Tired 2000 Protege lx getting Speed3 swap

Discussion in 'Mazdaspeed 3 General Discussion' started by mazdas4me, Nov 6, 2019.

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  1. Mauro_Penguin

    Mauro_Penguin Punk in Drublic. #BlackLivesMatter Motorhead Platinum Member

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    How easy does the protege body flex?

    I know one of the big deals with the mazda3 was how rigid the unibody was compared to previous chassis' that mazda was producing before. Dont want any popping windshields, or doors bending fenders after such an in depth swap.
     
    Mauro_Penguin, via a mobile device, Nov 13, 2019
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  2. mazdas4me

    mazdas4me Greenie Member

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    Bracing/supporting is on top of list. I have speed body to see where everything is stronger, and will support/brace accordingly best I can. I am also going to transfer the behind dash A pillar support bar to the protege. Strut towers will be fully braced, and tied into firewall like speed. Corner bracing at lower c pillars like speed, and just generally making it similar to speed bracing and locations. Rear subframe mounts and frame need supporting too. It still may twist, creak, and groan when done, but I will try to get it stiffened up so it doesn't.
     
    mazdas4me, via a mobile device, Nov 13, 2019
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  3. mazdas4me

    mazdas4me Greenie Member

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    IMG_20191113_170200.jpg IMG_20191113_165855.jpg IMG_20191113_170045.jpg IMG_20191113_165958.jpg IMG_20191113_172903.jpg I got the dash removed today. These cars are so close in so many ways I just can't believe it! Even the floor to bottom of windshield is the same. The dash has a crazy thick support bar that connects the A pillars together, as well as providing dash support, and lower mounting points. Replacing the complete firewall, and floor pan in one piece is looking very promising.

    When I cut out speed firewall, as I get to lower bar mount, I plan on cutting outward into A pillars and cut out the lower dash mounts still attached to firewall. That will allow me to bolt up dash to speed firewall once welded into place on the protege, without aligning anything. It will provide all the pedal mounts, center console mounts, seat mounts, trailing arm mounts etc...

    Tomorrow I plan to, remove Master, abs unit, pedals, and remaining wiring harness. Then finally start cutting it up into manageable, and useable pieces. Once cut up, the Protege will be disassembled for final measurements, and decide if it is a go, or not... I am 99% sure at this point I can make it all work. I will need to remove engine/trans, front subframe, center console, seats, and carpet out of the Protege. Once I am at that point, and plan on moving forward, I will make the "official" build thread.

    Stay tuned! Please, if you see something maybe I am overlooking, or think you have a better way of doing something, I am open to all suggestions and comments.
     
    mazdas4me, via a mobile device, Nov 13, 2019
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  4. mazdas4me

    mazdas4me Greenie Member

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    Protege dictionary meaning:
    Dependant Pupil

    Opposite of Protege is Mentor.

    Mentor dictionary meaning:
    Counseler/Teacher

    It definitely won't be a "Dependant Pupil" anymore.

    I will call it "Mentor", because it will be schooling other cars!
     
    mazdas4me, via a mobile device, Nov 13, 2019
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  5. mazdas4me

    mazdas4me Greenie Member

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    Making some progress... I got the left frame rail cut off, windshield area cut out, and started cutting out firewall and floor pan. Need more sawzall blades. I did all that with 1 sawzall blade, and 1 cutoff wheel on an angle grinder. IMG_20191115_164532.jpg IMG_20191115_164136.jpg IMG_20191115_164155.jpg IMG_20191115_164456.jpg IMG_20191115_164246.jpg IMG_20191115_164217.jpg IMG_20191115_164331.jpg IMG_20191115_164309.jpg
     
    mazdas4me, via a mobile device, Nov 15, 2019
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  6. Easter Bunny

    Easter Bunny Professional Engineer Motorhead Platinum Member

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    FYI I have had good luck with the longevity of DeWalt bimetal blades
     
    Easter Bunny, via a mobile device, Nov 16, 2019
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  7. mazdas4me

    mazdas4me Greenie Member

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    I'm going to buy new blades this morning. I will see if they carry the DeWalt. I appreciate it!
     
    mazdas4me, via a mobile device, Nov 16, 2019
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  8. mazdas4me

    mazdas4me Greenie Member

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    The Mazda3 spoiler fits the protege body shape perfectly! The speed spoiler mounts the same, just using this for checking fitment. I can make the speed spoiler look factory installed it fits so well. That's how close these bodies are to each other. IMG_20191118_131104.jpg IMG_20191118_130933.jpg IMG_20191118_130924.jpg IMG_20191118_131014.jpg IMG_20191118_131026.jpg
     
    mazdas4me, via a mobile device, Nov 18, 2019
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  9. mazdas4me

    mazdas4me Greenie Member

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    All stripped down. Cutting off top, then the complete firewall/floorpan. IMG_20191118_152206.jpg
     
    mazdas4me, via a mobile device, Nov 18, 2019
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  10. Mauro_Penguin

    Mauro_Penguin Punk in Drublic. #BlackLivesMatter Motorhead Platinum Member

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    That is a lot of scrap to be cutting up. I hope you are selling it for a few bucks.
     
    Mauro_Penguin, via a mobile device, Nov 18, 2019
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  11. mazdas4me

    mazdas4me Greenie Member

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    Firewall, floorpan, and rear frame rails should be cut out tomorrow.
    After that, clean up, organize.
    Next I will remove engine/trans, front subframe, and rear subframe from the Protege. That will give me much more room to set stuff in place, and come up with a plan.

    I am super happy with everything so far... IMG_20191118_152346.jpg IMG_20191118_152244.jpg IMG_20191118_170430.jpg IMG_20191118_170354.jpg IMG_20191118_170335.jpg IMG_20191118_152433.jpg
     
    mazdas4me, via a mobile device, Nov 18, 2019
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  12. mazdas4me

    mazdas4me Greenie Member

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    I will keep a lot of it for body repairs. My Datsun 510 has both quarter panels rusted out. I plan on using the roof material to fab up left and right patch panels for it. What I don't use/keep, I will just put out front on the City of Santa Clara's yearly free dump pickup.
     
    mazdas4me, via a mobile device, Nov 19, 2019
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  13. mazdas4me

    mazdas4me Greenie Member

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    IMG_20191119_131034.jpg IMG_20191119_130947.jpg IMG_20191119_131136.jpg IMG_20191119_130823.jpg IMG_20191119_131112.jpg
     
    mazdas4me, via a mobile device, Nov 19, 2019
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  14. StreetSpeed6

    StreetSpeed6 Diesel Slayer Silver Member

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    StreetSpeed6, via an iPhone, Nov 19, 2019
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  15. mazdas4me

    mazdas4me Greenie Member

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    Alright, got my base to work with. Of course it will need further cutting/trimming to fit. But that's as far as I am going with it. Now to get the Protege apart! IMG_20191119_160525.jpg IMG_20191119_160312.jpg
     
    mazdas4me, via a mobile device, Nov 19, 2019
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  16. mazdas4me

    mazdas4me Greenie Member

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    The 09 Speed3 Sport weighed 3160 lbs with 1/2 tank fuel. 00 Protege weighed 2450 lbs with 1/2 tank. 710 lbs lighter, but once I install the Speed engine/trans, sub frames, bigger wheels/tires, etc, It will be much heavier than 2450 lbs. My guess is it will end up at 2950 lbs once completed.
     
    mazdas4me, via a mobile device, Nov 20, 2019
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  17. Easter Bunny

    Easter Bunny Professional Engineer Motorhead Platinum Member

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    isnt the block in the protege iron? the aluminum DISI block will offset some of the weight gain from the turbo parts
     
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  18. mazdas4me

    mazdas4me Greenie Member

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    Yes, Protege has iron block. But engine is not the only weight being added. The Speed transmission, front & rear subframes, anti sway bars, exhaust, seats, all weigh more than Protege. Plus all the added bracing, and overlapping metal. I'm hoping it will be super light, but I'm still guessing around 2900 lbs when all done, 1/2 tank fuel, Speed spare tire installed, etc...
     
    mazdas4me, via a mobile device, Nov 20, 2019
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  19. Bigelow

    Bigelow Greenie Member

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    This is an awesome project. Good luck with the build but it looks like you know what your doing.
     
    Bigelow, via a Samsung mobile device, Nov 20, 2019
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  20. mazdas4me

    mazdas4me Greenie Member

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    Tools/materials/services/general things used for this project... not listing common sockets/wrenches for general disassemble/reassemble.

    Harbor Freight 7.5 amp sawzall
    Angle grinder w/6" cut off wheel
    Wire Feed Welder using .030" shielded wire
    Tape measure/Laser
    Seam Sealer
    Brake Fluid
    Recharge A/C
    $ for trip to dealer to bleed brake system and verify ecu for B.A.R. certification
    B.A.R. certification

    Almost ready to start stripping Protege down...

    Here are some of the measurement differences from Speed to Protege:

    Protege/Speed

    Weight: 2450/3160
    Wheelbase: 102.8"/103.9"
    Firewall to radiator: 32"/31.5"
    Front frame rail inside width: 36"/35.5"
    Top of front frame rail to ground: 19"/21" (protege lowered 2")
    Track width: 66-1/4"/68-1/4"
    Overall length: 174"/175"
    Hood width @ strut towers: 56-3/4"/61-1/4"
    Center front axle to center of valve cover: 10-1/2"/7-1/2"
    Overall width: 66-1/4"/69-1/4"

    The biggest difference being the engine, trans, subframe, and struts are mounted about 3" more rearward on the Speed.

    I can't wait to start the "official" build thread. I still can't find anything major preventing it from working.
     
    Last edited: Nov 24, 2019
    mazdas4me, via a mobile device, Nov 24, 2019
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