Jazzmeson's MazdaManiac Greddy Turbo Kit
 

Figured I'd start a thread and join the major horsepower club. I purchased a used MazdaManiac kit from a friend of mine several months ago and never really got around to getting it installed until recently. Me and gregs have been working on gathering missing parts and making signifcant changes in order to make this kit work better and look more presentable. The turbo was recently rebuilt by ATP Turbo after suffering from oil starvation from the previous owner. A good amount of changes has taken place since I received the kit and hopefully the extra expense will be worthwhile in the long run.

Parts List

• MazdaManiac Greddy Turbo Kit (Garrett GT3071R mated to a Greddy manifold.)
• Custom One-Piece Intake Pipe by Ace'd Auto Worx
• Custom Inlet Pipe by Ace'd Auto Worx
• Custom Oil Drain Tube by Ace'd Auto Worx
• 45 Degree Barb and Fluorosilicone Hose w/ Fiberglass Sleeve for Oil Drain
• Custom Greddy Intercooler Brackets for 2" Spacing Beneath Crash Bar by Ace'd Auto Worx
• Necessary Hardware and Gaskets from McMaster-Carr & ATP Turbo
• SIS 4-Ply Black Silicone Couplers & T-Bolt Clamps
• Secondary/P2 Blue Injectors & P1 Yellow Injectors
• NGK R6725-10.5 W/ Added Shims L & T
• eBay Oil Sandwich Plate
• AEM 30-3300 Methanol Injection Kit
• Innovate SCG-1 Solenoid Boost Controller
• ARK Design SBT Turbo Timer
• aFe Pro Dry S Cone Filter
• Greddy Oil Pan
• Treadstone MAF Straightener
• HKS SSQV III Uncirculated
• Brettspeed Tuned via Cobb AP
• BHR Ignition System
• Walbro 255LPH Fuel Pump

Goals: Between 8-10 PSI if everything cooperates.

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I will be updating this thread with photos once the car is finished this weekend. I have tons of progress photos, but I would much rather showcase the final stretch of the build once we put it all back together.

Brett and Gregs will talk you through the tuning process as it gets dialed in, but you should eventually be able to hit 13psi with that meth injection kit without too much concern. Just make sure you keep an eye on AFRs at high loads. As a rule of thumb, you don't want AFRs above 12 under boost, and you definitely want to be under 11.5 on anything above 9psi, otherwise you're in the danger zone.

Good luck. Looking forward to the pics.

Edit: BTW, I have a similar turbo and I used a small spacer plate between manifold and turbine housing. I got some really nice gains from porting (grinding) out the inside of the assembly where the spacer plate meets the manifold and turbine housing. If your setup isn't that smooth where the mani meets the turbine it'd probably be worth your while porting yours also. I posted a few pics on my thread.

Thank you, I really appreciate your help. I definitely will be keeping an eye on my AFRs once we have it all setup and ready to hit boost. My EBC also has a failsafe which I'll be setting up soon along with the methanol kit. As far as porting goes, it didn't cross my mind until you mentioned it. Now I wish I could have done that before the install, but I suppose that will have to wait until I have a reason or need to remove everything again. Hopefully not. *Crosses fingers*

https://cimg7.ibsrv.net/gimg/www.rx8...40c55bc43d.gif


congrats on the turbo build, can't wait to see it at SevenStock.

Pics coming this weekend! Looking forward to SevenStock, hope the car makes it fine.

This was a challenging install, I'm so happy to be apart of it and the overall look is just beautiful!

:sweatdrop WTF, that was such a cock tease (still no pics). :lol:

Bump! Several photos added with all the piping installed before we test drove the car. The final look should be ready around next week. I can't thank my fabricator Aron from Ace'd Auto Worx enough for all his help and talent and gregs, the master mind from start to finish to get my car to its current state, Brettus for his great advice and excellent tuning, as well as the rest of the Rotary Lounge crew for their continuous support and good vibes. Without these guys, I would have never had the motivation to get this far.

Ugh, eyelids and stickers on an otherwise incredible car!

Bring that thing to the dyno, we wanna see some numbers!

I'm against stickers as well, but I'd gladly throw on a few to help out those who've always helped me. No dyno yet, but hopefully soon once the final map is dialed in.

Jazzmeson: we'll have it on the dyno soon enough... :evil_laug

I love this car. Good work man, I hope you get her dialed in quick.

I smell a dyno day coming soon. :suspect:

Thank you Scott, I appreciate the advice you've given me as well during the process. I'm hoping sometime next month we can get into tuning.

Here's some pictures I took while I was having fun with the install

Here's a before and after of the oil drain supplied with the kit, I'm sure you can figure out what's the before and after
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p-shaw :p:

I think it looks great, do what you like, not what other people like :D:

Nice work man!

Great looking build man, can't wait to see the final product! Looks like you've got all your bases covered and you're definitely in good hands if you have Gregs and Brett on your side. :icon_tup:

That drain setup looks great.

greddy pan... jealous.

Thank you so much everyone! I've been driving the car very carefully while I'm on Brett's base map. Other than that, installation was a success and no leaks or issues to report. A few cosmetic changes will take place this week, so no final pics yet.

^^ can't wait to see this bad boy in person next weekend.

Tuning will be delayed for now. Idle was reading at 4.2-4.3 g/sec at 900 idle RPM with +20% trims... Turned out to be a pinched SSV gasket. After fixing that, I'm unfortunately still reading at an average of only 4.7-4.8 and occasionally 5 at the same idle RPM with +10% LTFT. I'm going to do a smoke test on the car tomorrow and clean the MAF as well to see if it's possibly leaking from anywhere else. I tried spraying all the possible areas I can think of with carb cleaner with no luck on idle change...

If you need help making a smoke machine out of a cheap fog machine let me know. It works awesome and has made life a lot easier over the years. Also, what base map are you running and has your MAF been scaled?

Thanks Scott, I appreciate that. Fortunately, my work has a tester I can use so we'll see tomorrow. I'm currently on Brettus's base map right now without any scaling.

Ah well that explains it. If you need anything just let me know, I have some basic tuning notes that we use locally, it won't help you with boost tuning but it will show you how to scale the MAF. But if Brett is doing your tune, you should follow his directions.

If you could post up a thread for that it would be awesome . So many guys have problems doing a leak test .

I shall do it, it's super easy.

Cleaning the MAF didn't do any good, so that's out of the question. Moment of truth is tomorrow once I hook the machine up... Other than that, like Brett just told me earlier, I may be chasing my tail here. :Wconfused

Yeah man, I bet it's not a leak. I went thru several intake setups and each one required me to scale the MAF for each one. The MAF scaling being off can cause all kinds of wired issues.

Jaemeson; stop breaking shit! :fruit:

I used to think Jaemeson and Jazzmeson were two different people . So confusing .

Didn't find anything from the smoke test. Looks like we're good to go from here after we scale the MAF.

Tuning is delayed yet again. I attempted a 3rd gear WOT with stable AFRs, but experienced a bad boost spike from just under 6 PSI creeping past 8 to who knows where... I'm using a 7 PSI wastegate actuator, so I'll have to check and see if it's having trouble opening. This occurred past around 6300 RPM approaching towards 7K RPM. The car definitely wasn't happy and it seemed like I hit fuel cut and tons of smoke came out the rear. Not to mention a loud crackle when it occurred, most likely detonation. Motor is fine though, drove it casually with vacuum sitting at 850-900 RPM/16.2-16.8 Hg at 1,500 ft altitude.

Any logs from this? Any flashing CEL or codes? Vacuum testing the actuator is easy, it may need adjusting.

No flashing CEL when it occurred. All codes are just typical catalyst and air pump codes which were all removed. Me and gregs tested the actuator before install and was moving freely, but we'll have to do a double take and see if it's having trouble opening as it sits.

My bet is that you just need to mess with the boost controller some more. Mine took forever to get dialed in and I am always improving on it's setup. Also, check the boost cut feature. On mine (HKS EVC-S) I had to mess with the percentage that it cuts boost when it hits the set limit. If the percentage was too high it would cut boost too much and abruptly.

If you can fit one on your setup I would look into a Turbosmart internal wastegate actuator, they are nice. Your wastegate might just be being pushed open from exhaust pressure.

We're actually relying on the wastegate spring for the meantime since the controller hasn't been plumbed yet; it's set at 5 PSI. We ruled out the actuator and the wastegate itself, they have no trouble opening after testing again earlier. I gave it another WOT in 3rd with the WG tied open this time and it's still overboosting approaching past about 6 PSI once it hits close to 6000 RPM. Backed out right away since it creeps up so quickly...

My setup is/has been very similar to yours, and mine behaves as follows: With my WGA spring measured at 9psi, I was seeing no more than 7psi of boost (exhaust back pressure blows the WG open). With the WG unlatched and swinging freely, I saw no more than 4psi, and this was a very predictable linear increase in pressure, only seeing 4psi near redline.

It sounds like the exhaust flow through the turbine housing and out of the wastegate is severely restricted. Have you got any pics of the hot-side outlet of the turbo showing the wastegate flap and how far it can open?

Also, I mentioned previously about the inlet to the turbine housing from the exhaust manifold. It possible (though probably not that likely) that this area is causing excessive backpressure, which may be contributing to your issues. Do you have any pictures showing how rough/smooth that area is?

Unfortunately, these are the only photos I have prior to installation. Turbo was rebuilt by ATP according to previous owner before I bought it.

https://cimg8.ibsrv.net/gimg/www.rx8...0b56a6b63c.jpg

https://cimg9.ibsrv.net/gimg/www.rx8...0ce3458607.jpg

https://cimg0.ibsrv.net/gimg/www.rx8...df7c76bb9b.jpg

Looks okay, but I spy a crack that may be an issue eventually. Hook that boost controller up man.

Yup, hence the photos prior to buying the kit. I'll get to work soon and finish it all up though.

Looks like the turbo has to come off. We're still having problems controlling boost pressure. Hitting 9 PSI by 5700 RPM with the wastegate left open! Who knows how high it crept up past that when I was hitting close to 7K... Once it's taken apart, I'm going to enlargen the port significantly and look for any other possible restrictions. Unfortunately, this is a problem beyond what a boost controller can fix...

Boost creep is almost always a wastegate issue. Sucks you have to take it off. Welcome to the world of boosted RX-8's :)

Yeah, it's too bad that wasn't the case this time. :(

Other notable mods I currently have, but may not really a play role aside from the exhaust is a TurboXS cat-back and cat-less race pipe, 4.77 final drive, and 8 lb Racing Beat flywheel.

I wonder if the turbo rebuild was botched.

Good question... ATP is very reputable here, but at this point I really have no idea anymore.

I developed the SARX Greddy wastegate actuator with ATP, they were excellent to deal with in sending a spare Greddy to them and going back and forth with changes to the design, etc. I'd be surprised if they screwed up the rebuild.

It's pretty unusual . Never heard of this on this turbo before. Only thing I can think of is that Jaemeson's exhaust has much less backpressure than others with this setup.