1.6 ZM going forged

[Witchdoktor]

goal is a strong, reliable, and quick spooling 15psi daily driver.
I'm guesstimating 240whp and 280wtq (will be dyno'd after
broken in). Originally I was going to put forged miata B6
rods and forged B6 pistons as HiBoost did and relaxed did (his
forged ZM build here (http://www.mazdas247.com/forum/showthread.php?t=123637826.com/)), but with the help of kooldino I was
able to have Arias make a piston to go along with a B6 miata
forged rod (belfab racing) that's a direct swap. If you go with
B6 rods and B6 pistons the pistons will have to be shaved
1mm, the ZM and B6 rods will both fit the crank but rod
length is different. The pistons are 78.5mm (.020 over) with
8.5:1 compression ratio. EMS will be the same as before -
kooldino's mpi/smt6 (ignition and injector controller) setup
except prethrottle body injector will be replaced with 4 extra
injectors into the intake manifold. cooling system being
upgraded - adding an awr radiator (and will be able to
relocate it towards the driver side/away from the turbo/mani),
oil cooler being added, wrapping turbo and building heat shield
for exhaust manifold. transmission upgraded with quaife lsd,
plus adding lightweight flywheel. IHI VF24 was p&p and jet
coated black along with the exhaust manifold and downpipe.
Intake manifold and head being p&p by speedcircuit. keeping
the exhaust as is, 2.5" with one cat.

thread updated as build continues.

- Arias pistons 78.5mm (+.5) 8.5:1
- belfabracing B6 h-beam forged rods
- speedcircuit stage 2 head
- awr aluminum radiator
- oil cooler
- indigo lightweight crank pulley
- fidanza lightweight flywheel
- quaife lsd
- P&P intake manifold (w/4 extra injectors)
- ACL engine bearings
- P&P turbo (Deadbolt monster port & compressor housing outlet port)

kudos to speedcircuit, biknman, and bagman1

belfab h-beam rod with arias piston
http://www.msprotege.com/members/Witchdoktor/forged/belfab%20&%20arias.JPG

block bored and honed
http://www.msprotege.com/members/Witchdoktor/forged/bored%20&%20honed.JPG

arias pistons (http://www.speedcircuit.net/)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0703.JPG

arias vs stock
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0706.JPG

BelfabRacing forged rods (http://www.belfabracing.com/product_info.php?products_id=1203&osCsid=8a31401c83d8618c5edfa22cb56e357f)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0427.JPG

belfabs vs stock
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0707.JPG

radiator (honda awr radiator from another forum, ebay carries them)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0579.JPG

oil cooler (http://www.jcwhitney.com/autoparts/Product/tf-Browse/s-10101/Pr-p_Product.CATENTRY_ID:2000851/p-2000851/N-111+10210+600004731/c-10110)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0580.JPG

quaife lsd (bought from a forum member, new it goes for around $1500)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0581.JPG

ACL bearings and thrust washers (ebay ftw yet again)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0419.JPG

fidanza lightweight flywheel (bought from a forum member, ebay carries them)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0492.JPG

indigo lightweight crank pulley (http://www.srmotorsports.com/Mazda_Protege_Performance_Power_Pulleys_Parts.html )
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0502.JPG

engine pulled
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0458.JPG

cylinder #4 had shitty compression and 50% leakdown (yes that is a piece off the piston)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0460.JPG

intake manifold, coolant line, and fuel rail lightly polished
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0473.JPG
http://www.msprotege.com/members/Witchdoktor/forged/manifold%2045.JPG

valve cover prepped (paint stripped and letters shaved)
http://www.msprotege.com/members/Witchdoktor/forged/HPIM0490.JPG

done

http://www.msprotege.com/members/Witchdoktor/forged/side%20valve%20cover.JPG
http://www.msprotege.com/members/Witchdoktor/forged/front%20valve%20cover.JPG

Deadbolt monster port

http://www.msprotege.com/members/Witchdoktor/forged/port%20turbo.JPG

compressor housing ported

http://www.msprotege.com/members/Witchdoktor/forged/port%20compreshousing.JPG

water pump, oil pump, thermostat (montgomery mazda/bagman1)
http://www.msprotege.com/members/Witchdoktor/forged/pumps.JPG

[Azaizai]

woo woo, gl!

[relaxed]

Good luck with everything and keep us posted!

[steve_protege]

How much does something like that cost, approximately? I wanted to kinda get some of the same work done, but was quoted a bit too high for my liking. I might go with the Miata high compression pistons and then get the engine work done. Port and polish the manifolds and head. I was thinking about getting a 3 angle valve job done, but don't know....What would boring the cylinders do? Anywho, Id port-match everything and bore out the TB, maybe. If I can get an idea as to what you are paying, I kind of know what to expect. You can PM me if you want with the price... Good luck and keep us updated!

[Captain KRM P5]

http://www.stevessundrybooksmags.com/Littleengine1.jpg

cant wait to see how this turns out mr. sugerman, post a lot of pics etc

[lilchild87]

Good luck and post pics ASAP! (rockon)

Btw how much for this change?

[Witchdoktor]

Good luck with everything and keep us posted!


no doubt. thanks for helping homie.

[Witchdoktor]

What would boring the cylinders do? Anywho, Id port-match everything and bore out the TB, maybe.

stock bore on ours is 78mm, arias pistons will be 78.5mm. the cylinders have to be bored to fit the bigger pistons.

old displacement 1597cc
new displacement 1618cc

when the motor goes off to the shop and I get with the machinest I'll know what exactly will be done. price will dictate how crazy I wanna go.

[unwritten-dinas]

Im happy witchdoktor, finally some 1.6L guys are making changes to get noticed, nadim got his HiBoost kit a few months ago, and im going Custom Turbo-Kit as well.

May i ask where did you order all this parts from? I'll be at 8psi daily with stock internals, as i've heard that the 1.6L is stronger than the 2.0L FS-DE and that it can take 15psi for daily without problem, but i dont like taking chances so as soon as i wanna up the boost past 10psi i wanna go forged.

Keep us posted. Congratulations once again.

[lilchild87]

Thx for the info, have any idea on the posible gain??

[Protege2K]

Geez, didn't know you were still going strong with this car. Good luck on your future projects.

[mazpro]

this is great news, i can't wait to see how this turns out.

good luck bro.

[jster28]

Good luck on the build. Post pics as the build is progressing.

Are you going to do anything with the tranny? I know the 1.6 tranny is only good up to about 200hp, then it needs upgrading.

[Arnhem]

Nice numbers, hope to see the result soon

[Witchdoktor]

Good luck on the build. Post pics as the build is progressing.

Are you going to do anything with the tranny? I know the 1.6 tranny is only good up to about 200hp, then it needs upgrading.

If I didn't already have an act clutch I'd add one.




cant wait to see how this turns out mr. sugerman, post a lot of pics etc

aye aye captain. pics coming soon.

[jster28]

If I didn't already have an act clutch I'd add one.

A lightweight flywheel from a miata, would go nice with your act clutch and engine build.(thumb)

[lilchild87]

I think if you replace some of the protege parts for the miata's, ur car may be a little bit lighter.. plus pistons and bearings.. you may get a pretty good take off

[Witchdoktor]

A lightweight flywheel from a miata, would go nice with your act clutch and engine build.(thumb)



ouch!

http://cgi.ebay.com/ebaymotors/Centerforce-Lightweight-Flywheel-Mazda-Miata-800826_W0QQcmdZViewItemQQcategoryZ33732QQihZ001QQi temZ110005189495QQrdZ1QQsspagenameZWD1V

if it weren't so much I'd replace the flywheel while the tranny was out. but cost vs benefit, considering my goals, it's not worth it.

[jster28]

ouch!

http://cgi.ebay.com/ebaymotors/Centerforce-Lightweight-Flywheel-Mazda-Miata-800826_W0QQcmdZViewItemQQcategoryZ33732QQihZ001QQi temZ110005189495QQrdZ1QQsspagenameZWD1V

if it weren't so much I'd replace the flywheel while the tranny was out. but cost vs benefit, considering my goals, it's not worth it.


(omg) 700 for that flywheel, what is so speical about that one?


How about something like this for half the price
http://www.heeltoeauto.com/AASCO-Aluminum-Flywheel-90-93-Miata-1.6L-pr-63.html , or a fidanza

[Witchdoktor]

damn you. now I'm googling flywheels


http://cgi.ebay.com/XTD-PROLITE-RACING-FLYWHEEL-90-93-MIATA-MX5-1-6L_W0QQitemZ190141958815QQihZ009QQcategoryZ33732QQ ssPageNameZWDVWQQrdZ1QQcmdZViewItem


XTD any good?

[jster28]

damn you. now I'm googling flywheels


http://cgi.ebay.com/XTD-PROLITE-RACING-FLYWHEEL-90-93-MIATA-MX5-1-6L_W0QQitemZ190141958815QQihZ009QQcategoryZ33732QQ ssPageNameZWDVWQQrdZ1QQcmdZViewItem


XTD any good?
:)

never heard of them, so don't know. Not bad price. This one is a chrome-moly one weights about 9lbs. The aluminum one like the aasco and fidanza are 8lbs. But way lighter then the stock which was like 15+lbs. If they had the XTD one back in the day, i would scarafic the 1lbs different and got that and saved some $. There wasn't much flywheels back a few years ago, so i got the aasco, after founding out the the miata flywheel fit. I learned this from biknman on another forum that had one too.

[lilchild87]

why you guys complain about 8lbs? just get rid of the stock hood and go for a fiber carbon

Or is any other good effect from the flywheel?

[Witchdoktor]

How a lightweight flywheel works

How does a lightweight flywheel work? Amongst the majority, there are two schools of thought concerning light flywheels. The first is that they do not contribute to power output. The second is that they do. Which thought is correct? In fact both, in a way, are correct.

If we measured the power output of an engine first with light flywheel and then again with the standard part on an engine dyno, no change in power will be seen to occur. At first it appears that the light flywheel has done nothing and was a total waste of cash. This is not the case. A dyno that shows max power at constant revs does not demonstrate what happens to an engine's power output in real life situations - like acceleration. If an engine is accelerated on a dyno (we are talking about a rate of around 2000rpm a second ) it would show a power output of around 20%-25% less than at the constant rev state.

The reason for this is that when accelerating a vehicle the engine not only has to push the total mass of the car but the internal components of the engine need to be accelerated also. This tends to absorb more power as the extra power is used accelerating the internal mass of the engine components and is why a motor accelerating on a dyno will produce less power than at constant revs. Also it must be remembered that the rate of acceleration on the engine internals is much greater that the rest of the car. This would then suggest that by lightening the flywheel, less power would be required to accelerate it and therefore more power would be available to push the car along.

[jster28]

^^ what he said. There is less rotational mass to turn, which in turn uses less power from the engine to turn the wheels. Simple physics

Lilchild- Good luck finding a carbon hood for a 99-00. And if you do it is around 600. Vis used to make them, but discontinued.

[lilchild87]

i got it know.. less mass to pull

the carbon fiber was just an option.. im gonna sell my car anyways hehe

then a good combination will be light flywheel, light pulleys and light & small rims

[biknman]

Just remember with using wheels of a different size your messing with the gear ratios which will change your power band. There are calculators on the web to figure this all out. But making wheels bigger or small than the Mazda designed them to be will move the power band around i.e. normally lets say in third gear at forty miles an hour would be at let's say 4500rpms a good boost rpm near the stock 1.6 motor max power rpm with the stock wheel/tires diameter. SO if you where to go with smaller wheels at the same speed and gear you might be outside the rpm of 4500 maybe even lower putting you out of the boost range and power rpms of the stock 1.6 motor. And its impossible without a large bank account to get new final drive gear (ring and pinion) for the F series to compensation for the wheel diameters change. FYI its also screws up your speedometer readings which in the stock ECU could effect some of the tuning especially if you have an automatic trans.

Note the fianal drive gear in the 1.6 Pro could use a let help any-who as it is geared from more ecnomy than get power to the ground. Maybe somthing like 4.30 like Mazdaspeed and Emco has out for the G series trans.

[Witchdoktor]

after consulting with the 1.6 king (aka biknman) I'm leaning towards the lightweight flywheel and pulley set

http://www.srmotorsports.com/Mazda_Protege_Performance_Power_Pulleys_Parts.html

[jster28]

nice. srmotorsport makes some good stuff. Sr motorsport also carrys indigo flywheel.

[lilchild87]

nice pulleys! good money to raise around 30hp.. no torque?

[Witchdoktor]

30hp, dunno about that. driveability comes before performance so I'm not sure about messing with the flywheel or pulleys just yet.

[lilchild87]

Nice man..cant wait to see them.. how much was all this? items plus shop?

[Witchdoktor]

SRmotorsports main pulley added to the list.

still unsure what I want to do with the flywheel at the moment. resurface the stock one or go with a lightweight. driveability issue is the weighing factor. after reading about stalling, idling issues, and low rpm issues with the lightweight flywheel I got a bit more researching to do.

adjustable cam gears (SRmotorsports) for $400. claim 8-15hp. bah

[D-rock240]

Subbing, your car is definitely one of my favorites. Been following it since the dual exhaust project, and that interior=hot!

@Biknman: Where in MD are you? That car looks sick.

[Witchdoktor]

engine got pulled and torn down. cylinder #4 that had shitty compression and 50% on a leak-down test had a cracked piston. lucky for me it didn't break off completely. all you had to do was scratch at the crack just a bit and then a piece just chipped off. (pics of it posted)

I'm going a different route with the pistons. the bottom end from the B6 miata is supposedly the same as the ZM protege but for some reason two different ZM people had to skim 1mm off their miata pistons to fit the ZM. human error? some variable between the two motors? don't know don't care. no need to risk losing warranties (parts and labor) and alter the pistons.

[biknman]

engine got pulled and torn down. cylinder #4 that had shitty compression and 50% on a leak-down test had a cracked piston. lucky for me it didn't break off completely. all you had to do was scratch at the crack just a bit and then a piece just chipped off. (pics of it posted)

I'm going a different route with the pistons. the bottom end from the B6 miata is supposedly the same as the ZM protege but for some reason two different ZM people had to skim 1mm off their miata pistons to fit the ZM. human error? some variable between the two motors? don't know don't care. no need to risk losing warranties (parts and labor) and alter the pistons.
Freaking awesome dude congrats to you for finally get something worked out for forged internals for all us boosted 1.6ers. You'd the man:)! I just haven't had the time or funds lately to get it done along with zero vendor interest that I could muster up. What compression ratio are you going to have the pistons (boosted motor) set up for i.e. 8.0 8.5 8.8 9.0? To low and we'll lose off boost power to high we won't be able to boost enough. I think stock is 9.0 so probably a 8.8 would be good. I guess the Arias engineers would be best for figuring this out.

Again thanks for your efforts,

[Kooldino]

8.3 - 8.5:1 would be the way to go here.

[relaxed]

Hey man, keep us updated on what's happening.

Here's my own rebuild:
http://www.mazdas247.com/forum/showthread.php?t=123637826

[lilchild87]

Hey man, keep us updated on what's happening.

Here's my own rebuild:
http://www.mazdas247.com/forum/showthread.php?t=123637826

i'll tell you again! nice engine!

looks nice and clean!

race someone yet?

[Witchdoktor]

Freaking awesome dude congrats to you for finally get something worked out for forged internals for all us boosted 1.6ers.


any 1.6ers interested in arias pistons contact kooldino

[Witchdoktor]

lightweight crank pulley and flywheel are in

spent the day doing a little bling-bling. polished up a bit the intake mani, coolant line, and fuel rail. then sprayed a few coats of 500 degree engine enamel.

half the day was spent prepping the valve cover.....sanding down the letters and stripping the wrinkle paint, I forgot how many coats it had.

[mazpro]

looks good bro, the manifold came out really good. are you going to leave the valve cover like that or going to work on it some more?

[Witchdoktor]

gonna go with the black wrinkle paint again but shoud look cleaner minus the letters. plus I'm gonna give it a bit of gloss and added protection with a couple light coats of engine enamel.

[Kooldino]

Bling bling.

[alex corriveau]

engine got pulled and torn down. cylinder #4 that had shitty compression and 50% on a leak-down test had a cracked piston. lucky for me it didn't break off completely. all you had to do was scratch at the crack just a bit and then a piece just chipped off. (pics of it posted)

I'm going a different route with the pistons. the bottom end from the B6 miata is supposedly the same as the ZM protege but for some reason two different ZM people had to skim 1mm off their miata pistons to fit the ZM. human error? some variable between the two motors? don't know don't care. no need to risk losing warranties (parts and labor) and alter the pistons.

the only difference between both motor is the head gasket. Use the b6 ze head gasket

B6 ze: 1.1mm # b6dc-10-271
BP: 0.7mm
ZM: 0.4mm

HKS also made multiply metal gaskets for B6ZE 1.2mm and 2.0mm.

it maiby simply that way?

http://i175.photobucket.com/albums/w148/alex_MSP/Bannire-Mazda-1.jpg

[Kooldino]

Interesting.

[alex corriveau]

i've put the b6ze one on my zm stick there with copper gazket spray and arp studs
and evrething goes great

on mazda motorsport, it cost about 40$


http://i175.photobucket.com/albums/w148/alex_MSP/DSC00693.jpg

[Witchdoktor]

painted the valve cover in wrinkle black. definitely came out better this time throwing it in the oven versus using a hair dryer last time. when it's fully dry I'll throw a couple light coats of clear engine enamel.

[Witchdoktor]

valve cover came out great. 2 hours in the oven at 200 degrees, then followed with two light coats of clear engine enamel.


parts do in this week.......awr radiator, quaife lsd, oil cooler

[vindication]

damn ricers and their damn put-puts.
nah, j/k about the ricer part.
this is gonna be the fastest tweed covered, 1.6L Protege out there. Tell us how you feel. :p

[Witchdoktor]

Quote:
Originally Posted by alex corriveau http://static.mazdas247.com/buttons/viewpost.gif (http://www.mazdas247.com/forum/showthread.php?p=3390376#post3390376)
i've put the b6ze one on my zm stick there with copper gazket spray and arp studs
and evrething goes great

on mazda motorsport, it cost about 40$




what all do you have done to your 1.6?

[lilchild87]

Quote:
Originally Posted by alex corriveau http://static.mazdas247.com/buttons/viewpost.gif (http://www.mazdas247.com/forum/showthread.php?p=3390376#post3390376)
i've put the b6ze one on my zm stick there with copper gazket spray and arp studs
and evrething goes great

on mazda motorsport, it cost about 40$




what all do you have done to your 1.6?

Are you also going for cams?

[Witchdoktor]

the only difference between both motor is the head gasket. Use the b6 ze head gasket

B6 ze: 1.1mm # b6dc-10-271
BP: 0.7mm
ZM: 0.4mm

HKS also made multiply metal gaskets for B6ZE 1.2mm and 2.0mm.

it maiby simply that way?




this is info I got from Mazda:

B6 specs:
Bore-78.000
Connecting rod length - 133.90+/-.05
CR Big hole bore - 21.838-21.890

ZM specs:
Bore - 78.000 - 78.019
CR length - 132.90 +/-.05
CR BHB - ????? not in any of my info.

[Kooldino]

Well look at that...longer rods...by 1mm. Shocker.

[Witchdoktor]

actually you'd rather wish the B6 forged internals were interchaneable with the ZM. I never came across arias pistons for the B6. so the question is does speedcircuit have the capacity to handle the overwhelming demand from the zm crowd. think about that mister.

[Witchdoktor]

oh yeah. awr radiator, oil cooler, and lsd came in.
I'll post pics when I'm not feeling lazy.

[evilmonkeyMSP]

You have a stalker.

[terbow]

nice build! whats up with that jim bell guy though lol

[Witchdoktor]

he's my lover.

I forgot to use lube last night. He's mad at me.

[terbow]

shame on you.

[redrims]

he's my lover.

I forgot to use lube last night. He's mad at me.

Whoa!! (boom04) (inout)

[Witchdoktor]

hey shem. long time no hear.

[redrims]

hey shem. long time no hear.

Yeh, I creep along from here to there, but I have been following this thread since the past week or so.

You've gotten so far with your pro. Things that I dreamed about doing to mine but never did. I actually wanted to build the 1.6 and swap a ZL-VE head onto my 1.6. That never happened. I probably would have ended up spending a gazillion dollars on that build.

[Witchdoktor]

Are you also going for cams?

nope. biknman said the ecu doesn't adjust well to the timing and customizing the valve cover is a pita. just not worth the hassle.

as far as cost that you asked, I'll break it down in the end. biknman is parting out his car so that doubled my parts total right there - lol. I just couldn't say no.

[lilchild87]

nope. biknman said the ecu doesn't adjust well to the timing and customizing the valve cover is a pita. just not worth the hassle.

as far as cost that you asked, I'll break it down in the end. biknman is parting out his car so that doubled my parts total right there - lol. I just couldn't say no.

Posting pics of the engine soon?

btw i think this is a great build for a cheap price.. as long as i remember you said bearings 100.. and some other stuff.. around 600 bucks total?

[biknman]

Ever see a 3gen Protege laid out for dispaly like this :)

http://im1.shutterfly.com/procserv/47b7d700b3127ccebcb7c558b87900000025100AZtGrNk0ct2 LA

http://im1.shutterfly.com/procserv/47b7d700b3127ccebcb7dece794a00000026100AZtGrNk0ct2 LA

[biknman]

Below is a picture of my block that has never be opened since it was sealed up at the factory. We just took the head off about week ago. What you are seeing is a 99 1.6 ZM short block with about 110,000 miles on it of which the last 30K where boosted at between 6-10 psi and of those 30K miles the last 300 miles where at 20+ psi in race car trim (IE not street driven). The entire time is was boosted AFR where always kept generous i.e. 11:1 at 8 psi or higher along with methanol injection bigger inter-cooler as the boost got higher and close eye on not only AFRs but EGTs. FYI we actually lost power usually 10-20 whp with the higher fuel ratio and methanol which could be balnced out a little with timing but the motor could take 24 psi all day. 24 psi did cost me a couple trannies though :).

Enjoy,

http://im1.shutterfly.com/procserv/47b7d700b3127ccebcb7de69f8dd00000026100AZtGrNk0ct2 LA

Tons more pics in my new album click link in my sig.

[biknman]

With proper management a forged rotating assembly with good flow though the head and the power adder of a turbo this motor is going to kick ass and kick ass all day long the ZM is the little unknown secret believe I know.

Keep the updates coming bro!



Posting pics of the engine soon?

btw i think this is a great build for a cheap price.. as long as i remember you said bearings 100.. and some other stuff.. around 600 bucks total?

[Blake]

shorter piston stroke FTW, good luck on your build hopefully it goes alot smoother than mine......Seized cams, hole in oil pump...

[lilchild87]

With proper management a forged rotating assembly with good flow though the head and the power adder of a turbo this motor is going to kick ass and kick ass all day long the ZM is the little unknown secret believe I know.

Keep the updates coming bro!

Wow i wish i could put a turbo and tune it with all that stuff :(

At least a supercharge for mine.. not sure about price tho

[D-rock240]

Ever see a 3gen Protege laid out for dispaly like this :)

http://im1.shutterfly.com/procserv/47b7d700b3127ccebcb7c558b87900000025100AZtGrNk0ct2 LA

http://im1.shutterfly.com/procserv/47b7d700b3127ccebcb7dece794a00000026100AZtGrNk0ct2 LA


Great pics! How come you're parting out?

[biknman]

Great pics! How come you're parting out?

To many race cars not enough time. If your interested in any anything your more than welcome to stop by some time and check stuff out. Or if you want to see the car before it history. PM me and I'll send ya my address. FYI lots of pictures can be found here: http://biknman.shutterfly.com/action/ :)

[redrims]

WOW!! Never knew you made a custom wide body kit for the car. Man that thing looked sick. Definitely was NOT a sleeper.

What other race projects are you working on?

[biknman]

I hate to get in on Danny's thread for a forged motor build. Sorry Danny. But the car was pure NON street legal trailed supermodified PHA S2 class race car for the last three years. Current project was an 03 WRX wagon, now with 532 WHP @24 psi just slightly modified :) Suby Wagon frankensteion race car. I'm preparing for the Pennsylvania Hill climber Association 08 Hill-climb (SOLO1) series in the S3 class and few TTs in the unlimited or super modified classes. I'll post pics of the project along with racing it in my album.

http://shim1.shutterfly.com/procgserv/47b7d736b3127cce98548bdd521600000027100AZtGrNk0ct2 LA



WOW!! Never knew you made a custom wide body kit for the car. Man that thing looked sick. Definitely was NOT a sleeper.

What other race projects are you working on?

[lilchild87]

I hate to get in on Danny's thread for a forged motor build. Sorry Danny. But the car was pure NON street legal trailed supermodified PHA S2 class race car for the last three years. Current project was an 03 WRX wagon, now with 532 WHP @24 psi just slightly modified :) Suby Wagon frankensteion race car. I'm preparing for the Pennsylvania Hill climber Association 08 Hill-climb (SOLO1) series in the S3 class and few TTs in the unlimited or super modified classes. I'll post pics of the project along with racing it in my album.

http://shim1.shutterfly.com/procgserv/47b7d736b3127cce98548bdd521600000027100AZtGrNk0ct2 LA

You should be pretty good on the track then, what was your time on the 1/4 with the protege bro?

[biknman]

lilchild87
No 1/4 times sorry the car was used for TT, Time Attack, Hillclimb (Solo1) and Autocross.

[biknman]

http://www.msprotege.com/members/Witchdoktor/forged/finished%20valve%20cover.JPG

Wow awesome job. I should send you my Rexs manifold to paint. I hate painting not my cup of tee. So again awesome :)!

[Witchdoktor]

Wow awesome job. I should send you my Rexs manifold to paint. I hate painting not my cup of tee. So again awesome :)!

thanx, I like it so much I ordered a different oil cap.

now back on topic to you littering my thread with you car (bow)

[Arnhem]

To many race cars not enough time. If your interested in any anything your more than welcome to stop by some time and check stuff out. Or if you want to see the car before it history. PM me and I'll send ya my address. FYI lots of pictures can be found here: http://biknman.shutterfly.com/action/ :)

parting out! (sad1) noooo
I adored your car...

[D-rock240]

To many race cars not enough time. If your interested in any anything your more than welcome to stop by some time and check stuff out. Or if you want to see the car before it history. PM me and I'll send ya my address. FYI lots of pictures can be found here: http://biknman.shutterfly.com/action/ :)

Sorry man, just saw your reply. PM sent.

[unwritten-dinas]

Not to hijack the thread Witchdoktor, but on the the subject, does anybody know what size the stock 1.6L injectors are? I'm almost done to start installing the turbo but would like to know the stock injectors size and how much PSI they can handle???, i'll stay at 5psi for a few months before i up to 8-10.

[Witchdoktor]

155cc. psi ?

when I ran 6psi with a fmu everything seemed to run fine. I can't say for sure because I never dyno'd it and was running a narrowband at the time. it came from biknman so maybe he'll chime in. plus I was using stock fuel pump if it helps.

[biknman]

155cc. psi ?

when I ran 6psi with a fmu everything seemed to run fine. I can't say for sure because I never dyno'd it and was running a narrowband at the time. it came from biknman so maybe he'll chime in. plus I was using stock fuel pump if it helps.

Ya 6 psi with a raising rate fuel pressure regulator that goes from stock fuel pressure around 40psi up to 70psi is pushing the stock injectors to their max duty cycle while try to target a AFR of say 12:1 under boost. I went with stock 1 gen Turbo Eclipse injectors something like 350cc and at 8-10 psi with 7:1 FPR running up to 90 psi and I was using up to 85% duty cycle also incorporated an SAFC at this point. To go above 8 psi I went with 550cc Mustang injectors the same raising rate but a mega squirt controlling the injectors pulse width and I only ran the injectors up to about 75% duty cycle at 18 psi also up graded the fuel pump to an Walbro 255gpr also started spraying methanol at 4psi of boost at 50spi ram-ping up to 100psi at 20psi of boost with a small nozzle on a Snow Performance system. Under boost I've always tried to target an AFR of 13:1 for 0-4psi, 12:1 for 4-8, and 11:1 for anything above 8 psi. Prior to the Mega Squirt I used an Super AFC (MAF) along with vacuum check valves (MAP) and O2 simulators to try and fool the stock ECU all the while always monitoring AFRs and EGTs which was constant pain in the ass. I worried all the time about what was going on so it didn't make for a very fun street vehicle for me. I even experimented with a POT dial on the water temp sensor. Basically anything above 8 psi you are going to need better fuel system and more control over timing and fuel to get the job done right.

[mazpro]

BUMP, Any updates?

[unwritten-dinas]

So for 5psi de stock injectors should be fine right?

[Witchdoktor]

So for 5psi de stock injectors should be fine right?


yes

[Witchdoktor]

BUMP, Any updates?


waiting for Arias to finish the pistons

[Ghostx]

hi all
may name is amro from saudi arabia and(sorry for ay english)

i need help to find parts tuning for may car mazda 3-1,6cc-107hp -manual gear - 2007

all thing (plug & pulley & Chiptuning Kit & Turbo Kit & short shift & calach )

thanks \bye

[Kooldino]

The 1.6L in your car probably isn't the ZM 1.6 discussed in this thread.

Also, your signature is too large, please shorten that.

Aside from that, welcome to the forums!

[Witchdoktor]

pistons arrived. everything going to the machine shop monday

one word kooldino....... beauti-fucking-ful!

[Witchdoktor]

any 1.6ers wanting to go forged keep in mind the arias were made according to the belfab rods specs (B6 miata). the arias will not work with stock rods and if you look into other rods make sure the specs match up to the belfabs.

[Bamba ZL-VE]

Please... can u tell me where i can buy the crank pulley for my 1.5L ZL-VE... I think is the same as the 1.6L (sad2)

[Witchdoktor]

http://www.srmotorsports.com/Mazda_Protege_Performance_Power_Pulleys_Parts.html

but I'd contact biknman first, he still may have his for sale plus the water pump and alternator pulleys

[Kooldino]

pistons arrived. everything going to the machine shop monday

one word kooldino....... beauti-fucking-ful!


omgpix?

[AzteCypher]

I got a question. I've been debating with a friend of mine on the need for a lightened fly wheel and an LSD for a car that will end up being boosted. I argue that both will be helpful in time attack and autocrossing. He argues that the fly wheel will benefit an NA car more than a turboed car, and that the LSD will only be good for drag racing. He's thick headed so info that ya'll can share would be greatly appreciated. Oh, this is my car we're talking about, I'm gathering bits and pieces as we speak so I can go turbo next year. I've got the 1.6L.

[redrims]

I got a question. I've been debating with a friend of mine on the need for a lightened fly wheel and an LSD for a car that will end up being boosted. I argue that both will be helpful in time attack and autocrossing. He argues that the fly wheel will benefit an NA car more than a turboed car, and that the LSD will only be good for drag racing. He's thick headed so info that ya'll can share would be greatly appreciated. Oh, this is my car we're talking about, I'm gathering bits and pieces as we speak so I can go turbo next year. I've got the 1.6L.

Having a lightened flywheel and LSD is a win/win. I have both, in both my cars. A lightened flywheel will allow you to go through your revs a lot quicker. If your motor can rev quicker, then you will spool quicker. Your turbo will still spool at the same rpm it's rated to spool at, but with a flywheel it will get to that rated rev a lot faster.

When you go to the an autocross, notice the cars with LSD, then notice the cars without LSD. On the cars without LSD, you will notice that when they start to exit hard out of a sharp corner, one wheel is barely moving while the other is smoking like a train. You don't want this. That will slow you down, as well as, uneven/premature tire wear.

The same advantages that a lightened flywheel and LSD provides for a N/A car, are the same advantages you will have for a turbo car. It doesn't change when add a turbo.

[Bamba ZL-VE]

http://www.srmotorsports.com/Mazda_Protege_Performance_Power_Pulleys_Parts.html

but I'd contact biknman first, he still may have his for sale plus the water pump and alternator pulleys


Who is he and how can I contact him?
Clearing something out... my engine is the ZL-VE 1.5L not 1.6L but i do believe that all stock pulleys are the same in both

[biknman]

Who is he and how can I contact him?
Clearing something out... my engine is the ZL-VE 1.5L not 1.6L but i do believe that all stock pulleys are the same in both


It's me biknman or Dave. Sorry all the pulleys are sold.

I do have the following left for sale: :)

Set of front AWR reinforced control arms with bumper steer correction ball joints all billow ball bearings (aka spherical bearings) in stead of rubber bushings. $350.00 plus shipping

AWR front adjustable sway bar end-links $30 plus shipping.

AWR full adjustable rear lateral links and trailing arms with billow ball joints and all the correct spacers. $200.00 plus shipping

ACT clutch with an HD pressure plates and new 6 pad (non sprung) clutch disc and though out bearing with stainless steel clutch line. $100 plus shipping

Also found a set of rear APC carbon fiber look rear taillights. Make offer plus shipping

Four stainless steel and one mild steel exhaust flanges for making a turbo or NA header. $50 each plus shipping

Front set of Ground Control adjustable camber caster billow ball strut top plates. $150.00 plus shipping

Rear set of AWR billow ball struts (aka spherical bearings) tops $100.00 plus shipping

And couple of rear CF wings/spoilers one that's straight and one that is 3D in shape and type. Make offer plus shipping

B&M stainless steel short shifter with Kartboy bushings and Kartboy Silver knob all mounted to the linkage for easly installation. $100 plus shipping

Lastly a rear 3gen 4x100 drum to disc brake conversion kit with (must have 16" wheels or bigger) Wilwood Dynalite four piston calipers, Wilwood two piece rotors, Wilwood single piston emergency brake calipers, stainless steel brake lines, all mounted up to the sock spindles ready to bolt up. $500.00 plus shipping. That's over $1200 in parts and there is no other kit like this out there. FYI Wilwood pads and rotors used in this kits can be found just bout anywhere in the world for replacement as they wear out. Designed to be compliant with the stock master cylinder volume and brake basis valve.

Thanks
Dave

[Witchdoktor]

dave - pm sent on brake kit (my bank account hates you!)

VF24 turbo went to a local shop for P&P, this should start spool up 300-500 rpm quicker. I opted not to upgrade the compressor wheel even though it would add power it would add lag. the goal is not big numbers but rather usable power. 300whp is nice on a dyno but I'd rather take 225whp that you can use.

[biknman]

dave - pm sent on brake kit (my bank account hates you!) SORRY :) Sent ya a PM

VF24 turbo went to a local shop for P&P, this should start spool up 300-500 rpm quicker. I opted not to upgrade the compressor wheel even though it would add power it would add lag. the goal is not big numbers but rather usable power. 300whp is nice on a dyno but I'd rather take 225whp that you can use. I agree! The ZM although a awesome FI platform is no good off boost. You'll never needs tons of boost to make power for the weight of the car so I'd also short for quicker spooling vs lots of boost up high, which will make funner to driver daily driver any-who.

[biknman]

THe rear drum to disc brake kit SOLD

THe AWR front endlinks SOLD

ANd I have one less stainless steel exhaust flange for DIY header.

Still have all the other stuff.

As Witchdoktor is doing by documnting the forged build of the ZM motor. If the two guys I've sold the fornt BBK kit and rear drum to disc conversion kit are willing to make some drawings(tracings) on graph paper of the brackets along with listing all the diameters and dimensions before they install them, that would allow all the the other 3gen 4x100 Protegees to build their own front BBK and rear drum to disc conversion kits. Also would need a list of either the part numbers for the Wilwood calipers and rotors or detail descriptions i.e. caliper mounting hole/tabs length, distance, and diameter then the rotor hat dimensions with the rotor overall diameter and thickness measurements. Armed with all that info one could get the brackets made at machine shop or make them yourself and then give all the info on the rotors and calipers to say good race shop like HRP WORLD, CDOC, Wilwood direct , AWR, etc and they be able to get the proper caliper rotors and some stainless brake lines with proper adapter to hook up to the stock hard lines and calipers. I had all the info but after several computer cashes and my home burning to the ground in 04 lost it all.

Thanks
Dave


It's me biknman or Dave. Sorry all the pulleys are sold.

I do have the following left for sale: :)

Set of front AWR reinforced control arms with bumper steer correction ball joints all billow ball bearings (aka spherical bearings) in stead of rubber bushings. $350.00 plus shipping

AWR front adjustable sway bar end-links $30 plus shipping.

AWR full adjustable rear lateral links and trailing arms with billow ball joints and all the correct spacers. $200.00 plus shipping

ACT clutch with an HD pressure plates and new 6 pad (non sprung) clutch disc and though out bearing with stainless steel clutch line. $100 plus shipping

Also found a set of rear APC carbon fiber look rear taillights. Make offer plus shipping

Four stainless steel and one mild steel exhaust flanges for making a turbo or NA header. $50 each plus shipping

Front set of Ground Control adjustable camber caster billow ball strut top plates. $150.00 plus shipping

Rear set of AWR billow ball struts (aka spherical bearings) tops $100.00 plus shipping

And couple of rear CF wings/spoilers one that's straight and one that is 3D in shape and type. Make offer plus shipping

B&M stainless steel short shifter with Kartboy bushings and Kartboy Silver knob all mounted to the linkage for easly installation. $100 plus shipping

Lastly a rear 3gen 4x100 drum to disc brake conversion kit with (must have 16" wheels or bigger) Wilwood Dynalite four piston calipers, Wilwood two piece rotors, Wilwood single piston emergency brake calipers, stainless steel brake lines, all mounted up to the sock spindles ready to bolt up. $500.00 plus shipping. That's over $1200 in parts and there is no other kit like this out there. FYI Wilwood pads and rotors used in this kits can be found just bout anywhere in the world for replacement as they wear out. Designed to be compliant with the stock master cylinder volume and brake basis valve.

Thanks
Dave

[vindication]

cool, keep us updated on the specs for rear drum kit diy

[D-rock240]

Good luck on that insane brake kit. I already had the 5 lug swap in the works when biknman started parting out, otherwise I probably would have picked it up right away.

[biknman]

Maybe as I did with the DIY turbo kit under my listing for the exhaust flanges I have for sale http://www.mazdas247.com/forum/showthread.php?t=123691052 I'll do a big wight up how the front and rear brake kit s evolved so it documented. But not snake Whichdoctor thread any longer I'll start a new one.
Good day :)


Dave
As Witchdoktor is doing by documnting the forged build of the ZM motor. If the two guys I've sold the fornt BBK kit and rear drum to disc conversion kit are willing to make some drawings(tracings) on graph paper of the brackets along with listing all the diameters and dimensions before they install them, that would allow all the the other 3gen 4x100 Protegees to build their own front BBK and rear drum to disc conversion kits. Also would need a list of either the part numbers for the Wilwood calipers and rotors or detail descriptions i.e. caliper mounting hole/tabs length, distance, and diameter then the rotor hat dimensions with the rotor overall diameter and thickness measurements. Armed with all that info one could get the brackets made at machine shop or make them yourself and then give all the info on the rotors and calipers to say good race shop like HRP WORLD, CDOC, Wilwood direct , AWR, etc and they be able to get the proper caliper rotors and some stainless brake lines with proper adapter to hook up to the stock hard lines and calipers. I had all the info but after several computer cashes and my home burning to the ground in 04 lost it all.

Thanks
Dave
[/quote]

[sgtflex]

No mean to jack your thread but I have a 1.5 japanese ZL-DE. Im looking to rebuild my engine and maybe forge. Will the rebuild kit for the 1.6 ZM work for me and also will I be able to go the same route as Witchdoktor with forging my engine with the miata parts or will it be too much to bore?

Jsut to clear up some stuff:
- Bore out by 0.5mm
-Bellfab Rods
-Unmodified Arias Forged Pistons or do they have to be machined?
-Will the Miata ACL race bearings work for my ZL?
-How about the Head Gasket, did that work direct for u or did you have to shim it?

[Witchdoktor]

no need to apologize for jacking threads. the pistons can be made to a different bore size. the question is if the ZM and ZL are the same.

[Witchdoktor]

Jsut to clear up some stuff:
- Bore out by 0.5mm
-Bellfab Rods
-Unmodified Arias Forged Pistons or do they have to be machined?
-Will the Miata ACL race bearings work for my ZL?
-How about the Head Gasket, did that work direct for u or did you have to shim it?


first thing to find out is if the crank is the same for both the ZL and B6. if so then that's a good starting point....if that's the case you can use B6/belfab rods, B6 bearings, and if the ZM forged arias pistons aren't interchangeable with the ZL (which i think is not the case) you could contact kooldino to go about having them made.

head gasket I haven't figured out yet, cometic looked at my stock zm gasket and couldn't make one from similar templets they got.

[Witchdoktor]

anyone with any helpful info by all means jump in

[Kooldino]

Can't wait to see this thing run.

[biknman]

first thing to find out is if the crank is the same for both the ZL and B6. if so then that's a good starting point....if that's the case you can use B6/belfab rods, B6 bearings, and if the ZM forged arias pistons aren't interchangeable with the ZL (which i think is not the case) you could contact kooldino to go about having them made.

head gasket I haven't figured out yet, cometic looked at my stock zm gasket and couldn't make one from similar templets they got.


First I'd try giving Mazdaspeed Motorsports Development a call might want to join them first and see what they can help you with then obtaining the Factory service manuals for the ZL and ZM engines for the detail information of the internals. I do know my ZM engine block has ZL cast in it in several places.
Next research the flowing links:
www.protegefaq.net (http://www.protegefaq.net) the greats resource of Protege info out there
http://mazdaengines.aokforums.com/ forum for the family of Mazda engine only
http://rebuilt.com/Mazda_Engines.htm a Mazda only re-builder
http://www.mazdaclub.com/mctech.htm Mazda owner site with lots of cross reference info
http://www.imazda.com/forums/index.php Mazda forum from around the world the Aussie and Kiwi's can be a wealth of knowledge on the 323 familia
Lasley I've heard tales that it is possible to bolt a ZL variable valve timing head on to a ZM short block so the quickest way may be to get a ZM short engine block and crank then forged rods and pistons Witchdoctors has sourced and bolt on your ZL head. Or buy from a bone yard, eBay, or www.car-parts.com (http://www.car-parts.com) a piston and rod pull your motor apart make the comparaisons. That's where I was headed I got a used BP piston and rod the factory manuals next would have been to pull my block apart and make the comparisons. Untimely nobody is going have the answer you'll have figure it out yourself as Witchdoctor did for the forged internals on the ZM engine. THe ZL and ZM family is just to small to get attention from the industry even though the little engines are proven beast for boosting.

FYI I have the factory service manual for the ZM short block if you need any info or would like to purchase it. They can easly be found on eBay, Amazon, or though Mazdaspeed Motorsports Development.

Good luck,
Dave

[sgtflex]

http://cgi.ebay.com/ebaymotors/MAZDA-323-PROTEGE-1990-THRU-2000-HAYNESS-REPAIR-MANUAL_W0QQcmdZViewItemQQcategoryZ34226QQihZ018QQi temZ280182495795QQrdZ1QQsspagenameZWDVW


Im guessing you mean this book?

[biknman]

http://cgi.ebay.com/ebaymotors/MAZDA-323-PROTEGE-1990-THRU-2000-HAYNESS-REPAIR-MANUAL_W0QQcmdZViewItemQQcategoryZ34226QQihZ018QQi temZ280182495795QQrdZ1QQsspagenameZWDVW (http://rover.ebay.com/rover/1/711-1751-2978-71/1?AID=5463217&PID=2509925&loc=http%3A%2F%2Fcgi.ebay.com%2Febaymotors%2FMAZDA-323-PROTEGE-1990-THRU-2000-HAYNESS-REPAIR-MANUAL_W0QQcmdZViewItemQQcategoryZ34226QQihZ018QQi temZ280182495795QQrdZ1QQsspagenameZWDVW)


Im guessing you mean this book?


That's more of a repair manual mainly but a very good resource to have. It will not give technical details on the engine like the Mazda Facorty feild service manual would. I'll try and take a picture of the cover this weekend and post it.

[biknman]

That more for repair manual mainly but a very good resource to have. It will not give technical details on the engine like the Mazda Facorty feild service manual would. I'll try and take a picture of the cover this weekend and post it.


Found it one http://cgi.ebay.com/ebaymotors/Mazda-Protege-Engine-ZM-Service-Manual-1999-and-newer_W0QQcmdZViewItemQQ_trksidZp1638Q2em118QQcate goryZ34226QQihZ011QQitemZ320182059690QQrdZ1QQsspag enameZWD1V (http://rover.ebay.com/rover/1/711-1751-2978-71/1?AID=5463217&PID=2509925&loc=http%3A%2F%2Fcgi.ebay.com%2Febaymotors%2FMazda-Protege-Engine-ZM-Service-Manual-1999-and-newer_W0QQcmdZViewItemQQ_trksidZp1638Q2em118QQcate goryZ34226QQihZ011QQitemZ320182059690QQrdZ1QQsspag enameZWD1V)

http://i24.ebayimg.com/08/i/000/be/da/98b7_1.JPG

In ebay use the serach terms "protege service"

Ialso recomend the service highlights http://cgi.ebay.com/ebaymotors/1999-Mazda-Protege-Service-Highlights-Fac-Manual-shop_W0QQcmdZViewItemQQ_trksidZp1638Q2em118QQcateg oryZ34226QQihZ012QQitemZ220136236522QQrdZ1QQsspage nameZWD1V

http://www.techsourceky.net/sxe218.JPGThanks
Dave

[sgtflex]

Hey guys,, good news. I found out the crank is the same on the 1.5 and 1.6

[Bamba ZL-VE]

both engines are essentialy the same, the only difference is that the ZM 1.6L engine has a 5.2 mm longer stroke than the ZL 1.5L
bore of both is 78 mm
Stroke for ZL 78.4
Stroke for ZM 83.6

Check this page for a little more info...
http://www.protege323.com/content/24_engines/index.php

[Kooldino]

Ok, so if the stroke is different, the rods are probably going to be different too.

However, the pistons that I had made for witchdoktor should work.

[Witchdoktor]

if you had a stock ZL rod and piston sent to you could you confirm this?

[biknman]

FYI I've added more info to my DIY turbo thread http://www.mazdas247.com/forum/showthread.php?p=3562189#post3562189

I'm still working on a intake manifold DIY along with brake up grades how to for the 3gen 1.6 Protege.

[Kooldino]

if you had a stock ZL rod and piston sent to you could you confirm this?

I'd need a stock ZL piston/rod as well as a stock ZM piston/rod

[Witchdoktor]

^ if any ZL person wanted to send in their rod/piston I've got the stock ZM rod/piston to compare

post up or send me a pm

[Bamba ZL-VE]

^ if any ZL person wanted to send in their rod/piston I've got the stock ZM rod/piston to compare

post up or send me a pm


IMO I think that the difference is in the crank shaft (I don't know if this word is correct in English but in Spanish is cigueñal) because of the higher RPM of the engine, but that is my opinion, if someone can compare both rods and/or crank shaft please post which one is different (dunno) cause I do know that piston size is the same.

[unwritten-dinas]

Bamba, where are you located?

[Bamba ZL-VE]

Puerto Rico

[unwritten-dinas]

We're close, im in Dominican Republic, are there any junkyards over there where i might be able to get a ZL head? I really want to Variable Valve Timing and ive been researching bout a way to control it and found out that pretty much a VVT-i controller (Toyota's own) will work for it.

[Bamba ZL-VE]

The apex v-tech controler can work, an RPM switch or controller, or even by a simple button like a nitrous activator, all those can work, but over here in P.R. the only ZL engine that I've seen is my own, and it was by chance that I stumbled upon it.

[biknman]

FYI for good ready I found this site that has some info on Mazda engine interchangeability: http://members.aol.com/solomiata/MX5Engine.html

[mazpro]

BUMP, any updates??

[Witchdoktor]

all parts are in. just waiting on the machine shop.

yes the waiting game sucks aardvark nuts

[Shane5425]

yes it does.. cant wait to see this monster alive again... still using MPI Tuning?

[Witchdoktor]

yep. this time adding an egt gauge on the 4th runner. 4th cylinder runs the hottest.

[Shane5425]

how much boost are you planing to run?

[Witchdoktor]

I ditched the mbc and got a 15psi actuator and sent the turbo to Deadbolt for their monster port service. I opted not to go with a bigger compressor wheel because I want as little lag as possible, you know first hand what the 1.6 power is without boost. I want this to be a boosting little whore.


DEADBOLT MONSTER PORT SERVICE
Better response, quicker spoolup, reduced boost creep, better "roll-on" acceleration, and quicker torque peak. Unlike most other porting services which simply smooth out the dimples and casting marks in the piece they are working on our system is different. We port match the exhaust housing to the downpipe gasket, resculpt the inside of the exhaust housing heavily, oversize the wastegate to help prevent boost creep, then smooth the area where the exhaust gasses enter the exhaust housing.

[Witchdoktor]

plus they ported out the compressor housing outlet port

they said spool up should start 300-500rpm sooner

[Shane5425]

nice.. i would estimate around 260 to 300whp

[Witchdoktor]

dyno numbers will be posted

my guess is 250whp and 280wtq

[Shane5425]

will you have anytype of lsd in your trans?

[Witchdoktor]

read the first post my kneegrow. I edit/update it as things go. biknman blew a head gasket and parted out his car. I picked up his awr radiator and quaife lsd :D

[Shane5425]

nice.. ok kneegrow...

[Witchdoktor]

update....I added a few more pics on page 1. engine gasket set, oil pump, water pump, thermostat thanks to jason baggie/montgomery mazda.

the head and intake manifold were sent to speedcircuit. the manifold is being ported and having 4 250cc injectors put into each runner, no more 750cc prethrottle body injector.

speedcircuit stage 2 head which includes:
-Special five angle valve job
-Bowl work to blend the stock machine cuts into a larger bowl
-Resurface
-Disassemble/clean/reassemble
-Sandblast clean
-Valve lash set
-Resurface
-Pressure test to ensure no leaks
-Completely ported and knife-edged intake ports
-Completely ported and knife-edged exhaust ports
-The extra porting and knife edging results in a larger port that is more consistent than the stock port, resulting in smoother power and better airflow

[Shane5425]

wow, geting 2 resurfaces... nice... lol

that 1.6l will scream when you get it backand running.. will it turn into a 1.7l with all that shaving and porting?

[Kooldino]

This should be fun. :)

[Witchdoktor]

wow, geting 2 resurfaces... nice... lol

that 1.6l will scream when you get it backand running.. will it turn into a 1.7l with all that shaving and porting?

engine displacement from the bigger pistons goes from 1597cc to 1618cc and I'm sure with the p&p mpg will be a bit less.

[Kooldino]

P&P may actually improve mpg. Guess we'll see.

[Witchdoktor]

assuming I keep off the boost.


uhm...uhm...suuuuure

[Witchdoktor]

but seriously if the mpg went up keeping off the boost that would be sick, even if it stayed the same I'd be happier than shit.

for anyone who cares this is kooldino's first 1.6 head being worked on, he's taking flow bench numbers before and after the machining. correct me if I'm wrong dino but the FS/2.0 stage 2 head flows 71% more than stock.

head gasket - will be stock, cometic needs a large order for them to fabricate a ZM head gasket.

autometer cobalt EGT gauge is in :)

[Witchdoktor]

my injectors came back from Witch Hunter Performance (injector cleaning company). great experience. I'll post their flow sheet when I access a scanner.

http://www.witchhunter.com/

saw the block today, bored and honed. crank half put together, rods and pistons look pimp together. the belfab H-beam rods checked out ok (thank you mr bell :D)

[Witchdoktor]

added krank vent to the list to eliminate blow-by

http://www.speedcircuit.net/product_info.php?products_id=239&osCsid=26cc8d4f10e3422e4c20cf5a6e1c574b

[Kooldino]

for anyone who cares this is kooldino's first 1.6 head being worked on, he's taking flow bench numbers before and after the machining. correct me if I'm wrong dino but the FS/2.0 stage 2 head flows 71% more than stock.

At certain lifts, yes. Overall, no.

[Witchdoktor]

block did not need to be decked, crank was in good condition too :D

I went to the sheet metal shop today, heat shield was made to cover exhaust mani and turbo, material was 16 gauge 304 stainless steel. gonna catch up with the art design place that did my trunk design to come up with something for the heat shield. right now I'm leaning towards fancy etched out lettering "for a good time call dino"

[Shane5425]

haha, thats gonna be sweet.... cant wait to see this beast... we gonna have to race man..... lol.. 1.6lT vs 2.3lT

[redrims]

Looking good, looking good :).... I can't wait to see the final product.