Endgame setup- BW s257sxe

Discussion in 'Mazdaspeed 3 Build Diaries' started by iamareios, Oct 23, 2020.

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  1. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    I started my journey with the usual suspects of mods to max out stock fueling and k04 turbo. Of course it wasn't enough (when is it ever?) From there I went with a BNR S4v1 and methanol making 410hp on a dynojet. Here I am, now telling myself this setup is it. Just enjoy the ride.

    Started with swapping to an Overspeed Motorsports build with the usual forged internals and upgraded valvetrain. The install went without a hiccup back in April. At that time I swapped over from a stock ported manifold to an ST manifold, ACT 6 puck clutch w/streetlite flywheel, and tr8 fmic. Performed the proper break in on the new motor and instantly maxed out stock fueling with the s4v1. I chose to scrap the methanol kit as it was not the path I wanted to continue with. I have had too many failures on my devil's own progressive kit to risk blowing this new motor. I need this thing to last.
    [​IMG][​IMG][​IMG]

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    iamareios, via a mobile device, Oct 23, 2020
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  2. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    Fast forward to this month, I have been getting the car together all month (having the 2nd car to myself, while my wife is gone for 30days helps) After talking with my tuner about my power goals he suggested staying with a return less fuel system. So I purchased the aeromotive stealth 325 itfp, an fittings, lines, SS controller, and got it all in rather easily.

    Next was swapping out the damond st adapter plate for their PI plate and rail to fit the 4 additional 1000cc injectors. I ran my lines and fittings according to a drawing I made while purchasing everything. Basically a quick disconnect an fitting from fire wall to passenger side of PI rail. And then quick disconnect from HPFP to driver side of PI rail.

    Wired up the SS controller and threw on the speed performance harness. [​IMG][​IMG][​IMG][​IMG]

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    iamareios, via a mobile device, Oct 23, 2020
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  3. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    I was able to score a CS exhaust manifold brand new in box from a seller on FB. I had it delivered to my ceramic coater to be coated. He did a great job on coating the manifold, .82 turbine housing, and kozmic vband downpipe!

    The Borg Warner s257sxe was ready to go in. Short of having to drill out the boost reference port. I have heard of some people forgetting these turbos needing that and just threading in your npt barbed fitting, causing all kinds of problems. I also clocked it as I run under route piping.

    1st big problem!
    The CS manifold uses a t3 elbow to secure to the t3 inlet of the turbo. Turns out BW sent me a t4 turbine housing. I discovered this after having it cerakote! What a headache that was. A week had passed until I received the correct hotside housing back from my coater. [​IMG][​IMG][​IMG][​IMG][​IMG]

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    iamareios, via a mobile device, Oct 23, 2020
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  4. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    After receiving the correct .82 t3 turbine housing, I then decided on swapping over from a tr8 to tr1035 intercooler. I already had the jbr crash bar and it required minimal modification to mount. I simply used shelving L brackets and had to drill one hole through the crashbar. I pre fit my existing intercooler piping and it turned out to fit better due to the tr1035 being 1 inch longer on each side. I did have to loosen all bolts securing the crash bar to the frame and tug up as high as the bar could go before tightening all bolts down. [​IMG][​IMG][​IMG][​IMG][​IMG]

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    iamareios, via a mobile device, Oct 23, 2020
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  5. JohnnyTightlips

    JohnnyTightlips Platinum Member

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    Does the Kozmic DP fit that turbo? I thought BW had a different style flange.
     
  6. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    It does. BW offers a 3" outlet on their housings. I test fit it with the vband clamp last night. The only issue is it comes deathly close to the alternator. I had to remove the plastic cover on the alternator to get it to fit. I'll probably make a heat shield out of some sheet metal and fasten it with the two original 8mm bolts

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    iamareios, via a mobile device, Oct 23, 2020
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  7. JohnnyTightlips

    JohnnyTightlips Platinum Member

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    That's totally normal and you do not need to worry about the alternator. I wrapped my Kozmic DP to help with that and it seems to be doing the trick. My alternator has 165k on it and is still working great. [​IMG]
     
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  8. Easter Bunny

    Easter Bunny Professional Engineer Platinum Member

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    My alternator with a stock turbo and downpipe only lasted 110k
     
    Easter Bunny, via a mobile device, Oct 23, 2020
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  9. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    Interesting and good to know. I had my downpipe ceramic coated. Hopefully no need to wrap it. Thank you!

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    iamareios, via a mobile device, Oct 23, 2020
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  10. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    2nd issue!
    The turbo is in and went without a problem with the CS exhaust manifold. I found one of the heater core coolant hoses in the way of the compressor inlet. I ended up running to the auto parts store and picking up 6ft of 3/4 hose to replace the hard line that runs along the top of the transmission to the oil cooler. I had to do this to be able to get the 4" ramfab intake in.

    The intake is a really nice piece. The maf sensor is mounted on the bottom for a cleaner look. The filter is a big ass filter treadstone offers to fill the space nicely. I'm about ready to fire it up. Just waiting on a turbosmart hypergate 45 EWG valve seat. I bought mine used and it did not come with one. It did come with a vband flange that I do not need [​IMG][​IMG][​IMG][​IMG]

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    iamareios, via a mobile device, Oct 25, 2020
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  11. lasangelos

    lasangelos Silver Member

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    I cannot stop looking at this engine bay

    [​IMG]
     
    lasangelos, via a mobile device, Oct 26, 2020
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  12. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    Hopefully by tomorrow night, it will be more than something to look at haha.

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    iamareios, via a mobile device, Oct 26, 2020
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  13. lasangelos

    lasangelos Silver Member

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    I’m right there with ya !
    Didn’t even manage to get pics today

    Godspeed !
     
    lasangelos, via a mobile device, Oct 26, 2020
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  14. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    Thanks man! The final pieces really are EWG related. I'm at a hard stop because the missing turbosmart valve seat. Also I've been trying to make the 2 piece dump tube that comes with the CS manifold work. I haven't had any luck due to the kozmic dp. I'm sure CS didn't design it with this downpipe in mind. Or under route intercooler piping setups at that. It simply just won't work. It rests pretty damn close to the block and travels too close down through the intermediate shaft for my taste. I purchased a 45 degree dump tube that I think will work. [​IMG][​IMG]

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    iamareios, via a mobile device, Oct 26, 2020
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  15. lasangelos

    lasangelos Silver Member

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    Full send !
    I just got a shop lined up to really speed things up

    Been roughing it the past few weeks lol


    Turbo smart dual port ?
     
    lasangelos, via a mobile device, Oct 26, 2020
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  16. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    Nice! I've had an extra car all month (Prius) and have been working on my car all month!

    Tial Q full VTA for my BOV.
    Turbosmart hypergate 45 EWG w/20psi spring assortment

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    iamareios, via a mobile device, Oct 26, 2020
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  17. lasangelos

    lasangelos Silver Member

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    I’m here for it
    [​IMG]
     
    lasangelos, via a mobile device, Oct 26, 2020
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  18. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    Car is up and running. I ended up getting a custom dump tube fabbed up by a local exhaust shop. My turbo oil drain wasn't draining properly as well, so I ended up clocking the turbine housing one more time.
    All is good now and no leaks with the PI system. Currently in the middle of tuning with Will (purple drank) We're only on our 3rd revision, but this turbo starts to spool quick @3k and hits boost target by 4k rpm (30psi currently)
    The s257sxe seems much quieter than my s4v1 was. Previously, I was able to hear the turbo spinning at low load. I don't mind it one bit.
    This is my first experience with an EWG setup and damn is it loud! I'm used to taking logs in 3rd gear and can no longer rely on that. 4th gear WOT logs from 3k-8k rpm is impossible to do here in San Diego. I'm going to have to start taking logs late at night or something [emoji23][emoji23][emoji23]

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    iamareios, via a mobile device, Nov 11, 2020
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  19. Awafrican

    Awafrican Moderator Silver Member

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    Glad she's running let's hear some turbo noises edit: spelling
     
    Last edited: Nov 11, 2020
    Awafrican, via a mobile device, Nov 11, 2020
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  20. iamareios

    iamareios Life is too short to stay stock Greenie Member

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    Anyone have experience with the radiator fan effecting idle? When I kick on the AC, the fan blows air straight onto the intake filter and the idle surges aggressively. More than usual for sure. Tuner suggested blocking the filter with a plate of some sort. Could be the big ass filter I'm running too.

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    iamareios, via a mobile device, Nov 18, 2020
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