At the new place now... I'm going through my parts and I seem to have 3 sets of rear calipers. I'm just going to use what I need and throw the other 2 sets away. I've become a bad packrat lol! I don't need all this stuff. Soon she will actually have brakes!!

 

Got into the differential. I'm gonna take it all apart and verify correct LSD disk thickness. Also gonna take the shell and sandblast and paint it. Does anyone know what that tab inside the diff cover is? It's the 6th pic, it's like some bent up sheet metal bolted to the back inside of the case.

 

Started working on the front bumper when I should have been working on the wiring. I think I was just sick of having it float around the garage taking up room when it's supposed to be on the car. The 2 sets of bumper mount brackets are from an S4 and S5. I got a good set from an S5 without knowing they were different So I had to go back and find an S4 set that wasn't broken... That wasn't easy lol. But there all good now, and anti-seized for future use

 

Got a but of harness reduction started and gave her a wash. It's probably been over a year since it even touched water. Dust this bad you have to actually scrub off.

 

Finally got the Bumper fitted, everything met up ok... The hood needed to be aligned a little but it wasn't to bad. It's been a long time since a bumper was on this car lol! I have been collecting a few sets of FTP's and now i finally get to use them

 

So that's it for now, It's been a long time since I updated i know. But here's proof that I'm still getting there, here I come sevenstock! I didn't take pics, but I cleaned and detailed the plastic belly pan that fits under the engine bay, ran a tap through all the mounting holes and it fit up nicely. Also, cleaned up and detailed the plastics that fit up under the front fenders, gonna get them mounted up soon. Currently working on the rear brakes, Differential and wiring, wiring, wiring...

 

It's good to see it back on the ground again! Looking good!!!

 

Wow, I'm a bit further than this! Guess I've been slacking on this thread. I'll try to take some time this week and upload more pics. Also, as a teaser... I've decided to use a different engine. This engine never came in this car. Guesses? lol!

 

Diff is all clean and painted, I had to get net pinion bearings from the dealer because I damaged one when I removed them. Also, got a new pinion bolt since I smashed the original (Be careful, they be soft) and new pinion/half shaft seals. I tried to get the proper pinion drag set but according to manual it looks like I'm gonna need a new pinion crush tube. After the pinion is done I'll start dissasembling the LSD unit.

Relay board built, still working on proper mounting for that. I'm actually gonna use the stock battery tray, that may not be permanent but that'll simplify things and help me finish faster so I fished one out of cl.

 

Well, I've decided to pull the s5 T2 in favor of a 13-re cosmo. Also, bringing in the differential to get the pinion drag and gears meshed properly. Also, found one of the actual greddy side front license plate mounts!

 

Well, I brought my differential into Pro Gear down in SD here. I told them everything I did to it and that I have another crush tube so they could do it all again for me, because I was worried it was not correct. (I thought it felt to tight) They said the pinion preload was set up just the way it was supposed to be! Much to my relief. If anyone wants more details just let me know. So I'm just going to continue with the rest of the differential myself and see how it goes. They didn't even charge me .

We ended up chatting for a while about other various things, the guys there are real down to earth people. It was really weird since that when I go to most auto businesses they don't care about you unless your paying huge. Anyway, I got to see a lot of their current work, and more tools that they have to make all the time. When I started the differential I have been looking for all the appropriate press tools and diff carrier stands ect... Apparently you have to make all that...

 

I put a few more hours into the new engine this week. Cleaned the LIM inside and out, took forever. Just brushes and picks in the sink with HOT water and soap, and gasket scrapers. Then a blow dry and coated with PB blaster and blown again. It may be old, but I want it clean! Installed the block offs and installed. I finally installed my first injectors to! 1000cc ID with FE Rail. It tool forever to get the plastic injector dispersal nozzles out of my donor motor cause I was trying to be super gentle, but worth it to not break the suckers

Also, it seems that my builder used 2 rear irons, requiring me to block off both of the coolant passages No need to fret guys, after searching autozone, and O'Reillys I finally found a match for the expansion plug! Woo! I brought a spare T2 housing into NAPA and found the correct size, only took them 3 days to get both of them though lol. They're 20MM people! We'll see if they hold! Much cheaper than mazdatrix supplied plugs I used on my last motor...

And if you noticed, I found different gaskets. I have the stock ones from Mazda, but while I was perusing eBay, I found a set that is supposedly good for minimizing the transmission of heat. The first set I got was cut so that there was no gasket material at all separating the primary runners but they contacted me a few weeks later stating that they got the cutters to revise the cut. They now appear good to me, but it took 3 shipping attempts. They made it right in the end though

I have a question for y'all though. The turbo it awfully close to LIM. Should I be worried? I'm gonna make a heat shield but that's still really really close I think. Anyone with some experience with this able to give a bit of advice?

*Now to start cleaning the upper and start working on the diff again. Maybe a few more weeks and I can drop the rear subframe and assemble all that I hope...

 

More progress yesterday, got the diff back from mark over at pro gear today. I have been so busy this last month that I haven't had a lot of time to work on this, so I had them do it for me. I sand blasted the heads of the diff cover bolts and cleaned all of them spotless, cleaning all the old lock tite from the threads and such, then hit them with some flat black hi temp paint. Gonna try to get this diff together this week in prep for the subframe drop this weekend. I also replaced the half shaft seals on the diff cover and installed new diff mounts on the rear and a mazda competition front diff mount. Let's get this puppy moving along... Also, finally finished fixing up a mount for the lower bumper. I had to make one from 2 of the better broken ones I found...

 

great attention to detail... and great information. I'm subbed now to see how you manage to stuff that RE monster in there

 

Thanks. I don't have a whole lot of time to work on her, but I did finish the bolts. I've got a desert trip to glamis all weekend, but I'll get this diff together soon enough. Something I have been looking for a long time was a replacement half shaft since I damaged one. Well, after autozone and oreillys confirmed that they were selling non turbo half shafts only, an checking everywhere else for the turbo ones I finally found that napa at least has different part numbers for the non turbo and turbo shafts. Sadly, they can no longer get the turbo ones. I looked everywhere for these things... After a long time of searches, a set finally popped up on eBay of all places, in Hong Kong strangely. 300$ later and there on their way. Parts be hard to find people!

 

Well, I got my diff back from Pro Gear and for some reason the differential cover didn't fit on the differential. I brought it back to them and they said they will try to figure it out. It looks to me like the pilot sections on the bearing caps we not set. Pics for y'all Also, I finally found a set of T2 Half shafts. Ebay, Hong Kong, and 290$ later and I have some half shafts for this thing. I thought the price was crazy but they wanted 400$!!!! If only I hadn't damaged my originals, you live and you learn. A bigger hammer would have gotten the original shaft out without damaging it the first time, and would have been quicker...

 

I cleaned up my new shafts, and snapped up some pictures for educational purposes.

First, clean the hell outta the threads. My wire brush was not getting the bottom of the threads clean so I spent some time with a pick to really get on there. Bolts now thread all the way down like butter. I was kinda figuring this out as I went along. Super messy, but this grease was shot and needed redoing.

 

I guess I forgot to get a picture of the cleaned up wheel bearing side (sorry). This was the hardest part since you are not supposed to dissassemble it. I used a combination of gasoline baths with brushes, PB blaster and more scrubbing. Once I got it as grease free as possible, I packed the whole joint with my favorite grease (pictured). I found that one of the shafts has both boots with small tears. I am attempting to seal them up with some of my gasket maker (the right stuff), I'll see how that holds. Then install the boot, and slide the boot for the next joint on the shaft in prep for the inside joint assembly.

 

Slide the two inner pieces on and get the retaining clip in place. Make certainly certain that it's installed and fully seated. Grease it all liberally, and slide the basket forward and turn so that the ***** have a hole to sit in. Grease and install the *****, then pack the whole thing. Don't just smear grease over it, but pack it inside the bearing and fill it. Pre-grease the inside of the casing.

 

Slide the housing on, and install the clip. Make sure you put the open end of the clip in a spot that that doesn't leave it exposed. Then just proceed to pack the rest of everything with grease. Again, remember, you gotta pack it into and fill all the holes, don't just spread it on top of the holes. Slide the boot on and lock down the clamps, then install the cover. Tap it on, gently, with a rubber mallet. And viola, ready to use

 

If you didn't already get rid of those old damaged halfshafts, I'll purchase them off you. Recoup a little of the incurred cost?

And nice write up