Fazdarx_8's Top Mount Turbo Build
 

Hey guys, thought it was time to post a build thread. I have been researching and learning a lot about the Rotary engine, at first I started with the basic bolt-ons and decided that boost was going to net the most gains. I really liked the look of the top-mount kits like Speed Force Racing, Esmerils kit, and Turblowns kit. I then noticed mawnees build thread, how he built is own kit, as well as others and thought, its possible. I started looking at raw materials; spoke with a friend of mine who is a TIG welder, Eric Furgison, about fabrication and welding. It became clear that I could make my own kit. I decided to keep things simple and go with a log type manifold, it works and I can keep Radiator hoses and the OMP in place. So after gathering necessary parts the Fabrication began
the 2.5inch 304ss log snakes its way to a t4 flange where a T04E Divided 60-1 trim turbo is mounted sitting beautifully in the middle of the engine bay, to get ride of the exhaust there is a 3inch down pipe connected by v-bands this flawlessly mates to the stock exhaust. The external wastegate/boost control is handled by synapses engineering that is re circulated VTA. Currently set at its lowest setting

The intake charge travels to a modest intercooler then around back up to the throttle body, where a Synapsis engineering BOV is re circulated into the intake to keep the MAF happy, speaking of the MAF, I relocated it farther away from the turbo intake to keep turbulence down, I made a custom MAF housing that matches the stock housing perfectly, so well that when the car started for the first time it idled smooth, vacuum lines are handled by quick disconnects. Planning to run 10-12psi. Here are the pictures!!!

https://farm8.staticflickr.com/7077/...31e1fa4e_c.jpg

Soldering extensions for MAF (this is unnecessary if you take apart the harness there is plenty of wire)

Upgraded fuel pump to walbro 255

Fuel Injectors KG upgrades (4 uncapped yellows)


This is how it sits
https://farm9.staticflickr.com/8308/...ded2a1df_b.jpg

So it took me long to post this cause I wanted more complete results
I was running 5psi, with Jeff’s base tune. later I bought rx-7 plugs
Rx7 plugs(NGK BUR9EQP)?? And datalog for the 10-12psi.

Its amazing at just 5psi, its so much of a rush for me that I can’t tell when the boost hits exactly it’s a blast and I am quite pleased with the results

I wanna thank
Mawnee
Eric Furgason
RX-8club

Congrats man, bet you can't wait for a final tune and dyno :)

nice build..and great details

Plans for dyno?

glad to see this up and running. everything looks very good and well built. im only at 2-3 psi right now and love the way 6th gear is on the highway for passing people.

Thanks guys
Turblown, once tune is done I would like to dyno, but it may be a trip to seattle for it. There is only one dyno here and its a run down shop with father time running it

Congrats on the completed build! It looks great! Just wait till you feel it all full boost, completely different car. You are gonna love it! :yesnod:

Wow nicely done fazda.... Can't wait to see dyno results

Looks great, Fazda! Good to see another FI 8 in the NW!

clean built turbo, good job

Thanks again guys, it was a good road, I learned alot by doing it myself, I picked up the spark plugs today, but I cleaned up my garage its been pretty filthy with all the grinding and cutting residue. will keep thread posted

looks to be a killer build. very nice!

Looking sweet man . Good work so far .

Good luck and drive fast for now on... Tuuuuuuuuurrrrrrrrrrrrrrrrrrrboooooooooooooooooooo !!!

Very nice! I have been leaning more and more to the top mount (when I'm ready to take my leap of faith lol). Looking forward to the dyno!

You are probably going to have problems with that MAF setup.
I would also worry about the materials used for the manifold, but only time will tell on that one.

You will want to change the orientation of the WBO2S.

The Synapse parts are absolute crap. You should reconsider them.

Unless you completed it after you took that photo, your fuel pump upgrade is missing a step.

sweet build!

Any specific reason why they are garbage? My Synapse BOV seems to work well enough after all the plumbing issues were fixed.

The MAF setup seems good, the car starts and idles smooth no hunting, and driving it feels like stock, well except boost :)

this wasn't mig welded, and it wasn't tig welded with just one type of rod

your my tuner, whats wrong with it? I get perfect 14.7 afr's at idle, and about the same with cruising, boost it goes real rich, (Base tune from you)

like the parts them self or the construction/placement of them? from what I have heard they seem to be good, good reviews not sure of irontanuki's plumming issues but my setup is running smooth, have a good story to share?

yeah, lol the pump actually got swapped, got a smaller o-ring, melted the plastic bits, reassebled and put it back in the tank

Looks cool, MM's right about that MAf setup. We went through 5 diffrent versions before a true poblem free standad was developed.

WHat kind of problems?

looks great, though I might have recommended using progressive sizings on your main log manifold. It is more challenging to fabricate that way tho'

T304 is not considered the best choice for a rotary manifold, especially FI

What would you recommend?
Seeing as I have the Synapse ..... and thought it was good stuff.

Really neat job on the build!

Best regards,

Chris

I can contest that doing things yourself you learn a ton! Great job and lets see that dyno! Nice to see Chris on this one to.

Looking great man! How bout some video clips on how it sounds :)

it seem with synapse products either some people hate it and some people love it. Though im unsure why people dont like them never really found that out. I personally lover their bov and WG once i figured out all the ports and how they work

Thanks guys, I cant wait til jeffs live tune in 8 days

I could do a video, sound may be so so, I am very pleased with synapsis.

congrats on the project. I hope it keeps going good, and you can keep happy.
My advice. Feel satisfied once you are happy, and ignore people here saying "more power! more boost! Dyno!" etc. Just get it how you want it, and then have fun in the car!

You need moar power! moar bewst! Dino ?

+11111111!!!!!!!+++++++++

LOl, double checking stuff and checking for leaks, and installing spark plugs!!!

haha, me & my big mouth!

So as it turns out when I took my first trip my wastegate was acedentilly set at 13psi, but I only seen 5 psi, turns out I had alot of boost leaks, so I figured it was my luck.

anyways I found all the leaks sealed everything, I think, there was this other wired sound when I presureized the system i hear a leaking sound from the motor or exhuast, just can't tell, I figured this must be the fuel jets. anyways I put in the fd spark plugs took for another spin, once again the max I see is 5psi, I keep trying to figure this out,

is there something more to this mystious leak?

bad boost gauge?, it came with a funny restricter T but I just took the signal right from the intake maniflod, where the two nipples are. one goes to boost gauge, the other goes to BOV


Or does MazdaManiac have a tune that restricts it to 5psi?

I want to be able to make it for this Tuesdays tuning event

He's not a magician ...

He may have timing retarded a great deal to limit boost on a base tune.

I thought a tuner could play with turbo response via timing, thats all. any other input Brettus??

my thoughts too mawnee!

It actually works the other way.
If you retard timing, EGT goes up and boost increases.

so is your base tune limiting boost, some how?

Fix the funny noise . Sorry that's all i got :)

here is a a thought.
Seafoam the car. Let sit, and start car. Its a very good exhaust leak finder because of the white smoke it produces. I found a small leak between the DP and turbine this way. Also if you have either a puddle under the exhaust manifold or a long narrow (1 1/2") wide spray patten after romping the throttle under the exhaust mani, your mani is either not tight enough, improperly torqued or you gasket is leaking. I found this out too.

Is there a doctor in teh house?

http://www.amazon.com/Auto-Mechanic-.../dp/B0034PVBPQ

yeah for 4.6 with is the lowest psi you should be on the lowest 2 ports. Also from the looks of it did you not back purge when welding the stainless?

LOl @ teamrx8!!!!

I am using the second spring, doing C & A should be 10 to 13 psi.

that makes sense im using the blue not the green and a EBC.

HAve you got your setup running and driving? Could try doing just the vacuum ports and not use the ebc see if you get 10 psi?

yeah it is running im working with kane on the tuning. we are messing with wot at ~4.5 psi and EBC zeroed out (EBC is doing nothing at the moment). I have the EBC to help gain spool time and the option to change psi with ease rather then be set. ill pry run just port c ~6psi and is the EBC from there up to 10-12. I will be doing dyno tuning along with EBC tuning here soon.

it works ...

I Lol at the docter comment, the link to that tool is very useful, sadly I don't have one, but I have used one before, great suggestion

09facter,

thank you for you suggestion of an exhaust leak, I found one right at the turbo, and after tweaking the wastgate's preload (thanks to bumblebee) I was able to get 10psi briefly as the wastegate opened to taper to 8psi, witch for now feels good to start tuning with. I keep forgetting as well that I have a given pressure drop on the intercooler too, silly me

I did some data logs tonight and plan to submit them, wish the live tuning event would happen sooner

car feels great, I am excited to see what she will be fully tuned!!!!