My new car!

Talk about your Rotaries!
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Operator
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Postby Operator » Sat Mar 24, 2012 9:14

chickenwafer wrote:I have 45 days to file a dispute with PayPal, so I figure I will wait until Monday and then finally threaten a PayPal dispute and see if that gets me an answer. I'm also posting in their vendor section on 7club. This is getting stupid.


Guess it's only one more day now. But I'd go ahead and start the dispute process. I've noticed that tends to get peoples attention. Though it shouldn't have to come down to that.
[font="Century Gothic"]APR 4 Program Tune - AEM CAI - Vogtland Suspension
JVC KW-NX7000bt HU - eD 6500 Front Comps - cDT EF-61's Rear fill -IDMAX 10" sub-
JL 1000/1 - JL 450/4
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chickenwafer
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Postby chickenwafer » Sat Mar 24, 2012 9:14

Yeah, I'm thinking about it, Dave. Do you still need a hand with your bumper?

Matt came over after I begged him to, to help me fit the downpipe after I got it all heat wrapped. It doesn't seal at the top of the turbine-to-downpipe flange no matter what gasket combo we tried with the bolts torqued as tight as I dared. I had roughly 0.003" of gas in-between the flange and the turbine.

So I need to figure out a solution for that now...one thing after another!!
:eek:

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Operator
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Postby Operator » Sat Mar 24, 2012 9:14

chickenwafer wrote:Yeah, I'm thinking about it, Dave. Do you still need a hand with your bumper?


Sure, but I don't get back into town until Monday.
[font="Century Gothic"]APR 4 Program Tune - AEM CAI - Vogtland Suspension
JVC KW-NX7000bt HU - eD 6500 Front Comps - cDT EF-61's Rear fill -IDMAX 10" sub-
JL 1000/1 - JL 450/4
[/font]



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Current:

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chickenwafer
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Postby chickenwafer » Sun Mar 25, 2012 9:14

Operator wrote:Sure, but I don't get back into town until Monday.


Cool, just let me know when you're available.


Did a little more work on the FD today. Got the low oil level sensor connected since the original harness plug for it got stripped off during the engine pull (forgot to disconnect it) so I cut the harness connectors off and crimped on a female/male spade terminals so it can be disconnected in the future if needed.

I also grounded the last grounds of the engine harness and the chassis harness and verified they were good with the trust multimeter.

While under the car, I also zip tied up the oil cooler -10AN hoses, re-did one of the radiator clamps on my v-mount that wasn't on correctly, and ran a 3/8" hose for the drain of my catch can. I tucked the drain hose up on the stock radiator mount so it's secure and out of the way, and then whenever I need to drain it I just simply need to jack up the front end and pull the hose down into a container, turn the petcock on the drain fitting on the catch can and I'm done.

I also think I came up with a solution (with the help of Matt) for how to fix the downpipe. The flange it angled so the bottom it contacting the turbine housing before the top can, and no amount of torquing on the bolts will fix it. I was worried it would be a complex fix, but then we came up with the idea to cut the downpipe about a 1/4"-1/2" behind the flange about 80% of the way through the pipe. This will allow the pipe to be positioned properly and the top flange to flex into place. I can then have my fabricator weld up the gap is causes.

Should be pretty easy (I hope), I just need to un-wrap part of the downpipe and remove it from the car to cut. Now I'm just left debating if I should do it now or just wait until later to fix it since the leak won't be horrible...I think if this oil neck is going keep delaying me, I'll just get it fixed now since I can, but if the neck and injectors will be here this week, I'll wait so the downpipe doesn't hold me up.

Lastly, I made a "duct" or cover template out of cardboard, to be transferred to some aluminum sheet metal, for cover the front gap of my v-mount, and, more importantly, cover the GodSpeed branding on the intercooler :lol:

Surprisingly didn't take too long, I got a template whipped up in about 15 minutes, I'm really happy with how it looks, just how I had envisioned it would. Now the hard part- replicating it out of sheet metal...

Anyways, a pic of the cardboard template:

Image
:eek:

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speedjunkie
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Postby speedjunkie » Mon Mar 26, 2012 9:14

Weird...looks like your car will be done before DGRR. Hmmmm....


LOL.
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chickenwafer
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Postby chickenwafer » Mon Mar 26, 2012 9:14

Haha, yeah, it should, but I've spent all my cash now on finishing the car in a hurry haha.
:eek:

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chickenwafer
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Postby chickenwafer » Mon Mar 26, 2012 9:14

Got some new fittings in today and the Garrett Turbo heat shield, along with some couplers. Pretty much everything went wrong though, haha.

First, the only part that worked- the turbine heat shield. I had to cut off about 2" from one side to get it fit properly and modify the mounting bracket, but it's on and looks pretty good IMO.

The couplers did not work as planned. Lining up the piping and couplers is proving to be a problem. I got a 90* reducer and it's not working as intended, so I need to re-think the charge piping from the turbo to the intercooler. Anyways...

Last was the most frustrating...the turbo oil feed. I've been through this about 3 times now. The last time I over-torqued a fitting and it twisted. So I got new replacement fitting in and made up the new hose..problem is my hose cutters (glorified bolt cutters) are super dull, so they mangle the hose when I cut it, and I don't really have any other option cutting the hose so I have to use them. So I had to cut and re-cut the hose multiple times before I could get a nice clean cut to insert in the hose socket. Long story short the hose ended up about 4" too short to reach for the turbo oil feed...FML.

So I found another long enough piece of -4AN hose and cut it with plenty of extra length...got the first fitting on no problem, then I had to try the 45* fitting. I got it on the hose and as I was twisting the hose firmed up like normal. I put the wrench on it to do the final torquing and before even a 1/4 of a turn with the wrench...SNAP! You've got to be kidding me. I sent an email to the seller on eBay, who I've spent roughly $400 in fittings with in the past couple weeks, so hopefully they take care of me and send me a new fitting.

Like I said, one thing after another.
:eek:

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VRx8
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Postby VRx8 » Mon Mar 26, 2012 9:14

Can't you just buy a 4 an hose already made? Just have some patience, everything is going to come together my friend.

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speedjunkie
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Postby speedjunkie » Mon Mar 26, 2012 9:14

I got my 4AN hose already made, it's an Earl's hose, 18" long, pretty much perfect length. Surprised it turned out that way though.

Man I hate nights like this lol.
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chickenwafer
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Postby chickenwafer » Tue Mar 27, 2012 9:14

Thanks Eduardo and Eric, means a lot! Stupid things just adding up!!

The eBay seller, getitfast1, stepped up and sent me another fitting! They even express mailed it for me and apologized. Super impressed, I will be sure to buy all fittings from them from now on.

So now that is (hopefully) fixed, I get another problem. Witch Hunter called me today so I knew it couldn't be good. One of my primary injectors is physically leaking from the valve body, externally...you've GOT to be kidding. He said it's trash and it was a miracle it didn't cause an engine fire as it was leaking roughly 30% of it's fuel at all times outside the body of the injector.

I checked online and it looks like brand-new these things for a good chunk of change, thanks to Mazda's arbitrary parts pricing. So now I need to hunt down a single primary (I'll buy two if I have to) injector so I can get this rolling...

I also haven't heard anything from RE-Speed yet, so I sent yet another email, this time threatening a PayPal dispute for the first time. We'll see how long it takes them to respond. If I don't hear anything for a couple days or so I'll just go ahead and dispute it. Problem is, i don't really have any other option for an oil neck...only thing I can think of is to take the stock neck to my fabricator/welder and have him replicate it in aluminum with the -10AN male fitting I need. That's about it.
:eek:

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speedjunkie
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Postby speedjunkie » Wed Mar 28, 2012 9:14

Wow, I didn't realize your injector was leaking that much. Holy crap lol. Maybe Zico has one he can sell. I'm sure I still have mine, but like I told you in the text, I have no idea where to start looking.
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chickenwafer
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Postby chickenwafer » Wed Mar 28, 2012 9:14

^Thanks man. I found some used stock primaries for $50 bucks with the rail so I bought them last night.

And, FINALLY, RE-Speed sent me a tracking number for my oil filler neck!! Wahhhoooo!!! Better late than never.

Unfortunately, I don't think I will make my self-imposed build deadline of my birthday, the 31st, which is this Saturday. My injectors should be here Friday, hopefully, but I don't think I will get the oil neck until next week. At least I was close to my deadline and I'm not missing it because of lack of my efforts haha.
:eek:

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chickenwafer
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Postby chickenwafer » Fri Mar 30, 2012 9:14

The stock primaries showed up today (no fitting for the turbo feed tho...) so I got to work removing them from the rail (a TON of fun if you've never removed side-feed injectors from the rail before...prepare for lots of cursing and red/purple fingers) which I eventually managed. I inspected all the o-rings and they looked great so I lubed them up and installed them in my rail and dropped them in the car.

Next up was installing the -6AN hoses I made up for the fuel system. I connected the fuel filter to the primary rail, then from the primary up to the secondary. I lubed up the o-rings on the Five0 injectors and stuck them in the KG rail then dropped them in. Of course the bolt on the rear rotor injector was a bitch because the rail kept twisting/moving and throwing off the alignment, but I got it.

I torqued everything down and tightened up all the fittings, then installed the FPR and turned on the battery, then the key to the ON position. I made up a small jumper wire and jumped the GRN and F/P ports in the diagnostic plug under the hood...I was quite nervous, and for some reason, I was just convinced something would go wrong...fuel would seep from a fitting or a hose connection, the fuel pumps wouldn't fire (all new dual in-tank Denso Supra pumps that I also re-wired), or just something, you know.

But nope! The pumps kicks on instantly and hummed to life, I heard fuel rushing through the lines and soon the gauge on the FPR was spiked at 40-45psi as both pumps were running. I couldn't smell any fuel and I used my hand to check every connection I could...felt solid. No fuel felt or smelled. I let it run for a full minute and I still senses no leaks. SUCCESSSSSSSSSSSSSSS!! Finally something went right it feels haha!

So as of right now I just really need the fitting for the turbo oil feed and the RE-Speed neck, then to make up the hose that connects the neck to the catch can, and I'm ready to fire this pig up. Tentatively shooting for next weekend, Easter Sunday.
:eek:

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VRx8
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Postby VRx8 » Fri Mar 30, 2012 9:14

Almost there buddy! Dave how did you mounted your catch can, i was thinking about making a bracket and utilize the P/S and A/C bracket studs.

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speedjunkie
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Postby speedjunkie » Sat Mar 31, 2012 9:14

Sweet! I can sense a big cruise this summer.
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