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Mad Mat 22-03-2012 07:26 AM

Catalina
 
Hey guys,

Updated 2-01-2014

Engine:
original STAGE 1

- GTX intake mani
- BP NA Crank
- GTX injectors (sitting in work car)
- GTX ECU
- Mtuned fuel rail
- ARB head bolts
- FMIC (sitting in shed)
- CP 9.0:1 forged Pistons
- Manely forged rods
- GTX head with BP series 3 NA internals (cams, shims, ect)
- MX5 oil pump
- mazda waterpump
- VJ20 turbo and manifold
- HPC coated 3 inch exhaust & high flow cat


NEW STAGE 1

- GTX intake mani
- BP NA Crank
- Mtuned fuel rail
- ARB head bolts
- FMIC (sitting in shed)
- CP 9.0:1 forged Pistons
- Manely forged rods
- GTX head with BP series 3 NA internals (cams, shims, ect)
- MX5 oil pump
- mazda waterpump
- HPC coated 3 inch exhaust & high flow cat
- EVO 8.5 turbo
- Adaptronic 420c
- 1000cc injectors

STAGE 2

- Custom Turbo cams
- E85 Fuel pump and fuel lines

Gearbox:

- SW20 toyota Hybrid box
- Custom selection of longer ratio gears from multiple toyota boxes
- Quafe LSD
- 1st to 4th GT4 rally 3 piece syncros
- Extra 3rd and 4th gear oil squiters
- Full bearing kit
- steal 3rd to 4th selector Fork (still have the Ally 1st to 2nd Fork)
- Recondisioned Toyota levin superchaged Drive shafts (much thinker than the corolla shafts)

Exterior:
- JDM front bar + indicator relocation
- Type-R mini-skirts
- Mazda front lip
- Smoked side indicators
- Driving lights
- MS01's 17x8 +35
- KU36's 235x45r/R17

- 17x7" Osaka G-TEK OLD

Suspension:
- Yellow Speed coilovers 8kg fronts and 5kg rears
- Cusco adjustable strut tops
- Cusco A-arm brace
- full nolathane bush kit
- Whiteline rear swaybar
- v6 hub swap
- Eunos 800m front 2 spot calipers
- DBA rear slotted T2 disc and QFM pads

Interior, ICE & Electrics
- pioneer Bluetooth mp3 player
- Eclipse 6 inch Component splits
- eclipse 6x9"s
- Kenwood 4ch amp
- 2x Eclipse 12 inch subs
- 7" Dash screen (removed)
- SAAS pedals
- RX7 steering wheel
- Polished Gauge Rings
- Polished Lantis Sills
- indaglow gauges (voltage, oil pressure, and Air Fuel ratio, boost)

Other:
- Remote central locking
- Center console cupholders

[COLOR="Orange"][SIZE="4"]Future:-

Old Engine
- Custom CAI (POO)
- K&N Panel Filter
- 2.25" Cat back > Straight through > Twin tip sexy muffler :D
- Polished cam cover and exhaust shield
- Replace dump tip with small twin tips


I thought I should write up a project thread now seeing as I now am a part of the Mazda family again. 
So I am the now proud owner of a ba sedan that I bought off “Austdave” about two weeks ago. Since buying it I also got some spares with it too including a nice low km motor, so the first thing on my list was to swap out the old motor for the low km one. Well after 5 days of working on it, multiple cuts and scars but it’s now running  much better than the old engine, which had a little valve stem seal issue.

Before putting the engine in I stripped it down (it was already half way stripped already) to just the block and head and replaced all the seals i.e., cam shaft seals, crack seal, intake, exhaust, dizzy ring, the water pump was replaced, new thermostat, new rear main oil seal, new timing belt and tensioner’s. The only thing I didn’t swap was the head gasket.

http://i1174.photobucket.com/albums/...a%20ha/529.jpg
http://i1174.photobucket.com/albums/...a%20ha/528.jpg
http://i1174.photobucket.com/albums/...a%20ha/527.jpg
http://i1174.photobucket.com/albums/...a%20ha/517.jpg
http://i1174.photobucket.com/albums/...a%20ha/516.jpg
http://i1174.photobucket.com/albums/...a%20ha/515.jpg

can anyone see what i did here??? lucky i had a spare ;)

http://i1174.photobucket.com/albums/...a%20ha/510.jpg
http://i1174.photobucket.com/albums/...a%20ha/509.jpg
http://i1174.photobucket.com/albums/...a%20ha/508.jpg
http://i1174.photobucket.com/albums/...a%20ha/507.jpg
http://i1174.photobucket.com/albums/...a%20ha/506.jpg

Here’s were I’m at so far with the build, there was a little issue with the rear muffler that somehow got a massive hole in it after Dave touch the car hoist lol ;) but it’s ok as I didn’t like the light truck muffler anyway and was going to replace it with a new twin tip muffler.

I had some issues with a rattle gun as well, itself combusted in my hands when I was trying to remove the rear wheels off the car :o ow well

http://i1174.photobucket.com/albums/...a%20ha/519.jpg

As you can see here the original after market muffler was made pretty averagely with this nice chunk of metal in the way. The air grinder and air dermal too quick care of that 

http://i1174.photobucket.com/albums/...a%20ha/543.jpg
http://i1174.photobucket.com/albums/...a%20ha/544.jpg

Due to the rear muffler being broken I removed and the exhaust flange off it to use on the new muffler.

http://i1174.photobucket.com/albums/...a%20ha/540.jpg

and this is the first start of the engine after i got the timing right

http://i1174.photobucket.com/albums/...0ha/th_530.jpg

Clean_Cookie 22-03-2012 10:39 AM

Hey mate, where did you have access to those tools! Did you hire it or is it at a friends place. Uber keen once I start doing my engine swaps.

Mad Mat 22-03-2012 10:51 AM

Quote:

Originally Posted by Clean_Cookie (Post 287127)
Hey mate, where did you have access to those tools! Did you hire it or is it at a friends place. Uber keen once I start doing my engine swaps.

my mate has a man cave :) he is a retired machanice and has everytool or if he doesnt have it he knows some one with it ;)

Mad Mat 22-03-2012 10:55 AM

I found a set of shifter linkage bushes that I bought for my old Mazda but never got around to installing along with my old short shifter so I thought why not, and put those suckers in :)

As you can see i have heaps of clearance between the exhaust and the short shifter. I thought this was going to be an issue as it has been in the past, but due to the exhaust hanging just that little bit lower its a perfect fit :)

http://i1174.photobucket.com/albums/...a%20ha/531.jpg
http://i1174.photobucket.com/albums/...a%20ha/538.jpg
http://i1174.photobucket.com/albums/...a%20ha/537.jpg
http://i1174.photobucket.com/albums/...a%20ha/535.jpg
http://i1174.photobucket.com/albums/...a%20ha/534.jpg

The best job of all was the rear engine mount... even with the engine out it was a pig to remove. I had to drop the sub frame, steering rack, and bend a 17mm opened spanner to get the angle right to undo the nuts. Don’t know how people do it with the engine still it :eek:

http://i1174.photobucket.com/albums/...a%20ha/518.jpg


Along with all the spare parts I also scored a set of japspec front and rear bumpers which will be painted to suit the car when I get back from the UK in may :)

shorty3.8 22-03-2012 12:07 PM

holly crap its not red or blue lol!! looks good, so when is the maiden voyage??

Mad Mat 22-03-2012 12:23 PM

Quote:

Originally Posted by shorty3.8 (Post 287140)
holly crap its not red or blue lol!! looks good, so when is the maiden voyage??

if all goes well this arvo with the muffler and the brakes its coming home tonight and then going to rickies tomorrow arvo from storage while im in the UK. :)

Clean_Cookie 22-03-2012 12:32 PM

Going v6 brakes? And you should bring it on Saturday for us to inspect your dodgy work :p

Mad Mat 22-03-2012 12:38 PM

Quote:

Originally Posted by Clean_Cookie (Post 287148)
Going v6 brakes? And you should bring it on Saturday for us to inspect your dodgy work :p

will be in the future ;) and yes i will be to collect my goodies and install them too :)

project.r.racing 22-03-2012 04:08 PM

Did you have solid or HLA lifters?

DavoAust 22-03-2012 06:24 PM

Quote:

Originally Posted by project.r.racing (Post 287171)
Did you have solid or HLA lifters?

We never checked. Probably solids though. It doesn't have the HLA rattle on start.

And white thunder? Duddddeeee. That sounds like a porn name :p

derb 22-03-2012 06:48 PM

Well he couldn't go with White Lightning as people would think he loves Grease.

phildough 22-03-2012 07:03 PM

White chunder???

Cosmo Dude 22-03-2012 07:36 PM

You really need an exhaust like my V6 if you're going to call it thunder :D

Mad Mat 23-03-2012 08:25 AM

Quote:

Originally Posted by Cosmo Dude (Post 287196)
You really need an exhaust like my V6 if you're going to call it thunder :D

haha what does ur v6 have??? my new one sounds great tho :)

Mad Mat 23-03-2012 08:33 AM

so the car is now working and is sitting a my house awaiting a good clean :) here is what i got done last night.

i recieved my new exhaust to replace the one that self combusted (or thats what dave told me lol) yesterday :) so after some carefull fiddeling i installed her and i think it turned out 10x better than i imagined :)

http://i1174.photobucket.com/albums/...a/IMG_9865.jpg

the old light truck muffler that was on the car

http://i1174.photobucket.com/albums/...a/IMG_5422.jpg


http://i1174.photobucket.com/albums/...a/IMG_4490.jpg


http://i1174.photobucket.com/albums/...a/IMG_2026.jpg

now what does everyone think????? look ok??

http://i1174.photobucket.com/albums/...a/IMG_1581.jpg

i also ot the timing done at 7 degrees advanced, installed my HU quickly as i needed TUNES for the 60km drive home, and put the new tires on the front. :) over all im one happy camper :)

Clean_Cookie 23-03-2012 08:43 AM

What is it set at Matt? 7 or 7 over the stock 10?

Mad Mat 23-03-2012 08:46 AM

Quote:

Originally Posted by Clean_Cookie (Post 287245)
What is it set at Matt? 7 or 7 over the stock 10?

7 front TDC

Clean_Cookie 23-03-2012 08:48 AM

Why so low? On the bonnet it will tell you stock timing, I've got mine around 11 degrees i think?

Cosmo Dude 23-03-2012 09:06 AM

Quote:

Originally Posted by Mad Mat (Post 287240)
haha what does ur v6 have??? my new one sounds great tho :)

Looks like yours except the rear muffler is all shiny. 2 1/4" mandrel bent with 12" resonator. It's not exactly stealth.

Mad Mat 23-03-2012 10:43 AM

Quote:

Originally Posted by Cosmo Dude (Post 287249)
Looks like yours except the rear muffler is all shiny. 2 1/4" mandrel bent with 12" resonator. It's not exactly stealth.

Yer mines the same stealth wise as Dave heard me from 2 blocks away last night and thought it was a fart canon lol.. When it gets warn in I hope it will sound deaper and not so farty... :) ow and there is a resonator on it too about 15inch on I think.. The hole system needs a paint and clean out...


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