once upon a time there was a little 1.6 liter that wanted to go forged...

[Heywood Jablomy]

I cracked a piston on the stock engine running boost so decision time came, time to go forged. at the time it blew nobody made forged internals for the ZM. the crank to the ZM is shared by the B6 miata so rods are plug and play. rod length is different though from the ZM by being 1mm longer. juan at hi-boost and relaxed at mspro went forged with B6 rods and B6 pistons and machined off 1mm off the pistons to have it fit the block. I asked dino at speedcircuit if he could have arias make a forged piston to fit the block rather than shaving off a B6 piston, he was able to do so. so to list the build:

Belfab racing H-beam B6 miata rods
Arias pistons (.020 over with 8.5 compression)
quaife lsd
oil cooler
awr radiator
P&P head
P&P intake manifold
P&P exhaust manifold
P&P turbo (IHI VF24)
fidanza lightweight flywheel
indigo lightweight crank pulley
acl bearings
krank vent
awr mounts and inserts

this time around I'm installing an egt gauge. afr will be kept more conservative, prolly close to 11.5. turbo was sent to deadbolt where they ported the exhaust housing, compressor housing, and wastegate. I opted to keep the compressor wheel and not go with a bigger one, I'm sacrificing power for lag. the 1.6 without boost is a joke for those that never drove in one. it needs all the help it can get, deadbolt claims spool up to start 300-500 rpm sooner with their porting. got a new actuator, boost will be set at 15psi.

ems is the mpi/smt6 running off a 3 bar map sensor. 4 250cc injectors were welded into each runner of the intake manifold. stock ecu runs everything outside of boost, once in boost the extra injectors come on and the O2 sensor is clamped via a flyin miata voltage clamp and the maf sensor is clamped via a turboxs voltage clamp. the mpi controls the 4 extra injectors and gives you the ability to control timing.

the turbo, exhaust manifold, and downpipe were sent to jet coat and were coated with hi-temp black. the turbo will have a heat wrap and a heat shield was made from 16g 304 stainless steel. in addition to keep temps down I'm adding an oil cooler and upgraded the stock radiator to an awr radiator. blow-by will hopefully be non existent with the addition of a krank vent.

major props to biknman, speedcircuit, and montgomery mazda for all their services and help.

any tips or advice I'm all ears.

[Heywood Jablomy]

enjoy the pics you filthy animals.

http://www.themazdaforum.com/attachment.php?attachmentid=1057&d=1210723246

[Heywood Jablomy]

hi-boost exhaust mani peed & peed


http://www.themazdaforum.com/attachment.php?attachmentid=1060&stc=1&d=1210723639

[liquid_ag]

fucking awesome man!

[Heywood Jablomy]

hi-boost exhaust manifold flange

http://www.themazdaforum.com/attachment.php?attachmentid=1061&stc=1&d=1210723794

[Heywood Jablomy]

intake manifold

http://www.themazdaforum.com/attachment.php?attachmentid=1062&stc=1&d=1210723903

[Heywood Jablomy]

head peed & peed

http://www.themazdaforum.com/attachment.php?attachmentid=1063&stc=1&d=1210723974

[Heywood Jablomy]

block. shaved letters and wrinkle paint on the valve cover ftmfw!

http://www.themazdaforum.com/attachment.php?attachmentid=1066&stc=1&d=1210724042

http://www.themazdaforum.com/attachment.php?attachmentid=1067&stc=1&d=1210724120

[Z]

nice project man. i love the v/c.

[pdhaudio83]

i LOVE threads like these! :thumb:

[Kooldino]

Hot.

[D323]

sweetness.

[DemonIAm]

good stuff!

[SATimko]

wow. Nice!

[sumo_bob]

:hitit:

[Heywood Jablomy]

we'll see how much gets done tomorrow and tuesday. next two days are dedicated to the car. engine hopefully dropped in on monday, dare I think about cranking it tuesday. meh, we'll see.

[Heywood Jablomy]

block is just about ready to come off the stand. put transmission together and it's ready to be dropped.

http://www.themazdaforum.com/attachment.php?attachmentid=1149&d=1211416633

http://www.themazdaforum.com/attachment.php?attachmentid=1150&d=1211416642

[KrayzieFox]

Dude, that's a tits ass project!! Keep us posted :thumbs:

[kansei]

aweome stuff! This looks like a work log so I moved it to the work log subforum :)

damn 1.6 non-forged is a pretty boost happy motor, with those internals it should be madness.

[fez]

crazy awesome!!!!

[Heywood Jablomy]

engine installed today. so far no major issues. next up is making new intake pipe and remounting the radiator while the condenser is removed.


http://www.themazdaforum.com/attachment.php?attachmentid=1164&stc=1&d=1211504107

http://www.themazdaforum.com/attachment.php?attachmentid=1165&stc=1&d=1211504117

[liquid_ag]

awesome!

[Heywood Jablomy]

minor issues so far:

two small scuffs on the valve cover during transport and install. will have to touch up when done.

lightweight crank pulley was different diameter than stock pulley, stock belt didn't fit, advance had one that fit. (dunno what make and model the belt is from but advanced had it)

awr passenger inserts didn't fit, we hacked the dog shit out of them and made it fit with screws and nuts.

[Shane5425555]

so it begins.... if my 1.6l was a manual i woulds still have that turbo go cart.... this is just a really sweet build..

also, wtf did you get that username......

[Heywood Jablomy]

new fuel lines done, pretty much everything topped off and hooked up. now with the awr radiator it's taking up the space where the old intercooler piping was. new piping needs to be made, fun times.

[fez]

pics? :) moar pics?

[Shane5425555]

dont know if you noticed this, but i forsee a problem with you extra injectors, your motor is gonna buck from shifting, and it looks in the pictures like that strut tower bar is gonna take them out, it might just be the picture, but i would take another look at that..

[fez]

umm .. I think the injectors will be fine, but the intake mani might suffer... better get those 90 duro engine mounts ;)

[Heywood Jablomy]

I'll get pics as things progress. I could have kept the old ic piping and moved the radiator over but I'm keeping it as far away from the turbo/dp as possible. it's an awr for a civic, it's thicker but shorter in diameter.

the strut bar and injectors I don't see being an issue (knock on wood) but if it is I'll go with a different strut bar or go with none if I have to.

[Heywood Jablomy]

awr (honda) radiator installed. with it I'm now waiting on parts. new piping to reroute the ic piping and a steel fitting to weld to the coolant line.

http://www.themazdaforum.com/attachment.php?attachmentid=1948&stc=1&d=1212540322

http://www.themazdaforum.com/attachment.php?attachmentid=1949&stc=1&d=1212540332

[Heywood Jablomy]

also the intake pipe are the two 90 degree black couplers going into the passenger side fender. we cut the frame on the side to be able to run the intake pipe down instead of up.

[Heywood Jablomy]

I like the hi-boost mani/dp/turbo but I'm not wild where they place the filter.

http://www.hiboost.com/jpgs/KIT/Protege16Turboengine.jpg

[Shane5425555]

move it.. take out the passenger head light and put it there...

[Heywood Jablomy]

it's in the passenger fender. look closely and you can see the maroon colored K&N filter.

it's connected to two black 90 degree couplers.

http://www.themazdaforum.com/attachment.php?attachmentid=1948&stc=1&d=1212540322

[Shane5425555]

i am blind.... cant see ti..

[fez]

me neither.

[Heywood Jablomy]

you can see just a small portion of the filter. I'll get pics from the passenger side showing it better.

[kansei]

I see it.. small portion is a little exaggerated lol. More like tiny sliver. just follow the black intake tubing over and you'll see it between two black painted parts

[Z]

following the intake, i finally found it....haha. its really really small.

[Heywood Jablomy]

yeah it is. I'll post pics from the side to show it better. I think it's a much better place than in the engine bay.


thoughts on oil treated filters vs non treated ?

[Shane5425555]

are you running the maf still?? if so , no oil.. no maf, oil safe..

[Heywood Jablomy]

maf is on the hot side, right before the throttle body.

[kansei]

yeah it is. I'll post pics from the side to show it better. I think it's a much better place than in the engine bay.


thoughts on oil treated filters vs non treated ?

I run an AEM dryflow but for years before I had it.. like since 02, I've been running oiled filters (whether they be K&N or Injen or AEM pre dryflow days.. ). The oiled filters seem to come clean much more easily. When I clean my AEM dryflow, no matter what I use to clean it, it just never comes clean. They offer it in a gray filter media and white, mine is the white, and it is darker than the gray and I just can't get it any cleaner.

Performance wise I can't comment, I had oiled filters up until the time I turbocharged the car and have run the dryflow ever since.

[Shane5425555]

maf is on the hot side, right before the throttle body.

that totally doesnt make sense... do you mean cold side??


since filter is straight to turbo, you can do ither, turbo will cook oil before it gets to maf

[Heywood Jablomy]

not on the cold/intake pipe, after turbo and bov.

[Shane5425555]

not on the cold/intake pipe, after turbo and bov.

before or after the intercooler?

CAI pipe
Pipe from turbo to intercooler = hot pipe
pipe from intercooler to the TB = cold pipe

[Heywood Jablomy]

turbo--> intercooler--> bov--> maf

[kansei]

either way the MAf is far enough away (and on the other side of the turbo) so using an oiled filter isn't much of a concern.

[Heywood Jablomy]

any wear on the turbo getting oil ?

[Heywood Jablomy]

all parts are in (ss fitting for coolant line, ic piping). I messed with the car today, I was able to do only so much because the welder wasn't in today. hopefully tomorrow. dare I say I might be firing things up next week if all goes well.

pics tomorrow

[Heywood Jablomy]

couldn't get the welder today. I'm just gonna post pics when it's done.
whenever that is.