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07-12-2009, 11:25 AM | #1 |
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Orion's SP20 worklog
Exhaust:
Autoexe header 4-2-1 design (HPC coated) CES 2.5" cat and 60mm mid-pipe Racing Beat 60mm catback system Engine: AWR 70-duro mounts AWR drivers-side engine mount inserts Twiggy-spec custom cams RR Racing Under-Drive Pulley Remote oil filter re-location Optima Red-top in-boot relocation Mazdaspeed 1.3bar radiator cap Power steering cooler WeaponR coolant overflow tank Engine Management Microtech LT-10X Bosch 715 coil packs J&S Safeguard knock control unit Wide-band LS-01 AFR sensor Gearbox: Mazdaspeed LSD Fidanza Lightweight flywheel 626 5th gear swap Intake: Custom intake with 3-inch filter - retains stock MAF - two IAT sensors - HPC coated Chassis opening for cold air Throttle-body coolant bypass Rims/Tyres/Suspension: MX-5 17"x7" 10-spoke rims Kuhmo Excta KU31's 215/R17/40 Tokico Illumina 5-way adjustable shocks Eibach Pro-kit front and rear springs AutoExe 3-point front strut brace with Master Cylinder stopper Progress 21.5mm rear swaybar AWR adjustable rear endlinks Exterior: Mazdaspeed 2003.5 front lip Mazdaspeed 2003.5 spoiler Black side strip delete mod Black painted headlights Smoked side indicators EDM tail lights AeroGrid wipers New! In-Car Entertainment: JVC AVX-77 single DIN touchscreen - Bluetooth mic - Steering wheel remote Interior: Autometer gauges: - oil temperature - oil pressure - transmission temperature - exhaust gas temperature (EGT) - fuel pressure ScanGaugeII OBD-II monitor Mazdaspeed pedal set DaveB brushed gauge rings B&M short-shifter Black leather (silver stitching) shifter/handbrake boots Accessories: Cruise control Variable intermittant wiper upgrade Mazda Hi-Spec alarm Stebel Nautilis horn (139 dB) Mazdaspeed oil cap Power distribution fuse block
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild Last edited by Orion; 30-03-2012 at 12:38 PM. |
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07-12-2009, 11:26 AM | #2 |
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Photos
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild Last edited by Orion; 05-08-2014 at 10:19 PM. |
07-12-2009, 11:27 AM | #3 |
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Introduction
Hey everyone,
Seeing as my car has only just been recently named, I thought it was high time that I started up a build thread to keep up-to-date with the work being done. Without further adieu I present ‘Hugo’ who is my 2003 Mazda Protégé SP20. Hugo was purchased back in 2004 off a couple from Victoria who had been given a work car. I was actually looking at Starry Blue sedans but in I just couldn’t resist buying Hugo after I first jumped in for a test drive. I have been slowly adding mods here and there starting off with suspension and then ending up with custom cams and a Microtech ecu. I was thinking about going turbo recently but decided not to due to the cost and the reduced reliability. Besides, putting turbos on these cars has been done forever in a day and I want to try and do things differently. I realise that this could have been the very first post, but I thought that it would be more appropriate to have the mods list up-front to be kept up to date as things progress, followed by a pics post. I will keep the post after this as a “current projects / uninstalled parts” list so that you can see the future plans for the car. On the fifth post I will keep references to significant posts in worklog to try and make it easier for people to find information or a discussion. Other than that constructive feedback / comments / suggestions are welcome – although please avoid posting one-liners such as “nice ride” (a PM would be appropriate for those). If you would like to comment how about adding a bit more detail or perhaps make a suggestion as well. Cheers, Darryl.
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild |
07-12-2009, 11:27 AM | #4 |
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Future plans / parts
Projects to come:
JDM power folding mirrors Just need to connect the passenger side! Vibrant Vacuum block Installed but not hooked up PWM fan controller Cooling system - Stage 2! High compression engine transplant Nearing completion!
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild Last edited by Orion; 18-01-2016 at 01:09 PM. |
07-12-2009, 11:28 AM | #5 |
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Engine build
So over the last few years or so I have picked up some goodies which will be the start of a high-compression engine build. This will be a very long process as there are a couple of other projects that I need to finish up first before I get stuck into it. However, I have got the major components and I can slowly accumulate the other parts I need over the long-term.
Things that are done: - FS-ZE manifold Ready! - Strip down block Done! - Block hot-tanked, bored and honed Done! - Flywheel machined and clutch built Done! - Weld AN-10 bung into the main bearing support plate Done! - Balance rotating assembly and installed Done! - Put oil temp sensor in second oil pan Done! - Installing MAM fuel rail Done! - Cylinder head Reconditioned and installed! - Reinstall flywheel / clutch Done! - MSP Oil Cooler installed Done! - Modifying valve cover for COPs Done! - Install Focus cam gears Done! Mini projects: - Wire up COPs and fuel injectors In progress! - Install accessories In progress! - Painting accessory brackets Ongoing! Future: - Put baffles into the oil pan Started but will defer until after rebuild! - Finish wiring PWM fan controller Still trying to figure out what went wrong the first time!
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild Last edited by Orion; 13-12-2016 at 12:41 AM. |
07-12-2009, 08:49 PM | #6 |
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Join Date: Sep 2004
Location: Logan prefecture
Car: Touge monster
Posts: 7,585
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Hudo? Hugo is evil, and cannot be trusted! Hudon't!
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07-12-2009, 10:06 PM | #7 |
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Hugo is not evil!!
The other thing with Hugo, is that it seems all the cheap personalised number plates are taken. I will have to keep looking at at various combinations and see what is still available. Any opinions (from anyone) as to what colour combinations would work with the car? I was thinking a dark blue plate and silver writing. Would that be too much? Should I go with some other colours to break things up a bit?
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild |
07-12-2009, 10:17 PM | #8 |
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Join Date: Oct 2005
Location: Ipswich, Queensland
Car: 2002 Mazda Astina SP20 2006 Mazda 6 GY Wagon
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Hey Darryl, are you looking for something SP20 related, if so I know the plate for you Also dark or royal blue with silver lettering would be good on our colour cars, I honestly cant remember what my colour is
Also one question, I noticed at the skidpan day that you were running slotted rear rotors, but the fronts were not? Any reason for this?
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07-12-2009, 11:45 PM | #9 | |
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Quote:
I would actually like to take the SP20 badges off the car and put some of these on the front grill and rear boot (but in silver or polished): I would keep the rear 'Mazda' emblem as it is - silver/polished. As for the rears being slotted. At my last service I was told that the rear pads were about done and would need replacing within 4,000 kms. So I ordered new pads and discs for the rear, and also a set of braided brake lines all around. I knew the rears were going to be a pain to change so I bundled the lot up and had it all done at a shop. Turns out that the rear pads had a lot more life left in them than I was lead to believe But at least now, I can get the front rotors/pads early next year (before the next Skidpan Day) and put them in myself as most of the hard/tricky jobs have been done.
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild |
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08-12-2009, 12:03 AM | #10 |
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Join Date: Oct 2005
Location: Ipswich, Queensland
Car: 2002 Mazda Astina SP20 2006 Mazda 6 GY Wagon
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PM sent re plate combo
Im actually thinking about going about and bleaching my badges I have here, ridding them of all the chrome, and painting them dark grey, could seem to go well with the dark blue, black would be a little hard to see... this is what I am talking about Rear pads arent as bad as what everyone says, thats unless you cant find the hidden allen key bolt!
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Last edited by marcs_sp20; 08-12-2009 at 12:07 AM. |
08-12-2009, 01:39 PM | #11 |
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Join Date: Aug 2005
Location: Salisbury - Inner City
Car: 1997 BA Hardtop - Had a 2003 BJii J48 Sport20, and 2x bg SOHC astina hatches
Posts: 5,011
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nice read up mate. i love the list of mods u have got can i borrow some hee hee :P
na whats a EGT gauge, & a Scangauge II unit?????
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08-12-2009, 02:03 PM | #12 | |
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Quote:
The only thing that mod that I would consider going back to are the Espilier springs that I used to have on the car. Unfortunately sold them off about a year ago when I got the Eibachs. Best performance spring out there. Good things: - even drop, so maintains the balance of the car - firm spring rates, which meant that the car would turn beautifully into corners Bad things: - linear spring rates, which meant driving around on rough Brissie roads gave you a decent massage - the even drop meant that the car kept its a$$-high look which was none too flattering E.G.T. gauge - exhaust gas temperature gauge. I am currently an O2 sensor bung drilled and tapped to put the EGT sensor into the bung at the front of my headers. Scangauge - a small dashunit that displays data from the stock ecu and sensors, and does other funky stuff like calculate fuel usage rates and trip range etc. See here www.scangauge.com.au/ I want to get one of these moulded into my radio surround but need to find someone who works in interior plastics to help me.
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild |
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08-12-2009, 02:35 PM | #13 |
HONEYWELL REPRESENT
Join Date: Aug 2005
Location: Salisbury - Inner City
Car: 1997 BA Hardtop - Had a 2003 BJii J48 Sport20, and 2x bg SOHC astina hatches
Posts: 5,011
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wicked as. i'll pm u on the egt. i have some questions about that
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17-12-2009, 09:34 AM | #14 |
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Well, I FINALLY picked up my drivers-side AWR mount this morning. It only took 4 months and several attempts at posting it from ProtegeGarage in the States.
Well, you were right Gav. I ended up getting a factory second. 80% of the welds lookd good but there are definitely more than a few that were rushed jobs. The bracket that connects to the engine is a slightly different shade than the main unit, and some of the powdercoating on the main unit is cracked. Im not going to send it back - I might not see a new one until 2011 . I will be sending a rather curt email to Ken at PG and Tony at AWR when I get into work this morning. Simply bad customer service all around. On the other hand, Im looking forward to installing it in the next couple of days and seeing/feeling what the results are.
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild |
17-12-2009, 09:47 AM | #15 |
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Join Date: Sep 2004
Location: Logan prefecture
Car: Touge monster
Posts: 7,585
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Yeah, they might not respond to it well, but then again your a good customer and have certainly spent enough $$$ on them by now. So I say, make your objection known to them, and they might even impress you with their response? Point out the fact you waited many months, and then what they delivered is an embarresment to the usual quality of their work, and by no means the usual show piece they sell...
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17-12-2009, 01:36 PM | #16 |
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Car: 2002 Mazda Astina SP20 2006 Mazda 6 GY Wagon
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That seriously sucks I hope you got a discount, did you know you were getting a factory second?
I just hope when I order the kit from Tony next year that they arrive within reasonable time and are what they are pictured as... Also in regards to the convo we had last night, when you upgrade headlights, I may just snap them off you
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20-12-2009, 09:36 PM | #17 |
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Engine mount problems aside, I did manage a bit of progress tonight. After one failed attempt to thread my transmission temp sensor into the bung, I gave it another go with the help of my bro. Look below:
The one on the right is the first (err, unsuccessful) attempt - the disc on top of the sensor head is a washer. We originally thought that the we would need to create a seal at the top, but it turns out that the thread is tapered (slightly smaller at the bottom) and will seal up on its own. What happened was that it was so hard to screw the sensor in that we did realise how close we were to the bottom of the thread. So when the head of the sensor hit the washer, we didnt feel it bite and as we turn a bit more we ended up shearing off the top of the sensor The one on the left is the good one - I was keen for one more half turn, but my bro was a bit more gun-shy after the first try. We can always tighten it up a bit more if it does leak a bit (not likely). Just have to change the transmission fluid now so that I can swap the bungs out and then I just will have to connect the sensor and all done. Easy peasy. Got some Royal Purple sitting in the garage, so will give that a try this time around. Then just have to get my DIN triple gauge holder sorted
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild Last edited by Orion; 05-08-2014 at 10:21 PM. |
08-01-2010, 01:51 AM | #18 |
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So on New Years Day, I finally got around to changing the gearbox oil. I jacked the car up and put pan under the transmission. I put the spanner on the drain plug and give a mighty heave, and the bolt loosens immediately. So as the old transmission fluid is draining I went to work on the fill plug - whole different story. We now suspect that the transmission shop used an air tool (i.e. rattle gun) to put it on as it was a b!tch to get off with the breaker bar. It came off eventually and we saw that it had been put on so tight that the washer had basically fused to the plug. See below:
Lucky I was installing a new plug with the sensor in it and could use the stock drain plug to replace the fill plug. The old gearbox oil had some metal filiings in it and Im hoping that a change or oil will help to prevent that and make shifting a bit smoother: Hopefully the Royal Purple will prove to be a better gearbox oil and there wont be as much metal filings when it next gets changed. Finally, here is a pic of the sensor sticking out of the gearbox, just to one side of the main support bar that the front and rear engine mounts are attached to. Sorry about the pic quality as it was late when I took it. ImageShack Now I just have to monitor the sensor for a bit and make sure that no gear oil is slowly leaking out.
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild Last edited by Orion; 05-08-2014 at 10:32 PM. |
11-01-2010, 01:05 AM | #19 |
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Autoexe strut brace installed!!
Well after a relatively unproductive year on the car last year, this year has started with a flurry. A couple of projects that have been sitting in the background are finally coming to fruition.
So I have had my Autoexe strut brace since the middle of last year and never got around to installing it. I had a few concerns as bits of the a/c system and other random things are connected to the brackets that join the stock SP20 strut brace. Well, I finally got some little things made and ready and then tackled the brace a few hours ago. Let me tell you it was a pain. Where the brace connects to the firewall, there are a/c lines, electrical wires, vac lines and then there is the intake manifold right there too. There was a lot of swearing with this install and small spider fingers were definitely useful. There is still a few things to tidy up but all-in-all the major part is done. Here are some pics: Old brace off and new brace ready to go: New brace installed: ImageShack A handy inclusion - brake booster stopper: New photo needed. I took the car for a quick spin around Mt Cootha after the install. I can't say that I was blown away by the improvement in the handling. It was better, more direct, but the car was already setup quite well to begin with. The major difference I felt was in the braking - much more initial bite and seemed to stop a lot better. When I get new front pads and rotors it should be pretty damn good Things left to do for the install are: - get two 14mm nuts without flanges as two just wouldn't fit inside the raised edges - add the remaining two bolts to the firewall connection point - tighten up the brake booster stopper a bit more - tidy up the a/c lines, electrical bits and vac lines After all that, I sure that the engine bay could use a good clean. Come to think of it, the whole car needs a really good clean. Oh, well for another day .....
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Exhaust: Autoexe headers; Custom midpipe; Racing Beat catback Engine: AWR mounts; Twiggy cams; Custom CAI; RR Racing UDP; Mishimoto rad EMS: Microtech LT-10; J&S Safeguard; Gearbox: MSP LSD; Fidanza flywheel; 5th gear Rims/Suspension: MX-5 rims; Tokico Illuminas; Eibach Pro-kit; Progress RSB; AutoExe STB Exterior: MSP front lip & rear spoiler; Matt V headlights; AutoExe grill; EDM tails Interior: JVC AVX-77; Autometer gauges; DaveBs; B&M shifter Projects to come: Engine rebuild Last edited by Orion; 05-08-2014 at 10:34 PM. |
11-01-2010, 01:16 AM | #20 |
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Join Date: Oct 2005
Location: Ipswich, Queensland
Car: 2002 Mazda Astina SP20 2006 Mazda 6 GY Wagon
Posts: 9,769
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Now to find another so I can have a matching one like my rear! I knew I should have kept it for myself
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