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cjsafski
03-08-2012, 06:48 PM
So I decided to finally make a thread for my car since I have some time to kill. First a little bit of background on the car. It was the first car I owned and bought it when I was 16. It has been an ongoing project for about 8 years now. The progress shots in this thread doesn’t quite show every step since I didn’t take a lot of photos during the process. The car was a bone stock 96 base model. Current mods are as follows:

Power Mods:

Jackson Racing m45 Supercharger kit (Dual Throttle Bodies)
DDM Works Intake
150mm Crank overlay pulley
DIY A/A Intercooler
Greddy RS BOV
Megasquirt 2
RX7 440cc injectors
DIY Toyota COP conversion
Exhintake Cam
Racing Beat Catback
Big Ebay Radiator

Other Performance:

Six speed transmission
4.1 Torsen
Tein Flex 9kg/6kg with EDFC
Hard Dog Hard Core Hard Top Roll Bar
3 Point Shock tower brace
15x8 6UL with 205/50 Nitto Neogens
15x9 TR wheels with 225/45 NT01

Exterior:

Togue Run Lip
OEM Rear mudguards
OEM Hardtop
Turn signal intakes
DIY NACA headlight cover
DIY Hood

Current Pic:


http://img.photobucket.com/albums/v651/Xekueins/IMG_7660.jpg

This is pretty much how the car looked when I bought it. The only mods visible at this time were a hardtop and the headlight cover I made.

http://img.photobucket.com/albums/v651/Xekueins/_9084144.jpg


I got tired of my car being slow so I supercharged it. In retrospect this was not the best decision. Open diff, stock suspension… yeah fun times

http://img.photobucket.com/albums/v651/Xekueins/IMG_0637.jpg


Added a roll bar so I didn’t die.

http://img.photobucket.com/albums/v651/Xekueins/hdr-roll2.jpg

I hated the giant pop ups since I am short and they block my view so I adapted a set of Eagle Talon lights to the car.

http://img.photobucket.com/albums/v651/Xekueins/Lights/Picture008.jpg

http://img.photobucket.com/albums/v651/Xekueins/Lights/Picture017.jpg

Also got some 6ULs to replace those shitty wheels.

http://img.photobucket.com/albums/v651/Xekueins/Lights/Picture026.jpg

A set of Tien Flex Later

http://img.photobucket.com/albums/v651/Xekueins/hdr1.jpg

I then dabbled with an air water Intercooler setup for a while. That thing was a turd. I recommend never getting one.

http://img.photobucket.com/albums/v651/Xekueins/11.jpg

I got tired of the powercard sucking so I built a megasquirt for the car.

http://img.photobucket.com/albums/v651/Xekueins/IMG_1372.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_1363.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_1376.jpg

Designed my own shiftlight because racecar.

http://img.photobucket.com/albums/v651/Xekueins/4.jpg

http://img.photobucket.com/albums/v651/Xekueins/2.jpg

Finally got rid of the air water intercooler and went to an air to air setup. Couldn’t have been happier.

http://img.photobucket.com/albums/v651/Xekueins/IMG_1591.jpg

Then I took it and got it tuned. Made 190 to the wheels which was respectable.

http://img.photobucket.com/albums/v651/Xekueins/2009MiataDyno0001.jpg

Because Racecar

http://img.photobucket.com/albums/v651/Xekueins/157063_807216893775_6420021_44038776_840772_n.jpg

Designed my own hood for cooling.

http://img.photobucket.com/albums/v651/Xekueins/190518_836377076535_6420021_44690777_997814_n.jpg

http://img.photobucket.com/albums/v651/Xekueins/207176_917220800065_6420021_44947464_4917456_n.jpg

And the motor as it sits now.

http://img.photobucket.com/albums/v651/Xekueins/IMG_8164.jpg

cjsafski
03-08-2012, 06:56 PM
And now for what I do with the car. Besides letting it sit most of the time I try and get out and track or autox it whenever I can afford it. I am a grad student now so I have dozens of dollars and another project car. Recently been getting quicker with it. Managed a 44.89 at Adams Kart Track in Riverside.

http://img.photobucket.com/albums/v651/Xekueins/lagunabackcopy.jpg

http://img.photobucket.com/albums/v651/Xekueins/1-2.jpg

http://img.photobucket.com/albums/v651/Xekueins/267254_964986641935_6420021_45587471_6665644_n.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_7323.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_7554.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_7499.jpg


http://www.youtube.com/watch?v=_I7UDpLmTNU&list=UUMzoa2brARUAy6YZ-QbBuOg&index=1&feature=plcp

EUNOS 96
03-08-2012, 07:30 PM
Sickest montego ever

kung fu jesus
03-08-2012, 09:29 PM
Droppin Washingtons like it's goin out of style!

morr
03-08-2012, 09:37 PM
Sick build! I love all the DIY stuff too, very cool!

I<3flippyheadlights
03-08-2012, 09:53 PM
Your car is amazing, love the eagle talon lights!

kung fu jesus
03-08-2012, 10:37 PM
Chris is the evil mad scientist of the SOCAL Miata scene.

cjsafski
03-09-2012, 12:25 AM
This car is probably the saner car I own. The volvo is quite mad and makes very little sense.

I<3flippyheadlights
03-09-2012, 01:58 AM
I think I have seen pictures of your volvo somewhere... I just have a feeling. And now I'm looking into the headlight conversion. Were you the first to do that?

cjsafski
03-10-2012, 04:03 PM
Awesome. The supecharger bracket cracked.


http://img.photobucket.com/albums/v651/Xekueins/2012-03-10_12-46-58_512.jpg

cjsafski
04-04-2012, 01:04 PM
I recently built the car a CSP style wing. So far it seems to be a success. At low angles as pictured it definitely seems to decrease drag since my fuel mileage went up. At higher angles it seems to stick better on corner exits.

Also some decals thanks to Miata Life

http://img.photobucket.com/albums/v651/Xekueins/IMG_8574.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_8589.jpg

WASABI
04-04-2012, 06:01 PM
Nice build thread. I really like your home grown solutions to your mods. The hood is my favorite! Great car!

-Jim

cjsafski
04-05-2012, 01:37 PM
Thanks for the compliments. Here are a few pics from the 2012 Miatas at MRLS.

http://img.photobucket.com/albums/v651/Xekueins/472917_10150625175350658_669370657_9711447_8401208 23_o.jpg

http://img.photobucket.com/albums/v651/Xekueins/456167_10150624531205658_669370657_9707833_1866310 503_o.jpg

http://img.photobucket.com/albums/v651/Xekueins/468101_10150625175950658_669370657_9711454_1129582 278_o.jpg

Lastly my miata parked next to my volvo. I was surprised that weekend that neither broke anything. Put over 800 miles on each not to mention the track time on the miata.

http://img.photobucket.com/albums/v651/Xekueins/IMG_8683.jpg

EUNOS 96
04-09-2012, 01:44 AM
301030093012

cjsafski
05-06-2012, 05:59 PM
So the supercharger setup gave up at life. The bracket that holds the blower to the manifold cracked into two pieces and can not be fixed. Tried welding the crack previously but it didn't hold. I am going back to na for a while since I need this car as a dd. My volvo spun a bearing and I am dropping in a built motor soon so I don't have funds or time to deal with the miata.


http://img.photobucket.com/albums/v651/Xekueins/2012-05-06_12-31-42_112.jpg

cjsafski
05-15-2012, 08:25 PM
So I was in the junkyard looking for a few parts and was drawn to the magnificent curves of this engineering feat. A 1995 Buick Riviera!

http://upload.wikimedia.org/wikipedia/commons/9/99/1995-1999_Buick_Riviera.jpg

Well not really. But they have a 3rd gen m62 supercharger in them and the nose on it looked very similar to the m45 in the Jackson racing kit. Sure enough the noses interchange which means the front bracket for holding the blower to the head fits on.

http://upload.wikimedia.org/wikipedia/en/6/6c/95RivEngine.jpg

So here is the blower on the bench once everything has been stripped from it.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-15_14-49-23_973.jpg

Since the blower is fairly long I took a sawzall and cut off the back flange to get a little more room.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-15_15-36-00_952.jpg

I then drilled the two holes near the top and tapped them. Where they are located you can drill all the way through and not hit anything important.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-15_15-52-56_272.jpg

Instead of using a miata throttle body I decided to use one from a volvo. The 16v 740 series has a fairly slim throttle body. The same throttle body should be on a volvo 850 turbo too. The Throttle body lines up perfectly with the holes I drilled out and is exactly the same size as the inlet.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-15_18-16-14_26.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-05-15_16-45-26_316.jpg

Only the top 2 bolts for the throttle body go into anything. I plan to jb weld a thin plate to the blower between the blower and tb to block some passages I dont need. With rtv the tb should seal fine.

Here it is in the car. Fitment is tight with the firewall. I figure using some of that accordion type intake stuff should work.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-15_16-15-24_836.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-05-15_16-15-29_769.jpg

And lastly the m45 nose on the m62.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-15_17-25-04_705.jpg

iamdallas
05-16-2012, 12:25 AM
I'm going right now to buy one!!

How much did you pay for that charger?!

cjsafski
05-16-2012, 01:09 AM
In total the blower was around a hundred dollars. On a half price day can get them much cheaper if you are lucky. This blower seemed to be in as good of shape as my m45. Just the coupler was worn so I just used to one in my m45.

ZooAtlanta
05-23-2012, 11:53 AM
very interested in what you are doing now

kung fu jesus
05-23-2012, 01:23 PM
You're gonna shoot your eye out.

cjsafski
05-28-2012, 12:05 AM
I built the bracketry for bolting it to the motor today. Just need to weld up some of the brackets and they will be completly done. Haven't had much time to work on it since my masters thesis was due to my committee.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-27_16-01-26_531.jpg

iamdallas
05-28-2012, 01:03 AM
How do you plan on making an outlet manifold?

kung fu jesus
05-28-2012, 07:04 AM
Because it is Chris' car, I suspect he will make the outlet manifold out of scrap steel, an old volvo part, some JB weld and the lids off pudding cups.

And it will be magnificent.

And hold up to 16 psi.

cjsafski
05-28-2012, 07:44 PM
Because it is Chris' car, I suspect he will make the outlet manifold out of scrap steel, an old volvo part, some JB weld and the lids off pudding cups.

And it will be magnificent.

And hold up to 16 psi.

How did you know? Pretty much plan to make it from some steel sheet I have laying around. It will be a little heavy but should get the job done. I originally thought of modifying the supercharger outlet from a supercharged thunderbird but didn't think it would clear the miata hood.

cjsafski
05-29-2012, 11:03 PM
Built part of the outlet manifold today. Getting the outlet pipe just right was a pain. It probably wouldn't work with a stock hood but fits fine with the cuts in the hood I made for the old blower.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-29_19-12-54_517.jpg

kung fu jesus
05-30-2012, 06:39 AM
man, I wish you had done this about a year ago. I could have helped you make that by drawing it up in solidworks. Making the mounting plate for the outlet mani on a waterjet, then you could weld up a "box" sort of design on that.

Agent☣Orange
05-30-2012, 09:31 AM
This is too cool! Wish I had these skillz.

shane
05-30-2012, 10:18 AM
wow rad build, I like every bit of it, looking forward to M62 dyno/and more vids

iamdallas
05-30-2012, 02:52 PM
Mmmmm. Looking good. Wanna make me one of those while you're at it?

cjsafski
05-30-2012, 09:47 PM
Got the manifold finished today. That was a bit of a pain to make with the tools I have so sorry iamdallas I have no plans to make another. I painted it wrinkle black to hide the welds I was too lazy to grind down. More pics later when the paint is dry.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-30_14-46-47_134.jpg

iamdallas
05-31-2012, 12:52 AM
Looks beefy. How much does that sucker weigh?

kung fu jesus
05-31-2012, 06:05 AM
unibrow engineering. strong like bull.

cjsafski
05-31-2012, 09:16 PM
I don't have a scale to weigh the manifold but it surprisingly not that heavy. Anyways a minor update. Painted the blower, brackets and outlet. I plan to put it together tomorrow. Don't know if I will finish it since I am redoing my intercooler setup too.

http://img.photobucket.com/albums/v651/Xekueins/2012-05-31_18-55-31_597.jpg

iamdallas
06-01-2012, 12:22 AM
This is the best thread EVAR! :D

Agent☣Orange
06-01-2012, 01:17 AM
Better. And. Better.

kung fu jesus
06-01-2012, 05:51 AM
Damn, Chris! You busted that out quick! I expected you to still be curled up in the fetal position after wrapping up teaching those physics classes to undergrads.

cjsafski
06-02-2012, 07:50 PM
Major update. It's all in and running! Had a few hicups along the way. I originally tried to use my old DDM intake that I had on the JRSC kit seen here at cars and coffee this morning.

http://img.photobucket.com/albums/v651/Xekueins/2012-06-02_06-58-44_749.jpg

It made 9psi for a bit at 2000 rpm then wouldnt make boost well. It would start at 5 psi then taper to 1 psi at redline. I figured it was my bypass since I knew it was screwy. Nope. Check out how the supercharger tried to eat my foam air filter. It cloged the intake to the point of major restriction

http://img.photobucket.com/albums/v651/Xekueins/2012-06-02_09-57-44_904.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-06-02_09-57-53_443.jpg

So I had to redo the intake. Right now the car seems to be having a misfire problem. The supercharger stuff works fine so I just need to work on the tune. The car is running a little to lean which is probably the problem. As far as boost pressure goes it makes 9 psi at 2500. Haven't gotten it to redline yet.

http://img.photobucket.com/albums/v651/Xekueins/IMG_2875.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2863.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2881.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2882.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2872.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2871.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2870.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2868.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2864.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2860.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2857.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_2856.jpg

kung fu jesus
06-02-2012, 08:01 PM
holy carp, dude! that is fuggen' AWESOME!

I<3flippyheadlights
06-02-2012, 09:09 PM
Your two cars are awesome.

ashmagash
06-03-2012, 12:54 AM
As if your car didn't try to kill people enough before... :)

cjsafski
06-03-2012, 01:32 AM
Ugh the misfire it had after I put the blower on got really bad tonight. Had to have the car towed back from SOCM it was so bad. Seems like either one of the injectors or the coils died on #3. Will diagnose it tomorrow to see for sure. I am suspecting fuel problems. Logs show 97% duty cycle from 440cc injectors at 8 psi and 6000 rpm. That doesnt seem right to me especially when a log from earlier in the day shows that exact same cell having a 76% duty cycle.

iamdallas
06-03-2012, 02:42 AM
Injectors? An mp62 at 9psi would probably need more juice than 440s, right?

cjsafski
06-03-2012, 04:11 PM
Injectors? An mp62 at 9psi would probably need more juice than 440s, right?

Using witchhunters calculator it seems to think if I want 300 hp and 80% duty cycle I need 490cc injectors. Obviously this setup will not make that much power but I just wanted to input ridiculous numbers. Also from experience with the volvo 440 may be big enough.

I found the problem with the car. One of the toyota ignition coils went bad. I switched one with one from my Dad's Camary and it ran fine. Seems like the car will be down for a bit until I get another coil.

iamdallas
06-03-2012, 11:42 PM
Using witchhunters calculator it seems to think if I want 300 hp and 80% duty cycle I need 490cc injectors. Obviously this setup will not make that much power but I just wanted to input ridiculous numbers. Also from experience with the volvo 440 may be big enough.

I found the problem with the car. One of the toyota ignition coils went bad. I switched one with one from my Dad's Camary and it ran fine. Seems like the car will be down for a bit until I get another coil.


Great. Really looking forward to it. :D

cjsafski
06-05-2012, 10:35 PM
Well I got a new coil and the car runs fine now. There still seems to be something wrong with the system though. On a pull from 2k to redline boost will increase linearly to around 10 psi at 4300 rpm. It then tapers off to 8 psi at redline which I would not expect from a supercharger. I am thinking the 90 degree coupler in the intake going to the supercharger is being sucked shut. It is tweaked funny since it barely fits and when the foam filter was clogged it would crush when I revved it. I am thinking of getting some of that autozone ricer flex intake stuff and giving that a try. It is 3" so hopefully that will help.

kung fu jesus
06-05-2012, 10:49 PM
find a coil spring and put it in elbow, maybe try cast (http://www.cxracing.com/mm5/merchant.mvc?Screen=PROD&Store_Code=CXR&Product_Code=EB300-90-CAST) or pie-cut?

as loud as your m45 was, the m62 must sound like a soprano air raid siren.

cjsafski
06-05-2012, 10:54 PM
Problem is that fitment is pretty tight back there.

http://img.photobucket.com/albums/v651/Xekueins/IMG_2857.jpg

iamdallas
06-06-2012, 12:52 AM
Intake through the firewall?

kung fu jesus
06-06-2012, 06:45 AM
Problem is that fitment is pretty tight back there.

Yeah, I saw that. The cast elbows have tighter radii than mandrel bent. Maybe measure, or try, to get a better idea of the space you need to work in. Perhaps a smaller diameter like 70mm/2.75"

cjsafski
06-06-2012, 08:17 AM
I am already using 2.5 diameter for the intake which is probably why it is choking. I want to avoid going through the firewall. The only solution I can think of is flexible tubing. I am worried of it crushing too but since it is 3" maybe it will hold up. Also looks like the FFS kit uses that stuff for an intake.

cjsafski
06-06-2012, 09:46 PM
Tried some of that autozone flexible stuff and couldn't quite fit it in there. I rerouted the intake and it doesnt seem to be pulling on that coupler as hard now. Boost at redline went up to 9 psi but it still seems low. I may go to the junkyard and try and find something more solid to replace that coupler.

http://img.photobucket.com/albums/v651/Xekueins/2012-06-06_18-21-53_223.jpg

I<3flippyheadlights
06-12-2012, 09:12 PM
This thing is.... crazy

samulis
06-13-2012, 12:25 AM
Hi.

Great build!
Are you sure that the belt isnt slipping? That seems to be common problem in mp62.

cjsafski
06-14-2012, 07:23 PM
I don't hear any belt slip. Used to have issues with it a while ago so I am used to the sound.

I finally got around to a radiator cowl cover. I just modified the old one so it isn't pretty but gets the job done.

http://img.photobucket.com/albums/v651/Xekueins/IMG_2886.jpg

I<3flippyheadlights
06-14-2012, 07:31 PM
Thats a whole lotta tape sir.

cjsafski
06-14-2012, 07:39 PM
I always tape off all the holes in the mouth since this car does see autox and track time. It helps a ton with coolant temperatures.

I<3flippyheadlights
06-14-2012, 07:56 PM
Really? Well thats a fun fact.

grrrant
06-15-2012, 01:02 AM
Great build, wish I knew more about boosting like you and other folks..

kung fu jesus
06-15-2012, 06:31 AM
I always tape off all the holes in the mouth since this car does see autox and track time. It helps a ton with coolant temperatures.

You, sir, need to peddle your gorilla taping skills to a certain endurance racing team.

I hear they lost their tape master recently.

cjsafski
06-15-2012, 10:55 PM
You, sir, need to peddle your gorilla taping skills to a certain endurance racing team.

I hear they lost their tape master recently.

Ya I am with them this weekend. Fyi they were complaining about loosing this so called tape master.

cjsafski
06-20-2012, 01:04 PM
Found my missing boost. The BOV was leaking. After adding in the second spring it makes 12 psi at redline and 13.5 at 4500 rpm. Guess it means I still need to tighten the BOV more. It looks like it may be a good idea to toss some stronger rods in this motor soon.

kung fu jesus
06-20-2012, 01:21 PM
Phht! Drive it till it pops.

I want a flyby video of said car making 13,5 psi.

Demon I Am
06-20-2012, 01:41 PM
Wow, this is a great build. I wish I had fab skills/equipment.

kung fu jesus
06-20-2012, 01:55 PM
I think the incredible part of Chris' builds are the level of performance without fancy fabrication skills. That's not a slight on him, it's a testament that just about anyone can just go and do it.

Demon I Am
06-20-2012, 02:14 PM
Yeah, that's what I was meaning. It does take an uncommon level of imagination/ingenuity to create something like this though.

cjsafski
06-20-2012, 04:29 PM
Like Steve said you would be surprised what you can do with basic skills and tools. For instance all I used to make the manifold was an angle grinder, welder, file, vice and a big hammer. A lot of it is just planning the design to take into account the lack of resources you have.

Also I will eventually do some videos. Been busy working on Tom's engine swap and supercharger installation, 14 hr enduro with 949 and now swapping a built motor into the volvo.

cjsafski
06-21-2012, 10:44 AM
Not miata related but since my volvo doesn't have a build thread here and this is what has been delaying my work on the supercharger I thought I would post it. Built motor bored out to 2.4l with h beam rods. Hope to get around 350 to the wheels with it. Know someone with the same buuild who made 400 on e85 so I think it is doable.

http://img.photobucket.com/albums/v651/Xekueins/2012-06-20_17-40-09_21.jpg

I<3flippyheadlights
06-21-2012, 10:59 AM
That's a very mean volvo man.

kung fu jesus
06-21-2012, 11:07 AM
How's the tranny swap coming along with that , Chris?

It took me a minute to figure out the color scheme on that valve cover, too. :lol:

cjsafski
06-21-2012, 12:42 PM
The trans wont go in for a while. Wanted to get the motor sorted out first.

cjsafski
07-02-2012, 04:55 PM
Finally did a coolant reroute for my car just in time to go to Adams Kart track tomorrow. Trying to get as much done as I can before I start on my PhD next week. I did a simple diy setup by flipping the front and rear thermostats. For the hose I used Autozone part XL 1215. Don't know the correct application for this hose but it is $20 and works very well.

Here is the 1.8 thermostat cover on the back of the head. Probably would interfere with the normal coils but I have coil on plug so plenty of room back there.

http://img.photobucket.com/albums/v651/Xekueins/2012-07-01_16-35-32_499.jpg

I needed to cut the hose and join it with a 90 degree turn to go down to the waterneck on the back of the head. I made this pipe with both a mounting tab and a bung for my coolant gauge to do so.

http://img.photobucket.com/albums/v651/Xekueins/2012-07-01_16-10-40_857.jpg

Here is the hose going to the back of the head with the above part mounted to the valve cover.

http://img.photobucket.com/albums/v651/Xekueins/2012-07-01_18-31-57_846.jpg

And the finished project.

http://img.photobucket.com/albums/v651/Xekueins/2012-07-02_14-02-55_525.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-07-02_14-03-05_846.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-07-02_14-03-29_799.jpg

kung fu jesus
07-02-2012, 07:14 PM
that is sooo ghetto fab, and I love it!

iamdallas
07-02-2012, 07:40 PM
that is sooo ghetto fab, and I love it!

Couldn't gave said it any better. Soooo awesome and cheap!

cjsafski
07-02-2012, 08:28 PM
Sadly can't claim this as a completly unique idea. I crewed for a chump car that had the same sort of reroute. You know it is bad when you look to chump cars for inspiration.

Demon I Am
07-02-2012, 08:44 PM
Homebrewed engineering ftw!

cjsafski
07-02-2012, 11:23 PM
So for once I installed a legitimate part! 949 racing's stainless brake lines.

http://img.photobucket.com/albums/v651/Xekueins/2012-07-02_18-26-53_253.jpg

I<3flippyheadlights
07-04-2012, 12:35 AM
You actually installed a pre-made part!? You need to make SS lines sir, not wimp out and "buy" some.

mhogan0
07-04-2012, 05:03 PM
this is reediculus omg Ilove that charger mani :slayer: it is total awesomeness

cjsafski
07-04-2012, 10:08 PM
So I finally get to post some vids of the new setup. Went to Adams to see how it did. Car definitely had more power. I had to adjust the wing up quite a bit to keep it from powersliding everywhere. Although in that position it creates a ton of drag. The car was having massive overheating problems. Seems like the cap was bad since coolant was pouring out of the overflow. Regardless this was the fastest car there that night by far and I got a new personal best of 44.55.


http://www.youtube.com/watch?v=bNeTG4vw6MA

Also decided to tap the tire slalom there which resulted in some minor damage. The white marks are paint from the tire I hit. I can pop the panel back out too. This is probably the third or fourth time I have hit those tires.

http://img.photobucket.com/albums/v651/Xekueins/2012-07-03_19-29-51_37.jpg

kung fu jesus
07-05-2012, 07:38 AM
Car looks really well-balanced, Chris!

Meh on the panel damage. Take off the fender, should bang out like you said. The white should mostly buff out. Ask Evan for help with that.

EvDog
07-05-2012, 10:58 AM
Word, I can clean that up real nice.

cjsafski
08-27-2012, 10:10 PM
Mor ribs for her pleasure. I got a few more ribs cut into the overlay pulley that I had so now I can run a six rib belt. The tensioner pulley fits a 6 rib belt. I need to get another buick nose pulley though since I messed up the one I had. It happens to be slightly smaller too which will mean time for more boost soon.


http://img.photobucket.com/albums/v651/Xekueins/2012-08-27_17-52-21_317.jpg

cjsafski
08-28-2012, 07:11 PM
6 rib coversion done. With the slightly smaller nose pulley it makes 13psi on a warm day opposed to 11 in similar conditions. Me boosta

http://img.photobucket.com/albums/v651/Xekueins/2012-08-28_16-30-54_276.jpg

SM16RMSM
08-28-2012, 10:43 PM
Oh, the sweat whine of a supercharger. Music to my ears. Very nice. Have you had the car dyno to see what kind of power your making at the wheels with the M62 on?

Mexican_Guy
08-28-2012, 11:05 PM
:S if it was impossible for me just to follow you in a simple curb (my soda fall of in my pants by the way lol) now you will run more awesome! keep it up cris!

kung fu jesus
08-29-2012, 07:21 AM
Chris, you never fail to amaze.

I<3flippyheadlights
08-29-2012, 08:58 AM
:applause::applause::applause::applause::applause:

cjsafski
09-18-2012, 04:42 PM
This just happened.

http://img.photobucket.com/albums/v651/Xekueins/2012-09-18_14-09-43_429.jpg

The bracket that holds to the blower to the head wore funny as seen in the below pic. This caused the blower to angle down and resulted in nose bearing failure.

http://img.photobucket.com/albums/v651/Xekueins/2012-09-18_14-10-50_99.jpg

Mexican_Guy
09-19-2012, 07:24 PM
:S wen you post it in facebook i dint see anything wrong damm

I<3flippyheadlights
09-19-2012, 08:07 PM
I was thinking to myself, "where did his blower go? Did he use some crazy, scientist magic and turn it into an air filter?"

iamdallas
09-19-2012, 10:48 PM
Dammit! That sucks man. Maybe that's what happened to mine. Hmmmm.

cjsafski
10-23-2012, 10:55 PM
A little bit of progress in getting my boost back. Been too busy with 949 racing recently to get much done. I decided to repair the bracket by welding material where it deformed then milling it back to the correct shape. I forgot to get a pic of the finished job.

http://img.photobucket.com/albums/v651/Xekueins/2012-09-25_17-26-58_833.jpg

Then I rebuilt the nose myself with new bearings. Not to hard to do after all.

http://img.photobucket.com/albums/v651/Xekueins/2012-10-07_12-45-52_919.jpg

While the blower was out decided to clean and polish the surface the rotors ride on. Looks like the blower ate something at some point but I am going to pretend I didn't see that. Also ported the triangle shaped outlet a bit.

http://img.photobucket.com/albums/v651/Xekueins/2012-10-19_16-49-33_914.jpg

After getting the setup back in the car it went 5 min before shredding the belt. The rebuild on the nose seems ok so I need to figure out what happened. I suspect the idler pulley since it seems kind of jacked up looking.

I<3flippyheadlights
10-23-2012, 11:14 PM
Your thread makes me excited to have a supercharger and scared all at the same time.

cjsafski
10-24-2012, 12:09 AM
The unmolested m45 kit was pretty reliable. This recent problem seems to be related to a boss on my head being stripped. Well aside from the pulley issue. The idler has grooves worn in it from almost 55k miles of use. Other than that only other problems I have had were bad bypass valves which are a common failure.

I<3flippyheadlights
10-24-2012, 03:21 AM
I'm hoping to pick up a simple m45 kit actually. Might upgrade it after seeing as how I'll be running a standalone. What do you think I would get out of a m45 kit with a full exhuast, little intercooler and a decent tune? I'm shooting for anything over 150.

cjsafski
10-24-2012, 01:35 PM
On a 1.8 the base it should make 150 on a healthy motor. Mine made 155 with the stock kit. On the first page of this thread I have a dyno with the mods you describe plus the crank overlay.

I<3flippyheadlights
10-24-2012, 02:43 PM
I'm rocking a 1.6l engine man. :/

cjsafski
11-11-2012, 12:46 AM
Well the car is still not quite running. I had problems with the moss tensioner I had and had to bend it back to the right shape. I then let autotune run and well it seems the wideband was completely out of calibration cause now it runs stupid rich and stumbles. Of course stupid me forgot to save the previous tune. I forgot to recalibrate it too when i was under it today doing another project. :(

So today I finally decided to put an oil cooler in the car. Something it desperately needed. I used a volvo cooler with a cooltek thermostat and mated it to the oil filter relocator I had on the car. There was no space in the mouth of the car so I had place it on the steering rack.

http://img.photobucket.com/albums/v651/Xekueins/2012-11-10_15-30-50_456.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-11-10_16-32-39_573.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-11-10_16-50-49_545.jpg

cjsafski
11-13-2012, 11:08 PM
Did something not racecar. Although it was nice that the protege Valve cover relocated the breather line to a place where it was no longer crushed shut by the blower.

http://img.photobucket.com/albums/v651/Xekueins/2012-11-12_14-59-34_319.jpg

cjsafski
12-18-2012, 09:26 PM
New motor hopefully going in this weekend.

NA Block:

Bored out to 1.9+
GTX Rods
OE Replacement Pistons

99 Head:

Supertech Oversized Valves
Mazdaspeed Miata Intake Cam
Gutted Intake Manifold.

http://img.photobucket.com/albums/v651/Xekueins/2012-12-18_16-21-41_652.jpg

Here are the pics of the gutted manifold (left) next to a stock one. I have seen dynos of this helping a lot with top end power.

http://img.photobucket.com/albums/v651/Xekueins/2012-12-18_16-16-00_67.jpg

I<3flippyheadlights
12-19-2012, 12:19 AM
Is your old engine good? You blow something up?

cjsafski
12-19-2012, 01:04 AM
The old engine is as there as it has been. Going to be tracking it more and at 14 psi i didnt expect a stock block to hold up for too long. Also wanted to up the power more. In miata challenge boost points are the same whether you have 150 or 500 hp so going for as much as I can.

Heyitsryan
12-19-2012, 08:22 AM
Interesting build thread, sorry to hear that you're having so many problems. The car is looking pretty sweet though.

How much did you pay for your built head all together? I'm interested in doing a '99 head swap myself.

I<3flippyheadlights
12-19-2012, 11:37 AM
Whats your end goal going to be with that big ass supercharger and new engine?

cjsafski
12-19-2012, 01:15 PM
I am aiming for somewhere in the 250+ region which should be doable. The trackdog car has similar mods and made 288 hp so who knows it could make a lot more.

Can't really comment about the cost of the head. It was already on the motor when i bought it.

I<3flippyheadlights
12-19-2012, 01:31 PM
Badass dude.

Slampen
12-19-2012, 03:20 PM
Whp?

cjsafski
12-20-2012, 10:49 PM
Yup whp

Got my mazdaspeed miata intake cam today. I plan to get going on the swap tomorrow.

http://img.photobucket.com/albums/v651/Xekueins/2012-12-20_19-22-04_824.jpg

I<3flippyheadlights
12-20-2012, 10:58 PM
Yup whp]

sarcasm?

cjsafski
12-20-2012, 11:17 PM
No sarcasm. I made 190 to the wheels on a stock na 1.8 at 7 psi. Not too unreasonable that at 14psi on a 1.9 with a large valved 99 head to reach 250. The reason most people hate on the blowers is everyone runs stupid bandaids that are worthless for power or has the ffs kit and raves about the 5th injector bs while making no reasonable power.

I<3flippyheadlights
12-21-2012, 12:04 AM
I thought you meant it like

"whp?"
"yup, whp"

As in, yup I got wheel horse power :P

I know damn well you are gonna make some power out of that car. Would be crazy if one day you hit 300 with a blower.

Stealth97
12-24-2012, 11:05 AM
I like where this is going :) Love me some SC whine..

cjsafski
12-25-2012, 02:34 AM
New engine is in and running like a champ. While pulling out the old motor I found a lot of interesting things which in order were:

Radiator was missing a lot of coolant and resivor dry.
Intercooler had a hole in it near a sensor I put in
Front main leaking
Only one motor mount bolted in. Other nut peaced out
Missing coolant possibly found, in the exhaust port of #1...
Rear main leaking

Anyways some pics

http://img.photobucket.com/albums/v651/Xekueins/IMG_0577_zps34c04f3c.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_0579_zps9f5585c0.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_0590_zpsc6aafd73.jpg

Raiding the old motor for parts

http://img.photobucket.com/albums/v651/Xekueins/IMG_0574_zps378507f4.jpg

Engine out

http://img.photobucket.com/albums/v651/Xekueins/2012-12-22_17-42-01_57.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-12-23_13-58-46_159.jpg

Engine completed. Decided to break in the motor naturally aspirated to get rid of the temptation to full throttle.

http://img.photobucket.com/albums/v651/Xekueins/2012-12-24_15-53-35_64.jpg

http://img.photobucket.com/albums/v651/Xekueins/2012-12-24_15-53-26_889.jpg

I<3flippyheadlights
12-25-2012, 02:40 AM
Damn! That old engine held up like a champ!

Now why are you waiting on the supercharger install?

*edit* fantastic install

maharaj
12-25-2012, 04:17 AM
Sweet looking install....isn't it just sooooo much easier to go through an engine when it is out of the car?!

cjsafski
12-25-2012, 12:48 PM
Damn! That old engine held up like a champ!

Now why are you waiting on the supercharger install?

*edit* fantastic install

Trying to be nice to the motor during break in. Otherwise I would probably do a 14psi pull leaving the garage and kill the motor.


Sweet looking install....isn't it just sooooo much easier to go through an engine when it is out of the car?!

Yes it is. Cleaned up the engine bay and painted a lot of the motor. Also cleaned up a lot of my wiring so it no longer looks like a rat made a home in the engine bay.

cjsafski
01-04-2013, 12:00 AM
So the motor didnt survive. This was a known possible outcome for it since it was originally in a different car for a bit car and had oil pressure issues then. A few hundred miles into the breaking compression was low and it seemed to be burning oil. Leakdown also showed issues as well. Peaked in there with a borescope and saw some vertical scores. Popped the head off and it didn't seem to happy inside. So time for a new plan.

http://img.photobucket.com/albums/v651/Xekueins/2013-01-03_13-17-32_399.jpg

While I had the header out I decided to do something about the nasty internal welds that block a bunch of the ports.

http://img.photobucket.com/albums/v651/Xekueins/2013-01-03_13-46-24_636.jpg

So I welded the header from the outside and proceded to grind the welds down. Not done yet but it looks a lot better.

http://img.photobucket.com/albums/v651/Xekueins/2013-01-03_15-35-26_434.jpg

cjsafski
04-08-2013, 12:46 PM
Minor update. Not much has gotten done since I have been waiting forever for the new motor. I decided to clean up the new blower I will be using.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130326_142132_900_zpsd87b0543.jpg

The rotors on the right are from the gen 2 m62 I was using and on the left are from the gen 3. Notice how the gen 3 are epoxy coated and the gen 2 are bare metal. Well at least under the oil residue. I was pretty pleased with the condition of the new blower I got from the junkyard for $50. Almost good as new.

Also the welds on my supercharger manifold were starting to crack since I ground them down to make it look prettier and used probably to thin of metal. It is hard to see in the pic the cracks.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130326_152617_308_zpsdb106117.jpg

I decided to take a look at the supercharger manifold and decide if I wanted to redo it or not. Especially after finding cracks in the old one and buying the tools to weld aluminum. Here is an analysis of the manifold I have been running.

http://img.photobucket.com/albums/v651/Xekueins/904274_10100813003995335_769594893_o_zpsa281c76d.j pg

Notice how the velocity of the outlet is much higher than the inlet. This suggests to me that the outlet is a major restriction. This makes sense since the manifold outlet area is less than that of the supercharger outlet.

Here is my first idea for a replacement.

http://img.photobucket.com/albums/v651/Xekueins/902832_10100813094743475_433550998_o_zps0efb6427.j pg

The outlet velocity is still higher meaning there is a pressure buildup in the plenum. Looking at the area of the design the manifold area is still less than the supercharger outlet. Keep in mind the design is simple since I am trying to model something I could easily build.

To remedy this I tried increasing the diameter of the outlet.

http://img.photobucket.com/albums/v651/Xekueins/FloXpress_snap1_zpsab449688.jpg

I like this design since the restriction no longer seems to be the outlet diameter. Also the area for the outlets is roughly the same and the velocities through both are similar so I guess this is my best bet. My best understanding of building spercharged setups is blowers tend to like as little of a restriction as possible so I think I will go with this design.

I got the spoolgun for my welder in the mail so I decided to finally learn how to weld aluminum.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130406_175623_086_zps1fa94763.jpg

After playing around with it for a bit I was finally able to get a nice bead. Once you figure out the settings and that you have to hold the gun differently than mig steel it is pretty easy to use. The bead along the bottom is better than my usual steel bead lol.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130406_171017_231_zps736b0188.jpg

Also used an old useless volvo manifold to test cutting the flange off and rewelding in preparation of doing the honda manifold. I found one super cheap on ebay so figured why not. The welds are not the prettiest but should work.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130406_175456_269_zps5a203dec.jpg

Worked on my new manifold a little. Burnt up the few tips I had and the only "hardware" places near where I live are useless chain stores. The material I am using is a little too thick for my welder which is part of the reason I am killing tips. I need to hold the gun super close or else I can not get a pool started and sometimes it would melt the wire in the tip. And yes I do suck at welding aluminum but hey I just started.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130407_131418_341_zps7ab47c01.jpg

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130407_160832_800_zps9b19b0f6.jpg

Lastly is not quite related but a new addition. That will probably appear time to time in this thread since I don't want to make a separate build thread. A 2005 msm with a full Flyin Miata intake and a FMIC already. No real plans for the car other than to drive it. Having it as a daily opens up some new options for my NA

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130326_151353_533_zpscbb17d64.jpg

ctrench
04-08-2013, 01:10 PM
ok coolest shift light ever!!! do you have a thread on how you made it???

cjsafski
04-08-2013, 02:12 PM
I never did a full writeup on it but made a diagram of the circuit. I might have changed it a little but this should work.

http://img.photobucket.com/albums/v651/Xekueins/meh-1.jpg

Parts list from an old post:

ICs:

lm311 Comparator
dm74121 Monostable Multivibrator
lm3914 LED Bar Graph Driver

Capacitors:

.22 uF (x1)
.47 uF (x1)
1 uF (x3)
10 uF (x1)

Make sure you get the polarity right on these or else they explode. The side that goes towards negative is usually marked.

Resistors:

1 kohm (x2)
2.2 kohm (x2)
4.7 kohm (x1)
10 kohm (x2)
10 kohm Potentiometer (x1)
100 kohm Potentiometer (x1)

5V Regulator 7805
10 LEDs of your choice
Project Box
Board
Wire

ctrench
04-08-2013, 02:22 PM
damn, i have some knowledge with circuit boards and stuff, but this looks a little past my level :(

kung fu jesus
04-08-2013, 02:50 PM
Monostable Multivibrator


Say this part slower and softer for me.

Martin
04-08-2013, 03:47 PM
ew

cjsafski
04-15-2013, 09:43 PM
My post dissapeared :(

More parts hoarding. I found a Skunk2 knockoff intake manifold for a b18 on ebay for $70 because there were some messed up machining marks near the flange. Big deal. I need to cut it off anyways. This mod has been shown to be very beneficial on a boosted car.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130410_173627_240_zpscb3862e1.jpg

Here are the defects

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130410_173644_702_zps8cd29851.jpg

The internal casting is not bad for a knock off

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130410_173541_557_zpsf6457e2c.jpg

As you can see the runners are pretty close to the miata intake manifold gasket I have.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130410_173848_905_zps598fe9a7.jpg

For a throttle body I plan to mod it to accept the Volvo 960 64mm throttle body. Need to figure out what idle valve I am going to use. Probably going to use the volvo one I have been running.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130410_173732_569_zpse25a561e.jpg

cjsafski
04-15-2013, 09:51 PM
Bought a legitimate part for a change! APR 250 mega wing as seen sitting on the msm for yucks. Should give a *bit* less drag than the wing I made.

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130415_172850_351_zps6de9dedb.jpg (http://smg.photobucket.com/user/Xekueins/media/IMG_20130415_172850_351_zps6de9dedb.jpg.html)

http://img.photobucket.com/albums/v651/Xekueins/IMG_20130415_172837_010_zpsba431976.jpg (http://smg.photobucket.com/user/Xekueins/media/IMG_20130415_172837_010_zpsba431976.jpg.html)

I plan to mount it pretty much the same way the one on Crusher is done.

http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash4/466711_397063743701468_2113501343_o.jpg