Well today, I finally got started on the S5 turbo II I bought last week. Spent most of the day cleaning up the interior, doing some weight reductions to car, installing a Walbro 255HP fuel pump, and swapping seats from GTU parts car. Which saved 4lbs per side. I still need to clean up the interior some more, install my DEFI gauges and Mazdaspeed steering wheel.



I talked about keeping the AC and Power Steering on the car, but more and more I open that hood, the less I want to keep it.



Goal tomorrow is finish building up the motor from short block form (which might be harder than it should, considering my rotary parts got mixed in with DSM parts) and installing the motor and transmission.



Stay tuned to this thread tomorrow for more pics.



https://www.nopistons.com/forums/gal...1104204162.jpg

https://www.nopistons.com/forums/gal...1104204691.jpg

https://www.nopistons.com/forums/gal...1104205160.jpg

https://www.nopistons.com/forums/gal...1104205777.jpg

Excellent!

even if it ended up ADDING 20 pounds to the car I would have swapped out those seats



good luck on your new car

Todays Update:





Well I didn't get the motor in today as I hoped. I have mis-placed or some parts have been thrown away, so I am going to have to locate them. I got most of motor put back together, but I am going to have to buy or make some block off plates though.



So I spent most of the day removing the AC and PS, I have been taking my time with it, because I might want to put it back in one of these days.





Here is the motor just about ready to go into the car.







https://www.nopistons.com/forums/gal...1104282998.jpg



Engine bay shots before I touched the car today.



https://www.nopistons.com/forums/gal...1104283392.jpg



Someone must have thought that th oil cooler makes a great jack point. Its nice to have a parts car.



https://www.nopistons.com/forums/gal...1104283876.jpg



Another shot of the Oil Cooler.



https://www.nopistons.com/forums/gal...1104284218.jpg





Well I finally get to use this intercooler its been laying around for almost 3 years now. It was a pricey Spearco unit, with a S4 Koyo Radiator, for good messure.



https://www.nopistons.com/forums/gal...1104284984.jpg



And the engine bay after the work, I still got more to pull out and I want to clean all the dirt and grime out of the engine bay before the motor goes in.



https://www.nopistons.com/forums/gal...1104285466.jpg

LMAO @ Oil Cooler.





Do you have any idea who could have done that?

Only idea I has is someone tried to jack the car up at that point.



No progress yesterday, I ended up hosing out the the engine bay and debating about cleaning it up more, decided to wait till I blow this motor up before I repaint the engine bay.

i gotta get a pic of my engine bay up when rob gives it back to me, there's the body harness and two ground wires...thats it.



kevin.

we used to joke that i need the ac to blow UNDER the hood, cause thats where i've spent most of my time on my fc

I dont even bother cleaning the outside of my car just the bay since thats all i see...

Good job!! Keep us updated. I like the new seats.... much better.

I didn't get to take pics today, I was conned into doing a brake job on POS Geo yesterday, so no work on the FC. The engine is mounted in the car, I clean the engine bay up a little bit, but it was decided that I am waiting to till I blow this motor to really clean up the engine bay and repaint it.



Still need to find a transmisson mount bracket and wire in the Haltech E6X, build the Manifold for the T72, It might run at the end of Jan.

https://www.nopistons.com/forums/gal...8_99_21271.jpgSome more progress on my car. I finally got ahold of transmission bracket and now the drive line is back in the car. Clutch still needs bleeding but I am going to hold off till I get a braided steel line for it.



https://www.nopistons.com/forums/gal..._99_589655.jpg







The intake manifold is coming back off again, found out the lower is S4 and I am trying to bolt up S5 manifold. It just doesn't work, I know I tried for half out trying to figure out why doesn't it bolt up.



After being a little pissed about that little surprise, dug out my spare lower manifold which I know 100% is S5 manifold, still needs to knock off the 1 inch of dirt, and my spare S6 FD manifold. I hope the port matching will be done sometime this week.







https://www.nopistons.com/forums/gal..._99_783012.jpg



Starting wiring up the Haltech, still near a 1000 wires... well, more like 20, but its coming.









I hope to get the intake manifold changed out this week, and if things go well and parts come in, the turbo and intercooler setup should be done sometime next week.



I also found out also my turbo has 3.5 inch outlet, I was planning to run a 3 inch, I don't want to neck down the piping after the turbo, so I guess the custom 3.5 inch exhaust is going on.

what turbo are you using?



kevin.

Its Turbonetics T72 Ball Bearing Q trim with 3.5 inch outlet

ok thats why its bigger then mine, i knew it had to be huge.



where you located? anywhere near nj?





Target Horsepower? ECU you're using? fill me in.



kevin.

Sorry I am in Little Rock AR



I am using a Haltech E6X, no real goals on HP, it will make what it makes, it will be limited by the fuel system right now. I will be going out of the country for a while, so I might have the fuel system upgraded while I am gone. Right now its just 1000/1600cc injectors and Walbro pump.



Nice thing is that I have unlimitted access to dyno so it will be tuned well. https://www.nopistons.com/forums/pub...IR#>/smile.png

UPDATE:



Well I complete a little more work on the car in the past few days. I was really thinking about using my FD upper intake manifold, but decided against it at the last minute. I clean up my S5 Lower intake manifold and installed it. I also pretty much finished up the Haltech install, just a couple of lose ends with GPOs take care of and clean up mess of wiring I have. I really don't want to clean the wiring up till I KNOW for sure everything is wired right.



https://www.nopistons.com/forums/gal...99_1370247.jpg



Parts car to the rescue, with a oil cooler and I had some braided stainless steel oil cooler lines laying around, top one (return line) likes to kink though. I will have to fix that problem





https://www.nopistons.com/forums/gal...99_1266017.jpg





Another shot of the oil cooler. (Also could double as a intercooler for a turbo Honda https://www.nopistons.com/forums/pub...IR )



https://www.nopistons.com/forums/gal...99_1358325.jpg







Had the turbo exhaust housing thermal coated. Its a .96 Q-Trim with 3.5 inch v-band outlet.



https://www.nopistons.com/forums/gal..._99_898920.jpg





Turbo is temp installed on the car. I am using a cheap turbo manifold for right now, I had to space the turbo out with an extra T04 flange to keep the compressor housing from hitting the water pump housing. Said thing is its 45 dollar TiAL flange doing the spacing.



The turbo is T72 ball bearing unit, the turbine wheel has been lightened up a bit. The 90 degree bend is going to have to be cut off and faced the right way.



https://www.nopistons.com/forums/gal..._99_583346.jpg





I hope to start it this weekend, if I have time, and maybe even beat on the dyno with it.

nice job. Im running a wolf 3d v4, with a t78. It's still in the build process (body getting redone etc). I have a 90 degree tube on top of the turbo as well, i think its much nicer then some silicone hose donig the 90 degree thing https://www.nopistons.com/forums/pub...IR#>/smile.png.



Anyway cant wait to see your results as not many are going big with fc's at the moment it seems, but maybe warmer weather will bring them from hiding.



i aiming for 550hp at 20psi, but we shall see once its all done and built.



What type of intercooler are you going to be running?



Anyway look forward to the completion of yoru build,

kevin.

I am runing a Spearco unit, I have had it for over 2 years and never did anything with it. Its big, rated at 1280 CFMs and it way to expensive. I want to say I have around 1200 injust the intercooler, but back then intercoolers where pretty expensive.



I am still waiting on some little parts. If I am lucky I might get to start it this weekend and beat on the dyno a little bit.

UPDATE time again.



Intercooler is mounted, Don Polk of Polk Performance was kind enough to surprise me with piping completed, radiator is almost mounted also. Will Damion got tired of looking at my mess of wiring and cleaned up a little bit.



Pics of the plumbing and turbo.





https://www.nopistons.com/forums/gal...99_1260140.jpg





Shot of the piping, I am going to paint them tomorrow, later this year I will probably have them powdercoated.





https://www.nopistons.com/forums/gal..._99_427241.jpg





Messed around with the interior a little to day, installed my Mazdaspeed steering wheel.





https://www.nopistons.com/forums/gal...8_99_89701.jpg







I will post some more pics of the progress tomorrow.

ohh that steering wheel is hot.



kevin.

WOW, that is so awsome, got i wish i just had money and time to blow on my car like that, Nice job, cant wait to see the fianal results. I love these build up threads, they're like kids that you can watch grow.

After 4 months or so, I was able to start work on the car again. I haven't acomplished as much work as I would like, I even went backwards at a few things. I decided to have my intake manifolds thermal coated, along with my intercooler piping, also decided change up the fuel system a little bit. I ordered one more gauge and still have a few more to order. Put some new wheels and tires on the car, wheel are on the cheap side, hell the tires are twice as expensive as the wheels. But, they fit about right and look good, little on the heavy side though. I haven't weighed them yet though.



Test fited the Rotary Extreme FC2000 front end. Fitment is better than I thought, it will need a little work, but nothing my inexperienced self isn't afraid to do.







The new wheel setup. 17X7s up front and 17X9s in the rear. I want to say they are 35mm offset also. The front centercaps will not fit though.



https://www.nopistons.com/forums/gal..._99_426253.jpg



https://www.nopistons.com/forums/gal..._99_765866.jpg



https://www.nopistons.com/forums/gal..._99_567588.jpg



https://www.nopistons.com/forums/gal...99_1159292.jpg



Thats right, 275-45-17s on the rear. They fit pretty good, the rear fenders will probably have to be rolled though, I think they might rub a hard rear weight transfer, which is ok, because I have fender rolling tool that I never use.



515 Innovations gauge pod



Pod need a little prep work, I assume that they left the holes smaller than 60mm to fit to each gauge. But I got tired of sanding pretty quickly.



https://www.nopistons.com/forums/gal..._99_413737.jpg





After a bit of sanding.



https://www.nopistons.com/forums/gal...99_1369141.jpg



After painting it. I went with semi gloss black paint. The gagues are DEFI Link Series.



https://www.nopistons.com/forums/gal..._99_870818.jpg

My manifolds after being thermal coated.



https://www.nopistons.com/forums/gal..._99_742706.jpg







Here is the FC2000 front end after being test fitted. I bought this front end hoping that it would cover my intercooler. The stock S5 front with factory front lip left around 2-3 inches of intercooler showing. We did have to trim 3 inches off the opening to get it to fit to the intercooler, I was kind of hoping to use the driving/fog lights also, but I don't think its going to happen. The intercooler pipping takes up space. I am pretty happy with it and was shocked that it fit as well as it did.



https://www.nopistons.com/forums/gal...99_1284288.jpg



BTW anyone need a turbo II hood? I have a hood being made right now for the car.



https://www.nopistons.com/forums/gal...8_99_29064.jpg



https://www.nopistons.com/forums/gal...99_1473220.jpg

looks good. Now all you need is a torsen in the rear to get your new tires to go.

Looking good, I like it!



Are you going to do a bunch to the suspension too?

[quote name='donhayes' date='Jul 10 2005, 10:12 PM']looks good. Now all you need is a torsen in the rear to get your new tires to go.


[/quote]





I have a KAAZ sitting next next to the car.

[quote name='89 Rag' date='Jul 10 2005, 10:20 PM']Looking good, I like it!



Are you going to do a bunch to the suspension too?


[/quote]





Oh yeah, but I want to get everything and do it at once. I think I am going to order a set of Kei Office coilovers it. Just takes time.

those rims are so hot i want to lick them



no homo

When I said they where cheap, I meant it, I don't quite remember how much I paid for tires and wheels, but I believe you can get a complete set of those wheels for around $400

Yeah A local shop in ARK has them for I believe 450 for a set of 17x9's, But you car is nice man hope to see you @ centerville sometime.

I got mine from Polk Performance. Pretty much all my parts and work come from there. Hell the shop in the back ground is Polk Performance.



It be up a centerville, its been a while since I have raced there.

Dyno & Performance in Fort Smith has a set on the shelves, POLK does excellent work though. Do you have any numbers off of the dyno their?





Is that Don's new shop?

The late pics yes, thats the new shop, earlier pics are at the old one. New one his huge, the area that those pics where taken is in the "car storage wing" of the shop. Its 20k sqft.

Newest updates!!!!!!!!



Well foward progress once more.



UPS man delievered this nice part from Mazdatrix



https://www.nopistons.com/forums/gal..._99_345282.jpg



Believe it or not, it was fairly hard to come by and this was the only color they had. It seems that everyone is waiting a shipment right now of them. This will help with installation of my Oil Temp and Oil Pressure gagues.





I talked Don Polk, into porting my thottle body.



https://www.nopistons.com/forums/gal..._99_185835.jpg



It was bead blasted afterwords to give that odd texture.





Finally mounted my DEFI link controller. I kept debating about where to put and how to do it. Just decided to keep it simple and double side velcro it in place.



https://www.nopistons.com/forums/gal...99_1337235.jpg



I have to really go through everything and clean up the wiring in the next few weeks and also decide what deck is going to go in the car.



I have two more DEFI gagues on order, if they ever show up they will go nicely with the other 3.



https://www.nopistons.com/forums/gal..._99_405343.jpg



Pics really don't do them justice.





Tomorrow I am going to try to finish up some little things I have been putting off and the big thing, figure out why my Haltech has no spark.

BTW anyone need a turbo II hood?





yes i need one how much are you asking?

[quote name='mazdarx713b' date='Aug 1 2005, 12:12 PM']BTW anyone need a turbo II hood?

yes i need one how much are you asking?


[/quote]





I have been asking 200 if you pick it up. PM me for more info.

where did you get that guage panel for over the idiot lights?

[quote name='86se7en' date='Aug 1 2005, 06:00 PM']where did you get that guage panel for over the idiot lights?


[/quote]





5one5 innovations. Guy did a group buy for them over on the EVIL board early this year and I got in on it.

Small Update:



Spent the day mounting the radiator, cleaning up some wiring (thanks Damion), putting my manfolds back on once more, and of course fixing fuel leaks.





https://www.nopistons.com/forums/gal...99_1929246.jpg



All the intercooler piping and intake manifolds have Techline thermalcoatings applied to them. Making my parts car motor really stand out of place, I really should have spray painted the bitch black when it was out in back in Feb. I am not pulling the motor out till it blows (even if I have to keep adding oil to the motor because the oil pan is leaking)



I have block of plate coming for the BAC valve also, so that will clean things up little bit. I think I am gonig to go a little more aggressive with hiding wires when I blow this motor up.



https://www.nopistons.com/forums/gal...99_1829194.jpg



You can see here my nice new Pineapple Racing alternator bracket, I am waiting for alternator spacer from Mazdatrix to finish it up.



Put water in the radiator today (planing to switch to mix after I know all the leaks are fixed) and what to you now, water pissing out of the weap hole in the water pump just by filling the system. Off to buy a water pump this weekend too. So far for the cheap and easy project.



More and more I look at my engine bay makes me sick. I will have to spend a good day cleaning up wiring and changing things around and off course the motor.