Project 'Add Power'!

Caporegime
Joined
11 Mar 2005
Posts
32,242
Location
Leafy Cheshire
Some of you have been following my attempts to FI my mazda for a while now, right from the start of my GT28 setup which got put on hold due to manifold issues, right up till last month when i finally got my hands on a Jackson Racing M45 supercharger.

I've always found my car fantastic fun to drive, show it a tight country road and you can't help but smile and put your foot down, however i found the straightline speed on more open streatches of road a bit of a drag, its not a slow car by any stretch of the imagination, in stock trim mine makes 140bhp which is good for 130mph and 0-60 in 7.7ish seconds, but it seems to suffer from midrange pickup issues which can make fast overtaking not quite as quick as i would like.

To combat this i made the decision to FI my car, i changed my mind from a turbo setup to a supercharger for several reasons, firstly power delivery is very linear, which should retain the cars balance down a country road, for example when powering out of a corner, also with a supercharger i don't have to tap into the cars oil or water supply, further simplyfiing the installation.

So after the long wait for parts from the USA i finally have all the bits to make a start on giving my mazda some added zip!

Many of you will know the car in question, but for those who don't it looks like this :

Mazda2.jpg


In a previous project when i fitted my K&N Typhoon induction kit i'd already removed vast amounts of brackets and fittings so this actually simplified stage one of the superchager fitting since i din't need to remove loads of standard mazda junk first.

Original Mazda engine pic (Not my car!) :

t418ydc%20en.jpg


Which changed to the following when the induction kit was fitted :

July5.jpg


As you can see the standard Mazda airbox is gone, as it loads of the connecting pipework & brackets.

A few months back i fitted most of the electronics in preparation for doing a project like this, currently the car has a Boomslang harness, Emanage Ultimate (Fuel / Air / Timing / Knock), Innovate Motorports LC-1 & XD-16 (Wideband O2) and a 4 bar Greddy Map sensor, all of this allows me to map the car either off AFR or MAP, infact with these two inputs i can actually put the Manage into autotune mode and it will work out a basic map for the car by itself.

So with this out of the way, project 'Add power' went into stage 3 at 5pm when i got home from work, i finished work at 7:30 ish so a good 2.5 hours work.

In this time i have removed all signs of the Typhoon induction kit, removed the manifold heatshield / screenswash bottle and associated brackets, attached the supercharger mounting brackets to the manifold studs and engine block, mounted and aligned the supercharger onto the hangers, started to attach some of the vacum lines, fitted the crossover pipe between supercharger outlet and throttle body (not needed at the moment but i needed to seal up the inlets).

Pics in next post :
 
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Supercharger1.jpg


Supercharger2.jpg


Supercharger3.jpg


Supercharger4.jpg


Jobs for first thing in the morning include painting the crossover pipe, which i finished sanding back to primer today, fitting some heatshield matting to the manifold and coolant pipes, if i can get this done in a few hours i will be happy.

Then i can move onto moving the powersteering pump onto its new hangers, removing the throttle body and mounting it onto the back of the supercharger, mounting the dummy throttle body onto the engine, routing a new throttle cable from the cabin & many other things i don't even want to think about at the moment!

More updates to follow when the happen :)
 
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Does this mean I'll have to get my hands dirty tomorrow :eek:

Can't believe the progress in one evening though, 'grats :)
 
Great project, interested to see how easy it ends up to fit and how you find the results.
What sort of power are you expecting?
 
The more hands willing to get dirty the better, you can all hand me tea and jaffa cakes :p

I'm looking for 210bhp at the fly with about 10 / 15% transmission losses once the power finds its way to the road wheels!

Hopefully this should be good enough for sub 6 second runs to 60 :)
 
Firestar_3x said:
The more hands willing to get dirty the better, you can all hand me tea and jaffa cakes :p

I'm looking for 210bhp at the fly with about 10 / 15% transmission losses once the power finds its way to the road wheels!

Hopefully this should be good enough for sub 6 second runs to 60 :)

Very similar power to Will then! Would love to have a ride in it when done, love mx5's.
 
I've got a new supercharger outlet on order from MOSS UK, which is taking forever to turn up, its the new design so should flow better but i can run with the old one for the moment.

Few more pics from tonight :

On the first two you can clearly see the rubbing marks on the outlet, this is one of the reasons i want to change it!

Supercharger5.jpg


Supercharger6.jpg


J&S Safeguard, which is knock monitoring and ignition retard, not sure if i'm going to run this since my Emanage will do the same job, however i'm thinking better safe than sorry atm:

Supercharger7.jpg


Dummy Throttle body, this going in place of the current TB (Left side of the engine:

Supercharger8.jpg


Upgraded engine pully, this is the 9psi version, stock kit come with 6psi, just one of the extras i got through buying the kit from the USA second hand:

Supercharger9.jpg
 
Firestar_3x said:
NP Catch me at the RR, Will and Myself no doubt will be comparing notes and arguing whos best ;)

Unfortunately I have an exam on the same day as the RR. :( Yes I know an exam on a Saturday! Hopefully there will be a late summer RR, may have a few goodies by then if insurance doesn't kill me...
 
Hi there

Looks pretty cool this.

Whats the dummy throttle body about, won't it just work with your cars stock thottle body?

Why the knock sensor, again cannot you not tune the car via its original ECU and a laptop on a dyno to get everything running nice without the addition of more piggyback computers?

I suspect the turbo car will feel faster due to that ace turbo rush feeling you get, but I reckon as the OP says the supercharger will keep the power delivery same as before making the car more usable and a quicker A-B machine, plus superchargers don't have lag issues. :)

Will be interested to see what you and Will have to say about each other cars. :)
 
Hi mate,

The reason behind the dummy throttle body is so the real throttle body can be moved to the back of the supercharger, this allows for better control of the throttle since you are adjusting the air input about the same space down the intake as you would be on NA.

The stock ecu is really thick, it can't be reprogrammed, so basically it won't add fuel or reduce timing when on boost, it will actually try and cut fuel making the engine detonate, so a piggyback is needed to take over from the stock ecu, the piggyback will also allow me to do runs and log various sets of data so i can see whats going on with the car.

I too think the car will be of better use A to B and also means wet weather driving should be easier :)

I can't wait to try will's car out, i didn't get chance to go in it last time and i've not actually been in a turbo mx5 yet only supercharged ones.
 
Firestar_3x said:
Hi mate,

The reason behind the dummy throttle body is so the real throttle body can be moved to the back of the supercharger, this allows for better control of the throttle since you are adjusting the air input about the same space down the intake as you would be on NA.

The stock ecu is really thick, it can't be reprogrammed, so basically it won't add fuel or reduce timing when on boost, it will actually try and cut fuel making the engine detonate, so a piggyback is needed to take over from the stock ecu, the piggyback will also allow me to do runs and log various sets of data so i can see whats going on with the car.

I too think the car will be of better use A to B and also means wet weather driving should be easier :)

I can't wait to try will's car out, i didn't get chance to go in it last time and i've not actually been in a turbo mx5 yet only supercharged ones.

Hi there

Ok that makes sense. Guess Ford did a good job with the Mustang ECU then as you can control everything via it and adjust as you like. So a tuners dream I guess as it supports datalogging too. :)

My car is fine in the wet just requires less throttle or smoother inputs in the wet and it can still move quick on a wet road. But too truly enjoy the performance it does need to be dry for obvious reasons when having that much power.

The BMW on the other hand is RWD but because its a 190BHP car and heavy it easy to drive on full throttle even in poor weather conditions and still remains on the black stuff. I am still considering getting an M5 which obviously would then have similar problems to the Mustang in the wet if your too heavy footed.

In the US the turbocharged Mustangs tend to be quicker down the 1/4 mile but the supercharged versions quicker on road courses no doubt due to better torque out of corners and good linear power delivery. :)

What can the MX5 engine output safely before it will put a rod through the block or loose the bottom end?
 
Problem i've got is the car is light so in the wet its very easy to get it sideways without doing too much, must be a lack of weight over the back end, in the dry after a hard run i've actally had the thing understeer first, after my mot a few weeks back the guy (Paul Sheards) thinks i need to do a full geo since the cars never been touched, i'm trying to think what setup i want, i'm going to wait till i've put my coilovers on before having it done but out of the factory the car is set to be on the safe side so if you go into a corner too fast tit will understeer first.

From what a read the bottom end is very strong good for upto 300bhp, but you are likely to throw a rod at anything over 240 / 260bhp, i know some guys running over 400bhp with wiseco pistons and rods running a lesser compression ratio than stock.

Still not been in your car yet, i will have to grab you at the RR!
 
[huzeeee] said:
:eek::D Looks like a good project, do you need any low compression head gaskets etc or is it a straight bolt on.

Thankfully nothing else (Engine wise) needs changing, the 1.8 unit is actually out of the Mazda 323 turbo so the block and bottom end is more than up to the job, compression is clearly different in NA form from the original 323 turbo but this only limits top power you can push through it before having to change things like pistons and rods.

I'm not sure if anything past 230bhp will be that usefull in an mx, its not a heavy car and i think you will find yourself sideways more than anyother direction :p
 
Woah Mark, like El said, superb progress in just over 2 hours.

I'm really pleased that you've started a project that you've been planning for god knows how long... as well as it being something a little bit different.

Looking forward to seeing this in the near future :)
 
agw_01 said:
Woah Mark, like El said, superb progress in just over 2 hours.

I'm really pleased that you've started a project that you've been planning for god knows how long... as well as it being something a little bit different.

Looking forward to seeing this in the near future :)

Cheers Andy :)

I'm pleased i've got it underway as well, having 4 full days off from work just seems like the right time to do this, coupled with the good weather we have been forcast for this weekend, feel free to pop down if you want, i can't promise it will be finished but i will have my head stuck under the bonnet till it is :)
 
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