well for my power goals :icon_tup:

Wheels
 

Got some 17x9.5 SSR Comps from Fritz. Not the best shape, but they are damn light. They came with 275 slicks.

https://cimg3.ibsrv.net/gimg/www.rx7...dac1eb9c3e.jpg

Test fitted the 275 just to see how it would fit. Too bad I don't have a trailer :(

https://cimg2.ibsrv.net/gimg/www.rx7...e29711d949.jpg

Since I can't run slicks on the street, decided to go with 255 RE-11s. Know the 71s are the latest thing, but i'd like them to last longer than a season

https://cimg9.ibsrv.net/gimg/www.rx7...2f5ea00fa6.jpg

In comparison to the 275s

https://cimg0.ibsrv.net/gimg/www.rx7...cacffe59ed.jpg

and in comparison to the stock 225s

https://cimg3.ibsrv.net/gimg/www.rx7...667b830294.jpg

I like the 17" SSR comps because they seem true to the stock wheel.

https://cimg5.ibsrv.net/gimg/www.rx7...a9aaedcff7.jpg

and mounted...

https://cimg6.ibsrv.net/gimg/www.rx7...5572a637f1.jpg

and from the rear.
(need to get a diffuser :blush:)

https://cimg8.ibsrv.net/gimg/www.rx7...995610d48c.jpg

I was a little concerned at first about fitment of a 255 tire on the 9-1/2 rim since the 275 looked to fit nicely. I'm not into the stretched look, but I've read for track you want a slightly stretched tire. Turned out the 255's on 9-1/2 is pretty much perfect :icon_tup:

https://cimg1.ibsrv.net/gimg/www.rx7...927fea6ab1.jpg

Tow Hook
 

So I added a FEED tow hook to a large RHD Japan buy and when I went to fit it, it did not seem to fit the '99 bumper :scratch:

Oh well, so goes trial and error. I noticed Griffith Performance Engineering on ebay sells tow hooks so I tried it out. It's a horizontal hook which rubs somewhat against the radiator opening which I covered with some electrical tape.

https://cimg2.ibsrv.net/gimg/www.rx7...21565fdecc.jpg

I had to do a lot of massaging to the holes to get it to fit with the '99 bumper

https://cimg8.ibsrv.net/gimg/www.rx7...34122a7a87.jpg

Then I retried the FEED hook and wouldn't you know it, it fits :egrin:

https://cimg0.ibsrv.net/gimg/www.rx7...7cc4ce2606.jpg

https://cimg1.ibsrv.net/gimg/www.rx7...5bcb2e01c6.jpg

https://cimg2.ibsrv.net/gimg/www.rx7...0447ce3d96.jpg

The FEED hook rubs the radiator opening as well and does not protrude past the opening. I opted to leave the Griffith hook in. It doesn't seem think he makes this style anymore and opted for vertical hook.

Mazda RX 7 Front Left Tow Hook C West re Amemiya | eBay

Hope it fits better.

Brake Ducts
 

I first started tracking completely, I mean completely stock, including the brakes which quickly warped. I since upgraded to Hawk DTC 60/30 and found them to be great for track work and they seemed to do ok on the street. Only downside is somewhat forward brake bias and that they dust like crazy.

With seemingly working brakes and absolutely no data on brake temps, I purchased some home made ducted backing plates.

https://cimg3.ibsrv.net/gimg/www.rx7...deaf944b07.jpg

Painted and installed. The opening are directed squarely on the middle of the rotor.

https://cimg8.ibsrv.net/gimg/www.rx7...06a3430820.jpg

The problem is there's nothing out there to connect to the '99 bumper/lip so I had to go the dreaded fabrication route once more. I ordered some small NACA bumper openings and hi temp hose

https://cimg0.ibsrv.net/gimg/www.rx7...e6668265f8.jpg

To get the NACA opening to fit, I cut all the flanges off and then cut some cut some slits to fit into the bumper. The bumper has a couple holes at the opening formed with the lip for a brake duct, so I drilled corresponding holes in the top of the NACA openings

https://cimg5.ibsrv.net/gimg/www.rx7...6fce523e5e.jpg

This seemed to fit okay

https://cimg9.ibsrv.net/gimg/www.rx7...59b8fc38bc.jpg

https://cimg0.ibsrv.net/gimg/www.rx7...4870056ac3.jpg

Only problem was the depth of the NACA duct is larger than the bumper opening. This should be ok since it still pulls in air under the bumper. The problem is ground clearance.

https://cimg1.ibsrv.net/gimg/www.rx7...67118e7269.jpg

I then connected the hose

https://cimg2.ibsrv.net/gimg/www.rx7...e4672fbe6b.jpg

https://cimg3.ibsrv.net/gimg/www.rx7...9b93c878a4.jpg

https://cimg4.ibsrv.net/gimg/www.rx7...e1c5988d6f.jpg

I cut a small relief in the wheel well and zip tied the hose. Only problem is it seems to bind and kept pulling off the connection to the NACA duct. I've since done away with the zip ties and it doesn't pop off any more. There seems to be enough structural integrity to the hose that it doesn't need to be supported between the opening and the rotor. Time will tell if this works or not.

Nice update. I need to do some brake ducts eventually. Have you checked if the tires rub at full lock? Not much of an issue on track but it is on the street.

I really need to get off my ass and market my lip spacer. It would solve that brake in key size mismatch. Ducts looking good.

Good work on the car mate!

Have enjoyed reading this thread man!

Garage Surprise!
 

https://cimg4.ibsrv.net/gimg/www.rx7...36a5952969.jpg

:bigeyes:

Trapped six more of his buddies. :ar:

Probably shouldn't eat seeds in the garage :blush:

Having owned a Triumph (car and bike), Norton and now all 3 Rx7 gens, think i'm officially a masochist :lol:

Nice work in the brake ducts

Think there's some rub. Will see how it does over time and redesign if necessary

Auxiliary Injection Pt I
 

Decided to make the complex twin turbo rotary more complex by adding water/meth injection. Since i'm running a somewhat skeptical SMIC, thought this may be good protection. I'm not planning on going over 14 psi, even if I eventually go single so this is just extra insurance. Added bonus is the cleaning effect. I decided to go with the AEM 30-3300

Of course, this means another major electrical job :cursing:

https://cimg3.ibsrv.net/gimg/www.rx7...db0c4d95b0.jpg

It would have been nice to plan all the electrical out from the beginning vs piecing it together one job at a time. Decided I now need a fuse block which I wired up to a switched relay.

https://cimg4.ibsrv.net/gimg/www.rx7...16c743c364.jpg

Besides the electrical headache, where in the hell am I going to mount the tank and pump :scratch:

Since I don't have A/C or P/S, that's a logical place, but not for the tank that comes from AEM. I found a neat bottom mount tank (https://cometkartsales.com/G-Man-4-Qt-Fuel-Tank.html)

I opted to use the windshield wiper tank. It's a little smaller capacity, which is concerning, but not by much. The problem is how to configure it to work with the AEM system. First I pulled out the existing wiper pump (probably could have left it in tho) and plugged the hole

https://cimg5.ibsrv.net/gimg/www.rx7...2042c92bcd.jpg

Then I needed to attach the level sensor and meth feed bung. Problem with the sensor is that it's threaded. It would be nice to somehow get a plastic nut on the inside of the tank to screw on the sensor, but no way. That leaves two options, get another sensor or make the AEM work. I toyed with the idea of using a VW sensor which has a push fitting vs screw, but that's like another $30 when I already have a sensor, so I decided to give the AEM sensor a go. I used a hole saw (forget exactly what size) that was somewhat close to the thread size, screwed in the sensor, then silicon sealed the hell out of it. Next step was attaching the feed fitting. I took the blank I just drilled out of the tank and glued it to the bottom. This provided enough thickness to tap for the fitting threads. I sealed the hell out of that as well.

https://cimg6.ibsrv.net/gimg/www.rx7...2242f6af76.jpg

Now onto the pump. This needs to be lower than the meth tank. Great! The windshield wiper tank is pretty low so where the hell am I going to mount this effer :dunno:

I decided to mount it to the lower cross member. I cut a portion from underneath on the passenger side to accommodate the pump since the cross member is not structural

https://cimg7.ibsrv.net/gimg/www.rx7...b5b3ef9b3f.jpg

mounted...

https://cimg1.ibsrv.net/gimg/www.rx7...17592b0d4f.jpg

Auxiliary Injection Pt II
 

and installed...

https://cimg2.ibsrv.net/gimg/www.rx7...cd0d8dc8bf.jpg

I used 90 deg fittings (http://prometh.com/collections/fitti...nt=13254893635) off the pump so the tube wouldn't be going into the fans or engine. I also mounted an AEM filter on the driver side by cutting a circle into piece of sheet aluminum that's slightly larger than the diameter of the filter. This allows the filter to rest on top of the aluminum and I can unscrew the filter housing from the bottom

and the injector... I placed it after the intercooler discharge, but far enough from the throttle body so it has time to fully mix with the air/fuel charge

https://cimg8.ibsrv.net/gimg/www.rx7...c41498271c.jpg

https://cimg0.ibsrv.net/gimg/www.rx7...3d1e8ca33c.jpg

Next is the level warning light. Best place would be in the dash, but I didn't want to cut a hole in the dash, so I opted for an unused blank in the center console. I can kind of see it when i'm driving :rolleyes:

https://cimg0.ibsrv.net/gimg/www.rx7...e3f6bc15ba.jpg

Next is the controller. Another "where in the hell am I going to put this??". I decided to tape Velcro hooks on the back and Velcro it to the carpet

https://cimg7.ibsrv.net/gimg/www.rx7...a8a760837e.jpg

DONE! :jump:

This was no small job to say the least.

Of course, I now need a steady supply of...

https://cimg3.ibsrv.net/gimg/www.rx7...fd6539e207.jpg

Tune
 

So I had been running on a PFC with an unknown map for some time while I was breaking in the rebuild. Since I wasn't going into boost, I wasn't concerned about the map, however it wasn't that great. It idled really rich, like in the 10s and was hard to get below 1200 rpm. I know PFC don't idle well, but this was like crap. I really needed a tune.

Just when I got the break-in miles under the belt and was ready to get it tuned, IRP up and moved. :egrin:

Ok fine, waited for them to get settled, then they make the bold decision (and right one) to install an in-house dyno. :icon_tup: Problem was this created another 2+ month wait. :icon_tdow

Finally, I got it into the shop


I wanted a reliable tune, no more than 12 psi. Was able to squeeze out 289 mustang rwhp out of stock twins with emissions :ylsuper:

https://cimg2.ibsrv.net/gimg/www.rx7...a5dfb9f36e.jpg

I must say the difference is night and day. It's not 500 hp, but it pulls like a freight train and more than enough for track duty. Idle is greatly improved as well. Cold, it's at 1500, but settles down to 950. A little high, but liveable. AFR is much better too, around 13.

Gotta give kudos to Ihor and his team. They know their shit. In addition to the awesome tune, they sorted an incorrectly installed check valve (how the hell could I have done that???) and fixed a fuel leak (make sure you clamp the hell out fuel hose if it's SAE).

They also fabbed up a cold side pipe. Much better than that hose crap :icon_tup:

https://cimg0.ibsrv.net/gimg/www.rx7...730fe6bcba.jpg

Keansburg NJ
 

Did i mention Keansburg is rather spooky! :asthanos:

https://cimg3.ibsrv.net/gimg/www.rx7...6730afbb88.jpg

https://cimg5.ibsrv.net/gimg/www.rx7...cd072730a8.jpg

I really do love your build Tom. It's simple and addressing all the right things. I wish I would have taken your route in hindsight, I could have been enjoying my FD a lot sooner instead of being a jackstand racer for so long. Now I'm too lazy to do anything to it since it's running well. lol I still need to do brake ducts and water injection so I'll be copying you soon.

Good stuff, engine bay looks a lot better.

You need two. One in the garage on stands and one on the road

Edit: Make that you need three. The two above and a dedicated track car.

Or even better four!



https://cimg1.ibsrv.net/gimg/www.rx7...e2250e6d98.jpg

[Not my garage by the way]

Thanks, but i'm more into function over form. No offense to all those that polish or powder coat everything ;)

Strut Brace
 

So with the Xcessive motor mounts and Banzai oil pan brace and Greddy elbow, my Greddy strut brace does not clear the elbow.

I am using washers, but this is not a long term solution. Does anyone know a bar that will clear a raised engine?

https://cimg5.ibsrv.net/gimg/www.rx7...d8d84854eb.jpg

Well the R1 strut bar is adjustable but I'm not sure if it will clear

Think it's called "Improved Racing" strut bar

+1

Track Day
 

First track day in almost three years :celebrate

Only problem it was a misty wet day :mad:

I had really wanted to test out my suspension setup, but that's not going to happen on a wet track. Oh, and it's got 22 turns too :crzyeye:

https://cimg6.ibsrv.net/gimg/www.rx7...4e9385561d.png

Right out the gate, my backend comes around and I barely straighten it out. Hmmm, wet track or massive oversteer??? This dampens my mood on the whole day. When I got the car, low mileage FDs were a dime a dozen and the decision to track it was a no brainer. Now, and especially after three years to get it back on the track and who knows how much $s, I feel a little more cautious, which is not a good feeling to have. The day did dry for one session and I started to feel a little more confident.

https://cimg3.ibsrv.net/gimg/www.rx7...0b9be030d2.jpg

https://cimg4.ibsrv.net/gimg/www.rx7...af4a2e0851.jpg

https://cimg5.ibsrv.net/gimg/www.rx7...d446989987.jpg

https://cimg6.ibsrv.net/gimg/www.rx7...1ae173de38.jpg


My only pass-by of the day... (an SS Camaro :icon_tup:)

I got killed by AWD and traction control :awesome:

https://cimg1.ibsrv.net/gimg/www.rx7...7d2dc78a08.jpg

https://cimg2.ibsrv.net/gimg/www.rx7...cf440906f1.jpg

very nice!

more details on the track day! isn't it cool to have the only FD at the track?

my FDs have gotten more attention at the track than the exotics, over the years.

It's nice to see someone properly building/maintaining and enjoying the car for what it was designed for. I would be a little on edge wheel to wheel on a slick track day as well but I bet if felt good to get back out there if it's been 3 years for you.

man ... you guys and all your 99spec bumper. I can't stand the temptation!!I Want to just drop $$ on a conversation

beautiful car buddy

Great write up.

There was another FD, a LSx. He seemed to shy away which is what I get around other LSx FDs. Are the embarrassed???

I didn't get a lot of attention, maybe because there was this...

https://cimg4.ibsrv.net/gimg/www.rx7...9ffb6c1cba.jpg

I don't think they are embarrassed they just feel sorry for us rotary guys and don't want to rub it in LOL

Hopefully I'll see you at the track sometime in 2017. Let me know if you do any events with: chin, pca, bmw, nasa, audi etc.....

yeah the LSX guys are basically corvette guys.
they dont understand.

Good progress and good to see you getting back to the track. Where are you getting your meth BTW?

As for LS-FD's I have yet to come across one that's faster than me around Mid Ohio, but I've only run across 3 so maybe the fast ones aren't coming to my area.

A somewhat local speed shop. It's $45 per 5 gal. I cut it 50:50 by vol with distilled water so it comes to roughly $4.50/gal.

Mostly run NASA at Summit Point, but have started up with Trackdaze. Occasionally I get down to VIR. PM me if you're up this way, and will do the same if I get down to your playground

I really need to get a trailer to broaden my experience though. Maybe Watkins Glen :nod:

Hatch Struts
 

So when I put the 99 wing on, my hatch wouldn't stay up :(

I got some clamps from Mazdatrix to keep it up, but it's a pain to have to put on a clamp every time you want to raise the hatch

https://cimg4.ibsrv.net/gimg/www.rx7...ab3ccfb060.jpg

I know there's a different part no. for hatch struts with USDM wings, but is it strong enough to hold up a JDM wing? :scratch:

I called up Mr. Mazda Ray Crowe and asked for the solution and he shipped

https://cimg9.ibsrv.net/gimg/www.rx7...3d306977e1.jpg

Installation was a little bit of pain, but not that bad. You need to remove the rear quarter panels to get to the strut bolts and the hatch plastic to get room to unscrew the nut that attaches to the hatch. This needs to be removed first and installed last.

https://cimg9.ibsrv.net/gimg/www.rx7...447d7da824.jpg

I tried it after installing one side and it didn't seem to make any difference :squint:

Shit, am I going to have to source JDM struts and be out the cost of the USDM struts?

Installed the other side and it stays up. :bigthumb:

It doesn't shoot up, but it stays where you put it

https://cimg2.ibsrv.net/gimg/www.rx7...0f6b4d2d3f.jpg

nice! I had the same problem with the 99 wing on my previous FD. this is a good reference so people will know which struts to buy to carry the extra weight.