Hey all

[irishkev90]

A little bit of an intro. I'm 19 years old and own a 1998 Mazda Protege LX. 1.5L DOHC (Z5) and auto tranny (sad1). So far I have done minor appearance work and put on a short intake with parts from Autozone. I have big plans for this car but a tiny bank account, unfortunately. I am also a member of clubprotege.com, same username. You can check out more pics of my Protege there if you'd like.

I have decided to turn this into a build thread. If there is a specific section for this type of thread (I haven't seen one), then a mod can move it to the appropriate area. :)

[Speedkid]

Whats up welcome to the forums.

[o0n8]

welcome

[irishkev90]

Thanks for the welcome guys.

Wow, such an old post. Anyway..... I've done some work to it. Got it lowered on B&G lowering springs (1.5") and KYB GR2 struts with new strut mounts. Put on a Mazdaspeed front strutbar and JDM taillights and corners. I modified the USDM headlight housing and put projector headlights in and used the JDM headlight lenses. I've got some parts coming to upgrade the brakes to the larger ES front brakes and swapping out my rear drums for ES discs and a rear sway bar. Put in a JVC KDHDW-10 headunit, Alpine PDX-F4 amp, Alpine Type-S 6x9" 3-ways in the rear and Alpine Type-s 6.5" components in the front. Not much else has been done. Brake swap and body work should be the project for this spring/summer.

[irishkev90]

To start off, I'll list some of the stuff I have already done to the car, along with some pics:

Short intake
HID projector retrofit
LED DRLs
JDM tail lights
JDM corner lights/turnsignals
Mazdaspeed strutbar
Alpine Type-S 6.5" component speakers front
Alpine Type-S 6x9" 3-way speakers rear
JVC KDHDW10 headunit with aux input
Alpine PDX-F4 4 channel amp
B&G 1.5" lowering springs
KYB GR2 struts
New strut mounts
Custom 3rd/high-mount/center brake light

Pics:
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs298.ash1/22548_309041857217_647307217_3653156_5423192_n.jpg
When I got it

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs743.snc4/64355_437713777217_647307217_5397946_229024_n.jpg
Lowered and JDM lights

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs005.ash2/33631_437713977217_647307217_5397948_1385897_n.jpg
Lowered and JDM tail lights

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs182.snc4/37425_402339997217_647307217_4536240_2567758_n.jpg
Mazdaspeed strutbar

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs472.snc3/25899_326453877217_647307217_3712278_1650705_n.jpg
Custom intake

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs487.ash2/76010_456809897217_647307217_5709893_905389_n.jpg
Projectors in

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs233.ash1/16050_169527937217_647307217_2985419_6033152_n.jpg
Little personalized touch. The emblem used to be black. I painted it with model car paint.


To be done:
ES front and rear brake swap
ES rear sway bar
Cusco front lower tie bar
Miata wheels, 15x6
Summer tires
Clean EGR system
Custom fiberglass CAI (tapering from 3" at the filter to 2.5" at the throttle body)
Custom front and rear bumper
Custom trunk garnish
Alpine Type-R speakers front and back
Alpine Type-R 10" subwoofer(s)
Alpine PDX amp (to drive sub(s))
Engine/transmission swap? (Mmmm, KLZE 2nd gen Protege, yum)


Updates will follow when work is done.

[irishkev90]

New wheels and tie bar:

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs065.snc6/167499_495932437217_647307217_6307359_6416192_n.jp g
Buckle up, it's going to be a long trip.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs065.snc6/167552_495931957217_647307217_6307344_4493092_n.jp g
When I got home. Stuck the center cap in to see if I got the right ones. I did :)

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs882.ash1/179067_496329677217_647307217_6314955_1117063_n.jp g
I think it's seen better days.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs013.snc6/166298_496329832217_647307217_6314958_6244162_n.jp g
You can still read this, though.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs882.ash1/179038_496330062217_647307217_6314961_883538_n.jpg
OEM Mazda center caps.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs893.ash1/180110_496330217217_647307217_6314962_1601021_n.jp g
Oh no. That seems to be the worst of it, though.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs049.snc6/167990_496330332217_647307217_6314964_6483683_n.jp g
Made by Enkei.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs252.snc6/180033_496330452217_647307217_6314965_1058465_n.jp g
The whole gang. The color on the top two (especially the right one) is a little off (yellowish/goldish) compared to the silver center caps. The bottom two match perfectly.


Anybody know where I can find a refurbishment shop around upstate New York?

I might order one more from ebay as a fullsize spare.

[irishkev90]

Just purchased a Kia BP G-series transmission with intermediate shaft, mounts, driver's side axle, sensors, slave cylinder, shift linkage and shifter. All I need is the clutch line parts and pedal assembly. For now, I will bolt this to my Z5 until an engine swap comes around.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash1/181585_500959072217_647307217_6379120_1359392_n.jp g

[irishkev90]

Update 1:

Some pics of the mud guards installed. The far-away shot showing the whole car didn't come out so well, so I only have the close-ups at the moment. I'll try and take some more when I get a chance.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/184646_10150092234942218_647307217_6434032_6707421 _n.jpg
Front right.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash1/180651_10150092235797218_647307217_6434038_3410668 _n.jpg
Rear right.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/184091_10150092236612218_647307217_6434043_3469691 _n.jpg
Front left.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/180159_10150090856872218_647307217_6420813_7737305 _n.jpg
Rear left.

The right side ones seem to fit better than the left, hmm.

[irishkev90]

Update 2:

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/181769_10150101764897218_647307217_6525793_772562_ n.jpg

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/184366_10150101764642218_647307217_6525789_835493_ n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/189905_10150101764752218_647307217_6525791_2908744 _n.jpg

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/190165_10150101764497218_647307217_6525787_7244227 _n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/185948_10150101764302218_647307217_6525784_5367584 _n.jpg

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/184240_10150101764107218_647307217_6525782_939302_ n.jpg

[11B-33T]

Looking good and I wish you luck on the slow-but-sure progress of the build..

[irishkev90]

Thanks man, I cant wait to do this. But I want to make sure I've got everything I need, and know how to do it before actually starting. I don't want to screw something up since this is my only car.

[irishkev90]

My morning errands rewarded me with these.
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/190673_10150102530927218_647307217_6531859_7773262 _n.jpg


The old clutch fork boot...
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/183243_10150102531477218_647307217_6531863_3415446 _n.jpg

Also thinking about ordering an Mfactory helical LSD (28 spline) for the transmission. I've never taken a transmission apart before so I'm somewhat hesitant.

[irishkev90]

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/188661_10150106200872218_647307217_6572034_2413273 _n.jpg

Top left: Axle seals
Top right: Pressure plate washers
Center: Flywheel to crank bolts
Bottom left: Rear main seal
Bottom right: Pressure plate to flywheel bolts
Far right: Sketch book

[irishkev90]

What could this be I wonder quietly to myself...
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/200307_10150106976492218_647307217_6577547_7482859 _n.jpg

Yay!
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/198205_10150106975832218_647307217_6577544_875913_ n.jpg
SS clutch line, SS brake lines, Bronze-oil shifter bushings

[11B-33T]

Nice! Now more pics of stuffs being installed.

I wish I had monies to spend...(sad2)

[irishkev90]

I'm just waiting for nice weather to install everything. Oh, and all the parts, haha. Also have a fifth gear swap coming soon.

[ajkulish]

Wow man. You're doing this right. Props and keep up the good work. Maybe paint the wheels too :)

[irishkev90]

I have to do some minor repairs on the wheels, but I'm going to keep them silver. I like silver, haha. I've also got the front and rear spindles and e-brake cable for the ES brake swap. Just waiting on the rear sway bar, rotors and calipers. I ordered a spare gauge cluster the other day as well and it came in yesterday. I tore it apart to get the gauge faces out. I'll be doing some true custom gauges. None of that reverse glow, white face junk.

My dad suggested to pull the engine and trans out together and send the engine out to get "refreshed" at a local shop. He said it would take a week or two for the engine so that gives me time to do the brake swap and anything with the transmission to get it ready to go in. This dream is becoming more of a reality each day :D

[irishkev90]

My spare gauge cluster.
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/207996_10150149129332218_647307217_6778755_6320219 _n.jpg

Snapped the metal pegs for the gas and temp gauges. Good thing this is only a spare.
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207142_10150149127142218_647307217_6778739_779295_ n.jpg

Speedometer...
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207683_10150149127532218_647307217_6778745_7720752 _n.jpg

Tachometer...
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207397_10150149129022218_647307217_6778754_3910895 _n.jpg

Gas and temp...
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/208369_10150149128762218_647307217_6778753_7011421 _n.jpg

This film seems to be what makes the odometer screen green when it lights up. At least I hope so...
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/208395_10150149127027218_647307217_6778736_6652288 _n.jpg

Just need to take the speedometer and tachometer stop pegs out, scan the gauges, get Adobe Illustrator, and start customizing. :D Also got myself a new clutch master cylinder. Just needs some paint.


My brake swap stuff, more to come.
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/197152_10150117028032218_647307217_6671607_1584931 _n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/190123_10150117028927218_647307217_6671610_2455282 _n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/199608_10150117029597218_647307217_6671615_4998203 _n.jpg

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/190062_10150117030272218_647307217_6671619_5126155 _n.jpg
Driver's side.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/198973_10150117030727218_647307217_6671623_7923033 _n.jpg
Passenger's side.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/199999_10150117031202218_647307217_6671627_4862143 _n.jpg
The dust shield on the right got a little bent, but nothing that can't be straightened out.

E-brake cables and sway bar bushings are there as well. Also, everything has the ABS sensors and wires, my car doesn't have ABS, so it's useless to me, haha.

[irishkev90]

Custom bumpers :)
Just drawings of what I want, not the actual thing :(

http://www.clubprotege.com/forum/attachment.php?attachmentid=41332&stc=1&d=1267426397
Front.

http://www.clubprotege.com/forum/attachment.php?attachmentid=41421&stc=1&d=1267735477
Rear.

[irishkev90]

No updates yet, still waiting on parts. But I did manage to replace my upstream O2 sensor this morning. The idle was all over the place and stalled out randomly. Most people say to check and clean the EGR, but someone else mentioned it could be the O2 sensor. There was no code or CEL, but I got a new one anyway. So far the car is running fine, no more bouncy idle and no stalling. I'll check back in after work since it usuually does it then as well.

[irishkev90]

I've neglected this a little bit. Here's a little bit more:

Got my calipers and rear sway bar :D

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207912_10150153706842218_647307217_6819090_7853791 _n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/217656_10150153707697218_647307217_6819097_1329117 _n.jpg

Going to get new calipers.

Painted the front knuckles and rear sway bar brackets.

Passenger side. Cleaned, no paint.
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207082_10150156866252218_647307217_6851215_8190461 _n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207184_10150156867087218_647307217_6851217_2985540 _n.jpg

Driver side. Painted.
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/217517_10150156868077218_647307217_6851227_590451_ n.jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/215214_10150156869052218_647307217_6851237_3945467 _n.jpg

Just used some Duplicolor caliper paint since I had a can of it laying around. They're both painted now. No pics of the sway bar brackets, but whatever, you all know what they look like.

[irishkev90]

Cylinder 1 Misfire Detected. Code P0301. I'll be working on getting this straightened out soon, I hope.

[irishkev90]

Hopefully got the misfire sorted out. Cleaned the heck out of the EGR valve. Also used Never Sieze on the shaft. Moves wicked smoothly now. Also, got a 323 GTR shift knob. Needs some repairs, though.
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/225642_10150172955402218_647307217_7010227_5939521 _n.jpg

[irishkev90]

Got some more replacement goodies today :)

Bunch of bushings and endlinks:
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/222341_10150173861017218_647307217_7021051_68125_n .jpg

The front sway bar end links are different. The left one cost more, but wasn't bagged. They're both Beck/Arnley, though...
Left:
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/223357_10150173861227218_647307217_7021057_8318673 _n.jpg
Right:
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230024_10150173861477218_647307217_7021058_2735788 _n.jpg

Also, got all the boxes labeled so I know what's what:
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/222242_10150173861727218_647307217_7021059_5014421 _n.jpg


On a side note, I forgot about my Cusco tie bar. I was pleasantly surprised when I saw it sitting the corner, haha.

[irishkev90]

Okay, so the pedal assembly I got is from an EGT and isn't going to work. So I ordered one from a '98 Protege. Also, the shifter finally got here yesterday. Now all I need is a new brake master cylinder for a manual transmission, some hard and soft clutch lines and I think that's it. Also still waiting for my MFactory LSD. They had a problem when moving from one office to another and some stuff got damaged. They should be back up and running by now, though.

Pic:
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/222816_10150180470017218_647307217_7069808_7164923 _n.jpg