Protege Build thread 2015 (Tons of pics!)

[Maxx Mazda]

With the cooling system finished, I could send the exhaust out for ceramic coating. First, the manifold was planed flat to remove any warp and ensure a good seal.



While the exhaust was out at Top Gun coatings getting a nice coat of titanium ceramic, I turned my attention to the turbo. It received a full rebuild. The turbine shaft was polished to a mirror shine, and the center section was given a shot of ceramic.







A few days later, I got the parts back from Top Gun. The titanium ceramic looks great, and should help to keep the heat down under the hood without needing to wrap the exhaust.

[Maxx Mazda]

With the turbine housing back, I could reassemble and clock the turbo with all new gaskets:





With what felt like some mad tetris skills, I got all the components in place, mounted up, and torqued to spec.







The turbo just clears the block. I doubt its possible to go any bigger than this monstrosity!



Some shots of the bottom end

[TomcoPDR]

Tasty.

[Maxx Mazda]

As you'll see later, I actually ended up swapping out this 45* fitting on the turbo oil feed for a 90*. But, pics of it installed anyways, along with some other misc. engine accessories fitted.







As I got to work on the oil drain line, it's short length combined with how low the turbo sits compared to the drain posed a problem. Obviously, downhill flow was paramount, and while this was the first iteration, I ended up changing it as well later on.





Used a couple brackets to keep the ignition wires neat and tidy and away from the hot exhaust:





The intake piping was finished off now that the turbo was installed.

[Maxx Mazda]

All vacuum lines were replaced with high temp Turbosmart silicone lines. They are thick-walled and guaranteed not to collapse or balloon under high boost or vacuum conditions.









Next task was to figure out some sort of coolant overflow. I found an aluminum can down at Mopac, but the mounting bracket it came with was super sketchy. Drilled and tapped for some studs, epoxied them in and used some jam nuts for good measure:



With that taken care of, I measured out what I'd need for a bracket, and fabbed one up out of some aluminum stock.











With the bracket completed, it mounted into a stock mount on the frame rail:

[Maxx Mazda]

Only the best fluids for this build. I wasn't sure if I'd have enough of the Ate SuperBlue, so I picked up a can of Wilwood Hi-Temp racing just in case. The SuperBlue has been outlawed in Canada and is impossible to find.



I know there is a lot of literature out there on running an oil restrictor with a journal bearing turbo. In my specific application, because i'm taking oil directly off the filter outlet, and it's being regulated externally, I MUST USE ONE. Without it, the turbo ends up seeing upwards of 85-100psi oil pressure. I didn't like the Garrett restrictor I was running before, it was brass, stuck up way too far, and looked like shit. Since I was going to switch the 45* oil feed fitting for a 90* as mentioned earlier, inspiration struck. I decided to mount the restrictor directly INTO the fitting. It will allow me to easily swap it out for various sizes if need be, and it'll be completely hidden. Here is the 1/8" NPT hex plug that I drilled out to match the Garrett restrictor. Held beside the restrictor for comparison.





I grabbed a new 90* -4AN to 1/4" NPT fitting, and drilled and tapped the bottom end to accept the restrictor plug:







With the plug installed with some Loctite for good measure, it looks great, and yet nobody will ever see it:

[Maxx Mazda]

With the turbo oil feed taken care of, I decided to see what I could do with the drain side. I wasn't totally happy with the first one I came up with, and this build is about every little detail. "Good enough" isn't in my vocabulary.

Rather than the two 90* fittings and the straight drop out of the turbo, I made it a lot more free-flowing by installing a 45* onto the turbo, and going with a 90* and a straight fitting for the line.





Comparison pic of the old (bottom) vs new (top.) You can see how much better it's going to work.

[never]

Looks good!

[Twin_Cam_Turbo]

Spotted you wheel spinning your way up Country Hills just a short while ago

[Maxx Mazda]

This quote is hidden because you are ignoring this member. Show Quote

Spotted you wheel spinning your way up Country Hills just a short while ago

That was you?! Haha thanks for the game of tag! Damn thing can’t hook up. That was only 15psi of boost too, it loves the cold air. The tires obviously don’t.

Your tires are sticky as fuck I had to duck out from behind you, I was getting sandblasted.

Edit: your car sounds amazing in that underpass! Borla? My dad had the Corsa Indy’s on his C5 and they sounded close but not as rumbly.

[diamondedge]

Twin_Cam and I were just at Top Gear...finally got to see this beauty rolling. I was in the blue WRX wagon waiting to turn out and then I saw you drive past Maxx.

[Twin_Cam_Turbo]

This quote is hidden because you are ignoring this member. Show Quote

That was you?! Haha thanks for the game of tag! Damn thing can’t hook up. That was only 15psi of boost too, it loves the cold air. The tires obviously don’t.

Your tires are sticky as fuck I had to duck out from behind you, I was getting sandblasted.

Edit: your car sounds amazing in that underpass! Borla? My dad had the Corsa Indy’s on his C5 and they sounded close but not as rumbly.

Haha yes I wasn’t even really paying attention to behind me and I usually love a little squirt under the overpass but the second I saw the side of your car beside me I knew it was you right away. When you were in front of me I short shifted and fully was expecting you to walk away from me quickly haha. My tires are 140TW and they pick up a ton of road junk that’s for sure, didn’t know it was that bad behind me though haha.

I have SLP long tubes with a B&B PRT exhaust, it’s fairly liveable cruising but quite loud when you are on it.

[Maxx Mazda]

This quote is hidden because you are ignoring this member. Show Quote

Twin_Cam and I were just at Top Gear...finally got to see this beauty rolling. I was in the blue WRX wagon waiting to turn out and then I saw you drive past Maxx.

I slowed down to have a better look at your car! Ir is clean!!

- - - Updated - - -

This quote is hidden because you are ignoring this member. Show Quote

Haha yes I wasn’t even really paying attention to behind me and I usually love a little squirt under the overpass but the second I saw the side of your car beside me I knew it was you right away. When you were in front of me I short shifted and fully was expecting you to walk away from me quickly haha. My tires are 140TW and they pick up a ton of road junk that’s for sure, didn’t know it was that bad behind me though haha.

I have SLP long tubes with a B&B PRT exhaust, it’s fairly liveable cruising but quite loud when you are on it.

I noticed with my new downpipe and full 3.1” it’s loud but not overly so. Did you happen to hear what it sounded like? I think you had your windows up most of the time. I get a bit of drone at super low RPM but above that it just wails. I’m gonna have so many tickets this year haha

I don’t usually mess around on the street, but it’s too hard to resist in this thing. So much fun.