AZRR CYM FD Build Coming Together
 

Everyone,

Where do I start. I've owned the car since Nov. of 2000 and she was bone stock with 39K miles when purchased.

I noticed a nuisance coolant problem starting to develop in early 2002 that was diagnosed as an early coolant seal breach, but the problem didn't become catastrophic until Feb of 2008 with 56K miles. Parked in late February and pulled the engine in late March to take it over to Glen and Tom at AZRR for a medium street port. Decided to swap out the stock twins for a responsive smaller single turbo with good low end spool and 400 RWHP as my goal at 14-16 psi.

So, after lacking any motivation to work on the project this summer with garage temps in the 120F range, I finally got motivated in October.

I purchased a monster IC core from Garrett (12 x 24 x 3.5) with the intent on fabricating up my own Vmount. I drew from most of the best ideas I'd seen in our RX communities and designed and drew up all of the parts using heavy construction paper and wood to make mockups of everything from end tanks to mounting brackets.

It's been pretty involving, but I think the end result will be pretty sweet, plus I'll have the satisfaction of seeing something that I envisioned become reality. Hats off to all the kitmakers who came before me. I really appreciate your ideas and inspiration.

So, let's start the discussion. Here's what the car will have in it when completed. Hopefully this captures most everything:

Engine:

AZRR Medium Street port (Balanced Assembly)
Ground X lower intake manifold
Blowzilla TD61 Turbo (GT35R compressor with ball bearing cartridge and T4 divided hot section with 76 mm turbine wheel and 1.0 AR)
AZRR turbo manifold and DP
Dual Tial 38 mm wastegates
Tial BOV
Primaries (2 stock 450 cc RX-8 Renesis injectors)
Secondaries (4 1000 cc Yawpower injectors)
AZRR primary and secondary fuel rails
Weldon fuel pressure regulator
Walbro pump, but probably switching post break-in
Coil relocation kit
Stainless steel OMP lines
Garfinkle oil pan brace
Competiton Clutch lightweight steel flywheel with new ACT street/strip clutch

Engine Management:

Apexi Power FC
New Mazda engine wiring harness

Body (new items):

RE Amemiya AD9 CF hood (painted to match body color)
Shine auto FEED replica sideskirts in CF twill weave
Shine auto old style Amemiya rear diffuser
Aftermarket hood struts.

Below is a shot of the car with my old setup, followed by new pics of the car in it's current state of progress...

Engine will be ready for pickup later this week.

Thanks to everyone who've assisted me so far, especially Glen, Tom and Garrett over at Arizona Rotary Rockets. You guys are the best. Also, hats off to Aaron at Yawpower and Adam from Streetorstrip Concept. I wouldn't be where I'm at so far without all of your contributions!

OK, so here are some shots of the shortblock a month or so ago over at AZRR. It's so close now I can taste it. Hopefully this weekend.

.... a few pics to show you how I fabricated up my mounts using wood mockups to test fit everything. Also, a shot of the bare end tanks and IC core before welding.

Final post for today.... a few shots of the IC welded up and the final fitment images.

nice setup tell me more about this v-mount what kinda radiator are you running custom moddified twin flow???? i keep looking at vmaounts and the only kit i like so far is DEW's. i even applied to do testing on the kit but im a bit aways from him so i dont think hell go for it personally. but id like to find out more about your radiator setup for the v-mount if i end up having to make my own as well. i was gonna ask how you like your fuel setup tunning wise but you dont have it running yet let us know as i was looking at a very similar setup for my x-lim, i never though about dropping down to 450 primaries though. why did you drop the primary size?

z

Nice build. I want mine done. My car is over at AZRR right now. What HP are you shooting for? How has Glen been at the shop besides busy?

You got a cym!!!!!:o10::o10::o10:

Can't wait to see it all finished Tim! Keep working!:driving:

Looks great so far keep up the good work and keep us informed. :icon_tup:

I thought everybody in PHX has an A/C garage, lol.

I plan to move to Queen Creek, AZ in 2010 for work :) I'm really looking forward to the rotary scene out there and seeing that CYM in person!

I know... you bought Chris' car, correct? Sorry for the run of bad luck with the stock motor. She always kept that car pristine. I think Glen will take good care of you. Nice list of mods you've got coming as well. 400 RW is the goal, but I know it will be capable of more. I just need to resist the temptation to go higher once I reach my stated goal. Long term reliability and driveability is MOST important to me (at least right now!) ;). You're right, Glen is EXTREMELY busy right now, but he's having fun playing with their new ultrasonic parts cleaner. It does an incredible job getting old grease and grime off of engine parts.

Running a Koyo radiator. The bottom side outlet will be cut off and sealed up. I'm modding the engine side end tank to add a divided end tank and outlet on the drivers side of the rad. I'll post up some of my cardboard mockup pics tonight. 450 RX-8 primaries came highly recommended by Paul Yaw of Yawpower here in Phoenix. He has a longstanding reputation of building some of the best Mazda spec racecars in the country. He feels they are the best stock primary injector that he's ever seen. Incredible atomization. In fact Aaron who works for Paul is running them as stock primary injectors on a Gen 2 bridge port and it idles perfectly. As far as sizing goes I feel the dual 450s will be more than adequate for primaries.

Hmmm.... I thought you knew about this car Andy. I had it at Sevenstock's IV through IX, but haven't had it there the past 2 years, so maybe that's why you haven't made the connection. Can't wait to drive her next year ;) :)

Don't I wish my garage had AC. Quite honestly, I think I was just burned out on the car for a few months. It took me some time to get re-energized. Stay in touch if you happen to make it to Queen Creek. We have a great group of people who love to get out and drive!!

Tim, that wasn't a CA CYM...was it?

Actually, I bought the car on Ebay from a guy in Hawaii back in 2000 when buying something on Ebay was seen as being really "risky." He was getting zero bids on the car Stateside due to the logistics of shipping, which worked out well for me. I contacted him personally, got him to shut down his auction, then agreed to a price offline. Once we worked out the deal, I transferred funds to him and owned the car for 45 days before I ever laid eyes on her as I waited for the car to be shipped from Honolulu to Long Beach.

Longest 45 days of my life, let me tell you!!


proz07..... here's a couple of pics of my radiator mockup as promised.

Oh yea... here's a quick mockup shot of the hood after receiving it back from the paint shop a few months back. Bear in mind that nothing is bolted together in this pic....

This car is the reason my wife and I fell in love with FDs (and why we have one ourselves now) and she will be so glad to see you painted that hood. Definitely less ricey and more classy than the raw CF weave.

Ground X intake manifold? Is this another name for the Xcessive Manufacturing LIM or is it something else?

YAA!!! Does this mean we will soon see the big yellow banana on the road? As Jesse said, I love the new hood and I am so glad you painted it. It looks great. Make sure you let us know when you do the engine install. I am sure Jesse would love to help you with it.
Merry Christmas and see you New Years Day up on South Mountain (in your Honda Fit :driving:)!

Maybe the 99spec front end is in the works? i love that front end.

yes its chris's car and she did keep it in nice condition. Glen has been nothing but positive experience to deal with. I am shooting for around 450-475 but i want it to be tuned 350-400 for everyday driving. reliability is very key in my build as well. nice car and hope it says on the road longer than the other AZRR car. The white car out of tucson. I will have to come see the car when i get back from korea. cant wait to see all the rx-7 people in the az area.

I will definitely let you and Jesse know when I'm starting the install. Yes, Fit will be my likely driver on New Year's day. I should be close on the FD, but more than likely mid to late January on getting her back on the road.

Tes!

Andy, I really weighed the 99 spec front end, but in the end, I decided to keep the stock front end. I really feel that once you move to the 99 spec front end it moves the look of the car too far away from it's original design intent. I may change my mind in the future, but for now, this is how I feel about the "look" of the car.

ok i think i see what your doing originally a regular replacement koyo, and once you mod it it will be a dual pass with the in/out in the correct spot.
thanks
z

Pops - great build thread!

Glad you opted to keep the OEM US Spec front end. They look fantastic - much better, in my opinion, than the 99 spec's.

man i need to take a trip up from tucson and check you guys out !

Thanks Johnny Boy! Got your email... thanks for the support!

You're always welcome. We plan a trip or two each year down your way as well. I'll keep you in the loop if we don't connect before our next outing to the 'Ol Pueblo!

Just got back from visiting Glen down at AZRR. Motor should be coming home tomorrow. Until then, here's a couple of pics to show everyone what's going in my ride!!

Looking good Tim, you should make me some extra v-mount brackets.
James

:drool5: I want your motor...and your FD. Everything is really looking good!!! Keep it up:icon_tup:

Hey James.... funny, you know, everything I'm making for my Vmount kit, I end up thinking... I should just probably make 2 sets, since James is gonna want the same setup once I'm finished. Hopefully it will turn out to meet everyone's expectations ;)

Thanks rotorhead87. Yea, I've finally gotten off my butt and am starting to make some serious progress. Keep checking in, since this is the season to work in AZ garages, so it will definitely be completed SOONER than LATER.

Forgot to post these up earlier. The engine pull shot should have been the first in my thread ;) Also, wanted to give props to Glen at AZRR and show off the excellent port job on my plates and housings. Beautiful, beautiful work!

Well, we finally brought her home yesterday. Can't wait to get it installed and fired up. Thanks again to Glen and Tom from Arizona Rotary Rockets for all your hard work. Here's a couple of pics of the engine being loaded up by Glen (left) and Tom (right). Also, a shot of her sitting in my garage (but not for long). It was SOooo cool to have the engine delivered in Tom's REPU!! ;)

Got back from visiting my welder this morning. Completed our patchwork on the bottom of the Koyo. Patched 2 holes and moved the drain plug as you can see. Also tacked up my intercooler mounting brackets and installed for a test fit. Turned out incredible (IMO). Next up will be getting the engine installed and completing fabrication of my radiator end tanks with the motor in the car to verify correct positioning and angles for the radiator IN and OUT hoses.

Friday, January 2, 2009... thanks to those RCCAZ members who stopped over today to assist and support us in installing my engine. We got it in hooked up to the tranny and installed the motor mounts. Now, just a few days of hooking everything up, then finishing my fab work on the Vmount and remotely locating my battery and we'll take a shot a firing her up. Here's a pic of yesterday's installation activities and a shot of the IC in place for fitment purposes. Looks like it's gonna be sweet!!

Glad to see that beautiful motor finally in its home! Great work Tim as always and can't wait to see that beast driving around...

Thanks to you as well Aaron. I know from talking with Glen that you've had to jump through a few hoops as well to help us get to where we are today. Much appreciated. Like yourself, I can't wait to get her fired. Thanks again to yourself and Paul Yaw for the most excellent injectors and support!

No problem! We surely enjoy working with customers who understand all of the small details and put together a well setup car.

Very nice keep up the good work Rotary4life... lol.. :driving:

Thanks everyone. Finished up my radiator mounts tonight, so I thought I'd show off a few new pics. Next will be engine details, connections, then finalizing the radiator tank mods (nearest the engine) by my welder. Stay tuned.

looks like a shop did it ...great job rccaz...

Cant wait to tune that thing and gets some killing numbers

Thanks Glen... are you saying I should open a shop?? ;)

Beautiful car, awesome build. Congrats.

No, just that it looks like a pro did it ...silly, I dont need you as competition

LOL.... don't worry Glen ;) Just let me know when you want me to start work on your Vmount :)