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Project: Weeeelllll Sh*t (56k) BEWARE
This is some old news since it happened towards the end of November. My car is officially down :( I was driving behind a coke truck on the highway back to my hotel in Tulsa for work, when I started noticing a misfire / stutter when I pushed in the clutch. I was like "uh-oh" that's not right and started looking for the nearest exit. I pulled off the highway and as I exited the motor just died. I knew right off the bat that I have some big time motor issues.
I had my tool box in the back that I never took out during the Eureka drive and pulled the plugs to listen to the compression pulses. And as I suspected not all the faces sounded the same. :cry: Needless to say I spent most of the day getting the car home on the trailer and trying to figure out what to do. In all honesty I'm not to bummed out for it going. I have to maintain a glass half full outlook since this car was originally sold to me as having a blown motor. But through some researching, examining the car and fixing the bad parts I think I got a good year and a half of daily driving and fun out of it. That being said I never really trusted or felt truly comfortable with the motor in it. Every other day I was checking the coolant and topping it off since I could smell the sweetness in the exhaust when first fired up and also noticed a few drops of coolant coming from the bell housing area when ever I would get underneath the car. The oil pan leaked ever since I owned it with 3000 miles, which is always annoying and among other things. So, the FD is going to be down for a while as I gather parts to put the car back together and actually do the stuff I have always wanted to do. It'll be easier now since the motor will be out of the way. But I thought I might share with you guys and don't worry I'll still attend the events sans rotor...... FOR NOW :twisted: I've determined that the project name is appropriate. Some friends and I pulled the motor out and discovered how shitty it was assembled and yet astonished how long it lasted considering it's construction. Here's some pics of the tear down. The motor didn't blow up as I first had thought. The best way to describe its demise is that it pretty much gave up and fell apart. http://i834.photobucket.com/albums/z...t/IMG_1008.jpg http://i834.photobucket.com/albums/z...t/IMG_1013.jpg http://i834.photobucket.com/albums/z...t/IMG_1027.jpg http://i834.photobucket.com/albums/z...t/IMG_1029.jpg http://i834.photobucket.com/albums/z...t/IMG_1032.jpg http://i834.photobucket.com/albums/z...t/IMG_1036.jpg http://i834.photobucket.com/albums/z...t/IMG_1040.jpg And now the motor is out and here is when the big problems become apparent. Look at all this silicone! None of its suppose to be there, including the tension bolts. Who ever built this knew they screwed up and decided to cover it up with silicone. Which is now an ongoing joke at the shop if something happens. "just cover it with silicone!" http://i834.photobucket.com/albums/z...t/IMG_1044.jpg http://i834.photobucket.com/albums/z...t/IMG_1046.jpg http://i834.photobucket.com/albums/z...t/IMG_1048.jpg Regular RTV Silicone oozing out between the housings and plates http://i834.photobucket.com/albums/z...t/IMG_1050.jpg Well there's my leak i've been looking for! :uhh: The reason for this is because of the improper coolant sealing techniques used and improper torquing of the tension bolts as well as a misalignment of the added "dowling" http://i834.photobucket.com/albums/z...t/IMG_1053.jpg http://i834.photobucket.com/albums/z...t/IMG_1054.jpg http://i834.photobucket.com/albums/z...t/IMG_1055.jpg http://i834.photobucket.com/albums/z...t/IMG_1059.jpg http://i834.photobucket.com/albums/z...t/IMG_1061.jpg http://i834.photobucket.com/albums/z...t/IMG_1063.jpg The rotor made some slight marks, it's hard to tell in this photo but it's there http://i834.photobucket.com/albums/z...t/IMG_1064.jpg http://i834.photobucket.com/albums/z...t/IMG_1065.jpg http://i834.photobucket.com/albums/z...t/IMG_1066.jpg http://i834.photobucket.com/albums/z...t/IMG_1068.jpg The damn ORIGINAL water seals were still in there from when mazda assembled the motor, and this was suppose to be a rebuild! http://i834.photobucket.com/albums/z...t/IMG_1069.jpg A continuation of the rebuild progress that is being made with the motor. Before I start I just want to say thanks again for my buddies in teaching me the steps to rebuild my first motor. Like a majority of us know, 2/3rds of a rebuild is cleaning, but damn it's really amazing on how much there actually is to clean! And I'm 100% sold on pre-mixing/ water injection if it helps out in keeping the insides clean 8-) Here are some pics of the rotors in the tank being cleaned up, this is actually after they were sitting in a bucket of hardcore chemicals for a while dissolving the carbon and making it EXTREMELY easy to scrub off. So it's a multiphase process. I must also say that I scored a low mileage REW motor which is what I'm using to replace the one that broke..... http://i834.photobucket.com/albums/z...t/IMG_1163.jpg http://i834.photobucket.com/albums/z...t/IMG_1165.jpg This is after they were pulled from the tank and needed to be wiped down. http://i834.photobucket.com/albums/z...t/IMG_1167.jpg I took this pic of a dirty rotor and the cleaned one to compare the difference. The one on the left is a 12a rotor while the right one is a 13b. http://i834.photobucket.com/albums/z...t/IMG_1169.jpg Here is a pic of the plate getting ready to be cleaned and after the porting has been done. http://i834.photobucket.com/albums/z...t/IMG_1171.jpg Clean rotors FTW!!!! http://i834.photobucket.com/albums/z...t/IMG_1173.jpg An uncessary thing, but I decided to try out the water cooling mod. It took some time to do and a steady hand. After I finish this then the housings will be put in the tank and cleaned. <---catching on to a theme here ;) http://i834.photobucket.com/albums/z...t/IMG_1179.jpg Next up assembly!!!! Stay tuned :twisted: Since I'm taking the time to do this; as is the case with everything I seem to do, I had the housing powder coated chrome. Cleaned and pre powder coated http://i834.photobucket.com/albums/z...ercoating2.jpg http://i834.photobucket.com/albums/z...dercoating.jpg And the end result http://i834.photobucket.com/albums/z...dhousings2.jpg http://i834.photobucket.com/albums/z...dhousings3.jpg http://i834.photobucket.com/albums/z...edhousings.jpg http://i834.photobucket.com/albums/z...rontcover2.jpg http://i834.photobucket.com/albums/z...frontcover.jpg I managed to get half the motor put together but had to stop cause the remaining side seals that we had were to far out of spec for the rear face of the front rotor. Some new ones are on order. No question the motor will be fully assembled this week as just a few more hours of work needs to be done. Then once the tax return comes in I can place my full order of parts and the install process can begin!!! New seals and gaskets, this is what should of been done the first time when the motor was rebuilt. http://i834.photobucket.com/albums/z...t/IMG_1221.jpg 2mm RA Super seals FTW! http://i834.photobucket.com/albums/z...t/IMG_1225.jpg http://i834.photobucket.com/albums/z...t/IMG_1235.jpg http://i834.photobucket.com/albums/z...t/IMG_1227.jpg Oil control rings, lubed up ready to be put on the rotors http://i834.photobucket.com/albums/z...t/IMG_1229.jpg Oil control ring springs http://i834.photobucket.com/albums/z...t/IMG_1231.jpg Front cover with cleaned up stationary gear installed http://i834.photobucket.com/albums/z...t/IMG_1233.jpg Look new water seals with hylomar! <---- This was not the case when we tore apart the motor that came out of the FD http://i834.photobucket.com/albums/z...t/IMG_1237.jpg Front faced Front Rotor with Atkins corner seals and everything installed.... http://i834.photobucket.com/albums/z...t/IMG_1239.jpg Random picture of my buddy Greggs RX-3 sitting outside while I was building the motor http://i834.photobucket.com/albums/z...t/IMG_1241.jpg |
And the assembly continues
http://i834.photobucket.com/albums/z...t/IMG_1243.jpg http://i834.photobucket.com/albums/z...t/IMG_1245.jpg http://i834.photobucket.com/albums/z...t/IMG_1247.jpg Check the bottom of the pics for the specialized tool we milled down for us to use in grinding new side seals to spec, very very cool. Center plate ready for a rotor http://i834.photobucket.com/albums/z...t/IMG_1317.jpg Eccentric shaft installed http://i834.photobucket.com/albums/z...t/IMG_1320.jpg http://i834.photobucket.com/albums/z...t/IMG_1319.jpg Rear rotor with oil control rings installed http://i834.photobucket.com/albums/z...t/IMG_1321.jpg Rear rotor in place http://i834.photobucket.com/albums/z...t/IMG_1323.jpg http://i834.photobucket.com/albums/z...t/IMG_1324.jpg Rear housing installed http://i834.photobucket.com/albums/z...IMG_1326-1.jpg http://i834.photobucket.com/albums/z...t/IMG_1316.jpg http://i834.photobucket.com/albums/z...t/IMG_1325.jpg Rear plate installed http://i834.photobucket.com/albums/z...t/IMG_1328.jpg Rear plate with tension bolts numbered for proper torque sequence http://i834.photobucket.com/albums/z...t/IMG_1327.jpg http://i834.photobucket.com/albums/z...t/IMG_1329.jpg And Voila!! Finished short block http://i834.photobucket.com/albums/z...IMG_1333-1.jpg http://i834.photobucket.com/albums/z...t/IMG_1331.jpg A little side story involved during assembly. I finished placing the rear rotor in and was placing my last corner seal, when I looked down and noticed that there was an extra corner seal spring sitting on the staging area! I was like "oh no, I couldn't have forgot to put a corner spring in, I know I checked all the corners for spring return." I quickly asked the guys if they have ever had an extra spring shipped in the bag. And of course the answer was no. So needless to say instead of risking it, we just decided to pull it apart and double check. It turned out they did ship an extra one. Now on to the coolest part of the build I think. For those that are not familar with new side seals, there is a bit of triming to be done in order to get them to fit since they ship longer than what they need to be. We decided to use a junk rotor to act as our jig for grinding down the side seals. This is pretty ideal considering it doesn't allow movement side to side (potentially breaking). Some people may be actually doing it, but we haven't seen the actual rotor milled down like this to help grind the side seals. http://i834.photobucket.com/albums/z...t/IMG_1305.jpg We then milled down a side of the face to allow the seal to be grabbed and pushed along it's intended location as a guide/rail. http://i834.photobucket.com/albums/z...t/IMG_1309.jpg http://i834.photobucket.com/albums/z...t/IMG_1310.jpg http://i834.photobucket.com/albums/z...t/IMG_1311.jpg One corner was left untouched for about 3/4 of an inch and then stepped to allow the seal to be pushed down fully with one hand and guided by the other. Once the rotor was milled then it was placed in the drill press and a circular grinding stone was installed, guided inside the corner seal bore and locked into position. http://i834.photobucket.com/albums/z...t/IMG_1312.jpg http://i834.photobucket.com/albums/z...t/IMG_1315.jpg You can see the seal sitting and the rear is exposed so it can be pushed along http://i834.photobucket.com/albums/z...t/IMG_1313.jpg Next up, is getting it to long block status then the car itself; for it's modifications. |
Oops sorry mods, I just noticed your rotary car build up section. Newb mistake.......
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No worries, I moved it
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I saw the rotor being milled and at first I was like WTF?!?!?!?!??! SCALLOPING GONE WRONG!!!!... THen I actually read it.... cool idea. I have always wanted to build a jig of sorts, this is a dame good idea... I may have to do this myself!
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Looks super clean thus far with the updated progress. Sucks about the "rebuild."
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Funny story; I had an extra fire ring shipped in one of my packs. Caused me to tear down my block again as well.
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I'm curious about what the RTV was supposed to hide, especially on the tension bolts LOL.
And damn those rotors are super clean. Nice build! That's a nice RX-3 too. |
OMG that original motor is a joke... Nice build....
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:smilielol5::smilielol5::smilielol5: |
Thanks for the compliments guys. I have 3 of my buddies here with a combined experience of over 100 years and they said that was one of the worst motors they have seen put together. Really the pictures don't show the true nature of how bad it was.
I'm not by computer, but I have more pics of the build I'll share tomorrow. At least I know I'm not the only one that had experience with tearing apart a motor cause of an extra included part haha. That's a truly gut turning experience I don't want to repeat. |
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I'm going to stab you in the eyes like your other TX breatheren in 42 days :rofl: |
Build looks good.
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A few more pictures as promised I had left on the computer. This is the current status of the motor as I am awaiting for the rest of the parts to get back from the powder coater.
http://i834.photobucket.com/albums/z...t/afb0cb2c.jpg http://i834.photobucket.com/albums/z...t/6b3ec88e.jpg http://i834.photobucket.com/albums/z...t/03187249.jpg http://i834.photobucket.com/albums/z...t/fe20f0e5.jpg http://i834.photobucket.com/albums/z...t/0751f6a4.jpg http://i834.photobucket.com/albums/z...t/b7ca67bb.jpg I didn't like having the extra ribbing on the main pulley that will never be used, so I put it on the lathe and turned it down. http://i834.photobucket.com/albums/z...t/a93e20be.jpg |
:icon_tup:
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nice job on the engine build. i particularly like the work on the water jacket.
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Sorry to hear, but did you really need to swear in the title?
Title edited for posterity sake. Do you know who did the rebuild??? -Ted |
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As far as the builder; I'm not entirely sure. The previous owner said he was a local near Miami. I do know this guy did another motor for the previous owner and it too fell apart like mine, which he is seeking legal action now. |
There's nothing wrong with how Ted changed the title. It expresses the same feelings, we all get the point, and its a little more PC. One of my nicknames at work is "foul moth pete," and sailors have been seen running from bars covering their ears when I get on a roll, yet you will rarely see me swear in a post.
If you can find the name of the local guy in FL, it would be nice to know. Any other details? Turbo, mani, ecu, etc etc? It a beautiful car. |
There's nothing wrong with how Ted changed the title. It expresses the same feelings, we all get the point, and its a little more PC. One of my nicknames at work is "foul moth pete," and sailors have been seen running from bars covering their ears when I get on a roll, yet you will rarely see me swear in a post.
If you can find the name of the local guy in FL, it would be nice to know. Any other details? Turbo, mani, ecu, etc etc? It a beautiful car. |
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Coming from an FC owner whose car caught on fire due to a leaking PD... I could've died from the car blowing up on me, cause it caught fire while I was driving. Luckily, a friend was close-by to flag me down. One of the most helpless feeling in the world is to see your car burn with no way to put it out. To add insult to injury, I dragged the car to the Mazda dealer only to be quoted "over $5,000" to fix the damage - $300 x 4 for fuel injectors, $1,200 for engine wiring harness, etc. I know we're all adults here, but there's a time and a place for everything. I know I sound like a prude editing your title, but think about this... You might not care if you swore or someone else swears. Do you condone such language if you were surrounded by a class of kindergarteners? If you had kids, you'd understand. You're welcome to swear all you want in The Lounge section. (Did it come from there?) I'd like to think the owners and admins would want to keep the other sections a bit more civilized - like I said, there's a time and a place... -Ted |
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I agree completely, I didn't think it would bother anyone; but it's nice to see you guys have active mods doing what they are supposed to. The post wasn't supposed to have come off with malice. It was a question, so I answered with good intentions. I will find out more from the previous owner about who built the engine. I didn't want to get involved with the law suit which is why my information regarding the builder is limited.... Thanks for the compliments! The turbo is a Holset H1C with a custom manifold. Let me sort through the pics and post some up here in a bit. |
I forgot what it looked like before I pulled the motor, so some of the pics are reminders how temporary the set up was, haha. The intercooler was intended to act as a temporary means to cool the charge on a 9lb spring, while I saved up for a FMIC. So to sum it up, I'm embarrased to show the intercooler :302:
http://i834.photobucket.com/albums/z...p/3d2e47cb.jpg http://i834.photobucket.com/albums/z...p/a668b50a.jpg http://i834.photobucket.com/albums/z...p/fa94df00.jpg http://i834.photobucket.com/albums/z...p/26e638b7.jpg http://i834.photobucket.com/albums/z...eturbocopy.jpg Here are some shots of the before and after the hot parts getting ceramic coated. http://i834.photobucket.com/albums/z...t/IMG_0858.jpg http://i834.photobucket.com/albums/z...t/IMG_0871.jpg http://i834.photobucket.com/albums/z...t/IMG_0843.jpg http://i834.photobucket.com/albums/z...t/IMG_0878.jpg http://i834.photobucket.com/albums/z...t/IMG_0873.jpg http://i834.photobucket.com/albums/z...t/IMG_0868.jpg http://i834.photobucket.com/albums/z...t/IMG_0874.jpg And here is the list of stuff done and Plan on doing to the car :sifone: 1994 Mazda RX7 – Touring Chaste White on Black and Tan Interior – 163,000 miles on body Engine: Rebuilt motor by myself, 2mm rotors, Atkins Super Seals, Powder coated housings and front cover, water mod in housings, shimmed adjustable oil pressure regulator 417rotary.com Custom adapter for rear auto plate to bolt into a manual tranny and starter Banzai Racing poly motor mounts Banzai Racing oil pan brace Ford TA30 silicone for oil pan Cosmo 13B-RE metal front cover gasket Banzai GM 3bar map sensor kit- Plan on doing Spec Stage 3+ clutch kit- Plan on doing Single turbo wiring harness AEM Water Injection- Plan on doing Relocate battery with welders wire HKS Twin Power Ignition Plan on doing CJ motorsports fuel kit- Plan on doing ID 725 injectors- Plan on doing ID 2000 injectors- Plan on doing Aeromotive FPR 13129 EFI- Plan on doing Oil Catch Can- Plan on doing Ceramic Chrome Coat UIM and LIM Nissan Quest horn- Plan on doing Custom 2" Stainless Steel Manifold Holset H1C 18.5 cm single turbo Prescision Turbo 46mm wastegate -10 AN oil drain and -6 AN oil feed -4 AN vacuum line to wastegate Custom Greddy Elbow Greddy Type S BOV RX7store.net greddy knock off front mount intercooler kit with hard pipes all secured by t-bolts Custom 3” Downpipe, midpipe, and racing beat dual tip catback Turbo XS manual boost controller Pettit Crank Pulley Ebay Greddy knock off Power Pully Kit R1/R2 oil coolers and lines with custom relocated oil filter Custom Air Intake Custom Oil filter relocation- Plan on doing Custom Coil Pack relocation- Plan on doing FC style fuel filter relocation- Plan on doing Pettit 185 Degree Fan Switch Fluidyne radiator Pettit AST RX7.com upgraded fuel pump - Plan on doing Black Silicone Vacuum hoses Power Steering removed A/C removed Cruise Control removed Air pump removed Oil Metering Pump removed All associated emissions controls removed and covered with block off plates Drivetrain: Pettit Short Shifter Spec Stage 3+ clutch New slave and master cylinder JDM Transmission Race rear end bushings Tranny has Neo synthetic fluid Electronics: Apexi PFC Datalogit black box Greddy Turbo Timer (with vehicle specific harness) Interior: AEM wideband and steering wheel mounted pod Defi amber backlit water and boost "racer gauges" <--- Would prefer the old style defi guages with the white font like the stock guages. But couldn't find any used ones at the time.... Pettit TKT floormats 5 speed RX8 shift knob Custom leather boot surround and ebrake surround Tinted Windows Exterior: 18 x 8 and 9 staggered AZA Wheels; 225/40/18 and 275/35/18 R1 Lip 97 JDM Spoiler Glass Sunroof Suspension: Pettit Slotted Rear Rotors JDM Front Strut Bar Eibach Lowering Springs Tokico Struts Sound: Kenwood DDx514 multimedia head unit with plug and play adapter harness Bose sound speakers with snorkels still in the rear |
Some more minor updates...
FMIC mocked up and R1 oil coolers installed http://i834.photobucket.com/albums/z...t/5aace3f4.jpg http://i834.photobucket.com/albums/z...t/4b7c2db8.jpg http://i834.photobucket.com/albums/z...t/3c84ffd3.jpg The block off plates and caps powder coated http://i834.photobucket.com/albums/z...t/9c53292e.jpg All the accessories powder coated black, Our local powder coater is doing an excellent job! http://i834.photobucket.com/albums/z...t/6c901938.jpg http://i834.photobucket.com/albums/z...t/773707b1.jpg http://i834.photobucket.com/albums/z...t/2838c355.jpg http://i834.photobucket.com/albums/z...t/dfc9d3c9.jpg Now the upper and lower intake manifolds are being powder coated the chrome like the block off plates. http://i834.photobucket.com/albums/z...t/95f1771c.jpg |
clean build. What did you use to clean the rotors with? those things looked brand spankin new.
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great build bro keep us updated....
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http://www.bettymills.com/store/imag...4-0905.eps.jpg Apparently you can't buy the 5 gallon bucket with tray any more. Just a one gallon is sold. But damn does this stuff work, it's really nasty stuff. After the rotors soaked for several days, I put them in the parts cleaning bin and scrubbed off the carbon. I then used a brass wire dremel wheel to get the rusty type blemishes off. And then finshing it off cleaning with paint thinner to remove the remaining residue. |
^^^ Thanks very much :) did you just get that stuff at a local hardware store or what?
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I honestly don't know exactly where they got it for the shop. I do know that of all places to look, amazon sells it! LOL
http://www.amazon.com/gp/aw/s/ref=is...k=B12+chem+dip |
WIN! haha.. thanks again
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No problem.
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Dude, our engine bays are going to look almost identical LOL. I just had all my stuff either powder coated, ceramic coated, anodized or done in black oxide. Great idea LOL. Let me know if you have problems with the CAS reading the trigger wheel though. I got that done in black oxide so it's still very magnetic but I was curious about powder coat on it.
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nice build! id be careful with powder coating the cap... putting it in the oven might mess up the rubber seal and cause leaking...
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Ha, It does seem our cars are going to look pretty damn close! I was going to powder coat the end tanks on my intercooler black as well, but decided that would be a project to do later on. I actually read your post pertaining to the wheel during the time it was being powder coated. Like you, my concern was how the triggers were going to pick up the wheel. But since parts are being recoated, that original (or in my case realllllllly tarnished/ non existent) green coating are being sandblasted off, I don't know if matters much. I read in your thread a couple of guys either painting or powder coating the wheel and then sanding on the back side a little with no problems what so ever. I was told by our powder coater that the thickness of the coat is 001" thick. But I'll probably just sand the back to be safe too. I would like to know if the wheel is magnetic or not. My thought that it isn't, but i've been wrong before. Quote:
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I just thought about this, if the wheel needs to be magnetic why couldn't a person just paint it with the magnetic black paint from lowes? Sounds chincy but it would work.
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No the wheel isn't magnetic, but the crank angle sensors are, and it just reads off the steel wheel. If it's only .001" thick I doubt you'd have a problem, but I'd still sand it just to be sure too haha.
I did get my IC end tanks powdercoated too haha, and also the sides of it too. Everything but the fins themselves. |
Ok good, I'm glad my thinking was correct. How do you like your cj motorsports fuel kit? I take it you bought the primary and secondary one? And chances are you bought the black rails like I plan on doing huh ;-)
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Nice build....
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