The snowball of a build: 90 LSx Turbo Rx7

[Phish]

I figured its about time to post some progress and changes that i have made over the winter. The Shell was bought last spring/summer. The car is a 1990 Mazda RX7 GTU. It had the locked up motor and had very low original miles. The interior and exterior of the car was in near perfect condition besides the door dings. All in all it was a great find. Here is the car as it was purchased:

http://i232.photobucket.com/albums/ee44/Phish806/0502131714_zps883a6530.jpg (http://s232.photobucket.com/user/Phish806/media/0502131714_zps883a6530.jpg.html)

Once home in the garage, i swapped in the drive line from my precious project car (86 LSx Swapped RX7). The driveline included the Ford 8.8 IRS with 3.73 gears, Drive Shaft Shop Axles, TH350, and the turbo two brakes and hubs.

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0509131739_zpsmgnxlwf9.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0509131739_zpsmgnxlwf9.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0510131347_zpssqnag44f.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0510131347_zpssqnag44f.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0510131346_zpsmqogc0zf.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0510131346_zpsmqogc0zf.jpg.html)


Once the driveline was in the new car, I think pulled the old rotary out and installed the LQ4. At this time It was a stock bottom end LQ4 with a Comp Cams 232/234 .595 .598 cam. On top was a Ls1 intake (eventually a FAST 76) and ported and milled 862 heads. It was also spraying a 150 shot when feeling frisky. For fuel an AEM 320 LPH pump was installed along with Ford green top 42# injectors and Holley fuel rails to run E85.

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0604132158_zpssjwwmrao.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0604132158_zpssjwwmrao.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0723130914_zpstemaopu0.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0723130914_zpstemaopu0.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0625131942_zps047gjxqg.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0625131942_zps047gjxqg.jpg.html)


This setup did well and i dont really have any complaints. But like all car guys i decide i wanted more. I figured a topend swap and some headers would get me a bit more power and i wiould be pleased. I purchased a set of new LS3 heads and intake along with a 90mm throttle body.

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/1016131845_zpsdywpc84z.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/1016131845_zpsdywpc84z.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/1106131758_zpsbvln6ean.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/1106131758_zpsbvln6ean.jpg.html)

After installing the new topend i decided to clean up the engine bay a bit and did a wire tuck for the factory mazda harness along with moving the under hood fuse box. Also a catch can was installed.

http://i232.photobucket.com/albums/ee44/Phish806/1127131504_zpsea3195d0.jpg (http://s232.photobucket.com/user/Phish806/media/1127131504_zpsea3195d0.jpg.html)

Now all of this was exciting, but someowhere along the lines i decided i was not spending nearly enough money. So, this is when i decided to go turbo. I began to figure out all the details on how i would route all of the piping and where things would be mounted. I had to change up the radiator to move the outlets to the passanger side of the car. However with a new radiator the new fans did not fit it right. So, this lead me to have to build a new fan shroud to use with the ford fans.

http://i232.photobucket.com/albums/ee44/Phish806/1203130645a_zps70889f05.jpg (http://s232.photobucket.com/user/Phish806/media/1203130645a_zps70889f05.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/1203130645_zps9cb8bfe0.jpg (http://s232.photobucket.com/user/Phish806/media/1203130645_zps9cb8bfe0.jpg.html)

After finishing up the fan situation i ordered some turbo parts and started building up the hot side for the turbo kit. I used a truck manifold on the drivers side and a Fbody manifold on the passenger side. This would put them int he right locations and get them heading the correct direction for the piping i was going to create. The piping is 2.5" off each v-banded manifold joining at the passenger side and going up to the turbo. The wastegate (Precision 46mm) is mounted just after the piping merges into one and is planned to route back into the downpipe.

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0104140932b_zpsp7hwrydg.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0104140932b_zpsp7hwrydg.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0104140932a_zps6kibxv0g.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0104140932a_zps6kibxv0g.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0104140933_zpscn5vbwnq.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0104140933_zpscn5vbwnq.jpg.html)

Everything fit quite snug int he bay. One of my main goals is not have to cut out any support or make any major changes to the structure of the vehicle. Thus i chose my turbo placement. The turbo that i chose was a journal bearing Comp Turbos CT43 8079 with a 3.5" DP and a 1.15 A/r. I was very impressed with the quality of the turbo once it arrived and it should reach my goal nicely.

Once the turbo was bolted on to the new hotside, the DP was started to be fabricated. This is still a work in progress. The WG still needs to be routed into the DP. Again a tight fit but i believe it will still be a clean look when complete

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141018a_zpscy8c3rqz.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0111141018a_zpscy8c3rqz.jpg.html)

Now the cold side has also been mocked up and put into place. I am running a Ebay intercooler that most of the LS guys are running. however its a smaller 27" core. its 3" piping off the turbo and after the intercooler it transitions to 3.5" piping into the intake. Ignore the black section of pipe in the pics. I am waiting on a 3.5" aluminum straight section and just used something i had around for mock up. The 50mm RPS BOV will be welded into this straight section when it arrives.

Here are some pics of the cold side and some other random pics to show where i am at currently with the build. i am sure there will be more info and pics to come and i am sure there is a ton of info i have left out.

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141827a_zpsjfxghqae.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0111141827a_zpsjfxghqae.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141827b_zpsd7cte0wn.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0111141827b_zpsd7cte0wn.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141827c_zpskr9gk5ki.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0111141827c_zpskr9gk5ki.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141828_zpscftussny.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0111141828_zpscftussny.jpg.html)

[Phish]

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141828a_zpsfnk8veke.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0111141828a_zpsfnk8veke.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141829_zps07clm5mh.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0111141829_zps07clm5mh.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Car4_zps21ca0c42.jpg (http://s232.photobucket.com/user/Phish806/media/Car4_zps21ca0c42.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/Car1_zps61ef4a7f.jpg (http://s232.photobucket.com/user/Phish806/media/Car1_zps61ef4a7f.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/ICCRX7_zps15b17366.jpg (http://s232.photobucket.com/user/Phish806/media/ICCRX7_zps15b17366.jpg.html)

[JacobS]

nice!

[AutoMods]

thanks for sharing. looks clean. i like the wire tuck.

I'm curious as to how good the pte46mm wastegate will control boost for you. I have the tial 44mm and its always controlled boost well down to 5psi until I went from my 5.7 to the 6.0 and at the same time got a larger turbine wheel/less back pressure. After i went from the 68mm turbine wheel to the 75mm, my boost didn't want to say below 14psi anymore. not a big deal since 14psi is minimum is fine for me. I'm venting to the atmosphere.

my wastegate angle isn't the best but its not terrible

http://automods.com/temp/rx7_turbo_piping_700.jpg

[Phish]

yeah i am a little concerned about being able to keep the boost down. I believe my placement is a little better then yorus though but not by much. I only say that because mine will pick up most of the exhaust from the drivers side with how the piping is bent and flows. Its hard to see how all the sections bend and join together from the pics i have. I say i am giong to run 15lbs, however i think thats the limit of the stock bottom end. I know the bottom will eventually give out, just not sure when. I believe Andy is running 15-16 lbs in his stock bottom camaro. In a perfect world i would like to have it tuned to 15lbs and turn it back to 10lbs. Dunno if the WG will let that happen. If i cant hold it at 15, i guess i can always add a second gate - that would definitely be my last resort though.

[AutoMods]

you have this routed well. smoother then i envisioned when i was looking at on my car. i think the narrower fmic helps.

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141828_zpscftussny.jpg

[AutoMods]

yeah i am a little concerned about being able to keep the boost down. I believe my placement is a little better then yorus though but not by much. I only say that because mine will pick up most of the exhaust from the drivers side with how the piping is bent and flows. Its hard to see how all the sections bend and join together from the pics i have. I say i am giong to run 15lbs, however i think thats the limit of the stock bottom end. I know the bottom will eventually give out, just not sure when. I believe Andy is running 15-16 lbs in his stock bottom camaro. In a perfect world i would like to have it tuned to 15lbs and turn it back to 10lbs. Dunno if the WG will let that happen. If i cant hold it at 15, i guess i can always add a second gate - that would definitely be my last resort though.

you could add a 2nd gate on the drivers side easily but you'd have to dump that to the atmosphere. maybe you could set the drivers side wastegate to open a couple psi later and that way you would have a quieter system until boost creep occurs.

but i wouldn't worry about it until later, your setup might not creep

[Phish]

When i was first planning the kit, i was worried that the piping would be alot worse as well. However when i got making the kit, i realized it was going to be alot more clean and its actually just one 90 elbow from the turbo to the intercooler. I was really pleased to figure that one out.

As far as the wastegate goes - I am planning on seeing how this works and what it does. Hopefully i can hold it to where i want it with the current setup. I am unsure with the turbo being the size that it is.

I did get the piping mocked up to the WG back into the DP. I planned on doing a flex connector, however there was not room to fit it.

http://i232.photobucket.com/albums/ee44/Phish806/0112140955_zpsgr3qbpaq.jpg (http://s232.photobucket.com/user/Phish806/media/0112140955_zpsgr3qbpaq.jpg.html)

[c_mart_28]

Better just renesis swap it..

[stangvortech]

nice build!

[Phish]

Better just renesis swap it..

Be careful what you say. I just may have one of those laying around the garage ;-)

http://i232.photobucket.com/albums/ee44/Phish806/Mobile%20Uploads/0111141830_zps4carw8vk.jpg (http://s232.photobucket.com/user/Phish806/media/Mobile%20Uploads/0111141830_zps4carw8vk.jpg.html)

[AutoMods]

wastegate and recirc doesn't look fun to tighten.

i was kinda worried about the brake fluid boiling over by that turbo so i heat taped that line. will probably reroute the line this year

[Phish]

I thought about the line getting hot as well. I may have to wrap it as well jsut as a precaution. What did you use to wrap? My power cable is also kinda close to the DP. What woudl you suggest for a sleeve for the cable or a tape style wrap? Hav enot looked into any of that yet.

[AutoMods]

i used heat tape on the brake line and wiring and even the oil feed and return lines and vacuum line to the wastegate. i would guess heat wrap would be a bit better than tape

[RedRocketZ28]

My bottom end has seen 18-19 lbs it's fair share of pulls which would have been right at our slightly over 700 rwhp. 700 rwhp is getting close to the limit of the stock bottom end early year motors. Some have taken more, some less. Obviously a good tune-up goes a long way to keeping it alive.

[DustinsDuster]

damn clean car. i dig it.

[Phish]

I finally go the Downpipe welded, painted and wrapped. Turned out pretty well.

http://i232.photobucket.com/albums/ee44/Phish806/0117141652_zpsuclznhsa.jpg (http://s232.photobucket.com/user/Phish806/media/0117141652_zpsuclznhsa.jpg.html)


http://i232.photobucket.com/albums/ee44/Phish806/0117141649_zpscos9tqby.jpg (http://s232.photobucket.com/user/Phish806/media/0117141649_zpscos9tqby.jpg.html)

[AutoMods]

3.5" downpipe?

[oVa-Boost]

Is that the same lq4 I sold ya..

[Phish]

3.5" downpipe?


Yeah its a full 3.5" downpipe off the turbo and back to where the exhaust will "Y" off to exit the car as duals.



Is that the same lq4 I sold ya..

Yep, still rocking the same shortblock that you sold me. It was opened and cleaned up but still completely stock as it sits in the car. We shall see what it can hold and handle.

[Phish]

Well the hot side is FINALLY complete. All parts are wrapped up and ready to go on.


http://i232.photobucket.com/albums/ee44/Phish806/0122141627a_zpsjd9pvzcb.jpg (http://s232.photobucket.com/user/Phish806/media/0122141627a_zpsjd9pvzcb.jpg.html)


However my mind is still on heat control and keeping things from getting to hot. My first task was to build a heat shield since the downpipe runs so close to the computer:


http://i232.photobucket.com/albums/ee44/Phish806/0117141649_zpscos9tqby.jpg (http://s232.photobucket.com/user/Phish806/media/0117141649_zpscos9tqby.jpg.html)




So, i fabbed up an aluminum heat shield. This is is put into place. I still need to get some edging to trim the piece out to make it look a little more clean. However, i think it turned out decent, will do its job, and make the bay look alot more clean.


http://i232.photobucket.com/albums/ee44/Phish806/0124141715_zpsjhcx5o14.jpg (http://s232.photobucket.com/user/Phish806/media/0124141715_zpsjhcx5o14.jpg.html)




http://i232.photobucket.com/albums/ee44/Phish806/0124141715a_zpsqpbbm59h.jpg (http://s232.photobucket.com/user/Phish806/media/0124141715a_zpsqpbbm59h.jpg.html)



I finished heat wrapping my trans cooler lines and put heat sleeves overmy main power line and line coming off the ALT. Then i started installing the hot side for the final time. I cant install the WG or the turbo untill i get the heat shield mounted in there properly. I also need to pickup the Innovative MSBC1 and get everything ran and plumbed from it. I must say it looks alot better now that everything is wrapped.


http://i232.photobucket.com/albums/ee44/Phish806/0126140837_zpsrukczzb5.jpg (http://s232.photobucket.com/user/Phish806/media/0126140837_zpsrukczzb5.jpg.html)


http://i232.photobucket.com/albums/ee44/Phish806/0126140836_zpsds71jno6.jpg (http://s232.photobucket.com/user/Phish806/media/0126140836_zpsds71jno6.jpg.html)


http://i232.photobucket.com/albums/ee44/Phish806/0126140853a_zpsubmzn0j9.jpg (http://s232.photobucket.com/user/Phish806/media/0126140853a_zpsubmzn0j9.jpg.html)


http://i232.photobucket.com/albums/ee44/Phish806/0126140853b_zpsjvnybfv6.jpg (http://s232.photobucket.com/user/Phish806/media/0126140853b_zpsjvnybfv6.jpg.html)


http://i232.photobucket.com/albums/ee44/Phish806/0126140853_zpscyfzttj9.jpg (http://s232.photobucket.com/user/Phish806/media/0126140853_zpscyfzttj9.jpg.html)

[AutoMods]

nice heatshield, did you use a brake for that?

what fuel and what are you tuning with?

edit: looks like your probably running e85

[Phish]

Yeah, i work for a sheetmetal shop so i make things out of metal all day. it took me literally 10 minutes to crank that shield out.

Your right, e85 is what i will be running

Tuning will just be Efi Live. 2 bar map sensor tune since i have a 98 ecu in the car.

[Drifte]

Heat shield is legit.

[slow ride]

Ryan, you should have him make you one of those head shields.

[Phish]

Thanks fellas. I was contemplating having it painted the same color of the car when i get the TII hood painted. Not sure if it woudl discolor, or loose its properties of disipating heat so well. Still on the fence about that one.

[Drifte]

Thought about asking you if you had planned to color match. No idea how much heat the paint could handle.

[Phish]

I re routed the brake line and put the trim on the shield. Then ire installed everything so i can finnish up the exhaust. I have not been making much progress since my attention has been turned to purchasing a home. Trying to get it all back together so its easier to move when the time comes.

Ryan, FYI, i did not have to cut the line or change it in any way. I took it apart in the wheel well where it changed to rubber. Then i took it apart form the master cylinder. I was able to re route it so it goes into the fender under the shield that i made then follws the wheel well like before. took me about 10 mintures. (still have not bled the brakes).

http://i232.photobucket.com/albums/ee44/Phish806/0201141021b_zpsauqzh16o.jpg (http://s232.photobucket.com/user/Phish806/media/0201141021b_zpsauqzh16o.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/0201141022a_zpswpv1qu6i.jpg (http://s232.photobucket.com/user/Phish806/media/0201141022a_zpswpv1qu6i.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/0201141022b_zpsktn5bw7a.jpg (http://s232.photobucket.com/user/Phish806/media/0201141022b_zpsktn5bw7a.jpg.html)

http://i232.photobucket.com/albums/ee44/Phish806/0201141021_zps8xkteq29.jpg (http://s232.photobucket.com/user/Phish806/media/0201141021_zps8xkteq29.jpg.html)

[Phish]

I finally found some time out in the garage. I started on some Vac lines and oil lines and also got my cold side piping intsalled. First time it has been fully installed with all the correct pieces. I was waiting on getting my BOV welded up but now that thats finally done i was able to move forward


I cut the ports off of the LS3 intake. Then i drilled and tapped them to accept a NPT to AN fitting. I figured it would be a cleaner look then just the normal slip on rubber hose. The passanger side i will use to feed my selenoids for the boost controller. The driver side is hooked up to the BOV as you can see.


http://i232.photobucket.com/albums/ee44/Phish806/0216140933_zpsanvbljz8.jpg (http://s232.photobucket.com/user/Phish806/media/0216140933_zpsanvbljz8.jpg.html)




http://i232.photobucket.com/albums/ee44/Phish806/0216140933a_zpsaq1qr7k7.jpg (http://s232.photobucket.com/user/Phish806/media/0216140933a_zpsaq1qr7k7.jpg.html)




I also mocked up soem coolant lines. I am short one elbow from getting it completed. I will have to get that and get them along with the oil drain from the turbo installed for the final time. Here are a couple pics of the progress and how it sits now.


http://i232.photobucket.com/albums/ee44/Phish806/0216140932_zpsgrb3adev.jpg (http://s232.photobucket.com/user/Phish806/media/0216140932_zpsgrb3adev.jpg.html)


http://i232.photobucket.com/albums/ee44/Phish806/0216140932a_zpsctimttwo.jpg (http://s232.photobucket.com/user/Phish806/media/0216140932a_zpsctimttwo.jpg.html)

[JustinS]

Very clean setup Phish, why the chassis swap though?

[Phish]

Why the chasis swap? meaning the white car to the red one. The white car was an 86 s4 car. It had a second hand paint job by someone before i had gotten it. It was a flat white and has some busted interior peices that were really really hard to track down and were way pricy. The red car that i have now is a 90 S5 rx7. So its all one color including trim and mirrors. It also has some different tailights and minor changes in the bumper. It was a one owner car with very low miles and had been sitting in a garage most of its life. Besides soem door dings, it was in perfect condition. Interior was/is immaculant. The swap from the 86 to the 90 was a step up in almost all aspects. its all around just a cleaner car and is why it does look so well. i also got it for a steal and it was local as well. It was definatly worth the time and work to change it all over from one car to the other then build off of this chasis.

[Sleepy]

You have done a very good job, the turbo set up and the ls swap look like they were meant to be there.

[Phish]

It does seem to fit in there like stock. Pretty pleased with how its all fitting together.

I worked a little on the hold down for the radiator. Its also a cover for the front end to clean up the car and hide all of the wiring along with the intercooler, overflow, radiation, trans cooler, etc. It still needs to get painted but you get the idea


http://i232.photobucket.com/albums/ee44/Phish806/0217141643a_zpszqghq7fl.jpg (http://s232.photobucket.com/user/Phish806/media/0217141643a_zpszqghq7fl.jpg.html)

[Phish]

And now its black...

http://i232.photobucket.com/albums/ee44/Phish806/0218141851_zpsuegjm5tb.jpg (http://s232.photobucket.com/user/Phish806/media/0218141851_zpsuegjm5tb.jpg.html)

[Drifte]

Looks nice, gonna match the other heat shield with that black cover than?

[Phish]

I have a turbo II hood that needs paint matched to the car when it gets installed. I think i will have the aluminum heat shield over the computer painted at that time as well to match the car/bay. I do not like how it looks aluminum and out of place. I think red would be a little better then black as well.

[AutoMods]

neat. looks like a good tool holder too

[Phish]

haha, yeah i suppose it would work well for that as well. I will most likely keep it off the car untill the build is done so i dont get it all banged up and scratchd up. Something will happen to it though i am sure.

Now, its trying to figure out where to mount two trans coolers, and coils. The tetris game never ends with this thing