Tired 2000 Protege lx getting Speed3 swap

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.

 

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.

 

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.

 

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!

 

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.

 

FYI I have had good luck with the longevity of DeWalt bimetal blades

 

I'm going to buy new blades this morning. I will see if they carry the DeWalt. I appreciate it!

 

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.

 

All stripped down. Cutting off top, then the complete firewall/floorpan.

 

That is a lot of scrap to be cutting up. I hope you are selling it for a few bucks.

 

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...

 

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.

 

Looks like a crazy endeavor but a protege is 1000lbs less than a speed so will be crazy fast

 

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!

 

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.

 

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

 

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...

 

This is an awesome project. Good luck with the build but it looks like you know what your doing.

 

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.