saedrin

Greetings gentlemen, here will be my official build thread.. First few (edit: 3 pages, lol) posts are copy-paste from another forum, just to add some content.

This car is my daily, and has been for 6 years. I love the crap out of it, and will never, ever sell it. I beat it hard, put it away wet, and modify it for function only (looks like crap, don't care). It's my Millennium Falcon, if you will.

Anyways, on to the thread. First post after this is about 14 months ago.

AND GO.

saedrin

So I've had this car (2000 LS) for... 5 years now. Progression of modifications went from full bolt-ons (+2whp), to simple suspension (H&R Race, KYB AGX), and then added the FM Extreme happy meal. Car was still slow as *****, but very fun to drive. I've decided I want more power. Coming from a DSM/Evo background (other car is ~350whp DSM), I'm no stranger to boost, and the Miata seems like the perfect platform for some turbo fun.

So thus my power build thread.

First a list of what I have to install or already have installed that are relevant:

Corksport MSM front mount intercooler and intake
MSM turbo (+ full AN lines)
MSM waterpump inlet
XEDE 99-00 Ecu
Synapse Engineering Synchronic BOV/CBV (+ recirc fitting)
Hallman Pro manual boost controller
MSM 6-speed transmission (pickup this weekend)
FM Extreme happy meal clutch and 10lb flywheel
RB Race connecting pipe and Roadstersport 3 muffler (temporary exhaust)
New rear main seal, random cleaning and re-rusting to do on the subframe and chassis

Exhaust will quickly be replaced with a Begi MSM downpipe and a custom 3" v-band system that I can reuse when I upgrade turbos down the road. Also on the list to purchase is a new set of injectors once I'm comfortable with turning the boost up past wastegate pressure.

Anyways on to the pictures. I've already started so you're not going to see any pre-build pictures (sorry) but I'll do my best to capture this as I go along.

Engine out, time to get to work.


Engine bay, needs some de-rusting and I'm going to weld the pinion in my depowered rack.


Engine out, still has the markings from FM salvage on the cover.


Relatively clean in the back, going to hit the rest of it with some brake cleaner to get the gunk off.


Oil feed takeoff, forgive the ---- filter.


MSM waterpump inlet.


FM Extreme happy meal, could use a light resurfacing but I'll probably just deal with it.


Should be able to handle the heat from anything I ever upgrade to.


MSM Turbo, replacing the drain with something that actually fits this week.


Back side of the turbo.


Pile of random parts, wideband, filter, fittings, BOV, MBC, etc.


Dash, Defi metric boost + JDM tach. Going to try to re-crystal mod this car when I get my wideband installed, hopefully when I move to the GT2560 or something I'll be able to make power up there.


And that's where I'm at so far. This weekend I'll be picking up the MSM 6-speed from a forum member in Kentucky, then everything goes back together and I'll start harassing Begi for a base map.

saedrin

MSM 6 speed transmission (thanks dustinlib)


Repaired speed sensor (hint: make sure all connectors are disconnected when ripping drivetrain out)


Tomorrow I'll mock up the turbo drain, drill and tap the pan, and repair some wiring harness damage in the trans tunnel. Also going to remove my steering pinion and take it to work for welding to remove the center slop, and order new exhaust manifold studs and nuts as the stockers just pulled the studs out of the head and are now one solid piece.

saedrin

Good news, I was able to salvage the exhaust studs with an hour of hard work and swearing with assistance from a hand torch.


And then I drilled the oil drain...




So later this evening I'll clean out that drill hole of shavings and finally install the turbo in its resting position.

saedrin

Oil drain fitting installed, pan cleaned, and everything torqued up.


Turbo attached for line fitting.


How the drain is routed, I'll fab a bracket to make the line a solid downhill slope.


Coolant lines, yes they're a bit long, but functional..


Oil feed, probably should have gone with a strait end to have the adapter be at the ideal angle, but this will work fine.


So on tomorrow's list, I've got a bunch of wiring to repair, and the transmission to reattach. Slowly but surely making progress on this thing.

Trans wiring is screwed, have to strip the harness here and extend the connectors.


Oil pressure sensor... just ends. Stupid connector got mauled off, so get to fix that too. Also going to roll the car out and hose this ---- off the subframe, then do some rust stripping and repainting.

saedrin

Turbo is in the final position, lines hooked up and turbine outlet attached.


Installed my new rear main seal, a mild pain in the *** but I'm hoping this will be fine for another 100k+ miles.


Coolant line feed and return, anyone see anything wrong with this routing?


FM Extreme + 10lb flywheel reattached.


Andddddd.. the best part, 6 speed trans is bolted up and ready to go.


Going to drain the trans/shifter, finish the wiring repair, and then drop this stuff into the car and pray later this week.

saedrin

Small update, got some little things sorted out.

Repaired oil pressure sensor, wrapped it with electrical tape after this and hopefully no more problems here.


Small surface rust problems, I sanded down the stuff that looked bad, and just sprayed everything else with Krylon rust remover black.





Then went and did the same with a couple brackets and the driveshaft, all of which looked nasty.


Hoping later I'll get around to finishing up the prep and tomorrow I'll start putting the engine back in.

saedrin

Engine is ready to go into the car here.


Mild clearance problem with the dipstick and the coolant return. I'll rape it into position.


Speed sensor installed.


Wiring repaired. One of the two connectors that was messed up (the large, two prong one) was ruined so I just said screw it and cut it off. It's either the neutral switch or the reverse switch, both I can live without.


Reassembled the rack.


Going in, this is a serious PITA with one person.


Where I sit today. Tomorrow I'm having a friend stop by with fluids and a spare set of hands to get this thing in and bolted up.


Turbo!


Looking forward to this running, have my base map from Begi and XEDE is installed, hopefully I'll get everything good tomorrow and start enjoying it.

saedrin

New co-pilot and shift ****.


Engine bolted in and everything hooked up minus intake piping.


Synapse Engineering BOV


Coolant leak problem, the MSM outlet is longer, making the cross-over tube not fit on the exhaust manifold, so it pops out and leaks.


Needs to line up and it doesn't, getting this welded in place on monday.


Moar shift ****.

saedrin

First serious problem, Corksport FMIC routing for the MSM apparently uses this hole behind the driver's headlight, but the MSM headlights are much shorter where the 99-00 lights are longer, meaning I can't use the drivers side headlight until I get NB2 lights.


Also missing this coupler for the turbo inlet, apparently they expect you to reuse the stock part, which I don't have. Have a 90* on order..


Need new exhaust bolts to put this back together, in my infinite wisdom I lost the old bolts. Off to lowes... (don't hate my stock downpipe, it just wants to love you)


Last problem I can think of, is the BOV and the air-return for the Corksport intake are 1.25" and .75" respectively, and it's 100% impossible to find a silicone coupler this size, so I ordered a PVC reducer. (can you tell I own a DSM?)


Hopefully that crap will be in tomorrow and friday so I can fire it up and drive it around a bit.