2013 Mazda5 BT build thread

[azarashi]

Subbing to see the video once its posted. Next task is to convert to AWD right?

[Easter Bunny]

Next task is to get an LSD and upgrade it to two wheel drive.

[UnknownSuperhero]

This just keeps getting better and better. Looks great!

Curious how them motor mounts are going to hold up.

[ztnedman1]

Originally Posted by sac02 The engine is not built, and I don't have LSD (at the moment), so I'm keeping the power levels reasonable. Aiming for 250-260 whp. Not huge numbers, but a nice bump from the stock 157bhp. I know this may disappoint some people who were looking forward to a 450whp monster, but my goal is just to take it from "gutless" to "quick", and maintain driveability and reliability. 8-10psi, and 93 octane (no e85).

Sounds perfect for that car. Really hope it turns out well.

[mituc]

Originally Posted by sac02 I was creating an imgur album this morning, and realized I didn't include a completed shot of the engine bay.

You could really use a heatshield for the exhaust manifold... All those hoses and the cowl will suffer pretty bad from the heat coming up from it.

[sac02]

Originally Posted by mituc You could really use a heatshield for the exhaust manifold... All those hoses and the cowl will suffer pretty bad from the heat coming up from it.

Agreed, I had all the exhaust parts ceramic coated and thought it might be enough to keep temps down, but I'm adding a heatshield. I just found one locally the other day to buy actually.

[SpencerC]

Did anyone else realize that Mazda of Autobarn did this a few years back? I had no clue!

2010 One Lap of America: The Rise of the Giant-Killers at Mid-America

https://www.flickr.com/photos/bradsillars/4851476054/

Anyway, A little inspiration for you.

[mituc]

Originally Posted by Spencer@CorkSport Did anyone else realize that Mazda of Autobarn did this a few years back? I had no clue!

Yes, but it was a 2.3DISI-T transplant, not a turboed 2.5.

[Pu Manchu]

Nice job on being world-famous @sac02;

Originally Posted by mituc Yes, but it was a 2.3DISI-T transplant, not a turboed 2.5.

welcome to corksport research.

[SofaKingAwesome]

Originally Posted by Pu Manchu welcome to corksport research.

[galens47]

Fantastic build and thread! I look forward to more. I keep looking at your user name and hoping you are here in NorCal, I'd come and help anytime just to learn.

Grats!!!!

G


Sent from Uranus

[sac02]

Attached is the cost report for the turbo project. The grand total was about $4750.

Actual parts cost about $4670. By far the largest potential savings is to use a stock ms3 K04 turbo: at a used price of ~$300 it would chop $1k off of the budget.

I paid a bit under $100 for shipping, bought about $50 in required tools, and another $100 worth of tools that I wanted but didn't need (just needed an excuse). I don't count tools as part of the project cost, because I consider them an investment since I will keep them forever and use them for future projects as well.

Also, if you open the file, you can see at the bottom of the page that my total cost, all-inclusive for the life of the vehicle, is about $26k. (maintenance items like oil changes not included)

[SofaKingAwesome]

Great info man, now lets see it shred some tires!

[SpencerC]

I love the amount of organization put into that list. Nice details!

[sac02]

Keeping with my reputation for professional work, here is my latest addition: AEM Failsafe AFR/boost gauage.




Give me a break, it's working, and I have to be up for work in under 6 hours...

[Pu Manchu]

i've heard rumors of this mutant being spotted in the wild, but there's still no videos

[derek13p]

Originally Posted by Pu Manchu i've heard rumors of this mutant being spotted in the wild, but there's still no videos

It exists! I saw it in person at matts shop. Actually sounds very mzr.

[my2k13speed3]

Awesome build can't wait to see some videos of this thing... I see you have a scissor lift, which brand is it? What did it cost and how do you like it?

[WA_MS6]

Come on @sac02; WE NEEDZ UPDATE AND VIDEO!

[Easter Bunny]

Originally Posted by derek13p It exists! I saw it in person at matts shop. Actually sounds very mzr.

It's all the exhaust manifold.

[Badinfluence]

Originally Posted by sac02 Keeping with my reputation for professional work, here is my latest addition: AEM Failsafe AFR/boost gauage. Give me a break, it's working, and I have to be up for work in under 6 hours...

Good pick! What are you using for the "failsafe" wire or are you? I attached mine to a MAC valve that went directly to the WG and sucked pressure from the BOV so they both released pressure at the same time. Port 1 from Turbo nipple, Port 2 (Normally closed or un-energized flow to BOV) Port 3 to WG bypass

The Methanol Failsafe is a great product too. The calibration is a bit of a pain in the ass though for both of them.

Are you considering WMI?

AEM makes awesome "piggyback" / standalone computers if you want added control with or without using the stock ECU parameters. It also gives you logging. I have an RX8S2 project I am working on that I can't use an AP for, so I was looking at the AEM piggyback to precisely control boost and AuX fueling and backup fueling just in case, as well as log from my Failsafe Gauges. I ended up "crafting" my own out of an Arduino to save 700 bucks and give me more logging space.

The only thing I will tell you about the AEM WMI failsafe is the PTC fittings SUCK ASS. Replace them first thing or you will leak. I replaced mine with Stainless Steel compression fittings and solid tubing from the pump to the nozzle and I got more consistent Atomization and pressure because I picked the ID of the tube well.

[shnouz]

Originally Posted by my2k13speed3 Awesome build can't wait to see some videos of this thing... I see you have a scissor lift, which brand is it? What did it cost and how do you like it?

Post #17

[sac02]

Originally Posted by derek13p It exists! I saw it in person at matts shop. Actually sounds very mzr.

Well, it is an MZR, so...

Originally Posted by Pu Manchu i've heard rumors of this mutant being spotted in the wild, but there's still no videos

I drove past Steve last week and had to hang my head in shame at the lack of exhaust...

But I finally got it to the muffler shop last Saturday, woohoo! It no longer sounds like a shitty 4 cylinder with no muffler, it sounds like... nothing. Just stock, you'd never know.

Originally Posted by WA_MS6 Come on @sac02; WE NEEDZ UPDATE AND VIDEO!

So I haven't taken any videos because there's not much to video - I'm not making any boost so it's not fast, the BOV isn't making any fun sounds, nothing. You really want a video of a stock mazda5, haha?

[sac02]

Originally Posted by Badinfluence Good pick! What are you using for the "failsafe" wire or are you? Are you considering WMI? AEM makes awesome "piggyback" / standalone computers if you want added control with or without using the stock ECU parameters.

Currently I'm not wiring up the "failsafe" wire, I'm just using it as a AFR/boost gauge. I might do it in the future, but I kind of doubt it.

No WMI.

The goal for this project (reliable, hands-off, DD) definitely doesn't warrant a standalone, same for the expanded capabilities of a piggyback compared to flash tuning - for this project there is just no need, all it would be is added cost/complexity.

[jrotaryb]

Great thread - keep it coming!

[WA_MS6]

Originally Posted by sac02 Well, it is an MZR, so... I drove past Steve last week and had to hang my head in shame at the lack of exhaust... But I finally got it to the muffler shop last Saturday, woohoo! It no longer sounds like a shitty 4 cylinder with no muffler, it sounds like... nothing. Just stock, you'd never know. So I haven't taken any videos because there's not much to video - I'm not making any boost so it's not fast, the BOV isn't making any fun sounds, nothing. You really want a video of a stock mazda5, haha?

I just more or less want to see the final product.

[sac02]

Random datapoint here, but whatever. I have to talk about something, since the tuning is going slowly...

I was looking at my datalog that I took this morning, then went back to some of my old logs out of curiosity.

Maximum MAF (g/s) values that I saw:

Stock: 138g/s
NA tuned: 153g/s
turbo, "as close to 0 boost as possible": 167g/s

"As close to 0 boost as possible" means wastegate fully open, and I see 1.06-1.07bar at ~4500rpm, and 1.01bar at redline.

[1cms1]

Turbo compressor wheel is still spinning though so it will increase airflow a small amount.

[sac02]

Yes, you can't funnel all that exhaust gas around the wheel and through a 1" hole without spinning it up somewhat, that's why I said "as close as possible" in quotes.

[Shampu]

Can't wait to see this shit.
Subbing for eminent shenanigans

[Badinfluence]

Originally Posted by sac02 Currently I'm not wiring up the "failsafe" wire, I'm just using it as a AFR/boost gauge. I might do it in the future, but I kind of doubt it. No WMI. The goal for this project (reliable, hands-off, DD) definitely doesn't warrant a standalone, same for the expanded capabilities of a piggyback compared to flash tuning - for this project there is just no need, all it would be is added cost/complexity.

Electronic Boost Controller forTurboChargedEngine - Arduino Forum

I found that when trying to come up with a precision boost controller that would control my amount of boost without much variability. If you change your mind, or your into that kind of project, it is pretty simple. I am a big fan of Boost off and Boost on. WG set for 0 or 3PSI and the solenoid pulls boost away from the WG so it "builds" instead of "bleeds." Gives you better resolution control to if you use the Intake Mani instead of the turbo port.

If you get your tune perfected this would control your transition. I wasn't sure what kind of Boost Controller your currently using if you are using one. This is a hell of a lot cheaper than a Tru-Boost. Instead of an Arduino I use this. http://punchthrough.com/bean/ (Completely wireless BlueTooth)

[Putin 2.3T]

I feel as though this needs a bump...

[MS309]

Any updates on this? pics, vids? how is it running so far?

[sac02]

It was a long-awaited day when the tuner decided he was happy with the MAF and MAP calibrations and gave me the OK to start adding boost. Went through a couple quick iterations of adding a bit of boost, then confirming everything OK (AFRs, KR, fuel, etc.). Currently sitting at the limit of the stock fuel injector duty cycle at ~4psi, waiting for a new file before installing the larger injectors.

4psi is neat, 10psi will be more fun.

And I have to take a moment to gloat - I feel like all the work I did from researching turbos and compressor maps and agonizing over which turbo, and spending more for smaller IC piping (instead of the de-facto 2.5" or 3"), and spending hours getting the piping and wiring correct - it has all been worth it to do this correctly. I have not had a single issue that I hear about with EVERY other DIY turbo install - no water leaks, no oil leaks, no boost leaks, no rattles from loose intercoolers or pipes, no wiring issues, no heat issues, no nothing.

It just runs and drives like an OEM install (and the throttle response is excellent, the turbo appears perfectly sized) - which was exactly the goal going into this project.

[BlackFlag]

This has to be one of my favorite build threads, Fo sho.

[sac02]

I bought a speed3 trans (and other stuff) for a good price.

2WD, bitches!!!

[sac02]

On a pallet and on its way to me...

[sac02]

So the ms3 trans arrived at the freight dock last week, going to pick it up on Tuesday probably.

In the meantime, I started working on the sound deadening this weekend. I bought materials almost a year ago and had it on my to-do list since forever... Just now getting around to it. :/ I really should have put more priority on getting this done sooner, it really bugs me how damn LOUD this car is (and not in a good engine or exhaust note loud kind of way).

I'm using 1/2lb MLV instead of the more common 1lb MLV in the interest of weight. It should still be a vast improvement. It will be about a 40-50lb weight penalty, but in this case, for this car (DD) it is worth it - this thing is just a loud, echo-y, road noise-y, tin can.

[sac02]

ms3 trans has arrived. I was at the freight company at 6:00am sharp when they opened, and I had the energy to lift the trans into the car by myself in the morning. At home, at night, after a stressful workday - no so much. Had to wheel the hoist over to get it out.

[Ferdball]

Bump for update.