AlanD Posted July 31, 2008 Share Posted July 31, 2008 Having had my heart broken by Jay and Trevor tempting me back with various pornographic EP's, I bit the bullet, put the Mazda up for sale and bought this:its a 4EFE powered 1996 Sportif, with only 144,000 miles on the clock, only broken in sure!My main reason wsa the condition of the shell and drivetrain, as I want to play around with turbo'ing the 4efe till it expires, then move on to eith the 4efTe or 54fe and maybe a supercharger.Stealth is the key here, hence the name 'anti slag' as she'll neither be a show slag, or have any bling to give away her trump card.Plus, how can anyone not say the 'Gay Blue' or 'Y front alloys' look anything other than camp! that and the lightweight aircon, ie keep fit window winders!I await mockery in good jest! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 Stage one involved acquiring the following from kind sources:forgot to mention I needed to score a manifold at this stage! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 Then some more bits arrived at the party!Fender Bars,GT HubGT Caliper (just need an opposite mate now lol)Polished RockerRad Cap 1.1barHKS Panel Filtersoon I hoped to pick up the mani, gt shocks and seats too, then i'd be even closer! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 another little goodie update,I acquired a few more toys thanks to the legends that are Ted and Wee John!First up, GT Turbo rear shocks, should help out the boat like handling, good condition, just need a clean ;)Cheers for meeting me with them Ted!Next up came this haul of cool stuff from Wee John, I called in with something for him and came away with:GT Turbo discs, to fit the bigger calipers and hubs.A GT Turbo fuel pump, to provide the extra juice ill need even at low boostAnd the brucie bonus! a lovely pot, Cheers John, and Ted, im that little closer to the goal courtesy of you both, and for that I SALUTE YOU! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 its deffo a very sharp learning curve.We knew for a fact that high boost is not an option due to the high compression, and the fact that the head gasket may show distaste to the new addition of even more pressure, so as long as you guys arnt gettin too excited about huge figures then we're on a winner.My aim is to extract dollops of low down boost, by adding large amounts of fuel and retarding the Ign timing, necessary traits to stop it pre igniting.What we dont know, is how the injectors are working in there, be it fast short pulses, or long drawn trickles. All we can do is suck it and see. Rumours from the states are that this conversion works, and will happily accept the boost, but we're taking no chances and will try to have every avenue covered before going higher than atmospheric lol!If it comes to it, a standalone ECU may well be called for, which im willing to try, as should the lump still expire, it'll still be there for the next lump.again at this point, cheers to the local NI starlet supercomputers, you know who you all are ;) Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 so far the spec stands at:1x4efe4x Glanza shocks with suspected 30mm lower springs2x sets of GT brakes & mounts1x Thermostat block from GT1x Manifold2x CT9 turbos 1x Cat pipe1x Oil filter block from Gt2x GT discs1x GT strut brace2x GT Seats1x Polished rocker cover1x Alloy core rad1x GT pump4x GT injectors1x GT sump1x HKS panel filter1x backup 4EFTE head for not if but when we push too hard4x Kosei 15" wheels with bridgestone tyres! Excellent!all in all we're VERY close to having everything together, it became apparant that we needed to drill 3 mount holes in the area where the oil filter mounts to the block, to hold the GT one. Best mod of the day? the seats! without doubt the singlemost confidence inspiring mod ive ever done. Back when I built the 82 I tossed the stock seats within two days for Sparco monza's, but this time Im keepin these ones, the photo speaks volumes.comparison of stock Sportif seat and GT seat. I wish! Sparco Crimsons... yummmmmmayyyyyyI really cant loose the Y fronts quick enough!!!Excellent Koseis!more pics later of all the gear laid out, thanks again to Jay, also as ever, Big BIG thanks to Trev, Ryan, Wee John, Ted, and Jay in random order for the very appreciated help with parts, you guys are Starbo saints! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 ***UPDATE 08/03/08***the V6 has sold and went to its new home today... meaning the garage is now clear! So, I set about cleaning itout in preparation, then went and picked up my friend Lloyd and began!The vehicle having sat for a week, started on the button cold and exposed its bedragled valve stem oil seals:Video would have been more appropriate to capture the whole back yard filling up!I wanted to start with a good clean canvas so out came the gunk, and off came 12 years of grease and sludge...leaving this:note how bare she is, no A/c to worry about, in fact not even electric windows to worry about! loads of space for a FMIC here!no hanging about, bonnet off and engine strip commences!Na mani and turbo mani... a straight swap! but not yet...battery, mani, airbox, radiator etc out.oodles of space hereLloyd setting about the cambeltLloyd is a legend, fuelled by free booze, he sets about doing what he does every day in work, only indoors and with a smile on his face!The extent of the dosed oil seals is aparent. Note the oil residue in 1 & 396 Sportif kitten spec hubs are found not to be compatible with GT discs and caliperssize matters???? these have neither the diameter or the girth!checking out the thermostat housing from GT vs sportif housingcams.... check!dizzy etc gone, nearly down into the head.Cam lobes look great given 140k miles...proof as to the quality of Jays parts. NA thermostat housing on top, Jays GT housing beneath. Straight swap.With that we called it a night. Lloyd needed his beauty sleep for work this mornin at 8am, and we nearly had to tear him away, the guys love for EP is undoubtable. Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 ...coming back in from another nights garage action, and a little further on too.We also took a twist on the styling front, its definately shocking, but doesnt effect the outside styling in the slightest, you'll just have to wait to see the end results, but trust me it'll be worth it!we discovered the 4efe has a different oil pickup pipe, that fouls the GT sump, so rather than change the pickup and risk not making a good seal on the new one, we ammended the 4efe sump with the 4efte fitting.here's the head getting bagged up ready to go to be chemically cleaned by Lloyd at his work. We're going to fit stronger GT valve springs, new valve stem oil seals, valves and a re-seat at the same time, in order to give it the best chance in life.poor 4efe sump bagged ready to be molested and re painted.the bottom 4efe end. Note the different pick up on it compared to a mushroom shape GT one.I hope to pick up the FMIC on tuesday night, so heres the Daihatsu Rad in comparison to stock (alloy cored) rad. Note the width difference to allow the piping for FMICLloyd and myself spent literally ages last night prepping the block surface to allow the best seal possible when it comes to fitting the head back together, we sanded for a good hour with wet and dry to clean the surface as best as we could. Credit to Leanne for sitting with a scalpel the whole time cleaning back the sump and block surfaces to allow the black silicone to make a good seal when we re fit.we're ordering a full head kit, and timing belt tomorrow, and hopefully you'll be looking at build pics soon! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 another night and more progress!The reason in retaining the oil pick up is that its not unknown for the replacement not to seal 100% upon refitting, and thus cause hideous oil starvation problems.Plus it retains as much 4efe as possible, which is a target with this project.Lloyd, James (Jamz3k from here), and Thomas, were my helping hands, and we didnt do bad given we only had an hour or two spare this night.Lloyd fabricated the oil feed for the turbo today, by cutting and welding the GT feed to the 4efe sump, due to the 4efe being deeper and allowing the oil feed to be retained, as it fouls the 4efte sump.*modified 4efe sump**close up of turbo feed masked due to enamel painting**4efte top 4efe bottom**4efte oil filter and feed adapter complete with seal - Thanks go to Jays Garage for seal!**fitted 4efte oil filter block and 4efte PAS pump*all the while, James was getting busy with the dremel buffing down the heavily pitted fuel rail.Thanks James!Results:We lacquered the rail after much polishing. Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 Cheers Ted! heres tonights addition- a rather large front mount Intercooler! Wee John revealed that the pistons are High compression items, and that they would need replaced with GT ones, or the Head pocketed, or to try a thicker gasket, about 1.2mm Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 well heres the update as promised.Thanks tonight go to...Wee John, for the very generous Speedvision 1.2mm metal head gasket...and robbo for providing prime entertainment, and Lloyd again for the clean up mission last night!heres a test fit.I spent a bit of time cleaning the engine bay out, as I want to maintain the car for a good few years, so made sure all the cracks and nooks and crannys were crud free:heres a bit of a 50/50 suspension tower is before, bulkhead is an after.well hello sailor! robbo struck wood, sorry metal!...at the sight of the highly polished thermostat housing.go lloyd!the sign serves as a threat to my vehicles not to missbehave or face the fitment of cast iron cold war era russian car parts.Turbo looking shiney!few close ups of thermostat getting polishedhopefully we should have the head back tomorrow, along with head kit, and timing belt etc... Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 for teh kitteh to work out well = not go bang on first outing lol!this should hopefully help though: Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 We made a bit of progress on the Saturday but we're pretty much tied now waiting for parts.Some further cleaning was done to the thermostat housing:Then we set about removing the stock fuel pump:Stock N/a pump has black cap, GT/Glanza pump has brown cap. Just out of interest note how discoloured the 'uk' fuel sock is vs. the JDM pump sock.the GT pump fitted (just a straight swap, no cutting etc.)Next I set about stripping unnecessary components from the car like trims, rear wiper motor etc:back half stripped:Then today Leanne & myself went shopping, but she did let me stray into halfords where I acquired this:I know its not that accurate, but Ill be having the car set up with Innovate Wideband, so this is just to keep a check on conditions whilst on track etc. Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 Thie following week saw a few more parts added to the collection, like a Stainless IC kit and stainless battery holder created by Ryan, The Apexi AFC arriving, and an Adjustable Panhard Rod, supplied by Trev!Lloyd has been flat out on the head this week, having had it skimmed, replacing the valve stem oil seals, and re seating the valves took place.first of all, Lloyd took the valve assembly apart, by clamping the valve with his valve extractor, and carefully removing the collets, and retainer.this left the empty valve area, with the exposed valve stem oil seal (which ill abbreviate to VSOS) you can see the old seal deep into the assembly.we laid the assembly out onto the table, as can be seen above, from left to right:ColletsValve SpringValveNew VSOS with spring in placeOld VSOS with spring removedValve sucker for grinding in the valve seats.New beside old. pretty apparent lol!closeup of assemblycam side ready for assemblycombustion side ready for assembly. note the hammer is used to tap the back end of assembly to ensure collets are seated correctly.first we cleaned up the seats and valves with hyper clean, then set about grinding in the valve seats with 2 sets of coarse paste, then one set of fine. We cleaned the seats and valves between each stage, then finally wet the valve and seat, put them in place, and tapped them apart to listen for a popping sound, sign that a good seal was being made to aid compression.slipping a VSOS over a valveinserting the assemblyplease do bear in mind to lubricate the VSOS before fitment, to give it the best chance in life.lubricate the valve stem as well to ensure as little friction on first fire up, as no oil will be up around there for a small durationvalve and VSOS in place, ready for spring and retainer to be fitted next.compress the assembly carefully with valve compressorsonce in place, seat the collets and remove compressors taking great care not to upset the assembly, we used grease to stick the collets in place.closeup of complete assemblyrepeat this process sixteen times for all the valves and your done. Take care to use the correct colour of VSOS for each side (inlet and exhaust)below is a picture of the head kit that we used to rebuild the head.inlet and exhaust gasket setrocker seals and gasketswhile we have the block clean and exposed, we are going to fit oil temp, and oil pressure senders, here is the bag of assorted senders and adapters to fit the 4efe blockand last of all the adjustable panhard rod, cheers Lloyd and Trevor!this week im off, so hopefully will be able to start about re-assembly, and fit the coilovers and handling gear that will arrive soon hopefully too! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 now for a big update where you will see her really taking shape!Even though it was Easter weekend, we got quite a bit done, and quite a bit acquired too, thanks again to Trevor, Jay, Lloyd, and Ryan too, not to mention my long suffering girlfriend Leanne who put up with my EP based delussions as ever.Leanne and me had a day away to Portrush, home of seaside induced partying and general good sport in N.I. hordes of people flock there over the easter break. Leanne lives in Co, Down, about 40 minutes from Jay, and thus hadnt been that far north in a long long time, so she enjoyed the craic too, takin in quite a bit of gambling on the slots, and came away with quite a few tickets, meanin quite a few prizes for her lol!She deserves a lot more, putting up with me and my bloody projects lol!Even though we were away up north, my friends Bubbles, Lloyd and Nigel all decided they wanted to work off a weekends excess by hammering into the starlet. I on the other hand, toured about the country getting bits and bobs together like:An HKS Super Drager back box, cheers Jay:Test fitting:mildy large aint the word!Jay also scored me a lot of little bits I was missing like:a new timing belt: ;)turbo intake pipe to airbox pipe:and a host of bolts, screws and nuts, plus a PAS pipe.thanks again matey!Whilst at Trevors taking photos of stock, he looked after me with some pipe couplers and this tastey little item!A lovely Greddy turbo timer and harness:I also got the chance to take a pic of some of the battery relocation kit Ryan_V is kindly fabricating. It has yet to be polished and is fresh from his TIG welder...im sure you'll agree its fabulous work for someone who is only starting out in training, he has a bright future ahead of him in custom part fabrication.Right.....Here goes....Ive been avoiding posting photos of this, but seeing as I cant really take any more photos in the bay without the whole engine getting in shot, I thought id reveal the new colour scheme...Leanne Lloyd and myself decided late one saturday night, well under the influence of alcohol, that no one puts pink in an engine bay, so why dont we? We thought it might be a bit two much so decided on a two tone scheme...And here it is!cleaned up fuel rail in place:I think it contrasts with the bay perfectly!The Ep struggling to swallow the FMIC:Whilst away yesterday, Lloyd fitted the Speedvision metal head gasket, fastened the head down (48nm +90 degrees), fitted the cams, all the associated gubbins, the rocker, the rocker gaskets, inlet manifold, exhaust manifold, turbo, actuator, the heap!Shes now all timed up, and just waiting on a solution to my front mount issues...anyhow heres some more of the rocker and inlet in progress.and before anyone reckons ive destroyed a good car, I have all the parts to replace the pink bits should I get bored, but dont forget the main Ethos of this project, its not about how fast, how powerful, or how jdm the car is, its 110% all about FUN! and its got it by the bucketload! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 RPM and Shift Light (over revving is the major issue, and if your not informed, how can you protect yourself? Bee*R Limiter to follow later)Oil Pressure Gauge and sender...Happy Days! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 VIDEO ADDED!Video Added Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 Update! 6-April-08C pillar brace, Cusco Rear brace, RSR Front Brace, and Cusco brake stopper now addedI Love It!Charge Pipes Lagged, Rad in and plumbed, Boost pipe lagged.Cat guttedOMEX Clubman Rev Limiter to fit, and Sparco harness yet to fit. Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 tonight saw the addition of a few goodies. The first coming courtesy of Lloyd, who having his new SSQV, relinquished his trusty Bailey Bov onto the kitten!Nigel made up a handy little mounting bracket in his typical Blue Peter style from a power steering pump bottle mount, and a piece of stainless tube cut in two! Go ahead McGuyver!When I got home, Taylor, the little boy next door came flying round with a big box containing my rallynuts delivery:an Omex Clubman Rev Limiter:and a black Sparco Harness. I intend to fit plain black harness pads to keep it a bit stealthier.Good news also came in the form that I 'should' have my coilovers by the weekend, and the engine control method has been settled upon for definate. N.I. Groundbreaking 4efe mayhem abounds! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 so close now you can smell it!cheers to Jay Trevor and Petey for hookin me up with these:+ the Koseis from Jay =bonnet just juuuust fits with a few tweeks, bonnet pins yet to be fitted:ps car is a foot off the ground on axle stands!heat exits here ^^^ lolstay tuned for a serious dose of modification on saturday, its well worth checking back in for ;) Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 saturday was a hoot lol!we learnt huge amounts, mostly with afr and timing.Boost is generated from virtually nowt, and yes, the stock ecu cannot deal with it.Strangely the little ecu did a stirling job of fuel, with it not running dangerously lean till the point where positive boost came in. Chris was down from early in the day preparing it for stage two: management!we are near ready to go to the next step in fitting the piggy back, the stand alone injector loom is now in, and ready to go, all we need is a pulse back to the piggy and lift off should be imminant!we need a good CT9 as my current one has been sat so long the seals are gone. otherwise she is excellent! handling is go kart like, and stiff as a board, so so hard to believe she isnt the wallow-mallow that was the sportif stock spec. Im about to set up a standing order with the dentist for filling replacements!Im really pleased with the super drager and exhaust system, pardon the pun but she purrs like a kitten and is probably the quietest aftermarket exhaust system ive ever heard! (in retrospect this was a brash statement!) Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 here goes!'mischief'!is it going in or is it coming out?!toys gathering up...Figured theyd be thirsty!both bases coveredkeeping it in check.tried and trusted!but can I do the double?again its trd!how many on here have the full hat-trick of TRD?How I love being back! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 On the first run, I learned that with the High comp pistons, and even though I decompressed with the head gasket, that the rings wouldnt take much boost and quickly began to blow over, so the block has been out, a new one sourced, compression tested and fitted, this time running a GT gasket instead of the speedvision unit.Im going straight to TD04, running an RX7 intercooler frontmounted to try and keep lag down, as the smaller RX unit is more than capable of efficiently chilling the charge, and yet not take huge volumes of air to pressurise.The secondary injector loom is still wired, and the 'mi16' special ecu will be re-employed to control fuel and timing again. Im aiming for a meagre 0.8 bar, and can see no reason in it not working with Chris' very capable tune.The car has become a bit of a slag, but that was more accidental than anything. The more I poked at the car, the more the interior disgusted me, as it was all milldew in the back, as it was laid up for ages, I intended to replace it with an ep91 glanza V interior, but as yet one has to turn up for breaking!when the boot is shut the only visual give away is the C pillar brace, and the 'kitten inside' decal!I can assure you the car as a whole, looks totally crap, and I guarantee you if you saw it on the road youd think 'ricer in an NA, being a wanna-be' The silly-big Super drager, and the fact its sat on its arse further compounds that notion. The car has been tastefully modified by having the crap beaten out of the drivers door, and a few tastey 'scabs' around the car in general. The plan is to run this car for a bit, develop the engine, blow the smoke clean out of it, have a lot of fun, then buy a fantastically mint 'karat' ep95 shell in some shockingly crap colour =)edit: ps, 5 doors for sure! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 id been very busy of late detailling cars, and hadnt made much progress, but spurred on by my great TGTT friends Jay Chris Trev Weejohn RyanV etc, she's nearing stage two completion!!!Behold the TD04!!!This is her, circa 1.30 am this morning, after a heavy nights action with Wee John and Ryan!Many thanks to Chris, who travelled down and fitted the clutch and flywheel, then fitted the gearbox, and also to Trevor for providing a starter motor!We have the TD04, mani and lines fitted, and the inlet mani all re plumbed with samco, plus the injector rail now in a fetching blue!We have found the RX7 FMIC to be an excellent but tight fit in the ep91 front bumper tray, the only downside being the 65mm outlets, i'll need a reducer to fit my 50mm charge air piping!The TD04 is meshed with fresh Gauze, and I cant stress how tight the fit is running the mild mani.Next step is to plumb the rad, mount it, then design and build a nice charge air route. Shame theres 2 hopes of having it ready for sunday, Bob hope and No hope lol!Again thanks to everyone who has donated their precious time of late to get me on track! Quote Link to post Share on other sites
AlanD Posted July 31, 2008 Author Share Posted July 31, 2008 oh yes....forgot to mention I now own my nemesis wheel - The Sparco Crimson! They have eluded me so long, now theres no chance we'll part company! Quote Link to post Share on other sites
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