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Thread: Protege5: Harder, not Smarter!

  1. #1
    Weight Junkie Tamn's Avatar


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    Exclamation Protege5: Harder, not Smarter!

    Hey all,
    Guess I'll post up my build pics and stuff here since their just taking up space on the PC

    ATM I average 52-55 mpg highway on a EXTREMELY CONSISTANT basis. 50+ street driving. Maybe I'll make it to 60 someday...

    Seeing that I would eventually be at basically a power cap with the stock engine/tranny I decided to do some weight reduction...and kept going...and going...now its something of a impulse. Eventual goal, 2000 pounds? (boom06)

    Over the years I've added lots of things to my car, changed stuff around, trying to keep it clean and performance minded. I DO NOT ADD THINGS FOR SHOW. Anything I install or make is specifically for performance. No wings, carbon fiber fake wraps, flashy paint jobs, decals, gaudy rims, sub boxes or the like here.

    Big fan of DIY, and I'm hoping to learn much more about aerodynamics, fiber glassing and some other cool stuff while I putter around. If I screw something up its my own damn fault and I'll try and fix what I did wrong and next time hopefully I wont do it again. *knock on wood*

    Ok, now that my random rambling is done with....onward with the pictures...errr and modlist!!!

    Future Plans:
    Rebuilding engine with some forged goodies.
    Installing the turbo and all the necessary parts I have laying about.
    Megasquirt 2 full standalone ECU (also sitting waiting for turbo time)
    LSD would be nice to eventually get.
    Fiberglass Hood + pins
    Lexan/plexi? rear windows + possibly hatch
    Moonroof Delete in favor of lexan/plexi
    Smaller Dash/possibly fiberglass
    Underbody Tray and some Aero stuff for the front bottom end
    Side mirror delete/Interior convex mirrors
    New set of lightweight rims

    My 2002 Madza Protege5 has

    Lexan sunroof.
    K&M Typhoon cold air intake.
    SpooledUp racing 4-1 Header
    Hawk brakes (I run different kinds at various points of the year)
    AWR Hard Motor mounts.
    TWM short shifter
    Eibach Pro lowered springs
    AWR Sway bars
    AWR Adjustable end links
    AWR Deep Sump Oilpan
    Tokico Illumina adjustable shocks
    Sparco WRX-STI Harness Bar
    Sparco Competition Harness System (Red) - 6-Point Belt w/ up buckle (x2)
    NGK Iridium IX Spark Plugs
    Wedge Engineering Seat Brackets
    Recaro LS driver and passenger seats
    CORKSPORT 'Power Series' Exhaust System
    CORKSPORT Front Strut Bar
    CORKSPORT Rear Strut Bar
    Sparco Mugello Tuner Steering Wheel (Red w/ Black trim)
    NRG Quick Release Kit - Gen 2.5 (Red)
    Sparco Steering Wheel Miata Hub Adaptor
    Pioneer DEH-P4200UB CD Receiver (It actually weighed quite a bit less than the stock player)
    Bell M4 Pro Racing Helmet
    Fidanza 7lb Aluminum Flywheel
    SPEC Stage 2+ Clutch
    Garret Turbo from a Nissan (Rebuilding atm)
    Greddy Rs type Blow off valve
    CORKSPORT 'Power Series' Exhaust Silencer
    Stripped Backseat/trunk area
    INGA motorsports motorcycle battery HTX14 (HVT-8)
    'Odyssey SAE battery Terminals
    Mazdaspeed Protege Turbo Exhaust Manifold
    CXRacing 2.5" Universal Turbo Intercooler Piping Kit
    Greddy Profec B Spec II electronic boost controller
    Factory Nissan Shorty Antenna
    Altered customs FMIC 28" x 5.5" x 2.5"
    AC removed, wiper fluid system removed, rear speakers removed, cruise control removed, rear power windows removed. EVAP removed. Airbags + computer removed.
    Numerous other small mods, random lightening of parts, etc.

    Hanging out with a yellow P5!

    Pacific Raceways with the BMW clubbers!






    Exhaust manifold off a Mazdaspeed Protege

    Sealing the edges of my Grill Block into place.

    Making my Grill block out of Black ABS plastic.

    Ripped out my sound deadening stuff against the firewall. MESSY.

    Carpets gone :eh:

    Messing around with the rear doors. Removed the power window assembly and the speakers. Replaced with wire to hold my windows up. :lol:

    This is a "beforesh" shot of my rear wiper bracket.

    And this is what it looks like installed. Might paint it up later.
    I just got a craving for some cheese.... :lol:


    Aftermarket shift knobs were like 50 bucks from TWM, so I drew this up on AutoCad and had my dad machine this at work for me!

    I know theres some weight savings somewhere under here!


    3 POUNDS OF DIRT OFF THE UNDERBODY!!!

    BARELY squeezed the car into the garage when I got tired of getting rained on.


    Drilled out my coolant bracket and then painted it up with the same paint color as my car.


    Swapped that heavy stocker for a lightweight Harley Davidson Motorcycle Battery that weighs 9 pounds.





    Just some turbo stuff for when I rebuild the engine this summer. :P
    Last edited by Tamn; 08-02-2012 at 12:48 AM.
    2002 Madza Protege5

    Less is more, and I'm a big fan of more!

    Lightweight Tube Chassis Mid Engined RWD Tri Turbo Protege5 Build

    http://www.mazdas247.com/forum/showt...=1#post5911435

  2. #2
    Weight Junkie Tamn's Avatar


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    Just purchased some AeroCatch Pins for the hood I'm gonna attempt making.

    Went out and got 10 pounds of dry ice and used it to remove most of my sound deadening. I pulled out two 5 gallon buckets filled to the top of it. At least 30+ pounds, and then my ice all "melted" before I finished.

    Used a few aerosol cans of uh....bottled air? to finish the rest of the stuff, works ok, but its still not as nice as the ice.

    Gonna toss some paint over the spots where I removed the deadening tomorrow.

    Also gotta start thinking about those lightweight rims. Mmmmmmm

    It might just be my imagination, but my car seems to be rising higher on its springs as time goes on. I'm gonna need lower springs

    Heres some pics of the ice fun.





    Last edited by Tamn; 03-20-2012 at 01:11 AM.
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  3. #3
    Weight Junkie Tamn's Avatar


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    Don't forget the coke!

    Got my new hoodpins in today, mmmmm sexy...








    Repainting the floorpans where I stripped the sound deadening off this week. Not an easy job once the dry ice is gone btw...(boom06)

    Just wanted to paint the area's I removed the actual deadening. Popping a few coats of gray primer and then possibly some of my Classic Red spraypaint.

    Good thing I was paranoid with the taping off and garbage bags....spray residue everywhere! Be super careful if you try this!

    Gonna give my first shot at fiberglassing this week more than likely if the wind and rain will hold up. See how that goes
    Last edited by Tamn; 03-20-2012 at 01:29 AM.
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  4. #4
    Honor Super Omnia ajkulish's Avatar

    2007 Mazdaspeed3 GT & 2001 SC Protege

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    This is my kind of build. awesome work man! youve got me wanting to take my weight reduction even farther.....

    also, screw lowering springs man. i had some for a while and i thought they rode kinda stiff and what not but i got sick of pulling up to the line in autocross and slamming the brakes when i was told to stop at the start line, then having the car dip forward 2 inches.

    if you wanna save weight, and love your car more than you ever thought possible, buy coilovers. your car is awesome so far. i highly reccomend my ksport rr coilovers with an 800lb/in spring rate in the front and 650 lb/in spring rate for the rear (each coilover of course). they are also significantly lighter than stock suspension. i held my coilover made of aluminum and some steel in one hand, and my stock strut/spring assembly in the other, and the ksports are about 10 pounds lighter per assembly. they are expensive new, but you can come across em for cheap. hell, i got mine for $160. i look forward to seeing progress in this thread!

  5. #5
    Honor Super Omnia ajkulish's Avatar

    2007 Mazdaspeed3 GT & 2001 SC Protege

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    also get rid of that air conditioning. you can shed the compressor, condenser, canister, all the lines, and the entire assembly under the dash. i pulled mine to put in the supercharger and it weighed out to about 40 pounds of shit i got rid of.

    consider pulling the power steering if youre up to the challenge
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  6. #6
    Weight Junkie Tamn's Avatar


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    Quote Originally Posted by ajkulish View Post
    This is my kind of build. awesome work man! youve got me wanting to take my weight reduction even farther.....

    also, screw lowering springs man. i had some for a while and i thought they rode kinda stiff and what not but i got sick of pulling up to the line in autocross and slamming the brakes when i was told to stop at the start line, then having the car dip forward 2 inches.

    if you wanna save weight, and love your car more than you ever thought possible, buy coilovers. your car is awesome so far. i highly reccomend my ksport rr coilovers with an 800lb/in spring rate in the front and 650 lb/in spring rate for the rear (each coilover of course). they are also significantly lighter than stock suspension. i held my coilover made of aluminum and some steel in one hand, and my stock strut/spring assembly in the other, and the ksports are about 10 pounds lighter per assembly. they are expensive new, but you can come across em for cheap. hell, i got mine for $160. i look forward to seeing progress in this thread!
    Yea someday I may look into some more suspension components and change what I got. But honestly its totally in a sweet spot atm. Fantastic to drive on the street or the track, when those BMW Z4's look up with a surprised expression on a hairpin....makes me smile

    At the moment really trying to finish up my interior "setup" and working on some aerodynamics to hold me over while the gas prices rise.

    Quote Originally Posted by ajkulish View Post
    also get rid of that air conditioning. you can shed the compressor, condenser, canister, all the lines, and the entire assembly under the dash. i pulled mine to put in the supercharger and it weighed out to about 40 pounds of shit i got rid of.
    consider pulling the power steering if youre up to the challenge
    AC and all accessories have already been pulled. I was kind of 50/50 on the power steering, but...I think that's one luxury I will keep. I'll just make my passengers take off their shoes when they ride with me.
    Last edited by Tamn; 03-20-2012 at 01:41 AM.
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  7. #7
    Honor Super Omnia ajkulish's Avatar

    2007 Mazdaspeed3 GT & 2001 SC Protege

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    with coilovers i dropped about 3 inches of ride height, and got a splitter and picked up about 4 mpg on the highway
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  8. #8
    Weight Junkie Tamn's Avatar


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    Quote Originally Posted by ajkulish View Post
    with coilovers i dropped about 3 inches of ride height, and got a splitter and picked up about 4 mpg on the highway
    From my "research" going with a full "seamless" under body is the way I will be going. A splitter is more like a bandage to the problem. Its Good, works fine, but its not actually fixing the real problem. I've been stalking hypermiling sites for several years now seeing what those ingenious people think up.

    There is a optimum ride height I will be needing for the under body and I'll probably end up testing that later on. Got a few idea's in mind!
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  9. #9
    ......................... i12drivemyMP5's Avatar
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    Subbing for more ideas........not going full strip down on mine....yet, but will use what things I can. Car is lowered 1.4 all around, do have MP3 splitter. Have UDP and all lightened acc pulleys, int/hdr/hi flo catted midpipe/catback, VTCS removed, run 0-30w syn oil, syn ATF with cooler, long reach NGK zfr plugs, 1.8 coils, etc etc etc. Also have another header with 3rd o2 bung, MPI NA tuner, voltage clamp, Innovate wb02 w/afr gauge for future fuel map/timing tuning. Pulling 30-31mpg now, maybe 33-34 with roof rack removed...around 40 with the tuning would be great tho. My car is sportauto so not sure about lightened flywheel availability and not sure if standalone with oem ecu just doing the tranny is an option.

    Interesting build and results here. Keep it coming...........Oh, and, welcome aboard

  10. #10
    Cameron JDM_Pro5's Avatar

    2002 Protegé5

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    BrianMP5T
    Look up his account. He has the lightest P5 I know of (2300lbs). One thing he suggest is to get the Sport 2.0 bumper. It weighs 40lbs less. Everyone is shocked by that number, but it turns out the stock bumper has all kinds of metal crap in it. Yes the Sport 2.0 is probably less safe in a rear in collision, but 40lbs is a drastic change for a car anorexic like you

    Great build, great car, keep up the work!
    Last edited by JDM_Pro5; 03-20-2012 at 08:14 AM.

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  11. #11
    Registered Member zhy's Avatar

    I aint even mad!

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    Wow totally awsome project you got there
    I wish i'd have the money for a street car, damn i'd go under some serious weight losses like You did, props!!
    Follow my build/progress thread here!


    STICKY How-to by me : Custom LED cluster here!

  12. #12
    Weight Junkie Tamn's Avatar


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    Haha yes I have some serious weight problems. I do really love the sport 2.0 front end and have been looking at it for a while now. Add that sucker up to my future mod list

    Sidenote: Tried to do some yarn and coastdown testing "DIY windtunnel" testing for the racks removal.

    Did a few runs trying to get a baseline, then made some cardboard filler strips. Got back on the road and it started raining just then and ruined them. Derp.

    I got the real things in the garage, but I forgot to order up the clips to actually mount them with at the same time. XD

    Also thinking about ordering up one of those "fuel scanner" instant MPG response gauges for better tracking of fuel testing..which correlates into better aero testing once I start doing my underbodys and front end some more.

    Quote Originally Posted by i12drivemyMP5 View Post
    Pulling 30-31mpg now, maybe 33-34 with roof rack removed...around 40 with the tuning would be great tho. My car is sportauto so not sure about lightened flywheel availability and not sure if standalone with oem ecu just doing the tranny is an option.
    Interesting build and results here. Keep it coming...........Oh, and, welcome aboard
    Very nice. I averaged 35-36 with full interior and racks on my last spring trip to race at fontanna super speedway. Was pretty decent then and next time I go its gonna be quite more decent
    Last edited by Tamn; 03-20-2012 at 12:55 PM.
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  13. #13
    Registered Member P-Funk!'s Avatar

    Lancer Ralliart Sportback

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    I would regularly get 35 mpg by driving at 60 mph and not tailgating... I even added weight with the heavy azz sub speaker box... See my mods.
    I used to have a
    Black Mica Protege5
    Mods:
    MP3 ECU
    Hawk Pads
    OBX Header
    AWR Mounts
    Tokico Blues
    Eibach Pro Kit
    Underdrive Pulley
    Kartboy Bushings
    ThermoBlok Spacers
    Kumho ECSTA AST tires
    Fabricated Ground Wire Kit
    VTCS-Less Intake (Ported)
    Fabricated SRI w/ K&N Filter
    Fog lights on with parking lights


    Audio:
    Kenwood Head Unit
    Kenwood Mono Amp
    Custom 10" Enclosures
    Boston Accoustic 1" Tweets
    Rockford/Fosgate Punch 50

  14. #14
    Cameron JDM_Pro5's Avatar

    2002 Protegé5

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    Talk to a machine/fabrication shop about cutting a piece of sheet metal and making a whole underbody skid plate. You can leave access points for things like the oil filter, and make it bolt on all around so it's not too hard to take off if serious work is needed. Hopefully the aerodynamics will out way the weight of the plate.
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  15. #15
    Weight Junkie Tamn's Avatar


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    Quote Originally Posted by JDM_Pro5 View Post
    Talk to a machine/fabrication shop about cutting a piece of sheet metal and making a whole underbody skid plate. You can leave access points for things like the oil filter, and make it bolt on all around so it's not too hard to take off if serious work is needed. Hopefully the aerodynamics will out way the weight of the plate.
    Yea from the hypermiling sites I've come across, theirs 2 trains of thought on underbodies.
    Sheet aluminum or a material called cloroplast. Which is what like promo signs are made out of, a type of plastic material that is quite durable and super lightweight.

    Usually the guys mock it up in cardboard as I did for my grill block, then they do a bunch of testing to determine the "best" combination they can, then they make one out of cloroplast and eventually metal.
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