Discussion in 'Members Rides' started by pitty, Oct 23, 2014.
Nice work! Always impressed by the attention to detail you have.
Timed this guy. Nice people at FM sent me their timing gear tool slash bottle opener, so I was very excited to try it (what I really wanted to do was to 3d print my own timing tool, so I was actually the very opposite of excited). It goes between the timing gears and holds them where the timing marks are perfectly aligned.
Well, it turns out that in a situation where the crank cannot be fixed in position, it's easier to do everything without the tool. So I bolted on the crank gear with a brand new bolt, and score, this has a timing mark on it too.
And three minutes later it's done and tested.
Comparison of timing jobs between a '07 Mazda3 and '90 MX-5.
Many special tools
$40 friction washers
12 hours of labour
Hell on earth
No special tools
$40 total parts bill
2 hours of labour
Sunshine, rainbows, cherubs singing
Flipped the motor to remove the oil pan for cleaning and such. This was a mistake, because I only torqued the cam cover bolts pinky tight, did not consider how much oil remains in the engine after draining, and consequently dumped all of those dregs on my floor. Which was kind of interesting, because I drained the oil prior to pulling the engine, but a lot of it came out, leaving me with questions wrt how much oil is actually changed during an oil change? (A: Not all of it)
Oil pan off. It's sealed with silly cone from factory, and there's a windage tray sandwiched between the pan and the block, glued with more silly cone.
Years later, new timing cover gaskets arrived. When Rockauto offers you a "consolidated economy" shipping option, don't use it.
Whiteout on the timing marks... will probably fall off.
Valve cover installed for good. Hopefully won't have to remove it again during this project.
Re-sealing the oil pan!
As the pan, windage tray, and block are simply sandwiched, but have to be installed in stages, I chopped the heads off some M6 bolts to make four alignment studs for the parts.
Windage tray glued in first, then the pan, then bolts.
Bam, all done. (Actually done twice, because the first time around I forgot to torque down the bolts on a baffle inside the pan. All good things are worth doing twice. )
Had a bung welded into the pan for the turbo oil drain instead of the usual drill-n-tap approach.
Pulled the intake manifold to powerwash it and moved the engine stand to the back of the motor. Finally ready to install turbo bits.*
(This lump sure is cute and tiny without the manifolds)
* I'm not even sure if I should install the exhaust manifold now or do it after the engine is back in the car. The latter seems like it would make it easier to resolve any fitment issues.
Wait a minute, why does your oil return look so nice? Shouldn't you have taken it to a machine shop and had them use a punch, ream out a hole, and tap the sloppy results?
Did I mention the part where they originally welded it in threads inside the pan? I keep telling these guys, it's welding first, beer second. Not beer first, beer second, beer third, a fifth of port fourth, then welding.
Test fit to check oil line fitment.
Drain is too long, which is a problem as it's gravity-operated and should not have kinks below the drain point. Fortunately it's easy to disassemble the fitting and shorten the hose.
Supply is too long, which is probably not a problem.
I broke the wastegate actuator trying to make it fit. Winter starts tomorrow and my workspace isn't heated. More parts are waiting to be frivolously purchased.
willing, it thaws early, and global warming kicks in hard, and I finish this by April 14 just in time for the Fast 8 premiere.
And that's a wrap for this year!
Your turbine housing is the color of 's face.
Turbo blanket pls.
Yeah, it's not very cute, is it? I'll candy stripe it white and red if Perkins reports that his high temp paint holds.
Don't forget the blue!
Paint is not hold.
Well, the primer is hold, the black has flaked off and looks like shit.
Well, there goes that idea. Back to square one with the trump-face turbo.
I wish I would have just brought it to some professionals and have them do it. Guess I need to buy a new turbo and manifold now.
Stopped by the garage to check if anything caught on fire or got stolen, decided to do things.
Last I left the engine it was in this sad state.
First problem is the oil drain hose is too long. The drain is gravity-powered, so the drain has to be the lowest point in the system. I cut the hose to length and assembled the fittings properly. -10 hose is no match for a determined hacksaw user.
Done, and assembled! Looks good for gravity drain.
Why not make a feed line too? The one I bought on ebay sucked and had a wrong turbo-side fitting, so I got upset and went to town shopping for vibrant fittings to build oil and water lines, along with other things. Loot:
Vibrant makes a Garrett turbo-side fitting which converts the female inlet to a male -4 with a removable flow restrictor, as these turbos don't like an oil feed at full engine pressure. They include a bunch of different restrictors and a hex key to install them.
Assembling the hose ends with a basic wrench and a set of cheap-yet-effective summit brand AN vise inserts. I'm really liking how easy this is.
Both ends good to go.
Block oil port to turbo, just right.
Water lines next. Factory set up has some water ports for... lore knows what. Throttle body heating or something? I'm using them for turbo water feed. Drilled out the nipple in the water manifold and tapped it for 1/8NPT.
1/8 to male -6 converter goes in.
At which point I realized that I have 2 straight and 2 90 degree -6 fittings for water lines, and that is a mistake. Turbo side has to use the 90 degree fittings to avoid interfering the with manifold and such, so I thought engine side fittings should be straight, because the original water nipples are straight. What I didn't consider is that the original lines go into a different location.
So the straight fitting kind of works:
But the 90 makes for a cleaner path and a shorter hose:
Welp, using 90 degree fittings on the drain line. Done.
Now, back to Summit for an extra 90 fitting, before I can drill out the thermostat neck nipple and convert it to a water feed.
(Woshua's promotional spot for Simple Green)
Attempted to clean some grease residue from the bumper support with Simple Green.
Good lore Jesus Chest, this stuff is magical. Went over the rest of the bay:
Also visible above, new clutch slave with a stainless braided line leading to it. A lesson I learned from that fix is to never attempt to work hydraulic fittings without a flare nut wrench. Also learned that flare nut wrenches don't come in a combination you need. Every fitting in a Miata is either 8 or 10, and the wrenches are all 6/8 or 10/12. Ordered an 8/10 from the UK. Long wait, but feels good.
Discovered I'm that idiot which fitted the turbo oil feed to a water port last week. "I know the oil port is 10x1.5, so why does this 10x1.5 vibrant adapter not fit?" Oh, that's why, it's not the fucking oil port. It would have been a very awkward first start where I'd pump my oil pan full of coolant.
On the upside, I discovered that there is actually a water port on the block pretty much adjacent to the turbo, and it's right after the pump in the system, so it has the coldest coolant, as opposed to the usual thermostat neck port, which has the hottest. Made the water feed line to fit said port, and it's only about 20cm long.
Top, water. Bottom, oil. Easy to confuse if you have a brain the size of a walnut.
Now I'm wondering how I'm going to get these guys tight. Space for any kind of wrench is scarce.
Final bits needed to finish the oil/water setup arrive next week, and the week after that, weather permitting, the engine gets reinstalled.
Yeah, Simple Green is great, so long as you don't follow the silly instructions that tell you to mix it with water.
Yeah, I just spray it like a russian escort in Trump's hotel room.
Was cleaning the gearbox with it, snapped a shot halfway in:
(this is what happens when your oil seals are leaking for decades)
Pink clutch to handle the extra hamster powers.
Put the engine and transmission together with two hands, a scissor jack, and a leaky hoist. Maneuver the 50lb gearbox with one hand, hold the engine with the other. Not fun,
Next day, tuned the hoist with a replacement bottle. Right on time.
New fittings for the water lines. Waited a month for Summit to deliver that 150 degree elbow.
Slow drip gear oil fillup with a Jerry Rigg University spec apparatus made out of a jack handle.
Test fitting boosty parts.
This one's fun. FM says to notch the engine bay sheet metal and "hammer it flat". Ahahaha haha. Yeah, this looks great.
Fuck no. Cut it out, filed the edges, covered with totally random Ford red paint from the Tire.
Made a plastic skirt. Watching paint dry...
Hey, that's a nice match!
Fancy banjo fittings for turbo water lines.
Rinsing out the intercooler with "mineral spirits". Ended up spilling it afterwards. Garage full of fumes. Went on a fantastic voyage.
Downpipe has a slotted flange. Clever. Allowed for fitting my offbeat exhaust perfectly, but tightening those nuts once installed was an adventure.
Intercooler cold side with an intake temp sensor and an australian blow off valve. This thing is a work of utilitarian art.
Dubious routing of heater core hoses to avoid the new exhaust and fit the coolant reroute block. OEM-shape molded hoses don't work, unfortunately.
High flow cat and catback.
Two-piece downpipe. Another neat bit to facilitate fitment of various exhausts.
This is where I started the engine for the first time, got a brutal misfire, started diagnosing from the wrongest end of the flowchart, and eventually zeroed in on a (duh) broken injector connector. In lieu of useless diagnosis discovered that the compression is great, fuel pressure is spot on, regulator is tip top. Good to know. Then the ministry of bullshit and transportation told me I need to do a new emission test, so I can't renew my plates until I tune properly. Good times.
Hey there tiny hot rod!
Took her around the neighbourhood unplated like a real punk rocker. Things work. Still a couple glitches. Reassembly soon.
Very cool project!
This thing has come so far! So cool!
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