Mazdaspeed 3 build
 

I blew my motor and melted a hole in the #3 piston big enough to put your finger in it and it also melted the cylinder sleeve. They replaced the sleave and honed all the sleaves.



pistion with the hole melted thru



same but up close



the new pistions —:icon_thumright:



the new rods —:icon_thumright:

alright pics of the FMIC






hot pipe of the intercooler




had to move the power steering cooler lines up a bolt


done and on the car without the bumper


cold pipe from the intercooler


with the bumper on



another pic with the bumper on

took the gay honeycomb out.



wrapped the intake with aluminum bubble wrap. Need to warp the turbo inlet pipe and cold pipe. Thanks to Ziggo.

I had the head and intake manifold ported but for some reason I didn't put them on photobucket and deleted the pics. I fail.

The current mods are in my sig. My current tune is sitting at 311whp and 370wtq. I'm going to buy some nt555r's and tune for 3 gal of e85. Should put me around 330whp and 390wtq.

Very very nice. That is a hell of alot of hp for fwd. It should be fun!

Thanks. I dont get traction till 4th right now. Lol

Nice work. Why'd it melt in the first place and how's the torque steer?

I was having fuel pump problems so it ran lean. With solid motor mounts I dont get much...anymore. Before when I just had a rear motor mount it made lane changes for me lol

Let there be traction

Those are interesting connecting rods. I haven't seen that "t" cross section before. You'll love those tires. Last time I was at the track with mine, I cut .12 off of my 60' without a hint of traction loss. Rest assured, I'm working on the too much traction problem though.

Thanks. I can't wait to get the new clutch in/broken in and get these tires on. Then it's e85 time :)

Ok got the clutch in and broken in. Got the drag radials on. Those hook so well. Got the GS ebcs installed in 3 port mode. Tuning boost then start with e85 this weekend.

How much power are you looking at once you crank up the boost? What can the injectors handle? I think you have the stockers based on your signature but am not too well versed in the Mazda speed arena.

Well stock turbo and with e85 I should be running about 21psi tapering to 19ish at redline. This is a direct injection motor and dont have any aftermarket injectors. We are testing out 5th and 6th injectors that are installed in the cold pipe. But with meth there is one guy at 710whp and plenty of 500whp on stock injectors. But we really need aftermarket injectors.

To answer your question, with 21psi tapering to 19psi, with 3gals of e85, and about 23° of timing I'm looking at around 330-340whp and 400-420wtq

Well to update this thread, I finished my e85 tune. Running 21psi tapering to 16ish by 6500, 22° of timing. Car hauls ass. Peak tq is around 4100 (why idk usually it's around 3200) peak power is around 5300 which is prefect for my powerband.

It's time for a new turbo as mine has 62k miles and has been smoking for the past 15-20k miles. I got a used turbo and had my friend that ported the head and intake mani rebuild it and is going to port the back half and add a shim or two to the wastegate so I can hold more boost to redline. :)

:popcorn:

What were the official HP and TQ numbers?

I have not dyno'd it but ppl with less mods and 3 gals of e85 put down between 340 and 350whp and 380-410wtq. So I'm somewhere right in there.

How do you know where the peak hp and tq are without dynoing it?

What he said

Because RACECAR

That build looks sic dude. I have the same injector issues as you do since the cobalt ss uses a 2.0 DI motor. I'm not sure how your HPFP works but ours is a cam driven unit. We currently have 2 options, a new set of cams with a different fuel pump gear to turn the pump faster, or a 5th injector in the intake manifold. Our EVAP system uses a port right in the middle of the intake mani directly behind the throttle body. Its perfect for putting a 60lb injector in. For me, it would allow me to run straight E85 instead of having to mix it. I'm not sure how your car responds to E85 but mine will demand about 2300psi of rail pressure from 3000-6000rpm (on my e85/91 mix tune) and the car will only be able to provide about 1000psi rail pressure or less until like 4500rpm. I can't get enough fuel in the cylinders. Having the extra injector would allow me to get enough fuel in there based on boost levels. Just cruising around, I would run on the DI only, then if I needed the extra go juice, the 5th injector would get me there. There are a bunch of cobalt guys trying to do a dyno day this summer, I'll let you know when it is so you can get a run on the rollers, I think they are talking like $50 for 3 pulls on it but I don't have all the details as of yet.

I'm not sure what tuning software he is using (I'm sure he said earlier in the thread) but most will show peak airflow numbers, That is what I usually use as the guess for peak power at a given RPM. When I tune for my E85/91 mix tune it I get ALOT of airflow from like 3000-5000 RPM, my torque band looks like an LS block V8.

I don't see how you can get peak hp and tq numbers from airflow data. I didn't tune my Cobra, Steve at Powertrain Dynamics did, but I know that when my buddy (Ron's Friend on here) did his twin turbo GTO we took it to GTR to run it on their dyno to get the power numbers.

Ohhh I see what your saying now I totally missed the point you were making before, my bad... no, you can't determine peak numbers based on datalogs.... you can get a pretty good idea of where you car will make the power though. Example, when my car makes 'x' lbs/min of ve airflow at 'y' rpm, that RPM should yield the peak point in the powerband. as far as peak numbers, you can guess based on acceleration at a given weight but that is a total shot in the dark really. I totally missed what you were saying before lol, my bad.

Have you dyno'd your car to validate that?

Yea, for my car the datalogged airflow is almost a mirror to the curve of peak torque. I will try and find my data sheets to post up. I have the dyno runs on my other computer along with my datalog info

That'd would be cool to see. So max tq happened at max airflow. What about max hp?

I am gonna have to look at my logs. I dont want to shove my foot further in my mouth lol... I know that peak VE airflow (Volumetric Effeciency) is where you will hit your peak torque. But I don't know where the peak hp comes in on the logs. But I don't really care about HP since Torque is what moves you haha... what is that one saying: Oversteer is the back hitting the wall, unersteer is the front hitting the wall, torque is how far the wall moves when you hit it and HP is how far you along the wall... or something like that?

I'm not sure if these pictures will work since they are off another site. They ar kinda chopped and messed up but they kinda show what I'm talking about

Here is a picture of a log. Ok so in the second row down the white line is the VE airflow. In a 3rd gear pull @4400rpm the airflow is at 27.00 lbs/min. On this picture I wasn't looking for a VE shot but I was showing the fuel rail pressure drop.


In this picture you can see that the VE airflow is at 30.25lbs/min. If you look at the graph you can see the line kinda peaks between 4600-5000rpm. It's hard to see, sorry about that, and my injector pump had to catch up before the engine would make real power. But that is more or less fixed now.


And here is an old dyno sheet with a horrible slipping clutch and the wheels were losing traction on the dyno, just a shitty run but its all i have access to right now... sorry about the huuuge weird spot. It is on 91 octane so it isn't exaclty a proper analog for the comparison I'm trying to make.


That dyno is on a straight 91 octane tune, and the log is on an E85/91 50/50 mix tune, I couldn't find a picture of the log that went with this dyno run soooo the logs will show the airflow a little later, this was pretty early on in my tuning and I was still having pretty bad fuelling issues. hopefully it kinda answer your questions more than it confuses everyone

I use virtual dyno.

Sweet yeah let me know man.

Yes we have a HPFP that is driven by the exhaust cam. Our release valve opens at around 1950psi, ptp has a RV that holds to just under 2150psi. We have fuel pump internals that get us to 2k psi no problem but thats it.

I wonder if a new exhaust cam with bigger HPFP lobes would work for us.

What's virtual dyno?

It's a program someone made. You datalog your car. 4th gear start at around 2500 and takr it to redline. Just like a dyno pull. Load the log in VD and enter your car weight, driver/passengers weight, and tire size. And it gives you your estimated numbers.

The program has a bunch of cars main stats I.E. stock tire size, weight, and gear ratio.

http://www.mazdaspeedforums.org/foru...al-dyno-94798/

Have you scaled your car to know it's exact weight?

No. I've taken stuff out and have a bunch of shit in the hatch. Tool kit, small sub and amp, oil, coolant, baseball bag, a chair, a clutch with flywheel, and some other little shit. Hahaha

Any idea how accurate the virtual dyno is?

It's suppost to be really accurate and some ppl have found it to be +- 5hp and tq. But just like any dyno it varies.

Are you going to dyno your car to find out what the real numbers are? It'd be cool to actually see.

At some point, yeah but I'm not in a hurry.

So i got my manifold in on Friday

Wow some of those welds look like dog shit. Maybe just the angle? Or it was used and repaired by someone. Otherwise its a nice manifold.

I believe someone added the EWG on there as the welds are horrible on there. And it probably cracked so they repaired it. But it is coated. Don't know with what tho.

Btw I'm not planing on using the EWG with the stock turbo as it won't net me anything but more money lol

SHITS WEAK lol Looks good Josh. Well those welds don't but everything else looks good.

Hahaha thanks Jerry. As long as those welds hold I'm ok with it. Your vette seems to be treating you well.