*** HOW-TO: Polyfilled Motor Mounts *** 

  PERFORMANCE UPGRADES:

• ATX - MTX Transmission swap

• Mazda MX6 LS 4.10 5-speed

• Southbend DxD Torza-2 Clutch

• KLZE Heads & Cams

• Polished and balanced crankshaft/rotating assembly

• Pace Setter 2.5" Mandrel Bent Cat-Back Exhaust

• 2.5" SS Test Pipe

• Outlaw Phenolic Spacers (portmatched to ZE heads and 03 IM)

• Custom Dual Feed fuel rails

• Apexi N1 Style Muffler

• Front Mount Intercooler (24x7x2.5")

• Autometer Sports-Comp Gauges (FP, Boost, Water temp, Oil Pressure)

• AEM Wideband Oxygen Sensor w/ 2" Gauge

• DSM 1st Gen. Blow Off Valve

• Walbro 255 L/Hr Fuel Pump (Regular Pressure)

• Home made manual boost controller

• Home made short-throw Shifter

• NGK 7.5mm Spark Plug Wires

• NGK V-Power Spark Plugs (7 heat range)

• T3/TO4E Turbo (.48 stage III / .60 A/R) w/ 60mm wheel

• Solid Polyurethane Motor Mounts (Front & Rear)

• Forged Aluminum Diamond 8.7:1 C/R Pistons

• Mazda Millenia-S Forged Connecting Rods

• OEM 2-ply Head Gaskets

• Toga HP Rod & Main Bearings

• High-Flow OEM Oil Pump

• Total-Seal Piston Rings

• TopLine Motorsports Head bolts

• KLZE Heads

• KLZE Camshafts

• P&P/Knife edged KL03 Intake Manifold (gutted VRIS)

• Aeromotive Fuel Pressure Regulator 1:1

   SUSPENSION:

• 17x7" ADR Racing Wheels (17.8 lbs each)

• 225/45/17 ZR Kumho Ecsta Supra 712 Tires (BAD in snow!!!)

• Eibach Spring Coils

• KYB GR2 Gas Struts

   APPEARANCE:

• H4 Headlight Conversion Lamps

• Halogen Eurolite Blue Headlamps

• Custom Painted Intake Manifold & Valve cover

• Aluminum Accented Interior

• Aluminum Gauge Bezel

• Black & Gray Shift Boot

• Aluminum APC shift knob

• Blue Painted Brake Calipers

• Charcoal/Black Seat Covers

• SOON TO COME: FX Combat Chin Spoiler

• SOON TO COME: FX Combat Sideskirts

   ELECTRONICS & AUDIO:

• MegaSquirt v2.2 full engine management control

• MSD 6 with Blaster2 Coil  powering a 93/94 Distributor

• Pioneer 7400 MP3 Head Unit (55x4 watts)

• Matrix 3-way 5x7" Rear speakers

• Pyramid Super Blue 3-way 6 1/2" Front Speakers

• Factory Keyless Entry w/ Alarm

• Soundstorm 1300watt Amp

• Custom Rear Hatch

• Infinity 12" Reference Subwoofer @ 200w

• 6x9" Kenwood Hatch Speakers @ 65w

*This was the first pull on the dyno at a little over 6 psi in November of 2002. This was with a average sized T3 Garrett turbo. Engine was still non intercooled and running very rich!


* UPDATE: May 27th 2004: With the extra fuel injection setup and the intercooler I made a noticable jump in power from the previous dyno but the car would have been much better if it had been tuned to 12.3:1 air/fuel setup. But instead I had issues with a FMU and the fuel pressure was rising too slowly making a very lean condition from 0-3psi boost then from 3 to 10psi the car would go insanely rich (10:1 A/F). Their wideband o2 sensor showed the leanest and richest fuel curve they had ever seen, and I managed all this in in the same dyno pull, NOT GOOD haha! I had a ground wire arcing very badly making the car misfire on the dyno which was very clear in the power curve. Both pulls had similar fuel problems and arcing. At least this old motor survived the dyno session. But the new motor should show at least 280whp on 7psi of boost now that I can tune it.



HOT PIPES (Collectors & Downpipe)

*** New Engine Build Photos ***

T3/T04E 60mm Turbocharger
   
Honed Block and Crankshaft after hot tanking and polishing
       
8.7:1 Forged Aluminum Flattop Pistons & Millenia-S Rods (827 pins bore)
   
the Block
   
Getting closer to the finishing touches of assembly
   
Dropped the motor in the car w/ a basic setup still using the FMU for now
   

So as of right now I have the 12:1 FMU controlling the added fuel using the stock injectors for now. I have built and assembled my MegaSquirt unit but will be waiting to make a final decision on whether to go with coil packs or just standard timing controlled spark from the MS. It's been proven that you can run 12.5-13:1 AFR with a 10 or 12:1 FMU on stock injectors. Of course this is only at ~6psi, any higher and it forces the injectors into a static condition where the injectors begin cutting out. But for right now its hardly getting boosted on more than a couple seconds at a time so no worries. Plus this engine is fully forged so it shouldn't have any problems unless I were to run too much boost. Currently the motor has ~550 miles on it so its not seeing much boost or large amounts of throttle. Eventually I will be getting an electronic boost controller, installing MegaSqiurt to control fuel and spark, and then it will see the dyno and full throttle again. Others with similar setups have made as much as 290-300whp on 7psi from a T4. So I expect to see the same results very soon!

DrBrown@designbydan.com