Greetings fellow rotor nuts!



I have been away from the forums a long time. I used to go by the name, Newguy707.

A lot has happened in my life while absent, but I'm still committed to the rotary scene. My project has been steadily progressing through the years. Finding the time and drive to get certain things done has been difficult, to say the least. Especially after a physically demanding day/week.(I'm a student/general contractor/concrete specialist. i.e. Usually working in the Georgia sun all day). Now that we're finally getting some decent weather, I've really picked up the pace. I thought I'd post some pics of my work. Once it's in the car and the bugs worked out, I'll do a detailed post of the buildup. Many mods can be spotted in the pics.





Enjoy!



http://img103.imageshack.us/img103/5334/dscf1264dx0.jpg



http://img339.imageshack.us/img339/2524/dscf1265rq9.jpg



http://img259.imageshack.us/img259/2165/dscf1263be8.jpg









My other work(one of the better jobs)...



http://img209.imageshack.us/img209/2526/dscf0172xp0.jpg

Some build pics. I guess I should call this a hybrid motor?....







My parts bench in one of its more organized states: http://img503.imageshack.us/img503/7018/dscf0478ua6.jpg





Polished rotors! :yum: http://img217.imageshack.us/img217/2469/dscf0491qm2.jpg





When using Renesis stationary gears, always check the gear height, bearing clearance, and oil gallery alignments. And run a bead of good silicone on the rear gear! http://img207.imageshack.us/img207/1439/dscf0505xw6.jpg





Lucas oil stabilizer for assembly lube, topped of with some synthetic oil left over from my bike.http://img254.imageshack.us/img254/9207/dscf0501ch3.jpg

That looks fantastic. Very nice work!!! I can see you took your time with this. Nice job, Mr Midas!!



B

Which tool do you use to make the grooves in the canals around the sparkplugs?

Looks really nice man

I can't remember the exact name. It's a dremel cutting bit that looks like a mini circular saw. I mounted it up in the drill press and locked it at the different elevations. Afterwards, I debured the grooves with a round bur. If I had to do it again, I'd find a way to slip a sleeve over the cutting bit's shaft, preventing it from sawing to deeply. I was on edge the whole time knowing that thing was ready to trash my housings if I went to far.







Thank you for the compliments. The motor is going in either tomorrow or the next day. I wish the car looked half as good as the motor. Some day down the road it will... https://www.nopistons.com/forums/pub...1047683473.gif





Inside the front cover:http://img360.imageshack.us/img360/1694/dscf0587qr7.jpg







Custom made 16 gauge stainless steel oil baffle plate. (I've got a few more of these and plan on offering them in FS/wanted soon) Using some spare studs for alignment makes the installation quick and painless.



http://img390.imageshack.us/img390/2867/dscf0912du4.jpg

whats the gain on polishing the rotors?

Less likey that they will hold carbon deposits

Heat rejection

Looks bitchin' on forum pics

Adds a pro' look https://www.nopistons.com/forums/pub...IR#>/smile.gif

can't remember the exact name. It's a dremel cutting bit that looks like a mini circular saw. I mounted it up in the drill press and locked it at the different elevations. Afterwards, I debured the grooves with a round bur. If I had to do it again, I'd find a way to slip a sleeve over the cutting bit's shaft, preventing it from sawing to deeply. I was on edge the whole time knowing that thing was ready to trash my housings if I went to far.





I used an aluminum stand off as a spacer when I did my waterjacket grooves and it did make it go really fast as I only had to concentrate on keeping the housing flat on the drill press table. I didn't think about finishing the edges with a rounded bit; nice touch, I think I will use that next time.



Nice looking engine build.

I got rained out before I could get the 7 into the garage. On top of that, my printer decided to quit when I tried to print out some wiring diagrams. So, I got wet. Note to self: Getting a vehicle off jack stands on a gravel driveway in the rain is not smart or safe.



It's probably going to take a little longer to get it in and running. Might not even get a chance to work on it tomorrow. https://www.nopistons.com/forums/pub..._DIR#>/sad.gif







Some pics of the intake:





http://img478.imageshack.us/img478/2472/dscf0843ft6.jpg



The red color in the runners is Red-Kote gas tank sealer.

http://img478.imageshack.us/img478/96/dscf0844gn2.jpg

Shhhh! It's my super secret velocity enhancement modification! https://www.nopistons.com/forums/pub...R#>/tongue.gif At the very least, I'm hoping the runners won't be able to cake up as much power robbing gunk on the smoother surface.



Dynamic chamber. I riced it a little with what I'm sure is illegible Japanese for "Simplicity, Innovation".

http://img380.imageshack.us/img380/9599/dscf0853jx2.jpg



Throttle body, close-up of custom modified dashpot: http://img502.imageshack.us/img502/2203/dscf0898yw7.jpg



I'm hoping it works, if it does I've got three more with forum members names on them https://www.nopistons.com/forums/pub...IR#>/bigok.gif .



I might try to do some write-ups on the different things I've done. I have to see how well it all works first.

Ha - Is that an R/C car shock/spring, ?



Nice touch https://www.nopistons.com/forums/pub...IR#>/smile.gif

I finally made some time for the details. The motor and tranny are in!

It's still been slow going. Hopefully I'll be able to crank it before I go away for a week.



Here is the brake down of my NA 13B hybrid project:



The motor came from my 1988 SE and was built and modified with the following...



Short Block:



Original S4 NA rotating components(including counterweight because the car was an automatic).

Mods: Polished rotors, Teardroped E-shaft oil galleries, New stock bearings lightly clearanced.



Original S4 Irons.

Mods: Cermet A coating by JHB Performance. Oil galleries radiused. Pump cavities shaped and smoothed to near-polish. EGR blocked off. Front housing top oil feed plug drilled out and tapped. Stock intake ports smoothed out and flow matched(not enlarged much at all, just raised maybe 2 mil and given a slight radius). I didn't want to port it yet because I want to see how well the cermet and some other mods do for power.



S5 NA Rotor housings.

Mods: Cermet B coating by JHB performance. Water jackets grooved. Exhaust sleeve baffles removed and roof of sleeve lowered to improve flow(into headers which still need to be fabbed.)



New Renesis stationary gears.

Mods: Matched and radiused oil galleries. New bolts.



New FD oil pressure regulator.



New Mazda thick shaft tension bolts.

Mods: Silicone spiraled during assembly.



All seals and o-rings new from Mazda.

Upgrades: FD corner seal springs. Competition oil seal springs. Long side seals lapped by hand.

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Front Housing & Components:

Mods: Washered thermo pellet. Casting irregularities smoothed out. Oil gallery radiused and smoothed. OMP converted for 2-cycle injection and lines rebuilt.



New chain.



New turbo oil pump.



New bearing plate and competition thrust bearings.

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Oil System(external)

Mods: Oil lines rebuilt. Custom sandwich block for remote bypass filter and front bearing oil feed.

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Intake/Fuel system

Mods: Converted to S5 intake, fuel rails, and vac nest. All manifolds port matched. Dynamic chamber and VDI manifold runners internally coated. TB modified. S4 BAC valve modified to fit. Adapted S4 wiring harness to fit S5 intake and integrate custom made rpm switch control of VDI and six-ports.

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Cosmetic improvements.

Not much to say here. There was a whole lot of cleaning and prep work involved. Pictures speak for themselves.









Total(recorded) hours on the whole project: 575.5 Hrs



With the motor and tranny in the car now, it's just a matter of a little more fabricating and getting it all hooked up and adjusted. I just finished some brackets for the Koyo radiator and have a few other things to do before I crank it. Anyone have a stock cooling fan and AC Bracket they want to sell? PM me please! https://www.nopistons.com/forums/pub...IR#>/blush.gif



I'll probably post in the 2nd gen section when I get close to putting it on the road.