zero_cool's Wedge Progress thread

[zero_cool]

Ok
I have my little welcome thread before.
So now i'm making up my Project / Progress Thread
My current Bog Stock as a rock astina will be gettng a treatment over the coming months and being totally rebuild and come out as a weapon :)

So Far I have -
A Mazda 323 Astina SP

The Below List will be Striked out as I get them

Checklist

BPT Engine
EMS Computer System
17" Wheels - New Shoes! Them
Lowered Suspension
FMIC + Piping
3" Exhaust
Garret GT2871rs
Custom Exhaust Manifold
Upgrade CD Player
Boost Gauge
Oil Pressure Gauge
Water Temp Gauge
A/F Gauge
Darker Window Tint
J=Spec Tail Lights
Fix Electric Window Switch
Fix Ding in drivers side front 1/4 panel and door
Fix Headlight
Gearbox Rebuild
PAR Straight Cut 3rd
Mazspeed LSD
BA Astina Shafts Modified to suit my astina
Eat Pie
Take it for Tune.
Plumb Back Blow Off Valve.

Picture As It stands today ->

http://i5.photobucket.com/albums/y187/noomz/03012006361.jpg

Stay Tuned for Further Updates!

[zero_cool]

I Gots Some New Shoes For it :)

http://i5.photobucket.com/albums/y187/noomz/tx3/12112007433.jpg


Slight Photoshop Choppage

http://i5.photobucket.com/albums/y187/noomz/tx3/12112007434copy.jpg

IT HAS BEGUN :P

[Smikey]

That's without lowered suspension? Looks pretty good to me at that height already!

[zero_cool]

the picture above is how it sits at the moment, the bottom picture is a photochopped picture

[FEM]

very nice Bwaddy

cant wait to see more :)

[bourbon]

looks good bro...i see your gonna be testin the hotwire from fordlaser...youll be keeping that one when you do the conversion to bpt or putting a bpt one in straight away?? i might be interested in the bp one :D

[Smikey]

the picture above is how it sits at the moment, the bottom picture is a photochopped picture

ahhh no wonder, the photochopped height is good. i thought there looked like a height change between the two but i figured it might have been the angle of the shot.

[newman]

and **** it was one mission to get those rims :P

[zero_cool]

yahuh... that mission sucked the wang big time
but they won't be on the car for long,
i'll be putting the stockies back on it till i get other things on the car sorted :P

[bourbon]

looks good bro...i see your gonna be testin the hotwire from fordlaser...youll be keeping that one when you do the conversion to bpt or putting a bpt one in straight away?? ill be interested in the bp one :D

dont noif you missed this or not... :p

[newman]

if you read all the posts in that thread on fl.com bourbon, you'll find that the hotwire afm can simply be "reflashed" with the BPT 'software' if you want to upgrade from BP to BPT...

[bourbon]

i wasnt asking that and you know that...i dont wanna start ****...but just read what was said...yesterday you complained i didnt make it so you understood now when i do you go pick on that...get over yaself...quit picking on peoples posts aswell know one likes it

[newman]

i understood what you posted, and i replied accordingly. i don't understand the uproar... Perhaps an explination is required?

looks good bro...i see your gonna be testin the hotwire from fordlaser...youll be keeping that one when you do the conversion to bpt or putting a bpt one in straight away?? i might be interested in the bp one :D

from that i drew the conclusion that you would want to purchase brads BP n/a hotwire afm when he goes to BPT? to which i told you that if you had read the hotwire thread you would of known that they can be 'reflashed' and the chances of him selling would be minimal... so then i repied with.

if you read all the posts in that thread on fl.com bourbon, you'll find that the hotwire afm can simply be "reflashed" with the BPT 'software' if you want to upgrade from BP to BPT...

so why would you need to start sh!t? i wasn't even picking on your post! i would of done it if anyone else had posted the same thing. How's about you get over yourself and stop thinking im putting sh!t on you. Infact, i don't even think it was picking, i was just telling it to you straight out.

[bourbon]

i did actually ask zero_cool bud :p not you... after reading all your posts of late on here it seems like attacking everyone...ive had people tell me too...so its not only me...maybe you need to reword the way you say stuff ;)

[newman]

Would you like me to find posts where you've answered questions that were asked to other people, bourbon?

How am I attacking? There is a difference between 'attacking' and being blunt.
Im not the only person on agt that can be blunt, so don't treat me any different to the others that are blunt.

moral of the story, you should of read the hotwire thread before asking questions ;)

sorry to clog ya thread up brad.

[89sp1.8]

moving on now guys..

it begins nice mate,good luck. keep us posted with progress;)

[zero_cool]

dont noif you missed this or not... :p

Yeps I saw it :)

My cars just the test pig, I was a test car for the BPT afm's aswell

I won't be going Hotwire AFM anymore on my car, theres no need to since in the next 12months i'll be going to a BPT and not running an airflow meter at all :)

[bourbon]

ok no worries bud... :D

[zero_cool]

Some picture updates :)

Engine Now out, Gearbox finally seperated.

Condition of motor after pulling out? thats very debatable

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic021.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic021.jpg)
the donor car

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic005.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic005.jpg)
its coming out!

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic006.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic006.jpg)
its outskis!

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic008.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic008.jpg)
sitting on the floor in my garage

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic012.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic012.jpg)
Front side of the motor

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic013.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic013.jpg)
Got Leak? its one of many!

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic014.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic014.jpg)
side shot

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic015.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic015.jpg)
can anyone spot anything wrong here?

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic017.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic017.jpg)
Silicon holding the oil sender unit in?? wtf??

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic016.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic016.jpg)
the ass shot

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_pic019.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/pic019.jpg)
the other side, clutch had little chunks out of it, thrust bearing inside the box had seized up as well. but some nice overheating marks there

That concludes this evenings presentation.

A copy of this presentation is also available in audio book and braille print from leading retailers. for your nearest store. please contact your mum.

[zero_cool]

Well today I set out on a mission to put my new brakes on the Astina.

I wanted to wait till i had some lucas pads
but temptation gave into me.

Suprisingly they don't pull up all that bad with the bendix GCT's but they will be borked off soonish for thy lucas.
after a few short bursts the brakes were warmed up and they stopped me pretty damm quick which is what i aimed for.

anyways on with the show!

Here we have 4x DBA slotted rotors and Bendix GCT brakes

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes001.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes001.jpg)

Picture of the front rotor

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes003.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes003.jpg)

Picture of existing front rotor on the astina

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes005.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes005.jpg)

Having the 2 rotors side by side.. doesn't the slotted one look sex!

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes006.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes006.jpg)

I decided to do something silly and wanky.... don't worry i did wipe the paint off the rubbers

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes009.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes009.jpg)

pic of new rotor up the front

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes010.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes010.jpg)

when you get too impatient waiting for the paint to dry and wanting that wanky red calliper on

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes011.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes011.jpg)

what said rotor looks like behind the rim. (this one shall be repainted lol)

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes012.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes012.jpg)

a nice slotted rear rotor

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes016.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes016.jpg)

oh noes! no rotors at all!

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes018.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes018.jpg)

ahh there it is!

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes019.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes019.jpg)

red yet again.. this time i waited a bit longer for it to dry, I still wish i didn't paint them now though haha, because the paint will turn crap in 6 months and i'll have to do it all over again.. but meh..

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_brakes020.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/brakes020.jpg)



thats all thats it,

there is still a little bit of air in the system that i need to get out but its being stubborn and not goind anywhere grrrr!

Next thing on the list is that LSD on agt.com
then suspension..
I need it done, the car is handles like a boat haha

[zero_cool]

mmmMmmm.... EL Dials

http://i5.photobucket.com/albums/y187/noomz/astina/th_13022008576.jpg (http://i5.photobucket.com/albums/y187/noomz/astina/13022008576.jpg)

http://i5.photobucket.com/albums/y187/noomz/astina/th_13022008577.jpg (http://i5.photobucket.com/albums/y187/noomz/astina/13022008577.jpg)

http://i5.photobucket.com/albums/y187/noomz/astina/th_13022008580.jpg (http://i5.photobucket.com/albums/y187/noomz/astina/13022008580.jpg)

[89sp1.8]

interesting read,nice work.keep us posted:)

[MrShadow]

Those EL dials look great! Almost like the setup on the SP23 though that's actually a blue LED shining down onto a reflective surface... enough about that, this is a forum for Astinas!

Keep up the good work.

[zero_cool]

Something arrived in the mail today...

can anyone guess what it is?

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_17032008653.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/17032008653.jpg)

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_17032008654.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/17032008654.jpg)

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_17032008655.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/17032008655.jpg)

:)

[zero_cool]

Oh.. Well..

Looky here!

What does I happen to have stumbled upon.... :P
it seems to me like some PAR straight cut gears with custom made input shaft..
hmm...


http://i5.photobucket.com/albums/y187/noomz/th_PA280600.jpg (http://s5.photobucket.com/albums/y187/noomz/?action=view&current=PA280600.jpg)


Oh!

I now also have some BA 323 astina driveshafts which I shall be getting modified very shortly...

Its starting to come to a close!

have updated the front page

[mussing]

Out of curiosity, why are you using modified BA driveshafts?

[bourbon]

cause of the LSD...you need to swap 1 of the sides from memory...

[project.r.racing]

swap one side (passenger) and shorten 5mm on the other...

mazdaspeed 3 protege lsd

[zero_cool]

Yep,
I needed BA 323 astina shafts as they have a spline count of 28
whereas the BG has 26 spline
I use a hybrid of both the BA shafts and the BG shafts.

I use the BA layshaft with the outer end resplined down to 26 spline and shortened 4-5mm.
and I use a BA 323 astina CV cup on the gearbox end of the passenger side and put it onto a BG shaft.

[cazza]

Ahhhh, i love threads like this, its like the rebuilds life story!

Great read man, appreciate the effort put in posting everything up for us to see.

Keep it up, tis going to be SICK !

[mussing]

Yep,
I needed BA 323 astina shafts as they have a spline count of 28
whereas the BG has 26 spline
I use a hybrid of both the BA shafts and the BG shafts.

I use the BA layshaft with the outer end resplined down to 26 spline and shortened 4-5mm.
and I use a BA 323 astina CV cup on the gearbox end of the passenger side and put it onto a BG shaft.

So the effect is that you can use an LSD from a mazdaspeed 3 protegé?

[project.r.racing]

mazdaspeed protege

it's the USDM version of our 323 protege sp20, with a few added performance extras.

sorry the 3 bit was me not checking my typing...

[Clean_Cookie]

sounds cool. wish i could afford an lsd lol.
cant wait to see the finished result!

[zero_cool]

Cheers all,
I've got Newman heading over to my place to give me a hand with the conversion, i've done a couple before but handy to have a bit of extra knowledge aswell
planning the conversion in about 3-4 weeks time
should have it knocked over in a weekend
I've sent the shafts today off to an engineering place in sydney to have them resplined. should have them back by the end of next week.

LSD - there pricey buy very well worth the money
this + straight cut gears :P
= almost semi bullet proof gearbox

[Clean_Cookie]

so will this be a track only car or will you use it as a daily too?
seems like a lot of money into a "cheap" car...

[mussing]

What's the advantage of straight-cut gears? More reliable, sure, but how come?

[project.r.racing]

cast gear are moulded, have imprefections in the metals, shrink when cooling etc from the casting process. giving a small amount of tolerances lost.

straight cut gears are like forged wheels, cut from a single block of metal/alloy and hence have less issues as listed above.

[Rupewrecht]

Well no, i'd say the advantage of straight cut gears are that they mesh with the faces straight-on, not mesh on angle (which are normal helical-cut gears). Helical you'll find on all forward gears in conventional standard gearboxes, with reverse being straight cut.

So because the straight cut gears mesh straight-on, the teeth can be bigger, and therefor the gear is stronger and can take more load. When under load the gear is not being forced apart like it would be with a helical gear (as the angles aren't fighting against each other).

The only downside is that straightcut gears whine (like reverse does), but that's more a personal taste thing!

[zero_cool]

so will this be a track only car or will you use it as a daily too?
seems like a lot of money into a "cheap" car...

it will be used for both purposes.

and cheap car?
that I take offence too,
by no means a cheap car,
it suits my needs perfectly.

I think its a better platform to build on rather than a BA auto Astina

[zero_cool]

Holy Crap!
I should really do an update here!

I kinda got lazy with the pictures,
mid conversion
I did get pictures of the motor being taken out of the car
but nothing with it being put back in

I had some fairly big issues with the gearbox
my rebuilt box still isn't ready as they are having MASSIVE issues sourcing bearings and PAR have been totally and utterly hopeless, my left ovary could have given more advice / help then what they did.
so f**k you Par. thanks for sending me on a race around because you's are too lazy to actually look into something that you designed in house when I asked for specific information.. not just "yeah a bearing shop should help you out" that goes for both people at PAR..

*coughs*
anywho...

because of the fark around that i'm getting with this other gearbox I cracked the s**t and decided to just put in the BPT with the stock G series box.

The gearbox came out fine with no issues at all,
it attached upto the BPT perfectly as was expected.

put the engine in, wired it up and BAM!
it turned over
so then it was time to plumb up the front mount cooler

Note at this point the ASI cooler kits from EBAY
DO NOT!
I repeat DO NOT
fit an astina
as similiar as they are to the lasers they are still oh so much different
even after doing a s**t of chopping up of the piping kit, I only managed to successfully plumb up the outlet of the cooler to the intake
I had some crappy 2" piping lying about so i dodgied that up so it would atleast create half a sealed system

time to fire it up
cranked it over and it the car started first so,
It didn't hold idle but that would be because i had about 40 different air leaks around the system.

So i've ditched the front mount idea for the moment and have gone back to using a stock side mount cooler.

with the help of solractheslayer and my323.
We got the side mount cooler piping in and fitted
finally, it was hooked up and the car started first go
was so happy!
I was able to sit there and let it idle,

a fantastic feeling for anybody who has done an engine conversion, they all pray that it starts and runs..
which mind did!

Next up was bleeding the clutch and the brakes
bled all of them and I was able to successfully select gears and move it through the box,

at this point in time I had borked lower gearbox mounts
they were sitting in the holes of the cross member but they were not bolted in due to the bolts being sheared off.

I had a spare front gearbox mount which I used,
But I then sent out an SOS here on the forums asking for a rear mount which a member put their hand up and sold to me
THANKS!
Life saver!

please note that changing a rear gearbox mount is a royal PRICK!
it took me a good hour to change it!
having to unbolt the top gearbox mount and lower and raise the motor and box so i could get the bolts in grrrr...

It was time for a test drive
made sure all fluids were there,
hooked up the power steering,
took it for a run around the block!

Yay!

The car drives and boosts! woohoo!

I just need to fix up some little things

I have a leak from the power steering pump which i need to look at
not sure if its excess fluid lying about or whether its a seal that has gone..

Once the car is registered i'll take it down to the car wash and use their pressure washers there to get rid of the oil and check it out later

i'm sure that I have missed a few things but i'll look over this later and edit it as need be

So a rundown..

Pulled motor out
got angry at the gearbox
got angry at the front mount piping
put new motor and gearbox in
wired it all up
the car started
I drove it

all thats left now is an inspection and rego
then of course engineering!

[zero_cool]

2 quick photos of how it stands at the moment,
in these pictures, it hasn't been washed either

Click to make bigger

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_astina.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/astina.jpg)

http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/th_astina2.jpg (http://i5.photobucket.com/albums/y187/noomz/astina%20conversion/astina2.jpg)

[zero_cool]

umm..
Update,

I'm running the GT2871 RS now with a custom staino Manifold, 3" exhaust with 2.5" dump pipe
I need to get the FMIC piping fixed up as I have a leak but the car still goes okay

I'm still yet to fit the LSD gearbox as I've got a little one on the way so I need to car on the road 100% of the time.

I'm hoping in the coming weeks I can fit the LSD box and get the cooler piping fixed up

[zero_cool]

Not that much of an update here,
I still haven't fitted the LSD box to the car yet,
mainly due to time and money contraints,

I have the Greddy Piggy back ECU working again,
so I don't have boost cut at 11psi anymore,
when running the piggy back, the car turns into an animal
I love it!
I have no intentions of turning the boost up at the moment, as 11 psi on the 2871 is plenty, I already get wheelspin in 1,2,3 gears,
plus my injectors are maxing out (well it says so on the duty cycle meter thingo on the piggy back ecu)

I have painted the FMIC and piping all black to add too its stealth look which works well for me,

I now have a metal intake pipe from AFM -> Turbo and i've had 2 bungs welded onto the pipe for the BOV so I can plumb it back (having being running an atmospheric blow off valve for so long, having it plumbed back up again sounds really weird!)
and also a small barbed piece for the oil breather line on the rocker cover,
I'm trying to make the car as legal as possible so if at any chance I do get pulled up,
I can smile and show the paperwork and they can look under the bonnet and see that i've got everything done and legal
so they would then decide to look over the rest of the car and eventually ping me for having no water in the rear washer motor or something.


I have also taken it to an engineer and I need to get 2 things on the car fixed before he will sign it off,

1) Exhaust - 93db and the legal limit is 91
So i'll make that quieter for the day

2) air filter needs to be boxed in, so I took the liberty of making up an airbox of out sheet metal today,
I have to admit, I was pretty impressed with the outcome
it looks neat, its practical and is pretty much all sealed up bar a couple of things

I'll endeavor to take a pic of the cooler setup tomorrow

but pics!

http://i5.photobucket.com/albums/y187/noomz/astina/th_IMG_0893.jpg (http://i5.photobucket.com/albums/y187/noomz/astina/IMG_0893.jpg)
http://i5.photobucket.com/albums/y187/noomz/astina/th_IMG_0894.jpg (http://i5.photobucket.com/albums/y187/noomz/astina/IMG_0894.jpg)
http://i5.photobucket.com/albums/y187/noomz/astina/th_IMG_0896.jpg (http://i5.photobucket.com/albums/y187/noomz/astina/IMG_0896.jpg)

all I really need to do now is make the exhaust quieter which is very easy to do with household cleaning products and some mesh :P

[zero_cool]

I have also recently had the Top tank in the radiator replaced as It developed a crack in it,
the radiators these days are crap, what with all the plastic top tanks!
it cracked in a very common area so I am told,

I am also driving on the stock rims aswell due to myself getting defected which I believe I mentioned a few posts back,

Also,
the passenger side A piilar is missing due to a member of the forums here breaking it when they were getting out of the car (still waiting on the replacement??!?!)

aaannd the front bar -
I munted it slightly and drove into a towball when I was at warbzys place,
I was inching forward trying to clear space so his wife can get in the driveway
slowly.. slowly... BANG!
FFFFUUUUUUU


and the rear bumper got a little love tap aswell when I was in a carpark, it had those spastic concrete piilars all over the place
I thought I had cleared it!
Obviously not :(

I will eventually get the car resprayed, but its not a very high priority right now,

I'm more focused on getting the mechanical side of the car upto scratch before I look at the body.

ASAP- I need to replace the front left strut top as it is foobarred and creaking like mad, so thats going to go bang soon,
the CV's have gone funky again, but I won't replace these,
I will get new / reco'd ones when I get the LSD fitted,

I also need new Tie-Rod ends as my steering is a bit loose aswell (has some left-right play)

thats about it!

I was selling the dribbletech ecu however the buyer pulled out,
So looks like I won't be getting the Haltech that I was wanting, and a good ol' microtech shall be the brains of thy car!

[zero_cool]

Just a small update to the car,

I now have these

http://i5.photobucket.com/albums/y187/noomz/astina/th_IMG_0092.jpg (http://i5.photobucket.com/albums/y187/noomz/astina/IMG_0092.jpg)

[zero_cool]

Okay, another small update
I now have the LSD and PAR straight cut 3rd gear fitted,
car is very different to drive with the LSD installed, and 3rd gear just sounds awesome
big thanks to warbzy for helping me out with my driveshaft issues.
I had problems with the layshaft and that basically tipped me over the edge with this car, I just went "fark it" and didn't touch the car for about 3 weeks
I'm going to finish what i started with this car, and we'll see what happens then whether i sell the car off or keep it.

Johnny - No pictures of the cooler kit, as it was a custom made and home brew job lol

Youtube video of me taking it for a drive

http://www.youtube.com/watch?v=mK2cWbp9Ee0

after about 5000kms~ the machining marks will wear off the gear and get even louder.

that will do for now

so be careful of a navy looking astina in the north sydney area.. it might surprise you :P

[Mad Mat]

what every happened to this car???