1991 GXL Restoration and Turbo Conversion
09-02-13, 06:25 PM
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1991 GXL Restoration and Turbo Conversion
Hi all, my name is Justin i live just outside of Albany, New York. I picked up my 1991 gxl 3 years ago and I have been working on it ever since. The car was my uncles that he bought in 1990 brand new he drove it until 2001 when the white factory mazda paint started to flake (Like usual) and then parked it in my grandmothers garage where it wouldn't be removed from until 2010. I has been looking for a project for a long time and this was a great starting platform. The body is solid besides the surface rush which had stemmed from the flaking paint. The car spent 10 of 11 years in Texas while it was on the road no no rot had started to form. The interior also had no been effected by the Texas sun somehow. So i have accumulated the past 3 years while working on it so i figured id share my adventure with the community.
Last edited by j-roberts22; 09-02-13 at 06:43 PM.
09-02-13, 06:38 PM
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More pictures of painting
My first line of business was getting it to my shop where id be working on the car, I got the car started for the first time luckily my uncle drained the gasoline before putting the car in storage so i checked the gas tank and it was in perfect condition. I drained the old coolant and oil changed them out and despite the car not idling (Stuck BAC) i drove it from storage to the shop. First thing when it got to the shop strip the exterior and get it ready for paint. I stripped the entire car down to bare metal because i didn't trust the old paint to adhere to as it had flaked straight from the factory. I couldnt even begin to count the hours i had in body work on this car but it was all worth it in the end. I didn't take many pictures when it came to painting the car because it happened so fast. I worked fast so i could get the car on the road so i could enjoy some of the summer.
Last edited by j-roberts22; 09-02-13 at 06:41 PM.
09-02-13, 06:55 PM
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Fall
So i enjoyed what was left of my summer in the car blasting around every corner and enjoying how freely and spirited the rotary reved. I decided to make a few changes. For one the 20 year old OEM shocks and springs were worn causing the car to handle loosely and i couldnt stand the feel i looked into OEM springs but it turned out tanabe lowering springs and KYB shocks would be close to the same price. Along with the springs i got some craigslist wheels because one of mine was bent, they fit well for having an unknown offset. Alsol my radio was shot so i sprung for an after market pioneer unit and made a switch board that mounts directly under the sterio and painted it black to match the interior. Soon came winter and out the motor went. I managed to make a mess here i had the car in the storage barn when i took the motor out, Took about 3 quarts of gear oil to the face.....funnnn.
I painted the car pearl white with blue and gold micro flake and i feel this picture really shows the color.
The mess i made.
I painted the car pearl white with blue and gold micro flake and i feel this picture really shows the color.
The mess i made.
09-02-13, 07:19 PM
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jspec
I picked up a s5 jspec engine and tranny for 1000 bucks 100 compression on all 6 rotor faces and it came with a 3 inch down pipe a map, maf and the whole body harness from Japan Star Motors in albany. Out with the old engine in with the new. The turbo swap is going to be a completely stock swap besides for emissions and exhuast for now but i plan on upgrading later on. For now im running a mazda trix t2 tranny to na rear end drive shaft. The jspec engine also came with a knightsports tuned ecu the stock jspec ecu would only run it on one rotor. I also picked up this gem of a turbo 2 hood at japan star for 20 bucks it looks like someones wife went tiger woods on it.
09-02-13, 07:33 PM
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The Hood and some pictures after the coilovers
Okay after the turbo swap i decided it wanted to go a little stiffer on the suspension so i picked up k sport coilovers. These were one of the best investments i have made for the car. The ride is awesome i have them step up so they arent harsh but they reduced body roll severely. I am super happy. The only thing i could ask for is more camber adjustment i have them cambered all the way in in the front and no camber positive or negative exists. Also a picture of the hood after some severe metal work to straighten it out..... Also i took the car to the track 11 psi 3 inch exhaust the rest of the car stock run a 13.9 at 101 which i feel is pretty good for a ultimately pretty stock car.
OC meet in Middle town
A picture next to the 1986 gxl i picked up!
13.9 barely...best run was a 13.89 at 100 couldnt find the slip though
OC meet in Middle town
A picture next to the 1986 gxl i picked up!
13.9 barely...best run was a 13.89 at 100 couldnt find the slip though
09-02-13, 07:46 PM
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Pop
Sooooooo simple turbo inexperience and ignorance caused the first engine to go pop. I didn't have a wideband and after heat soaking for 10 minutes i took off from a read light on a 100 degree day and probably 160 degree intake temps and it popped. I disassembled the engine and some minor damage was done but i opted to buy a fresh block from japan star another 1000 bucks with a tranny. But this one came with some goodies. I went to pick up the engine and it had a knightsports 320cs turbo and some other goodies. This turbo came with a divorced wastegate hot side and a knightsports down pipe that the divorced wastegate dumps into. I immediately tore this engine down because i wanted a fresh start. I rebuilt it with all new atkins seals and rebuild kit. i am super happy with the way it came out. Im starting to play with the thought of a stand alone ecu at this point.
housing damage from popping the apex seals.
housing damage from popping the apex seals.
09-02-13, 08:03 PM
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pictures
Over the winter i also ended up changing the exhaust i was looking for something a little quieter.
This was the original
View My Video
This is with an obx muffler and two vibrant resonators. Dont mind the obnoxious BOV and the plastic i was painting in the shop the day of the video.
View My Video
This was the original
View My Video
This is with an obx muffler and two vibrant resonators. Dont mind the obnoxious BOV and the plastic i was painting in the shop the day of the video.
View My Video
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09-02-13, 08:21 PM
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Parts wave!!!!
We all love a good parts wave. I sat at my door around mail time every day waiting for packages.
First off once again from japan star some red Recaro seats i picked them up as a pair booth are in mint condition! I need to figure out how to mount them still but i do love some good old fabrication!
Second i picked up a godspeed intercooler kit from ebay....overall im happy with it. it needs some modification. i need to shorten up the passenger piping to the intercooler and tig it back together but thats not a big deal. Also something nit picky the plastic air vents for the brakes sit to high and i had to cut them to make this work im going to make some aluminum air vents that sit a little lower so i can retain the functionality of the brake vents.
First off once again from japan star some red Recaro seats i picked them up as a pair booth are in mint condition! I need to figure out how to mount them still but i do love some good old fabrication!
Second i picked up a godspeed intercooler kit from ebay....overall im happy with it. it needs some modification. i need to shorten up the passenger piping to the intercooler and tig it back together but thats not a big deal. Also something nit picky the plastic air vents for the brakes sit to high and i had to cut them to make this work im going to make some aluminum air vents that sit a little lower so i can retain the functionality of the brake vents.
Last edited by j-roberts22; 09-02-13 at 08:33 PM.
09-02-13, 08:31 PM
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More parts
My gxl diff had long been blown out of this thing since the first turbo swap and had been replaced with a open na diff temporarily it was killing me...so i stopped down at JPR Imports in New Jersey and grabbed a turbo 2 diff for a great price. Also while i was down there i talked to James about getting a tune! They had some crazy builds going on
I decided finally i needed to go stand alone. I picked up a megasquirt 3 with the ms3x expansion board and i love it so far. Very few modifications were needed to run the rotary and the wiring harness from DIYAUTOTUNE was clearly labeled. It doesnt have crazy processing power but its just right for my build.
I decided finally i needed to go stand alone. I picked up a megasquirt 3 with the ms3x expansion board and i love it so far. Very few modifications were needed to run the rotary and the wiring harness from DIYAUTOTUNE was clearly labeled. It doesnt have crazy processing power but its just right for my build.
09-02-13, 08:37 PM
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Okay so that brings me up to date ill have to grab some pictures of the interior also...i got a turbo for free in great shape its a gtp38r seems like its going to be more trouble than its worth...its huge....too huge and its only oil cooled....i think im going with a hx30 or hx35 gt35r or something of the sort....i want a big turbo but i still want the streetable feel that the hybrid turbo gives me. OH and by the way on the hybrid turbo at 14 psi i ran a 12.92 at 112 but i have since switched back to the stock turbo because im selling the hybrid to go after market! More updates soon!
09-14-13, 09:57 AM
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Very nice clean build...I see you are going with megasquirt as there are a lot of mixed emotions on using that standalone you'll hav to let us know your feedback on how it works for you...I am thinking about giving it a shot on my build
09-14-13, 11:51 AM
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Love the megasquirt 12.58 at 113 on the hybrid turbo. Tuning is easy installation was easy...I overall love it...I have had no issues with ignition noise or anything...the community is huge also
09-14-13, 12:05 PM
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Yeah this had some goodies it had a divorced wastegate setup which is cool and I get zero boost creep. Also it had a 3 inch downpipe and bigger injectors....I didn't use most of the stuff because I didn't trust it and just bought new products so I didn't need to worry about it...
09-14-13, 12:46 PM
#19
Yeah this had some goodies it had a divorced wastegate setup which is cool and I get zero boost creep. Also it had a 3 inch downpipe and bigger injectors....I didn't use most of the stuff because I didn't trust it and just bought new products so I didn't need to worry about it...
02-19-14, 07:01 PM
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Some winter progress
It has been a long while since i updated my build thread so i figured id add some pictures of my winter progress.
The knightsports turbo needed a rebuild so i decided rather than toying around with a stock turbo for any longer id upgrade. I got a used HKS t04E and a greddy manifold. This turbo had an extremely weird exhaust flange. It had a recessed groove where a solid mounted down pipe would sit.
So i made the decisions to modify it for a vband flange.
I had an HKS cast manifold but it didnt place the turbo high enough in the engine bay so it rubbed on the lower radiator hose. For now im running a 60 mm knock off wastegate. Id like to upgrade it but it will have to wait.
The knightsports turbo needed a rebuild so i decided rather than toying around with a stock turbo for any longer id upgrade. I got a used HKS t04E and a greddy manifold. This turbo had an extremely weird exhaust flange. It had a recessed groove where a solid mounted down pipe would sit.
So i made the decisions to modify it for a vband flange.
I had an HKS cast manifold but it didnt place the turbo high enough in the engine bay so it rubbed on the lower radiator hose. For now im running a 60 mm knock off wastegate. Id like to upgrade it but it will have to wait.
Last edited by j-roberts22; 02-19-14 at 07:10 PM.
02-19-14, 07:19 PM
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Along with the power i need so good rubber. I couldnt just get good rubber without getting rid of those hideous wheels i had.
The wheels are chromium black Xxr 527 tires are cooper zeon rs3-s
Front:225/40-18 +33
Rear: 255/40-18 +20
Also my front mount wouldnt fit with my stock bumper so i picked up a gp-1 front bumper and love it. Along with that i picked up some shine auto side skirts and aero gaurds.
The wheels are chromium black Xxr 527 tires are cooper zeon rs3-s
Front:225/40-18 +33
Rear: 255/40-18 +20
Also my front mount wouldnt fit with my stock bumper so i picked up a gp-1 front bumper and love it. Along with that i picked up some shine auto side skirts and aero gaurds.
Last edited by j-roberts22; 02-19-14 at 07:36 PM.
04-23-14, 07:22 PM
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More fun
Painted up my bumper side skirts and such...went to a few season opener car shows...and my engine is popped again...cracked the front iron. So ill be rebuilding with a street port and some supporting mods.
