Solarsurge's Ongoing 2013 LSM Build

Discussion in 'Mazdaspeed 3 Build Diaries' started by Solarsurge, Jun 26, 2018.

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  1. Solarsurge

    Solarsurge Gold Member

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    I had a build diary on another forum that I created before I really had any idea what I was going to be doing and where I'd end up with this car. Two years later, I've come across a donor block for an engine build and I'm finally giving her a complete overhaul, fixing bad choices I made, and going balls out on this project...wherever that may take me.

    Although drag strips are fun and I do a few passes here and there, my ultimate goal is NOT to create a 1000HP drag racing machine. I think that angle is pretty well covered. My goal is a highly refined FWD road racing machine that makes 500+ HP safely and reliably, with usable power across as much of the power band as possible, with as much durability as possible. I'm still working out final decisions for a few of the parts, but most of them are pretty well set. Some parts I want are very hard to find, so I'll have to update the details as I actually secure the parts.

    I have done 100% of the work myself so far, and I intend on keeping it that way with the exception of the machining and head work (that's being done by a machinist with a masters in fluid dynamics). Aside from updating the list as I go, I will also post pictures and talk about anything worth talking about. Please feel free to follow this build as I embark on this journey and chime in whenever you like. Also, feel free to give suggestions on things that aren't specifically mentioned. I'm always up for good ideas. Even the crazy ones.

    Current Power Parts:
    Cobb AP v3
    Corksport HPFP Internals
    Corksport 3" Power Series Intake
    BNR S4 v2 Turbo
    cp-e Delta Core FMIC Kit
    Corksport MZR BPV
    Custom PnP IM w/VTCS Delete
    cp-e Block'd EGR Delete
    Cobb Gen2 3" SS Turbo Back Exhaust
    Corksport OCC
    Grimmspeed 3-Port EBCS
    Bosch 3-Bar MAP Sensor
    JBR Plug-n-Play MAP Harness
    JBR Methanol Injection Spacer
    JBR Intake & Throttle TIGs
    NGK 6510 Spark Plugs (.025" Gap)

    Current Stability Parts:
    KW v3 Coilovers
    JBR Tru-Torsion.125 Front Adjustable Sway Bar
    JBR Tru-Torsion.125 Rear Adjustable Sway Bar
    JBR Tru-Torsion 1.25" Billet Sway Bar Bushing Brackets
    SPC Rear Camber Arms
    Moog Front & Rear End Links
    Corksport Mid-Chassis Brace
    Corksport Shifter Bushings
    cp-e xFlex Stage 2 RMM
    Stoptech Slotted & Crossdrilled Sport Brake Kit
    Stoptech Steel Braided Brake Lines
    Michelin Pilot Sport 3+ A/S Rubbers

    Current Curb Appeal:
    OPT7 LED Headlights/Fogs
    Corksport LED Light Kit
    Window Tint (35%)
    BaysonR Front & Rear Lip Spoilers
    Garage Vary Open Mouth Grill

    Upcoming Good Stuff:
    Manley Platinum Series 87.5mm Pistons w/.210" Wall Pins
    Manley H-Tuff Plus Rods w/625+ Bolts
    King pMax Tri-Metal Main & Rod Bearings
    ARP L19 Head Studs & ARP Main Studs
    Precision Balanced Rotating Assembly
    Custom Supertech Valvetrain
    Custom Head Porting
    Custom Transmission Work (TBA)
    JMF v2 PI Intake Manifold
    JBR Tru-3.5 Wide Path Aluminum Intake
    JBR Bypass Valve Hose
    Full Race Ceramic Coated Turbo Manifold
    Custom Fuel System w/Full Port Injection & Methanol (cooling only)
    Corksport Injector Seals
    DM PCV Plate & Dual OCC Setup
    South Bend Stage 3 Endurance Clutch
    Full Poly Suspension Bushings
    cp-e 75 Duro PMM & TMM
    Custom Body/Aero Parts
    And likely more...
     
    Last edited: Jul 11, 2018
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  2. Solarsurge

    Solarsurge Gold Member

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    Also, I just call her Arya right now because a girl has no name lol. She needs a proper name. Suggestions on that would be great as well. This is what she looks like right now. FullFrontal.jpg DatAss.jpg
     
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  3. John

    John Full Fledged Member Gold Member

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    Yours is female, eh? Mine's too much of a hooligan to be female. His name is Jack, after the Fight Club narrator. As in "I am Jack's colon. I get cancer. I kill Jack."

    Not sure how anyone else can name your car... it really should be something deeply personal to you in some way. Although I suppose these days you can say it identifies as a fighter jet.
     
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  4. Solarsurge

    Solarsurge Gold Member

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    When I said I did 100% of the work myself, I should have specified that I did so with the help of members of the NATOR community and sound advice and guidance from members on these forums (which I regrettably was too stubborn to take in some cases). So, this project is as much MY project as it is YOUR project. Arya is its current name, but It would be cool to get it renamed by the community.
     
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  5. John

    John Full Fledged Member Gold Member

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    Fair enough. I do recall suggesting some things and you being a bit obstinate about it. I am aackthpt on the old forum (I screwed up my nick in the transition, but I'm owning it). No worries though, some degree of stubbornness is a good thing.

    Thank you for not using that fucking flashing avatar shart here.

    How about Gloria. Either after the coffee company ( https://www.gloriajeans.com/ ) or, if you prefer we can go back to 1982: ... or you could classy it up even:
     
  6. Solarsurge

    Solarsurge Gold Member

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    LOL! That avatar was gold, as long as you understood that it was sarcasm. It's good to see you're still around, though.
     
  7. Solarsurge

    Solarsurge Gold Member

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    Transportation arranged to pick up car with donor block Saturday morning and first round of parts ordered. It begins!
     
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  8. Solarsurge

    Solarsurge Gold Member

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    Picked up the donor car today! Everything looks excellent. The bottom end looks exactly like you'd expect with 190,000 miles on the pistons, but the cylinders are silky smooth, no scoring, no issues. The head was also machined recently and the exhaust valves were replaced. We also found some freebies in the car we weren't expecting, including a cam timing tool, new VVT, timing chain, tensioner, and some other surprises. HUGE win today, even though my back is on fire and I think I need a wheelchair. I cannot believe the dude was selling this car so cheaply! Tomorrow we get to rip the block out and prepare it for the machine shop. Stay tuned!
     

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  9. Solarsurge

    Solarsurge Gold Member

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    Made some progress today. Whole front end disassembled and she's ready to come out, but we ran into a snag because the 190,000 mile old CV axles just will not come out. We need to get a CV puller to finish. Everything else is unhooked, though. She's only in by the engine mounts.
     

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  10. Solarsurge

    Solarsurge Gold Member

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    Happy 4th of July! We spent the day tearing out the engine. Finally got those axles out of the transmission, yanked the motor, tore it all down. Everything went pretty smooth today except for when I slipped off a bolt and punched the helical gear on the crankshaft slicing all 4 knuckles on my hand. As crazy as it sounds, this baby has 190,000 miles on the clock and the clutch still has plenty of life, the flywheel has ZERO wear, axles might as well be brand new, and the entire inside of the motor was pristine. The pistons were a little worn, but the rods, crank, and all the bearings were in great shape. Block stripped and ready to get cleaned and machined at the shop. Stay tuned!
     

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  11. MattK

    MattK Silver Member

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    Action shot! Hmm looks like a engine.
     

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    MattK, via a mobile device, Jul 5, 2018
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  12. Solarsurge

    Solarsurge Gold Member

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    So, I took my block to the machine shop and got amazing news. All 4 cylinders are perfectly round, crank pin and main journals literally have zero wear, everything is .000" from factory spec, main bearings literally look brand new. After 190,000 miles it's still like a brand new engine inside if not for the oil discoloration. I think I found a unicorn!
    --- Double Post Merged, Jul 5, 2018 ---
    That's a good lookin' dude right there, if I don't say so myself. :p
    --- Double Post Merged, Jul 6, 2018 ---
    Decided to go with Manley Platinum Platinum Series 87.5 Pistons w/.210" Wall Pins and Manley H-Tuff Plus Rods. Still researching bearings since Clevite H Series mains aren't made anymore for the speeds. Bummer.
     

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  13. Solarsurge

    Solarsurge Gold Member

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    Took the head to my head wizard. Turns out that whoever just did the valve job on the head before I got it did a piss poor job. The seats were visually uneven and I’m gonna need to redo the valves. I guess that’s fair enough considering the bottom end needed zero work. He is also gonna key my crank and precision balance my rotating assembly for me since I’m doing a BSD.


    Sent from my iPhone using Tapatalk
     
    Solarsurge, via a mobile device, Jul 10, 2018
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  14. Solarsurge

    Solarsurge Gold Member

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    OK, so all parts have been ordered, block and head are both at their respective shops.
    [​IMG]
     
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  15. Solarsurge

    Solarsurge Gold Member

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    Parts started arriving today!
     

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  16. Solarsurge

    Solarsurge Gold Member

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    More parts came. For some reason I felt pretty Manley today, so I went out and let er rip on a road trip one last time before I tear her down for the motor swap. Interestingly enough, I almost blew the silicone hot pipe right off the end of the turbo. The t-bolt clamp WAS about half of a cm above the end of the silicone hose, but somehow because of the tapered mouth of the turbo outlet the clamp slid down the taper. Oddly, the hose itself didn’t budge. Maybe time to call cp-e about a replacement hose because the only way that’s even possible is if it blew up like a balloon at the mouth and pushed the clamp down.
    --- Double Post Merged, Jul 14, 2018 at 3:34 AM ---
    Oh yeah... and who says you can’t have a race car that gets 30mpg? Psshhh...
     

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  17. JFSpeed3

    JFSpeed3 Silver Member

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    30mpg avg! I never get that much. It's not like a race my car everywhere either. Nice build list you have going.
     
  18. Solarsurge

    Solarsurge Gold Member

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    There's an age old expression... I believe it's something like "Measure twice, build the engine once." Something like that. Anyway, I'm in the process of building a MZR blueprinting tool. I'm handy with Excel like that. Needless to say, my engine will be built right. :p
     

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