Fenda's uber garage Engine Build
 

Howdy guys!

So this is my first ever "build" thread, both on here and on the 7 club. Over the past six years I've had a LOT of work done on my car, but I've never really taken an active hand in the work so I never felt right making a build thread since I didn't actually "build" it myself.

Well... After multiple rebuilds being done by a "reputable" specialist shop that all failed within a few thousand miles I said fuck it, and decided to take my engines fate into my own hands. I enlisted the help of my friends who know much more about engineering and mechanics than I myself do, and I had work done and parts made by some top notch shops and fabricators in our industry.

My own role in this engine build was minimal, however it was an incredible learning experience and I can't wait to do it again (though hopefully not TOO soon, lol). I've got to give credit where credit is due though:

I started fresh with a new motor from Ray Crowe. Ray is THE man to speak to if you're looking for OEM parts in America, he owns a 3-rotor FD himself and works in the parts department of Malloy Mazda/Hyundai. Seriously, if you need something call Ray! His work number is: (703) 490-8170

Le Virgin Motor:

http://i281.photobucket.com/albums/k...andNewREW2.jpg

Chip Ursu, of Chips Motorworks (http://www.chipsmotorsports.com/) did an AWESOME job on my rotors. I picked up a set of S4 N/A rotors for my engine and had them sent to Chip for lightening, balancing, and clearancing. Chip didn't just make me something functional, he took some old rotors and returned me a work of art! Seriously, when I saw my rotors I was tempted to call the whole rebuild off... I wanted to mount my rotors up on the wall, lol.

I seriously can't say enough good things about Chip and his outstanding service!!!

Said Rotors: So sex...

http://i281.photobucket.com/albums/k...S4NARotors.jpg

We broke down the motor that I had bought from Malloy and, while the S4 rotors were being worked on by Chip, my housings and irons were ported by Speed1 in Allentown, PA. Chris at Speed1 did a badass job of streetporting my motor. Again, my experience with Speed1 was probably one of the best I've had with a tuning shop during the tenure of my FD ownership, both in America and while living in the UK. I *will* be taking my car to Speed1 from now on for tuning and work I can't/won't do myself.

I picked up my apex seals from Adam at REC (www.rx7specialties.com) upon the advice that his black seals are essentially the RA SuperSeals, except that his won't gouge the shit out of your housings!

Elliot, from www.turblown.net provided me with a stud kit that will significantly help the life and reliability of my engine by allowing for more consistent tension without worrying about the stock ones giving false readings. These studs help alleviate potential problems that could be experienced while using the stock tension bolts in higher HP applications. The best part is that his stud kit doesn't require (expensive) machining to your irons and housings.

David Garfinkle is the freaking man!! I contacted him about his oil pan braces and he agreed to make another batch of them for me if I could help spread the word to other owners in the community. When I received his Oil Pan Brace I, like many owners before me, was incredibly impressed by the high standard of his workmanship. Needless to say, I feel sorry for anybody who doesn't have his brace and who missed out on this production run, since it seems they only come about once every year or three now.

Aaron at FFE (http://fullfunctioneng.com/) did an awesome job about supplying me with ID injectors and primary/secondary fuel rails. I'm not really sure where Full Function finds the time to R&D, and produce, the products they turn out... but from my experiences I'd say that it would be VERY difficult to find any company that can rival them, regardless of their size and budget. These guys are absolutely the REAL deal :bowdown:

After a quick phone call, and a nominal fee, the guys at Goopy Performance (http://goopyperformance.com/) hooked me up with their rotor prep kit. Honestly, if you're going to be doing any rebuilds on your own as either a shop or an individual than you should REALLY invest in something like this. In general, having the right tools for a job make the job better. When it comes to building an engine I feel it's safe to say that if you DON'T have the right tools for the job than you are doing something wrong... Goopy definitely provides the right tools :biggthumpup:

As far as the actual knowledge and elbow grease that went into this build... Brian, aka TitaniumTT, has been a fucking godsend. He took his weekend off to drive the 4+ hours from Speed1 down to my apartment in Alexandria for the build. Mike, aka RXtacy, came over to lend his considerable skill and training in Mechanical Engineering to the endeavor as well. Seriously, Brian and Mike spend a good 6+ hours measuring, and rechecking, the clearances to build my rotors to absolute perfection. Old man Bawbers, aka BrewerBob, came over with his wife on Saturday and lent his sarcastic wit, badass brewing skills, and cooking prowess to make the evening run smoothly with laughs, delish grilling, and top-notch home brews felt all around. My buddy Vlad, aka Max_Spd, came by with his buddy Sy (a new FD owner) on Sunday to help with actually building the keg. With this being my first hands-on engine build I was surprised how much prep work was actually required, if you want to do it right.

As far as the build itself goes, the tolerances were kept tight (like tiger!) and everything that wasn't specifically mentioned as aftermarket or special was 100% OEM and brand new from Ray Crowe.

I'm sure you guys are tired of reading though, and want to see pictures :cheers2:

Saturday

My work during the week (and Hurrican Sandy) started by cleaning, and then painting, the irons. While Brian and Mike were clearancing the Rotors on Saturday I cleaned up the irons of all the paint that oversprayed or dripped where it wasn't supposed to.

Rear Iron, Pre-completion:

http://i281.photobucket.com/albums/k...y/DSC04496.jpg

http://i281.photobucket.com/albums/k...y/DSC04499.jpg

And here is the rear iron, ready to go:
http://i281.photobucket.com/albums/k...y/DSC04508.jpg

http://i281.photobucket.com/albums/k...y/DSC04509.jpg

http://i281.photobucket.com/albums/k...y/DSC04510.jpg

Mike getting the side seal grooves ready:

http://i281.photobucket.com/albums/k...y/DSC04501.jpg

Brian checking up on his:

http://i281.photobucket.com/albums/k...y/DSC04502.jpg

Getting ready to check clearances on an apex seal slot:

http://i281.photobucket.com/albums/k...y/DSC04503.jpg


Break time!!!

Rotors were set where they rested, and I made the (first) hookah of the night. I learned how to make a proper hookah while living in Bahrain, I was taught by the Egyptian coal guys in Isis Cafe, in Manama.

http://i281.photobucket.com/albums/k...y/DSC04504.jpg

http://i281.photobucket.com/albums/k...y/DSC04505.jpg

That hookah lasted for a good hour or two before we finally lost interest and focused on making the rotors, and prepping the irons, again.

And another look at those rotors, because SEX!!!

http://i281.photobucket.com/albums/k...y/DSC04507.jpg

Mike shortening one of the side seals to fit the clearances that we ran for my engine. I'm dead serious when I say that Mike and Brian busted their asses getting these rotors ready. I owe a serious debt of gratitude to them for putting their time and knowledge towards helping me out!!

http://i281.photobucket.com/albums/k...y/DSC04511.jpg

:o16: :o16: :o16:

http://i281.photobucket.com/albums/k...y/DSC04513.jpg

All the clearances measured, and the seals being assigned their respective spots on the rotor.

http://i281.photobucket.com/albums/k...y/DSC04515.jpg

http://i281.photobucket.com/albums/k...y/DSC04519.jpg

http://i281.photobucket.com/albums/k...y/DSC04520.jpg

Greased up and ready for insertion baby :naughty::awesome:

http://i281.photobucket.com/albums/k...y/DSC04521.jpg


Fast forward to Sunday, we moved down to my garage and began assembling the keg.

(My next post will have the work done on Sunday, as it stands right now it's 11:30pm on Sunday night and I am POOPED!!!)

His record remains intact.:biggthumpup: He gave away half the parts needed to put it back together. And he painted the rest. Fast & the Furry.

Maybe you shouldn't have eaten so much Fatboy. And after hearing those noises coming from the bathroom, something else was pooped.:suspect:

At least I don't need to worry about your replies being in poor taste Bob, lol

So YOUR the one stealing Brian from us! I always here that he's in town AFTER he heads back north. MMMhmmm..

Looks good. You'll be in good hands with those guys backing you. However, next time I expect an invite. I'm looking at you B....

Looking good buddy :icon_tup: Did you get the front stack assembled Sunday?

So who is donating their pubs to this build?

Nope, gunna get those auto counterweight bolts first. I'm thinking we will do that next weekend, then finish making the long block.

I was going to finish posting up the pics last night but i got lazy, lol

I'll let mine grow a bit, then rip some out and stuff them in the intake and exhaust.

Yeah, I almost had him all to myself... If he hadn't brought that woman of his along I'd have sent my woman away and claimed little spoon :suspect:


I'll try to remember to give you a heads up when we go for weekend #2.

Looks awesome Levi. Nice to see you're finally getting a solid build. Can't wait to go for a ride in your beast come DGRR. :)

Thanks Glenn, yeah... I'm really excited about this :)

Gunna need to talk with you soon about pricing and options for going haltech :suspect:

Brought the little woman too huh? Watch out B... Virginia is for lovers!

If he spends too much time down here he may never go back to the cold north...

:rofl:

Yeah..... next trip down will be 12/2 or 12/9 or 12/16 or..... well..... you get the idea :rofl:

:rofl:














:suspect:















:awesome: ... :awesome: ... :awesome: ... :awesome:









:suspect:











While that is true..... PA has Intercourse :smilielol5:

Yeah..... especially if I don't get my Jeep put back together :banghead:

Now post pics of keg ASSembly

Emphasis on the ass :naughty:

Working on it boss man, and don't you worry Mike, I'm also focusing on your ass :naughty:

Is there anything specialized that I'm gunna need to do with that front stack? Or can Vlad and I easily hammer it out next weekend and finish making the long block?

Sim senhor ;)


So... Sunday morning we woke up a bit late, after Coffee and the arrival of Bawb and Mike (Bob was here before the coffee was even brewed) we started stacking the keg up.

Enter: My Garage..

http://i281.photobucket.com/albums/k...y/DSC04525.jpg

The majority of the assembly went pretty seamlessly. There were only 1-2 bottom corner seals that rotated wrong.

http://i281.photobucket.com/albums/k...y/DSC04526.jpg

http://i281.photobucket.com/albums/k...y/DSC04527.jpg

We used Quicksilver premix, Vaseline, and GTX 10W-30 for the assembly.

http://i281.photobucket.com/albums/k...y/DSC04528.jpg

http://i281.photobucket.com/albums/k...y/DSC04530.jpg

Nothing says "gigity" like brand new housings and irons.

http://i281.photobucket.com/albums/k...y/DSC04531.jpg

http://i281.photobucket.com/albums/k...y/DSC04533.jpg

Suck it Bawb!!! I did something for the engine (other than just painting the irons) lol

http://i281.photobucket.com/albums/k...y/DSC04534.jpg

http://i281.photobucket.com/albums/k...y/DSC04535.jpg

Almost there!!!

http://i281.photobucket.com/albums/k...y/DSC04536.jpg

I hate to see my rotors disappear from sight, but damned if I don't love where they're going...

http://i281.photobucket.com/albums/k...y/DSC04537.jpg

Almost ready for the studs :sifone:

http://i281.photobucket.com/albums/k...y/DSC04538.jpg

http://i281.photobucket.com/albums/k...y/DSC04539.jpg

Studs in, torque order written, down they go!

http://i281.photobucket.com/albums/k...y/DSC04544.jpg

http://i281.photobucket.com/albums/k...y/DSC04540.jpg

http://i281.photobucket.com/albums/k...y/DSC04541.jpg

That's where we ran into trouble.... When we tore down my old engine I put the bolts attaching the flywheel to the counterweight back into the counterweight so I wouldn't lose them. Then I turned them in with the junked engine.... Le Sad Day...

Being basically unable to go forward we decided to wrap it up for this session.

Brian hit the road for Connecticut with his paramour, Mike headed home, Vlad and his buddy dipped out and Bawb stuck around for another beer and some dinner.


Ideally I'll be able to get the bolts in and finish making the long block next weekend. The rest of the build will be on hold till Brian can make it back down though..

Once you get the flywheel on the front stack isn't too difficult. You do need to set your end play though (see below)

Attachment 12543

Attachment 12544

PS Don't throw away the spacer you don't use. I could use it.

Werd.... set end play to 15-20 thou, and make sure the torque is set to ~105-112ft/lbs not the 240-270 it calls for.... remember, it's an S4 front stack

^ That's 240-270 N-m, however that is still 180-200 ft*lbs

So you know vlad as well ... hmm.. what part of VA are you in??

I'm in Alexandria. We went to domestics vs. imports last November (with Rocky and crew) and you were going to help me retrieve my British friend from the airport for DGRR.

Not me.. I don't think. My life is a blur sometimes.

I work in Fairfax so jumping over to Alexandria is no big deal. Did you used to go to the Chik Fil A meets in Dulles?

Hmm... I could have swore you were at that Imports vs. Domestics car show at Budds Creek last year, I want to say it was the 5th or 6th of November. The person I'm thinking of used to be in the Navy as an Airdale.

I could be absolutely mistaking you, lol!

No, I haven't ever gone to one of the Chic Fil-A meets, though I've heard of them. I just didn't see the point since my FD has been down for (basically) the entire time I've lived up here, lol.

Ah - yup, not me. I haven't been to budds creek since 2001, lol...

Gotcha, lol. My bad =/

That would be me Levi lol.

Goddamned it! Thanks, lol. Too many letters and numbers followed by RX7 :suspect: lol

Haha Levi I see Brian has you injecting the vasoline... :suspect: :awesome:

Dont lie!!!!! Everyone LOVES that fucking syringe

go here
http://www.mazdatrix.com/b5.htm :puke:
and buy 11-plug..... you'll need it before you finish the front stack..... or before it comes off the stand anyway....

Oh, yeah.. I saw that on the atkins site as well. I'll pick one up once I have more monies in my account :(

werd... lemme know when you do and I'll shoot you some Summit part numbers as well and theres still the gas crap

Buy 1 of these http://www.summitracing.com/parts/aei-12333
And 1 of these http://www.summitracing.com/parts/fr...4-bl/overview/
And 2 of these http://www.summitracing.com/parts/sum-220166b/overview/

awesome build, looks like top notch work. did you get a weight on the rotors after the milling?

i also recently rebuilt my FD engine with s4 n/a rotors, but im still breaking it in. cant wait to start tuning it in boost!

Thanks a bunch man!! I really can't take any true credit for the quality of the build though, it would have been the same old crapshoot from the same old crooks if I didn't have people like Brian around to make build suggestions (and actually do the labor) and the different shops (like Chip) to take care of making all the pieces to my little puzzle turn out perfect!!! I'm just the thankful owner :lol:

Here is the complete blueprinting sheet I got from Chip when he was finished with my rotors:

http://i281.photobucket.com/albums/k...Balancing1.jpg
http://i281.photobucket.com/albums/k...Balancing2.jpg

Here is the link to what Mazdatrix holds each generations rotor to weigh in at: http://www.mazdatrix.com/faq/rotorwgt.htm

(note: FD rotors weigh 4328g (9.54lb), the S4 N/A rotors weigh 4553g (10.04lb), and mine weigh in at 4099g and 4243g!! Happy dance!!)


Dude, tell me about it!! I can't wait for Brian to get a free weekend again and bring his ass back down here so we can finish the build!! I'm gunna be a break-in FIEND looking forward to that boost tune!!

Unfortunately we're going to hold off on a full power tune (18-20psi+) until I can get rid of the PFC and put a decent ECU in there. With this engine and turbo I absolutely hope that I'll be making around 500whp in the 20-23psi range, potentially more. Wastegate (13psi) should net me around 400whp which will be PLENTY for bouncing around town ^_^

Brian,

I remember you mentioning that fuel lab had some decent filters (that came with mounting brackets). Do you think I should pick one of them up instead?

I was looking at this one:

http://fuelab.com/virtuemart/fuel-fi...fuelab-filters

Or this one:

http://fuelab.com/virtuemart/fuel-fi...fuelab-filters

You want the 10 micron filter, and you're going to be running -8 lines so you would want this one to reduce adapters.

http://fuelab.com/virtuemart/fuel-fi...fuelab-filters

Side note, why does your balance sheet say 20B and have a date of 6/17/09? It looks like that was his balance?

I think the -10 filter to further reduce any pressure drop.

Honestly that's a good question on the date and why it says 20B. I really don't think this is Chips 20B though.

Unless the actual body/media of the filter are a larger diameter on the -10 model it won't help you, and will introduce more chances for leaks.