Turbo Miata Build Thread (56K-Not Today)
 

I did a DIY turbo setup for my car. The goals were to build a setup that's powerful, but to keep the car a sleeper. I tried to keep it cheap, but… pretty much failed there. This is my first turbo setup and it was a huge learning experience. I've been collecting parts for about a year. Built a MegaSquirt II to run the engine Jan. 08' and have been running that ever since. This summer I mounted the intercooler and fucked with a SC project and then abandoned it. Then in August I started buying turbo ---- so I could turbo it over Christmas break.

I tried to buy used ---- to save money.

MS2E, wiring harness stuff, etc. $600
LC-1 w/controller $190
Intercooler(new-second hand) $90
"Tial Style" BOV and 38mm gate, Silicone bends, couplers, and T-bolts, some flanges I didn't use. All from Evans Performance
$330
Autozone air filter 20
New GT3271 bought second hand $350
T2 based Flyin' Miata Manifold(used) $120
2", 2.5", and 3" Mandrel Bend Builder's kit from Racing Solutions $210
Magnaflow muffler, glasspacks, hangers, etc $200
Tools needed to do the job $200
-12AN oil drain ---- from Summit Racing $68
-4AN oil feed stuff from Egay $40
Ebay MBC $20
---- from Autozone to finish the build $150
RC 550's low ohm(used) $150
ACT Extreme Clutch(used) $100

I don't even wanna add that up, but I'm sure it cost a lot more than that in reality.



Box of CDM goodness
Attachment 10684

Garrett GT3271 52 trim comp, .78 A/R divided turbine.
Attachment 10685


Got a deal on a FM manifold but it was T2 and had stripped threads. And it also didn't have a port for an external wastegate. So I adjusted the manifold a bit…

Before:
Attachment 10686


Had to retap the threads bigger then locktite some grade five bolts in there.
Attachment 10687

Next day I cut them off and used a file to get it flat.
Attachment 10688

Then redrill and tap to T3 bolt pattern
Attachment 10689

Then test fitted it. I drilled the heads of the bolts so I could wire them together.
Attachment 10690

Added an external wastegate port. Had a welder braze it on. I did all the other welds. Works.
Attachment 10691

Attachment 10692


Then I was pretty much ready to turbo it. So out came the motor.
Attachment 10693

Attachment 10694

Had to cut some of the car out of the way for my IC install.
Attachment 10695

Attachment 10696

And make some brackets to hold the IC and condenser.
Attachment 10697

And some 5/16 weather stripping to seal things up and keep the IC from touching the other heat exchangers.
Attachment 10698

And now it fits. 20x12x3 core IC hidden behind factory condenser.
Attachment 10699

Working late
Attachment 10700


TT oil feed. Worked perfect.
Attachment 10701

Got the ACT Extreme clutch installed. Locktite'd the bolts.
Attachment 10702

In the spirit of HMT, I tried gluing my broken motor mount back together. Failed.
Attachment 10703

Damn welders were all slacking around Christmas, so I couldn't get my AN fitting welded in and I didn't have one that would screw in and point up. So I tapped it crooked. This was really ------- hard to get right. Ended up using a socket.
Attachment 10704

Attachment 10705

Attachment 10706

Screwed in the 3/4 NPT to -12AN fitting. Not it points up.
Attachment 10707

And welded it in.
Attachment 10708

Ground the inside flat and welded it too.
Attachment 10709

Old backhoe I worked on.
Attachment 10710

Opened up the stock intake manifold to get rid of a resonace chamber and make the second set of runners actually feed the motor air.
Attachment 10711

Attachment 10712

You can barely see in this pic but I added two extra ports to the plenum for the WG and BOV.
Attachment 10713

And ground the fittings smooth on the inside. Porting done.
Attachment 10714

Turbo bolted on.
Attachment 10715

Made a hardine for the waste gate. Bonus points if you see what's wrong in the pics.
Attachment 10716

Attachment 10717

Ready to go back into the car.
Attachment 10718

Back home
Attachment 10719

Ghetto trigger wheel setup. Works fine though.
Attachment 10720

Attachment 10721

Got the oil feed and drain hooked up. Made some SS coolant lines for the heater core.
Attachment 10722

Attachment 10723

Got dark and cold so I turned the heater on.
Attachment 10724

Then made my IC pipes.
Attachment 10725

Attachment 10726

Attachment 10727

Attachment 10728

Then painted them in the dark. Don't paint ---- in the dark….

Attachment 10729

Attachment 10730

Attachment 10731

Attachment 10732

A/C and P/S still fit
Attachment 10733

Put a new timing belt, tensioner, and idler pulley while it was apart. All mazda ----. No pics.

Finished. Need to clean up the wiring one day.
Attachment 10734

Second startup.
http://i231.photobucket.com/albums/e...h_100_1946.jpg

Only problem was the cork oil drain gasket I made leaked. Redid it with some Fel-Pro ---- from a machine shop and it's fine now.

Washed it
Attachment 10735

I built the exhaust. Has good ground clearance.
Attachment 10736

Drove it a few days and had a fuel injector o-ring fail and almost caught the car on fine. (I fail, should have replaced them) $14 dollars at wal-mart later…
Attachment 10737

Here's my AFR target table I'm tuned to right now
Attachment 10738

And my spark table I'm running
Attachment 10739

I started out running waste gate pressure of 8 PSI and got it tuned there. Now I'm at 11 PSI and it's wicked. No traction in first or second gear from a roll. I get full boost by 3300 from a 4th gear roll, but in first or second I don't see full boost till after 4K. Overall it's fun to drive. Needs an LSD bad and something to help with wheel hop.

COP project in the works
Attachment 10740

So yeah that's it. Turbo miata. Put about 1K miles on it and so far everything is working well. I want to turn up the boost but I have no traction as it is.

Re: Turbo Miata Build Thread (56K-Not Today)
 

Nice setup but THE INTER"HEATER" BEHIND THE RADIATOR AND AC CONDENSOR? YO your sdrawkcab pal

Re: Turbo Miata Build Thread (56K-Not Today)
 

It's behind the condenser but in front of the radiator. Didn't affect IAT's much. I get 3-6*F higher than ambient temps when cruising, rising another 2-6*F when in boost. If I sit at idle for 5 minutes they go up ~30*F, but drop back to ~10*F over ambient as soon as I roll away. Here's a screen shot of a log with me brake boosting. AIT's logged in white at the bottom.

Attachment 10683

Re: Turbo Miata Build Thread (56K-Not Today)
 

Looks good, ---- me thats a huge turbo on a miata. That seems like a lot of retard at wot, 13degrees?? I'm on a different motor, but IIRC im at aroudn 20deg at redline with low 11's for afr. Very brilliant idea with the mani tho, how you filled the holes.

Re: Turbo Miata Build Thread (56K-Not Today)
 

Thanks. Doing the manifold took a while. I worked on it a couple hours every night after work for a week. As for timing, these mazda's don't take as much timing being an undersquare engine. But that map is somewhat conservative as well. I have all the active knock detection ---- to put on it, but it's too cold to work on the car. It's actually supposed to get in the fifties tomorrow, so I may get it on tomorrow.

And yeah, the turbo is big because I'm building a motor this summer and will up the boost. I'm around 250-270whp right now. Turbo should get me to 350whp no problem.

Re: Turbo Miata Build Thread (56K-Not Today)
 

Nice work!!! I like how you filled the holes in the manifold. Very inginuitive. I'm also workin on a BPT build. Doesn't the miata block have coolant and oil feeds on the front of the block?

Re: Turbo Miata Build Thread (56K-Not Today)
 

I havent tuned an undersquare motor, but I should be within the next 6months as i build my stroker. It sounds a bit wonky but I put a car radio noise suppressor on my MS power feed and it really cleaned up my 12v signal, you have quite a bit of fluctuation. You can also put a capacitor on the alternator if their isnt one.

Im surprised you went with EDIS by the looks of it for your crank trigger, if you are indeed using edis then It will be easy to do COP. I'm planning on using sr20det cops.

Re: Turbo Miata Build Thread (56K-Not Today)
 

The older miatas, up to some VIN in 94 had oil and water feed ports tapped into the block. Newer ones have the bosses cast into the block, but they are not tapped. I've heard of people tapping the coolant one with the engine in the car and just flushing the cooling system after doing it. But nobody's ever done the oil one with it in the car. FWIW, I"ve got another motor and I'll be tapping it for oil feed this summer when I build it.

Re: Turbo Miata Build Thread (56K-Not Today)
 

Somenone that knows Ms. TALK TO ME!!! Yeah, the noise sucks. I heard a 12V filter would help. Haven't tried it, but I want to. Noise used to be so bad I'd get resets and ----. Now it runs fine, but the noise messing with my AFR readout sucks.

Yeah, that's an EDIS setup. So how is it easy to do a COP setup with EDIS? All ears. These COPs have built in ignitors where the stock EDIS coil is just a coil. Or would that not matter? Any info one how to hook these COPs up would be great. I've got the stock sparkplug wires zip tied to the EDIS coilpack right now and that sucks...

Re: Turbo Miata Build Thread (56K-Not Today)
 

---- isn't it soooo annoying, i would get resets and ---- loads of disconnects. The one thing that really solved it was this like 3" 12 dollar radio noise suppressor i got from some electronics store. Put it on the power feed to your MS, I then put the capacitor from the EDIS on my coil pack. If you look on the diagram youll see the cap, goto the junkyard youll see the cap attached the the coil pack, get it. You can also put one of those on your alternator but i found I didnt have to, the one on the Ecu was enough. You can also put noise suppressor on your wideband, looking at your graphs tho it seems fine.

For the coilpacks, i havent done it yet but if you think of it we have 3 wires going into the Edis coil pack. 2 are power and 1 is ground, so 1 power is for half the coil which is 1/4 and the other power is for the coil half for 2/3. So my my car runs batch fire IIRC its been a looooong time since i wired it, just take the 2 power wires for the banks and wire the coil packs. Coil pack 1/4 together on the same power feed, and 2/3 and tie the ground in with a 25uf cap for good measure! I havent tested it yet, but I can't see any reason at all why it wouldnt work. Make sense?

While your wiring you should rewire edis so you can use antilag and spark rev limit.

http://www.extraefi.co.uk/Drawings/Edis_Wiring.JPG

Re: Turbo Miata Build Thread (56K-Not Today)
 

Hmm. I'm definately gonna have to get a noise suppresor. Checked walmart a while back and they didn't have any. But they're online for cheap so I'll order one soon.

As for wiring in the coils, the coilpacks I'm using are mazda Millenia COPs. They came off a motor that ran 14 pounds from the factory, so I figured they should be pretty stout. That and they were 12 bucks with connectors. :6 But I'm not sure on just wiring them up like you said. These are "smart coils" IE-built in ignitors. So These have 3 wires to each coil instead of 2. It's got Gnd, +12V, Trigger. +5V to the trigger will fire the coil. Pretty sure that's right.

Here's a pinout of my COPs.
Attachment 10680

And how would I rewire EDIS for rev limit and anti lag? Also I readup on EDIS and COPs after you mentioned it and I'm reading that pairing up coils affects dwell and all that too. And tha some would run two EDIS modules to fully charge the coils. IE-still wasted spark, but each coil has a module that charges it.

Re: Turbo Miata Build Thread (56K-Not Today)
 

---- you know what, I never thought about how it will affect dwell. Hrm I would also hate wiring in a 2nd edis unit, the thing is stupid I hate it and its a pita. I can't remember where the anti lag writeup is, youlll have to find it. Ill do some poking around and see what I come up with.

Re: Turbo Miata Build Thread (56K-Not Today)
 

Yeah, I'm afraid to go ------- with it to try something that's new and kill an ignitor or coil. Only car at college right now. This summer I was planning to ditch the EDIS and let MS read the VR sensor directly and let MS fire the COPs. So unless there's an easy way to do it now, I'll just wait and do it this summer. I should have just done it that wasy from the start. I used to have MS firing the miata's factory coil pack and launch control and flat shift were FUN. I miss that..

But I will definately be installing a noise suppresor soon. That would be awesome if it cleaned up the signals.

Re: Turbo Miata Build Thread (56K-Not Today)
 

Yea I agree, let the coil packs be run by the drivers on MS.

Re: Turbo Miata Build Thread (56K-Not Today)
 

BTW: teh 4g63 IIRC is also an undersquare motor and they run lots of timing np.

Re: Turbo Miata Build Thread (56K-Not Today)
 

I'm running around 176 kPa right now. So that puts me around 16* at peak torque climbing to 18* by 7Kish. I can probably add in some timing, especially around 7K. Most add in 4-5 more degrees from 5K to 7K.

As soon as I'm home for summer I'm gonna crank the boost up wicked high and see what this stock BP will take. :y Might have to get the 4 bar map sensor so I can go over 22 pounds.

Re: Turbo Miata Build Thread (56K-Not Today)
 

your turbo is not clocked.

what do i win?!?!

Re: Turbo Miata Build Thread (56K-Not Today)
 

Nope, not it.

Re: Turbo Miata Build Thread (56K-Not Today)
 

what about the big ass threded hole in your exh. mani? Do I win? lol

Re: Turbo Miata Build Thread (56K-Not Today)
 

Nope.

Re: Turbo Miata Build Thread (56K-Not Today)
 

On a side note guessing ---- is gay. The hardline (which I made reference to) was hooked to the wrong port. Which became quiet obvious on the first drive when I kept hitting overboost protection.

Re: Turbo Miata Build Thread (56K-Not Today)
 

Nice I like the car. I do have to say I thought you where full of ---- for not having finish the s/c project you had going; but this did turn out rather nice. Like the car and clean diy. Pm me if you want it add to the rest of the build threads.