1.6 ZM going forged

Witchdoktor

Banned
Contributor
:
99 LX
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), 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
belfab%20&%20arias.JPG


block bored and honed
bored%20&%20honed.JPG


arias pistons (http://www.speedcircuit.net/)
HPIM0703.JPG


arias vs stock
HPIM0706.JPG


BelfabRacing forged rods (http://www.belfabracing.com/product...=1203&osCsid=8a31401c83d8618c5edfa22cb56e357f)
HPIM0427.JPG


belfabs vs stock
HPIM0707.JPG


radiator (honda awr radiator from another forum, ebay carries them)
HPIM0579.JPG


oil cooler (http://www.jcwhitney.com/autoparts/...00851/p-2000851/N-111+10210+600004731/c-10110)
HPIM0580.JPG


quaife lsd (bought from a forum member, new it goes for around $1500)
HPIM0581.JPG


ACL bearings and thrust washers (ebay ftw yet again)
HPIM0419.JPG


fidanza lightweight flywheel (bought from a forum member, ebay carries them)
HPIM0492.JPG


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


engine pulled
HPIM0458.JPG


cylinder #4 had bad compression and 50% leakdown (yes that is a piece off the piston)
HPIM0460.JPG


intake manifold, coolant line, and fuel rail lightly polished
HPIM0473.JPG

manifold%2045.JPG


valve cover prepped (paint stripped and letters shaved)
HPIM0490.JPG


done

side%20valve%20cover.JPG

front%20valve%20cover.JPG


Deadbolt monster port

port%20turbo.JPG


compressor housing ported

port%20compreshousing.JPG


water pump, oil pump, thermostat (montgomery mazda/bagman1)
pumps.JPG
 
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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!
 
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.
 
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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.
 
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.
 
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
 
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