I Can Genpu, You Can Too!

[Solarsurge]

Yeah. It was f’ing cold. I had to go back inside every 30 min because I couldn’t feel my fingers and toes. lol


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[kTaLgsTo]

Yup, that was my cam install... I kept a pot of tea on the stove so I could go inside, pour a cup, and hold it

[Solarsurge]

New Issues:

1. Corksport MZR BPV is not opening anymore with the BNR S4. The surge is real. Took BPV apart, wave Spring was intact, cleaned it out, relubed it, still nothing. Luke at Corksport asked me to RMA it so they can test it. Back to stock BPV for a bit. Hopefully we get the problem sorted out.

2. I haven’t dyno’d the car yet since the new turbo install, but I have hit the point the stock clutch cannot take the torque and is starting to slip. It isn’t burning yet, but this turbo definitely has pushed the clutch’s capabilities farther than they ever were built to go. I think it’s finally clutch/flywheel time. FML. I guess it’s probably a good time to do some other little things while I’m down there. Thank GOD there’s some warmer weather ahead...

BNR is also sending me a restrictor bolt for the new turbo and I am getting a new BaysonR front lip thanks to the dead possum in the highway that I hit at 70mph smashing the first one into about 50,000 pieces. Thankfully only the lip was damaged.

More to come...




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[Fstrnyou]

At what psi did you start having issues with BPV?

[Solarsurge]

As soon as I put in the BNR S4. It was fine with the K04 all the way up to 22psi. Now it won’t open at all, at any PSI. I’m running spring pressure and anything under 15psi I get spooldown, anything over 15psi I get surge. No recirc at all.


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[Fstrnyou]

Hmm. Strange.
Mine works fine...for now.

[Solarsurge]

We’ll find out tomorrow when I take it apart again to put in the new restrictor bolt and check all the hoses.

I just got my OEM wheels repaired and new Michelin Pilot Sport 3+ A/S tires today. Tomorrow she’s getting a much needed full detail, alignment check, a suspension inspection to find out the source of some squeaks (likely need new bushings), and some other little things.

My clutch is also on its last legs and my VVT seems to have just started to rattle today. Soooo, looks like I may be in for an expensive week. 🧐


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[Solarsurge]

That ass, tho...




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[Solarsurge]

Finally got around to replacing my front lip that was smashed by a dead possum on the highway at 70mph. Still need to plasti-dip it matte black to match the rest of the trim, but my baby’s whole again.




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[LKTV]

Love the build man! I would suggest the BmSpec wing extension to help balance out the front lip and rear. BmSpec makes some superr high qual stuff, looks dope too!

[EwMPS]

Originally Posted by LKTV Love the build man! I would suggest the BmSpec wing extension to help balance out the front lip and rear. BmSpec makes some superr high qual stuff, looks dope too!

Agree!
Great looking Genpu!

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[Solarsurge]

Update:

I've been having a blast with the new BNR S4 v2 setup. I took it to the track, did a few 1/4 mile pulls, and did some testing. It has some issues that need to a bit of ironing out mostly related to structural rigidity, fuel delivery, and air flow, but it's fast. The time has come for moar powah! I decided to finally bite the bullet and make some very significant upgrades in the coming weeks. I'm still in the planning stage because this has to be done right, but so far, here's what I've decided on and why:

Cobb XLE BPV (Corksport BPV flutters)
JBR Tru-3.5" WP Intake (Moar Airz and better fitment)
JMF v2 with Port Injection (Moar Airz & Moar Fuelz)
Meth Kit Install (Finally)
Corksport Injector Seals (Moar Sealz)
New Plugs (Moar Sparkz)
Full Race Turbo Manifold (Moar Fastz)
Damond Stage 3 OCC Setup (CS OCC isn't Cutting it)
Damond PCV Plate (For New OCC Setup)
cp-e PMM & TMM (Too much wheel hop)
New Suspension Bushings (OEM Bushings too soft)
And more!

There's also a few more surprises in store, so stay tuned!

[Fstrnyou]

MOAR GOES!!!!
LESS SLOWZ!!!!

[JakeMS3]

I was starting to wonder where you went man...

[Solarsurge]

[Solarsurge]

I have some exciting news! I procured another Speed3 today for an absolute steal with a complete, running long block I will be tearing down to use as a donor for an engine build! The body will go to a friend whose frame rusted from driving on salty roads in Chicago. It's about to get real!

[Solarsurge]

Picked up the donor car today! Everything looks excellent. The bottom end looks exactly like you'd expect with 190,000 miles on the pistons, but the cylinders are silky smooth, no scoring, no issues. The head was also machined recently and the exhaust valves were replaced. We also found some freebies in the car we weren't expecting, including a cam timing tool, new VVT, timing chain, tensioner, and some other surprises. HUGE win today, even though my back is on fire and I think I need a wheelchair. I cannot believe the dude was selling this car so cheaply! Tomorrow we get to rip the block out and prepare it for the machine shop. Stay tuned!

[Solarsurge]

Made some progress today. Whole front end disassembled and she's ready to come out, but we ran into a snag because the 190,000 mile old CV axles just will not come out. We need to get a CV puller to finish. Everything else is unhooked, though. She's only in by the engine mounts.

[kTaLgsTo]

You're making my back hurt

[Solarsurge]

Originally Posted by kTaLgsTo You're making my back hurt

You have no idea... I already threw my back out last week on a downpipe install. I will be doing the engine build from a wheelchair lol


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[Solarsurge]

Happy 4th of July! We spent the day tearing out the engine. Finally got those axles out of the transmission, yanked the motor, tore it all down. Everything went pretty smooth today except for when I slipped off a bolt and punched the helical gear on the crankshaft slicing all 4 knuckles on my hand. As crazy as it sounds, this baby has 190,000 miles on the clock and the clutch still has plenty of life, the flywheel has ZERO wear, axles might as well be brand new, and the entire inside of the motor was pristine. The pistons were a little worn, but the rods, crank, and all the bearings were in great shape. Block stripped and ready to get cleaned and machined at the shop. Stay tuned!

[Fstrnyou]

WTF helical gear are you talking about?

[Solarsurge]

Originally Posted by Fstrnyou WTF helical gear are you talking about?

The one the balance shaft connects to.



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[Fstrnyou]

Oh shit. My bad. I forgot about that gear for some odd reason.

Well...good luck with the build. No sense in putting all that stock crap back in. Time to go full forged build. 700hp. GO!

[Solarsurge]

Originally Posted by Fstrnyou Oh shit. My bad. I forgot about that gear for some odd reason. Well...good luck with the build. No sense in putting all that stock crap backbin. Time to go full forged build. 700hp. GO!

Hah. There's a slight ridge at the top of the cylinders. I think it's just carbon buildup, but I'm waiting for the shop's evaluation of the block before I decide what pistons to order. If I'm gonna need to overbore it, I may go 2.5L. Either way, it's gonna be Manley H+ Rods.

[Fstrnyou]

I was talked into boring mine to 88mm, but I guess the only way to know for sure is to measure an 87.5mm piston and see what your P2W would be. If it's more than 3.5-4 thou, then bore it out.

[Solarsurge]

So, I took my block to the machine shop and got amazing news. All 4 cylinders are perfectly round, crank pin and main journals literally have zero wear, everything is .000" from factory spec, main bearings literally look brand new. After 190,000 miles it's still like a brand new engine inside if not for the oil discoloration. I think I found a unicorn!

[Solarsurge]

Decided to go with Manley Platinum Series 87.5 Pistons w/.210" Wall Pins and Manley H-Tuff Plus Rods. Still researching bearings since Clevite H Series mains aren't made anymore for the speeds. Bummer.

[Solarsurge]

Got a whole bunch of parts in. Got the block back from the machine shop. Since I’m still waiting for parts, I painted the block today.



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[kTaLgsTo]

I hate your avatar............

But keep up the pictures and progress

[Solarsurge]

Originally Posted by kTaLgsTo I hate your avatar............ But keep up the pictures and progress

Really?? I literally have zero swag. That’s why it’s the perfect avatar for me.


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[kTaLgsTo]

Its the dude in it man.... I don't care what he says... lol. Don't be offended, I just couldn't watch it again without saying something

[Solarsurge]

Oh yea, I forgot to mention before that when the head was thoroughly inspected, it turned out the recently redone valves were done poorly. The seats were obviously done by hand and were visibly uneven, so I made the executive call to go with a brand new, fully redone Supertech valvetrain. The head is also being custom worked, crank keyed, and rotating assembly precision balanced by a freaking wizard who works primarily on professional race cars and has taken an interest in my project. I'm so excited I can hardly contain myself. More info to come later.

[Fstrnyou]

I weight matched my stuff to within a few tenths of a gram. I asked to have my crank balanced, and paid for it, but saw no evidence of material removal. Maybe Mazda got it perfect.

[Solarsurge]

Originally Posted by Fstrnyou I weight matched my stuff to within a few tenths of a gram. I asked to have my crank balanced, and paid for it, but saw no evidence of material removal. Maybe Mazda got it perfect.

Manley was pretty good right out of the box. All my pistons were within 1g and the rods were all within .6g on the little end and 1.2g on the big end. I’m gonna get them even closer, but that’s pretty solid as a starting point.


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[Fstrnyou]

Ya. They weren't bad. My machine shop only matches to within a gram though, so I did mine myself.

The piston, ring pack, wrist pin and locks, and the small end of the rod are all considered the reciprocating parts. The weight TOTALS should match. You don't have to make all the pistons identical, or all the wrist pins identical. The ASSEMBLY should be identical. Measure everything individually. Then shuffle the components around to get the assembly close. Then weigh the parts as an assembly for an accurate combined weight. This will drastically cut down the amount of grinding/filing necessary to match them. The lightest assembly will be your target. Remove material from the heavier assemblies.

[Solarsurge]

Originally Posted by Fstrnyou Ya. They weren't bad. My machine shop only matches to within a gram though, so I did mine myself. The piston, ring pack, wrist pin and locks, and the small end of the rod are all considered the reciprocating parts. The weight TOTALS should match. You don't have to make all the pistons identical, or all the wrist pins identical. The ASSEMBLY should be identical. Measure everything individually. Then shuffle the components around to get the assembly close. Then weigh the parts as an assembly for an accurate combined weight. This will drastically cut down the amount of grinding/filing necessary to match them. The lightest assembly will be your target. Remove material from the heavier assemblies.

Yea, I’m well aware. I haven’t touched anything yet because I’m still waiting on my bearings before I weigh everything officially and start matching parts and grinding things down. I’ll cover the blueprinting tool I made later down the road. Everything is being measured, weighed, put within spec and balanced.


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[Fstrnyou]

The bearings will all be identical. But that only matters on the big end. You can match the reciprocating assembly while you wait.

[Solarsurge]

Originally Posted by Fstrnyou The bearings will all be identical. But that only matters on the big end. You can match the reciprocating assembly while you wait.

I’m also waiting for a new, more accurate scale lol.


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[Fstrnyou]

Consistent is more important than accurate. I used cheap eBay scales.