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Thread: FD3S build

  1. #1
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    Default FD3S build

    A bit overdue at this point as the car is more or less complete. I was compiling pictures from my past 3 phones and figured I'd post up some of the stuff I found.

    This post will contain the background of the car I guess. I'll keep working to update when I complete other projects on the car.

    1994 RX7 R2 -

    The car still in Japan. Basically stock at this point. Only mods I can remember were wheels, Endless brake pads, and Mazdaspeed type A springs/struts.




    Got a few track days in at Race City that year. I think at this point I had installed a cat delete, chipped ECU, and a modified airbox.








    Towards the end of the year, I decided to pull the engine apart as there was a lot more smoke than I would have liked for a stock engine.




    But unfortunately, the engine internals had nearly 100 000km on them. While many parts were technically within spec, I didn't feel good about putting an engine back together with the kind of step wear and housing markings that were present. I found a good deal on a streetported engine in Sask and slapped it in with the absolute cheapest turbo kit I could piece together (university student at the time)

    The colour scheme seemed like a good idea when I thought it up


    Single turbo harness conversion

    Custom 3" exhaust courtesy of Calgary Autoworks


    I also installed a Power FC around this time. 100% street tune at this point, running 8psi iirc. I got to do a couple more track days and then the mystery Sask engine succumbed to corrosion.



    HKS T04Z Bridgeport FD3S

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    Between buying the car and that point, I was lucky enough to have the opportunity to learn from some very knowledgeable rotary people. A lot of learning, research, disassembly and study of multiple engines guided my next move for the car.

    Brand new OEM 13B




    back in the car with the old turbo kit



    I also picked up some used Aragosta coilovers



    I think this was 2011? I got to enjoy the last 2 track days ever at Race City with that setup. The car put down 296whp @ 10psi at Toma's shop. I took it drag racing one evening but I'm terrible at that. IIRC the car went 13.7 @ 109


    So at that point, race city closed, I was bored with the power, and the turbo kit was starting to shit the bed. I figured I'd start collecting parts and if I'm lucky, I'll have a new track by the time I'm done with the build.
    HKS T04Z Bridgeport FD3S

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    Subscribed

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    I think the first thing I did was take the engine out and rip it apart. Felt like a bit of a waste as the engine had about 1100km on it at that point but hey had to be done. After studying the port geometry and timing of the original engine and looking at available templates, I wasn't really thrilled about using any of them. Fortunately, I was able to convince a good friend who knows these engines incredibly well to give me a couple hours of his time.

    We ended up going with a bridgeport that was sized to match the turbo setup I had purchased:



    I purchased all new seals for the engine including NOS OEM 3 piece seals. Very hard to come by, but fortunately not very popular here in NA. It was a pretty nervewracking build but I had a good feeling when it was done.

    Built a new downpipe to match up with the existing exhaust from CAW


    In place with the HKS wastegate

    Mostly together. There was of course a lot of little things going on that I have forgotten to post or don't have pictures of.


    First start:


    Drove the car for a couple days then went straight to the dyno


    That was a very long and trying process. By that point, the build had taken over 2 years iirc. Shit parts, lying manufacturers and suppliers, some risks I had taken knowingly or not all bit me on the ass when it was dyno time. Thankfully my friend had the patience to not kick my car out every time it had an issue. Over the next while I changed injector setup, wiring harness, boost controllers, ignition coils and setup, coolant fittings, and a ton of other garbage I've since forgotten about.

    Custom Rywire harness


    The sorting out process took so long that I got bored


    After I got the car back, I got straight to the bodywork. I found this sick DIY guide for over fenders so it was a breeze lol.


    TIG brazed:

    New wheels showed up


    APR NACA duct


    Rest of the panels fitted


    One of countless weight reduction measures

    Off to Stampede Collision for paint



    Lawrence and the guys at Stampede worked hard on the car and I was able to get it back and reassemble it in time to drive the car for 2 days before the snow hit.
    Last edited by 962 kid; 09-25-2016 at 09:35 PM.
    HKS T04Z Bridgeport FD3S

  5. #5
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    3 piece OEM seals? Those will never work, you need 3mm, ceramic seals, utilizing the latest carbon nano-tube technology, hardened with unobtanium and fired in the heart of Mt Doom.

    Love your FD! Nice to see someone taking the time to do things right.
    Originally posted by Arash Boodagh
    Before I start pwning all the members with my findings.
    Originally posted by Arash Boodagh
    Plus, is it true you can feed a pig elephant dong and it will still grow and build meat?
    Originally posted by Toma
    rx7_turbfoags best friend
    Toma the homophobe?

  6. #6
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    Had Mike Boldt Photo take a couple shots before I had to put it away for winter







    Over winter I decided to make the car a bit more of a weekend driver. The bridgeport is awesome but it's a bit of a chore to drive in traffic.

    My own design/fab swirlpot/AST. I'm pretty happy with this piece as it's a lot more than just an aluminum tank with some fittings on it. There are some critical design points taken from the OEM piece combined with an extra steam vent. You can also see my titanium intake pipe in progress.


    New shifter


    Titanium cold side pipe in progress. You can also see the titanium battery tray and lithium ion battery here.


    HKS elbow modification for 90mm piping and SARD BOV


    Made some carbon kevlar fender liners


    Hot side pipe



    Car Shop Glow LED combo lights
    HKS T04Z Bridgeport FD3S

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    Engine bay done. You can also see the coolant overflow I made in the back corner of the engine bay.


    Front end off to make the front undertray and oilcooler/radiator ducting


    Oil cooler duct templates. These were a huge PITA


    Next I pulled the dash and gutted most of the HVAC. Blower motor remains for defrost purposes. I was also able to buy one of the last OEM evaporator core deletes made. I don't really know why that part exists, but hey I'll take it.


    About this time I also installed some carbon door panels and sound deadening/carpeting in the back of the car. Gotta keep it somewhat civil.

    I also sent the Aragostas back to the motherland for rebuilding/custom valving. They came back with a 14K/12K setup. Bonus shot of Koseki-san of Scoot Sports showing me his custom FD coilovers:


    After that, I drove the car for the whole spring/summer. It was great, I put around 5000km on the car. Won a couple awards at car shows, made some improvements over the year. Cruised with some friends:





    Went drag racing. Ran a best of 11.7@128MPH. Again, I'm no drag racer. Best time was set with boost at 1.25 bar with a max of 1.4. Straight pump gas, no water meth.


    And finally, made it back out to the road course
    HKS T04Z Bridgeport FD3S

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    So I guess that brings us to the end of last year. After the drag racing and lapping day, I decided to re-make my exhaust. Too loud with the screamer pipe haha.

    Good thing I did. Found this in my newly prolapsed flex pipe


    downpipe in progress





    Tail section in progress. Midpipe muffler is a giant magnaflow, tailpipe muffler is a custom Reinhard titanium canister. I actually have pictures somewhere of the guy in Japan welding it up.


    Clearance was pretty tight with the 90mm piping and good ground clearance, so I had to modify a rear trans tunnel brace.



    done minus hangers


    after another track day:


    In the last pic you can see one of the pink suspension arms I purchased over winter. Made by SuperNow, I bought these to help with wheel hop and rear end predictability on corner exit.


    I also had fuel sloshing issues the year prior so I decided to redo my fuel pump setup. Out with the old aeromotive 340, in with the OEM SL65 fuel pump.



    I also installed a Holley Hydramat at this time. It's pretty miraculous stuff, but I had to try it for myself after playing with it at PRI. Seems to be doing the trick.


    I installed this as well. It's a dual needle manifold pressure gauge from a twin engine aircraft. I use it to monitor pressure drops across restrictions - right now its hooked up across the throttle body. I built a small bracket in the engine bay to allow me to change sources quickly for testing different things.


    titanium wheel nuts
    Last edited by 962 kid; 09-25-2016 at 09:22 PM.
    HKS T04Z Bridgeport FD3S

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    Had a bit of a break between track days so I installed a ProEFI 128 purchased from blackbirdts.com Car was up and running that weekend in time for the illmotion show and shine.




    Progress kinda slows at this point. I've simply been too busy to get the car dyno ready and complete the calibration on it, however I do want to have it done for the Oct 10 track day.

    Over winter I'll likely keep plugging away at shit. I bought these calipers a couple years ago, I haven't decided if I want to make them fit or just buy something.


    The wiring in the car is also starting to show its age. Most of the OEM wiring is unused at this point anyways so I'm thinking that over winter I'll rewire the car with a PDM setup
    click for larger version
    » Click image for larger version

    I also bought this from Scoot Sports. I don't think I'll be using it in the next couple of years as I'm happy with the current setup... but one day haha


    Bonus shot with my friend's FC


    I think that's about all the pictures I have. I'll keep updating this thread when I do stuff, but I'm not expecting a ton of progress for a couple months haha.
    HKS T04Z Bridgeport FD3S

  10. #10
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    awesome car!
    Looking for a new VW? How about a used vehicle? We are Central Albertas #1 source for pre-owned vehicles
    I will beat any deal on a new VW for beyonders

    Gary Moe Volkswagen/Gary Moe Used Car Superstore!

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  12. #12
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    Damn! Very nice build!
    I also like you buddy's FC a lot

    1994 Mustang - SBF swap in progress

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    .
    Last edited by 01RedDX; 09-23-2020 at 02:22 PM.

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  15. #15
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    Wow, well done
    CNC Guru*

    * This is not an advertisement or porn..... but pm me lol

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    Favorite FD build I know of! Fastest driver/car combo too

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    Wicked build thread, thanks for sharing

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    This is awesome!
    ...

  19. #19
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    Thanks for the kind word guys


    Originally posted by rx7_turbo2
    3 piece OEM seals? Those will never work, you need 3mm, ceramic seals, utilizing the latest carbon nano-tube technology, hardened with unobtanium and fired in the heart of Mt Doom.

    Love your FD! Nice to see someone taking the time to do things right.
    Thanks! Haha yeah the 3 piece OE seal choice has raised some eyebrows for sure. Works well for myself and some other local high power 13bs though
    HKS T04Z Bridgeport FD3S

  20. #20
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    Pics do not do this thing any justice...great build man!!...
    ...@therealarifjina...

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