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Ricky's Turbo Renny 2.0 Build Thread
Finally getting around to making a build thread to try and keep things at least -somewhat- organized as I work on making what I hope will be a fun, capable and powerful novice road course/race track/autocross car that still has most of all of your basic amenities and can be driven on public roads.
The base car itself is a 2005 MT (6 speed high-power for you non-N/A folks) Touring trim in Whitewater Pearl. The car used to be my daily driver up until early 2021 where I acquired a 2016 Mazda 6 to take its place as my daily. While I successfully accomplished many mods and upgrades prior to getting a new daily driver, quite a few of my modifications and upgrades were not done as nicely as they could've AND should've been due to time constraints of needed to get the car back up and running quickly as I did need it as my main method of transportation. Now that I have exponentially more flexibility with how long it can remain non-operational, I have the liberty to go back and correct prior mistakes and reverse shortcuts that were made along the way in an attempt to finish things quickly. That said, things will still be far from perfect... however they will be significantly better than they were previously at the very least. The next goal for this car is to hopefully meet or even surpass the 400whp mark (we will see how it responds during tuning when the day arrives) with superb drivability and an excellent powerband and torque curve... real, useable power and not just top end power with crappy low end response and subpar drivability. When the car is finally complete, I plan to take it to a few different race tracks and even take it back on a drive out to South Florida (I'm in SoCal mind you) to visit my family while on vacation and enjoy going back to driving through the Florida Keys where I grew up. Tracks to take the car to will include Buttonwillow, Willow Springs/Streets of Willow, and the one I look forward to the most being Laguna Seca where the cooler weather climate will do wonders for a turbocharged car on an iconic track. More to come |
The previous build...
Was a basically all DIY build with a Greddy Manifold as the base of it all. Turbo was a modified unit that was water cooled, a 60-1 compressor side with a 3" inlet and a TD06H turbine side with typical internal wastegate due to the greddy manifold. Poorly made IC piping, crap ebay intercooler (this one was way too big and blocking airflow to the radiator causing overheating issues. the previous one was far too small causing a restriction and high IAT's). It ran, it worked, made decent power... but the power I was trying to make my cheap, poorly done setup output caused me headaches. I also had a cheap ebay radiator which didnt help and I'm sure my radiator fans were on their way out and not pulling air as good as they could have. Not bad for a first attempt all DIY, but the lack of ability to really take my time because of needing to daily the car meant it was never really going to do much improving, and I would also be putting my engine at risk for damage on every drive due to the conditions the system put the engine under (high boost with sub-par IAT's, probably higher EGT's and EMAP than anyone would advise, etc). https://cimg6.ibsrv.net/gimg/www.rx8...eecf76b887.jpg This is one of the last times the car would be driven like this before being retired from daily drive duty and the process of doing things right would begin |
The first thing I wanted to do to differentiate this new build from the previous was to make some cosmetic changes to the exterior. I went with a KBD front bumper and side skirts, and later on I stumbled upon a carbon fiber trunk and hood. I also went ahead and removed the engine to do some changes and do some internal upgrades to the block for more power
https://cimg9.ibsrv.net/gimg/www.rx8...d362de31d6.jpg https://cimg7.ibsrv.net/gimg/www.rx8...89a551a519.jpg https://cimg6.ibsrv.net/gimg/www.rx8...7c66013d23.jpg https://cimg4.ibsrv.net/gimg/www.rx8...82218426ac.jpg https://cimg5.ibsrv.net/gimg/www.rx8...415e25a070.jpg The body shop took quite some time with the car just to paint the bumper and side skirts... (they also went and blended the fenders). The paint looks pretty good, they didnt do very well at fitting the bumper and side skirts however. No matter, I planned on going back in and working on the fitment further anyways. https://cimg6.ibsrv.net/gimg/www.rx8...83f3d069f7.jpg https://cimg1.ibsrv.net/gimg/www.rx8...d0b4c5c660.jpg https://cimg6.ibsrv.net/gimg/www.rx8...0905c88827.jpg https://cimg8.ibsrv.net/gimg/www.rx8...238bc2b528.jpg |
Now here's where we are going next.... I was successful in getting one of Brettus's manifolds, and I will be installing a Pulsar turbocharger on it that is a clone of the Garrett G30-660 with a 0.82A/R turbine housing and Pulsar wastegate that is a clone of a TiAL MV-R 44mm external gate (I have installed a genuine TiAL diaphragm into it and used valve compound to help smooth and hone the operation of the unit). A 7psi spring is currently installed.
https://cimg3.ibsrv.net/gimg/www.rx8...82f03baf8d.jpg https://cimg2.ibsrv.net/gimg/www.rx8...da29b55785.jpg https://cimg0.ibsrv.net/gimg/www.rx8...c1c8df5f98.jpg https://cimg3.ibsrv.net/gimg/www.rx8...1c84960376.jpg https://cimg4.ibsrv.net/gimg/www.rx8...39b34eadc4.jpg |
Previous events have made me come to realize that fighting to keep myself steady behind the wheel while racing is a major pain in the rear and is definitely making it difficult to have smooth, consistent input. A forum member here listed a roll bar up for sale and worked with me (thank you again @hufflepuff ) and I was able to purchase it from him. Fast forward several months and I finally got around to working towards the installation of it. I also got my hands on a pair of Corbeau Forza seats with double-locking sliders.
The Autopower roll bar is their street-race model if memory serves me right, with bolt-in harness and diagonal bars. The only issue I ran into with this is that the bar was built for a non-sunroof spec car (they do make sunroof spec bars when you order from them direct however) so I just had to get creative with the install. I ended up cutting my headliner and removing a couple of non-essential sunroof components to make things fit nicely. I also had to ditch the rear dome light, which is fine as I didnt use it anyways. https://cimg8.ibsrv.net/gimg/www.rx8...ad8b54c495.jpg https://cimg9.ibsrv.net/gimg/www.rx8...3a1d3e9c1b.jpg https://cimg8.ibsrv.net/gimg/www.rx8...0506a76adf.jpg https://cimg6.ibsrv.net/gimg/www.rx8...2d635d3eda.jpg https://cimg4.ibsrv.net/gimg/www.rx8...07782dc515.jpg https://cimg5.ibsrv.net/gimg/www.rx8...da5fd56701.jpg |
Getting back to this thread, a little info on the status of the engine build.
While I wait for Mazmart, I have begun doing some cleaning up of wiring in the engine bay and trying to clean things up to be more aesthetically appealing. Redoing the engine bay harness wrapping, taking out components and starting cleaning under and behind them (Like the fuse and computer boxes), I'm debating on spraying a little white paint to freshen up under the hood, and quite possibly doing a partial or full wire tuck. https://cimg6.ibsrv.net/gimg/www.rx8...afe6a17302.jpg https://cimg7.ibsrv.net/gimg/www.rx8...6bf7ed3e89.jpg https://cimg8.ibsrv.net/gimg/www.rx8...86120ab58f.jpg https://cimg0.ibsrv.net/gimg/www.rx8...21cad72935.jpg https://cimg2.ibsrv.net/gimg/www.rx8...4f70931e0f.jpg https://cimg4.ibsrv.net/gimg/www.rx8...acbe9c65f3.jpg https://cimg9.ibsrv.net/gimg/www.rx8...61e4702e1b.jpg https://cimg2.ibsrv.net/gimg/www.rx8...6f8237f63a.jpg https://cimg5.ibsrv.net/gimg/www.rx8...59d0d7a4e2.jpg https://cimg8.ibsrv.net/gimg/www.rx8...530f1828e8.jpg https://cimg3.ibsrv.net/gimg/www.rx8...3401cc283a.jpg https://cimg6.ibsrv.net/gimg/www.rx8...4d40f04990.jpg I also got my hands on some carbon fiber side mirror covers for $60 plus shipping, and I got a used TurboXS exhaust from a friend with both a high-flow cat pipe and a catless race-pipe from a friend for $400 ($450? dont remember) that I'm installing to have a better quality exhaust on this build than my crappy self-made exhaust. I just did a quick shine/tarnish removal by hand really quick to bring some of the luster back, its as good as I care to get it right now. Maybe later if it bugs me I will go back and machine polish, but right now I'm entirely fine without it. |
i had those cf mirrors on my black 8. sounds like a good plan buddy. after ya spend all this money when are ya gonna fix that bumper?
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Originally Posted by 200.mph
(Post 4972317)
i had those cf mirrors on my black 8. sounds like a good plan buddy. after ya spend all this money when are ya gonna fix that bumper?
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side cutting Renesis rotors is a big mistake. You can do that on a 13B, because it has the peripheral exhaust port and the two don’t interact on that engine. On Renesis plates with the side exhaust port though, it will be dumping exhaust gasses more easily back into the intake cycle.
It’s one of the mistakes that 13B people who don’t account for the engine differences make, Kyle Mohan being one. If you want to understand why that is go find the Renesis SAE paper and it explains that Mazda did the opposite just for that reason. Yet Renesis rotors are still very light. It’s just not necessary on these rotors, but also counterproductive. . |
Originally Posted by TeamRX8
(Post 4972347)
side cutting Renesis rotors is a big mistake. You can do that on a 13B, because it has the peripheral exhaust port and the two don’t interact on that engine. On Renesis plates with the side exhaust port though, it will be dumping exhaust gasses more easily back into the intake cycle.
It’s one of the mistakes that 13B people who don’t account for the engine differences make, Kyle Mohan being one. If you want to understand why that is go find the Renesis SAE paper and it explains that Mazda did the opposite just for that reason. Yet Renesis rotors are still very light. It’s just not necessary on these rotors, but also counterproductive. . |
Good find on that CF hood 😉. Seems to have a lot more flow than mine.
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balancing helps in many ways, it’s under-appreciated for sure.
the factory Renesis motors can and often are far off. It’s not readily recognized being that the rotor itself only orbits at 1/3 the e-shaft rpm along with the short “crank arm” of the e-shaft. However, it contributes greatly to bearing wear, rotor wobble into the side plates, and other such things because excessive vibrations and harmonics will impact wear and durability long term. The engine itself seems rather small and compact, but you have to consider the actual e-shaft span between the two main end plate bearings then also having two rotors orbiting about it between those two bearing points compared to the bearing placement on a crank shaft of a 4+ cylinder reciprocating engine. again, under-appreciated for sure … . |
Earlier this week I connected battery power back to the Rx8 for the first time in approximately 18 months, during which time I found a couple of small electrical concerns and gauge problems I need to address. With weather warming up and the last of the items I need arriving for me to assemble the motor, I'm starting to feel the motivation to make more progress. So I'll be posting a few updates now..
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So I did pick up my rotors, complete rotating assembly, etc back on September 12th from Mazdatrix. They cut the rotors for FD apex seals and balanced the assembly. Maybe its just me, but I do feel as if their people skills over there leave a lot to be desired... I likely wont do business with them in the future if I don't need to.
https://cimg5.ibsrv.net/gimg/www.rx8...e26db4d3a1.jpg https://cimg7.ibsrv.net/gimg/www.rx8...de16e6feab.jpg https://cimg3.ibsrv.net/gimg/www.rx8...94c55413a4.jpg I decided on going with a ACT 6-puck sprung clutch disc for my application since ACT recommended it over their full face clutch for any aggressive applications like track/road course or aggressive autox with higher power numbers. https://cimg7.ibsrv.net/gimg/www.rx8...d8b50d0797.jpg For the corner seals I have decided to go with IRP 13b corner seals to hopefully provide a much better seal over Rx8 corners without plugs. I am also not going to cut the side seals myself, and elected to go with pre-sized side seals based on the side seal identifiers on the rotors. It was hard to track down all the side seals I needed due to issues with stock/inventory and I had to purchase side seals from 3 different places, but I was able to obtain all of the sizes and quantities I needed. For the apex seals, I went with OEM Mazda FD seals for a reliable and quality solution vs an aftermarket seal. For my power goals I shouldn't have any problems with OEM FD seals. https://cimg9.ibsrv.net/gimg/www.rx8...d1a68774da.jpg As mentioned before I have the Chips 10.5mm stud kit and Pineapple Racing one-piece dowel rods as well... A new OEM Mazda coolant thermostat along with my lower temp oil thermostats from Rotary Performance and Mazmart REmedy oil pressure regulator, and this engine should run fantastic with a proper tune. Not to mention, using the KMR porting template I have ported the engine's exhaust ports (intake ports left alone). This should help provide a little bit of benefit to turbo spool at low end (which it should already spool very well as a low mount setup, and a 0.83A/R T3 turbine housing for my pulsar G30-660) https://cimg8.ibsrv.net/gimg/www.rx8...706e7ad3ac.jpg https://cimg7.ibsrv.net/gimg/www.rx8...1d8a6907d8.jpg Also went ahead and did some painting. Irons and Housings, LIM, heck I even did the engine bay to get rid of some ugly looking paint and rust stains. Engine bay was with a rattle can so it didnt come out the best, but I find it a pretty nice improvement. https://cimg4.ibsrv.net/gimg/www.rx8...7444e0cae1.jpg https://cimg3.ibsrv.net/gimg/www.rx8...e1e5524214.jpg https://cimg2.ibsrv.net/gimg/www.rx8...da99891dba.jpg https://cimg4.ibsrv.net/gimg/www.rx8...00ee7c4fb9.jpg https://cimg2.ibsrv.net/gimg/www.rx8...036de37650.jpg https://cimg9.ibsrv.net/gimg/www.rx8...f2727b7e32.jpg https://cimg1.ibsrv.net/gimg/www.rx8...5cd91ef685.jpg https://cimg6.ibsrv.net/gimg/www.rx8...a50280b6d6.jpg https://cimg0.ibsrv.net/gimg/www.rx8...4e9884cd16.jpg Sprayed inside the fenders black so if I modify my vents or go with carbon vents, you eye doesn't instantly catch the white frame underneath https://cimg7.ibsrv.net/gimg/www.rx8...59847bbb73.jpg https://cimg0.ibsrv.net/gimg/www.rx8...2030a66db8.jpg Going with a Wilwood Superlite front caliper setup. https://cimg5.ibsrv.net/gimg/www.rx8...a26e522514.jpg Didn't like how my LED turn signals showed yellow in the reflector housing, so replaced the bulbs with some cheap fleabay bulbs with a black base to eliminate that https://cimg2.ibsrv.net/gimg/www.rx8...eabffe8e60.jpg https://cimg8.ibsrv.net/gimg/www.rx8...648d64535a.jpg https://cimg6.ibsrv.net/gimg/www.rx8...efa31261f9.jpg |
did you have something else done that required them to put blue marking die on the full sides of the rotor? :scratchhe
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Originally Posted by TeamRX8
(Post 4980679)
did you have something else done that required them to put blue marking die on the full sides of the rotor? :scratchhe
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I recall the discussion; maybe that explains the other thing then.
I picked up a Pulsar G30 V-band 0.92 IWG recently. It intrigued me to give it a try on the -770, being between the 0.83 and 1.01 that Garrett offers. It’s short/compact enough that even with an adapter it still fit within the 1.06 T4 housing profile. The downpipe will need to have an additional joint due to the outlet position difference and swapping in stub pieces for each. . |
So updates are still on the slow side, but you can anticipate things picking up with temperatures rapidly rising and rain going away making extended hours working outside easier.
I sold my OEM 3rd gen Mazda 6 wheels, as well as the 19" wheels I was running on my Mazda 6. Bumped up to 20" wheels on the daily.... and all the shuffling around with wheels/tires got me itching for some more fresh looks with the 8. Fast forward a couple of weeks and I got a great deal from a fellow forum member on some sticky Pirelli P-Zero Slicks in 265/660. My Motegi Traklite 3.0 wheels on my 8 already had some Federal 595RS-RR tires that have tons of life left and I didnt want to just sell them... but I wanted to put the slicks onto the Traklites, so I bought some Vordoven Forme 9's to be the daily wheels for the 8 that received the Federal tires from the Traklites. https://cimg9.ibsrv.net/gimg/www.rx8...a76b5447a6.jpg https://cimg8.ibsrv.net/gimg/www.rx8...dfa2e00acf.jpg https://cimg9.ibsrv.net/gimg/www.rx8...7c92012bd9.jpg https://cimg2.ibsrv.net/gimg/www.rx8...64ded033e3.jpg I got some collars in the mail for the 4 point harnesses to keep the harness straps from sliding around on the harness bar. I started to dress my LIM and get things ready to install onto the engine and most importantly I got the engine assembled. I still need to put on all of the dressing onto the block but things are coming together nicely and I'm taking my time to make this build much nicer than the last. https://cimg0.ibsrv.net/gimg/www.rx8...4947bac594.jpg https://cimg2.ibsrv.net/gimg/www.rx8...376973ff2a.jpg https://cimg4.ibsrv.net/gimg/www.rx8...6bd89a7712.jpg https://cimg4.ibsrv.net/gimg/www.rx8...c880bc9e64.jpg https://cimg9.ibsrv.net/gimg/www.rx8...fdd17a52d4.jpg Brake rotors need to come off and get cleaned and turned, they look pretty terrible unfortunately from sitting for the last 18 months. Soon the new braking system will be installed so I am very excited for that as well. https://cimg1.ibsrv.net/gimg/www.rx8...029c1eabc7.jpg https://cimg7.ibsrv.net/gimg/www.rx8...2f46c3927a.jpg |
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Rebuilt and painted rear calipers to match the front Wilwoods. Removed the copper calipers i rebuilt like 6,500 miles ago and gave them to a local member for free who was having issues with his brakes. https://cimg2.ibsrv.net/gimg/www.rx8...364bb1cd28.jpg Installed the front and rear calipers. Talk about an easy install!! Highly recommend the Keisler kit! Rotors are getting replaced with some Racing brake slotted rotors front and rear. Already have the rotors, will install them next week. https://cimg7.ibsrv.net/gimg/www.rx8...a75e551ebb.jpg https://cimg9.ibsrv.net/gimg/www.rx8...dc01bb2665.jpg https://cimg0.ibsrv.net/gimg/www.rx8...d2dda7dd9f.jpg I got my hands on and installed a 5 speed manual JDM transmission. Bought a upgraded shift bushing to toss in during install, which was smart because the factory one was completely obliterated. Also for whoever it might help, the output shaft seal on the 5MT is the same seal as the S2 6MT. https://cimg5.ibsrv.net/gimg/www.rx8...86b17d7484.jpg https://cimg6.ibsrv.net/gimg/www.rx8...01d27ac724.jpg https://cimg7.ibsrv.net/gimg/www.rx8...89a365301f.jpg https://cimg8.ibsrv.net/gimg/www.rx8...7b5a40f4d5.jpg Finally, I have the engine in the car... Goal is to make it to Sevenstock this year, so progress is about to really ramp up! I have more updates to share, but will do so when it's appropriate. |
Nice update. Hope you make it in time for your event. It looked to me like you had a nice set or Work wheels but then I googled vordoven.
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Yeah, Works are super nice but I personally decided to go with this brand instead to allocate more money towards other parts of the build. Plus I have the sticky compound tires on the Motegi traklites which makes more sense being a lighter weight wheel
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Ricky you probably mentioned the answer to my answer but I didn't notice it while reading your threads, but please answer here :) .
why are you keeping the exhaust fresh air pump all all those components on the car ? |
Originally Posted by MilosB
(Post 4985814)
Ricky you probably mentioned the answer to my answer but I didn't notice it while reading your threads, but please answer here :) .
why are you keeping the exhaust fresh air pump all all those components on the car ? |
Originally Posted by Ricky SE3P
(Post 4985819)
I'm in California, so I will need to keep the engine "stock" with air pump and stock cat, exhaust mani, etc so I could smog the car (its due). ..
If you are using mazda edit you can disable the check of the corresponding ecu parameters and remove them from "readiness" monitors which I assume is what they check.. (But I could be wrong obviously as im not there). Also sadly I got in with Versa so am missing those editing parts my self. |
Originally Posted by MilosB
(Post 4985821)
I assumed that to be the case.
If you are using mazda edit you can disable the check of the corresponding ecu parameters and remove them from "readiness" monitors which I assume is what they check.. (But I could be wrong obviously as im not there). Also sadly I got in with Versa so am missing those editing parts my self. I have flashed my car back to the original PCM dump on MazdaEdit, so everything is as from factory... However, I don't know what kind of footprint the MazdaEdit software has left on the PCM and if I will have issues with it. So I'm kinda in uncharted waters currently. I will report back as soon as I have made that attempt with a pass/fail result for everyone. |
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