My T2 build

OK guys I have been working on this build since last September....

I have done a full write up and thread on www.rx7club.com (sorry if I was not alloud to link this

http://www.rx7club.com/showthread.php?t=689880

HOWEVER for those of you who are not members or cant access that forum I have pulled all the critical tuff out with pictures and I will post it below...

Notice most of my questions have been answered however and questions, comments or answers u may have please post.. I want this to be as big of a thread here as it was in that shit hole...

THX for looking..


THE THREAD STARTED!!!!!



DATED 9-19-07














So today I picked up my turbo engine... I got it for a great price however I will be taring it apart because well it is a piece of work..

This is what I do know of it..

SUPOSIDLY it is supse to be a BRAND NEW engine with no miles the guy I got it form (an aquaitnece of mine) said that it was all nice and clean before he put it in his car then it got nasty dirty between working on it and pulling it back out..

Anywho this is what I do know..

the engien was turned over and fired it idled for a minute but shot flames out the exhaust the entire time then it died... He found out he has a bad wire harness..

as far as the engine here is exactly all I know (have been told)

S5 T2 keg with s5 T2 internals
s4 T2 front cover (s4 T2 omp, S4 T2 alternator)
S4 T2 intake manifold (lim and uim)
S4 Turbo and S4 turbo manfiold
S4 T2 trans (no reverse)

I plan to completly pull the engine apart, label everything, and check for age, wear, etc. Replace the gaskets, o-rings anything else that may need replaced.

Street Port the engine

get a S5 twin Scroll turbo and header

powder coat the intake, and paint the housings etc.

Replace EVERYTHING wearable (water pump, double atl pulley, belts, slave cylinder, thermostat, gasket, check all sensors for ohm resistance etc)

Anywho the cost of everything u see is 500.00 So what do u think?

This is going in my S4 n/a coupe (I will keep the S4 intake setup so I can use the
S4 wire harness)

DATED 9-22-07

Well last night I went outside and started removing everything and bagging up parts etc... here is what I acomplished in abotu an hour, hour and a half..







And here is a pic of the engine openings (best I could get)



Well today was the day for the big tare down and boy was it a fun one lol... I learned quite a bit and got to see alot first hand and it was a blast..

On the other hand I got to see what a NOT NEW engine looks like... both rotor housings appear to be a GREAT shape.. not flawless but in very good shape. The irons also appear to be in GREAT shape.. The rotors are a different thing though.. they are COMPLETLY covered in ash and carbon.. I am going to have to give them a good soak and cleaning to see if they are ok.. otherwise the sides and the apex seal lips seem to be ok (more specing will be needed to verify)

The irons have not been ported (never told they were just stating facts), so those will get a good street port.

anywho onto the pics.


The tool:


WAIT thats not the tool thats RX7Tuner aka Brian, (the Muscle/Brains of the opperation)

The tool (flywheel nut removal tool):


I was suprised that is a HUGE tool and that nut is HARD AS HELL to get off especially with the engien not on a stand.

Another tool (flywheel tooth holder):


sorry thats a bad pic of it I should have taken it out of the bag but we need to move on!

The rotors:






The last one shows you where it was nicked a bit form a screw that was droped into the engine (prior to be buying the engine, however it looks like the only damage was on the rotor and not the housing)

The housings:






I know the picture quality is not that great however I can take more pics tomorrow we were busy and I wanted to snap some quickies and move on!

The irons:





Using your fingers on both the irons and the houisngs you dont feel ANY imperfections or scratches/gouges.

The e-shaft:


Again not a great pic but it also is in GREAT shape

Today I am going to un bolt the tranny and hopefully get the engine on higher ground.

Later today Brain AKA RX7Tuner is gonna come over and help me disasemble the entire engine and this way twe can start looking at what this is REALLY like...

I will update this thread later with more pics. BTW I did turn the engien over last night (ratchet on the pulley bolt) and it turned over VERY EASY and had compression (I could hear it POPPING out of the intake port)



Keeping the rotor seals correct Brian said "lets draw our diagrahms":





The clutch that came out of it (for sale slightly used looks fine should be a S4 T2 clutch kit 50.00 shipped USA)




The aftermath:




All in all we had a fun day. We started by going to pickup a S5 engine for Brian, then we grabbed lunch (THX Brian for that), then we came back to my place and got so nasty and dirty but it was a BLAST...

Look forward to more pics, info etc very soon!!

DATED 9-23-07

Well I cleaned up the rotors and they look ok.. the one rotor has a few marks in it and for osme reason it looks like it has a defect that is on EACH SIDE IN THE SAME PLACE (but nothing on the housing) I cant figure that out.. anyways on to the pics how do u guys think they look? Useable? are they going to be prime rotors to use or do I need to get different ones? I think one looks just fine (the front one) but the rear one I have no idea on.. RX7Tuner said it is fine I just want another opinion to make sure before I spend any money on other things. The rear rotor is the one that concerns me only because I dont know if this is ok or not?


ANYWHO

Front rotor:





Rear Rotor:




^^^^^^^^^this is the mark I am talking about it is on the same rotor all 3 faces in the same spot!!








^^^^Those last two show the spots I was talking about on the 3rd face of the rear rotor..


What do u guys think?


BTW as for cleaning (which I am not done yet) I sprayed the rotors down with brake cleaner used a flat blade screwdriver to scrape off the THICK carbon buildup and then used a PLASTIC wire wheel (drivin by a drill) to clean off everything... I have roughly 1 hour per rotor time into them as of yet but I dont want to put anymore time into them if they need to be replaced

DATED 9-30-07

Ok so it has been 4 days and what have I acomplished.. well not much...

I have bought a digital micrometer, and magnetic dial indicator. a new set of screw drivers, 2 pick sets and today I started to do some more cleaning..

I started by cleaning all the grooves on the rotors (around the rings and in the apex grooves) I used a side seal, brake cleaner, 2-3 different size crew drivers, a wire brush and a pic and all the grooves appear to be almost so clean u would eat off of them. I then used a flat file and smothed down the apex seal corners (where there was a bit of roll back, and I hit that one small spot on the rotor face that was raised a touch.

I will get pictures of the rotors for you later . Afterwards I decided to clean the mating surfaces of the rotor housings... I started with the rear housing.. after some time with the wire wheel (being cautious not to hit the chrome section with the wheel) I managed to clean it up very well and then snap some pictures.

unfortunatly I did find this as I was snapping pics

here is what the rest of the housing looks like

















Hopefully this is still a useable housing and will not give me a drop or a big drop in compression... I want to do this build correct but I dont want to have to buy more housings if I dont have to.

I went out and cleaned up the front housing and I see the same thing.






the good of the frt housing







Now on to the clean rotors (I think a good soak will bring osme of the color back and then one more hit with the wire brush after they soak for a a while)











Anywho so what do I do.. replace the housing or are they good housings?

DATED 02-02-08

OK some time has passed, I have had a while to deliberate and figure out what is next...

I have decided to use the housings... After inspecting them in person a bit better I think they will be just fine for what I am planning..

I have since bought the following

NEW Mazda 2 piece apex seals (2mm)
New Mazda apex seal springs (inner and outter)
New Mazda side seal springs
New Mazda 93+ Corner seal springs
New japan exterior gasket set (same set as sold by atkins half the price)


This weekend I will start wire wheeling all the plates and housings and getting them prepped for paint... After painted I will begin on doing the Street port.
Once the street port is completed hopefully I will have ALL my internal stuff so I can start on assembly...

I will update this weekend with progress pics of the cleaning and parts..

Sorry it has been so long but this project is now back on track.

OK after about an hour or so of cleaning the rotor housings with a wire wheel n a drill this is the final product





Now tomorrow I plan to go buy my paint and get that done.

Also here is a few pics of my current parts I have for the build.

2 piece Apex seals



Apex seal springs



S4 N/A engine gasket set (most gaskets can be used the rest sold and I will buy the few gaskets I will need extra.)





more pics and updates to come!
btw I am trying to pick a color.. humm just not sure yet what to paint the engine



DATED 02-09-08

Well after about a 2 hour bath in ATF the carbon came right off the corner seals and I was able to see that they will be just fine u to reuse... I just need to buy some plugs cause mine were toast... (yes I will be installing new plugs)

More updates tonight after I clean the irons..


DATED 02-10-08

Todays updates....

Today I painted the engine rotor housings.. the pics are not great but you get the pics..

the best red I could find today in high temp paint was Chrysler Import Red (wish it was darker)





And I pulled my oil control rings out of the ATF today.. I wiped them off, cleaned the carbon off of them and put them in a bucket of oil to soak... after they were in the oil for 20 minuted I pulled them out and put them in a ziplock bag (still coated in oil) and have them stored until I get to that parts f the build







DATED 02-11-08

ok let me catch up..

I have not painted the irons yet, I still have to clean up the intermediate and rear iron before I paint them and yes Gunmetal (iron cast color to be exact) is the color I will be using...

I only want to use the plugs because I think on my first rebuild I would feel more comfortable with using them.. I don't doubt u one bit Kevin.

As for the SS model.. BWAHAHAHA thats hilarious lol... Why would u want to compare your 7 to a gm product tagging it "SS" I think its more a "SS7" I don't know hahaha.. your car is not close to STOCK lol...

ok I will be pulling the tape off tonight and possibly painting the irons (I highly doubt it) I will get more pics later..

THX guys!


DATED 02-14-08

well I just dropped another 225.00 on parts last night.. I purchased the following

Atkins Viton oil control o-rings
Atkins thermal pellet
Mazda OEM side seals
Mazda OEM corner seal plugs
Mazda OEM mim gasket
Mazda OEM o-rings for the lim
Mazda OEM oil control seal SPRINGS (all brand new ones)

All the mazda stuff is due in tomorrow.. The Atkins stuff will prolly be next week sometime...

I think I have almost everything I need to make the build go through.. so more cleaning through out the week. paint the irons, buy the street port templets and tools and get to work porting the engine.

I hope to be ready to assembly by March 30th (my date to have the engine ready for build)

I will shoot pictures of the parts once they roll in the door..


Well I just ordered my Front and Rear e-shaft seal to so those will be here tomorrow also.. another 10.00 in parts lol.


DATED 02-15-08

ok well my parts have shown up (some of the masses I just bought)

In the picture attached u will see

ALL side seals
ALL oil control seal springs
Front and rear e-shaft seal
Turbo outlet gasket
S4 T2 mim gasket
Corner seal plugs
LIM coolant o-rings

I am still waiting for my Viton oil control o-rings and thermal pellet to show up.




DATED 02-17-08

ok here is some pics of the keg sandwiched together..

yes I forgot to paint the top of the rear iron but it is painted now... and the "13B Mazda" has been sanded down so it is metal color...







DATED 2-17-08

Well I just bought some

84-85 13B NT low impedance square top center port 680cc orange 195500-0900 injectors.

I heard they flow like 720cc injector on FC's so these will be my secondary injectors..

I am sending out my other injectors (550cc's) to get them cleaned and flowed so I can use two of them for primarys



DATED 02-18-08

See thats cool to hear. I like hearing success stories cause then that gives me confidence...

today I bought:
a tube of hylomar (in my posession)

from Pineapple Racing I purchased:
Medium street port template
exhaust port template
S4 T2 omp block off plate
S4 T2 air control valve block off plate
crank sensor cover plate (with ninja )
omp injector block off plugs


so I should see those before the weekend...

I cant wait I get to start porting here very soon.. I am so siked!!!


DATED 02-19-08

Well while I await my pats to show up I have cleaned up the work bench down stairs and I am going to pull all of the parts on it ...

Yes Brian this is where the porting will take place lol..

I will update with any more info or pics as things change


DATED 02-20-08

My purchase from Atkins showed up today

Viton oil control o-rings and the thermal pellet.



more to come after my Pineapple Racing purchase shows up

DATED 02-22-08
ok so today I have received

From Xboxthug360:
S4 T2 ECU
S4 T2 afm
S4 T2 water pump housing

From Pineapple Racing:
street port template
exhaust port template
crank sensor cover (ninja)
ACV block off plate
S4 omp block off plate
OMP injector plugs (however I just realized I only bought 1 pair...)

I will take pics tonight when I get home...

I also just bought from Japan2LA:
both S4 T2 fuel rails
SS clutch hose

just bought my walbro 255lph fuel pump.

OK guys here is some pics of the parts that came in and the painting I have done...

Painted CAS



CAS with Pineapple "ninja" cover


S5 thermostat housing (not sure yet if I will use it)


S4 T2 water pump housing



S4 T2 ECU


S4 T2 AFM


Pineapple Racing SP template


Pineapple Racing exhaust porting template


Pineapple Racing block off plates


Painted water pump pulley


Painted crank pulley


Painted front cover



OK thats my updates for today.. I plan to do more work and painting this weekend...

As I receive more or get more done I will post pics and updates...

As of right now including the engine and all the parts I have bought I roughly calculate about 1800.00


DATED 02-24-08

OK today was the day I began to port the irons...

I was quite scared but RX7Tuner was there to push me and make me do it lol...

I used the Pineapple racing template above and gave it the newbie porting Spooled up Racing push lol...

The grinding is done, I need to lots of sanding right now so I will have these done by wednesday I hope....

here is the current pics of the irons... (don't be to mean) lol

Front iron intake port


front iron port




Intermediate iron front port


Intermediate iron intake ports




intermediate iron rear port


Rear iron port job




rear iron intake ports





The mess on the table from afterwards



So what do u think?


I did the front and rear irons and RX7tuner did the intermediate iron... (I did not think he was good enough to handle the bigger ports)

Brian thank you very much for all your help today.. I am going to port the housings tomorrow and get to sanding so Hopefully Friday we can start assembly...

THX again... keep the comments coming..


Well I could not go to bed without getting the exhaust ports cut..

here are the pics, not sure which port is which housing but these are the pics I took.. again I still need to sand but I atleast got it cut tonight..

looking in from the outside



from the inside out




Talk more please!!! lol



DATED 02-25-07

Here is a couple pics my buddy took with his phone of work in progress







Well I got to the sanding tonight... I am done with the rough paper now and for the next two days I will be using 220g (maybe just the 150g) to get the perfect shine on them.. but here is some pictures from tonight

Exhaust ports





Front side on the intermediate iron


Rear side of the Intermediate iron


Intake ports on the intermediate iron


Rear iron port



What do u think?



DATED 02-26-08

Well I FINISHED sanding the ports tonight.. Tomorrow I will start bak to the rotors and get them 100% ready for the build then on to the next item in row....

I plan to have my table COMPLETELY organized by friday night... Saturday is the build...


Dave

[djmtsu]

Looks good. Did you slip a few times porting?

I did the front and rear iron and my buddy (the tool lol) did the intermediate housing...

we did both slip while porting but NONE of them I feel will cause any problems most of them you cant even catch with a nail or read with my dial indicator.

[djmtsu]

That is what I thought, they didn't look too bad to cause problems.

The build really does look like it is coming along quite well. You need to post pics of the car !!!!

The car

OK so today I got home to see I got 2 package

1 from japan2La:
2 S4 T2 fuel rails
1 SS clutch hose

1 box from Pineapple Racing:
1 60c syringe
1 engine stand adapter

here are the pics of the parts




Here is a pic of the NEW engine stand (yes the one I borrowed would not work, so I had to buy one) and my front plate bolted on.




Saturday is the big day I cant wait

[SoGlow7]

Good build so far, can't wait till end result. Im still deciding if i wanna do a t2 swap on my 86 also, or to just do basic rebuild on my NA for reliability. But good progress

[Jarred]

That looks sweet so far! I'm getting idea's for my future TII swap into my '86 gxl.

Tonight's update

I received my 720cc injectors (secondaries)


then I went down stairs to the basement (aka dungeon) and I cleaned all my engine internals and got them sorted on the table for Saturday... Yes u will notice I bought all new hardware too..









Well thats it for tonight I will update later after I get more done... I actually think I am done until i start to build it Saturday

Good night all I'm off to bed!

This afternoon we start the build... wish us luck