Another turbo P5 thread...

[khaosman]

well the engine is out

lol yep, making backwards progress

The gauges are soldered up and ready to rock, just have to connect them to the sensors in the engine bay which will be easy. I'm going to clean the engine bay and wire up the Microtech.

Also need to bore out the engine stand brackets so the transmission bolts fit through. Once that is done I can start figuring out how the heck that broken tee is coming out (not easily, that's for sure). I'm also going to put on the new intake manifold assuming it ever gets here (Ken promised it'd ship out this weekend). Throw another gasket on the oil pickup in the pan.

So maybe it'll be running some time in the coming week(s). It depends when this stuff arrives and how many problems I run in to. I already placed an order for stuff I broke (just a dust seal )

 

[khaosman]

And here are a couple pics of Saturday's work:
http://www.khaosman.com/gallery/turbo3/DSC09454
The next three or four photos are new...

 

[djarkitek]

hmm, machine shop? lol, or you can always try a reverse titanium drill, mine could'nt make it through the super strong tap, but maybe you'll have better luck. or heat it up...and try

 

[khaosman]

hmm, machine shop? lol, or you can always try a reverse titanium drill, mine could'nt make it through the super strong tap, but maybe you'll have better luck. or heat it up...and try

Definitely isn't looking too hot, that is for sure.

More fun too... the wires on the Microtech are too short to run them along the factory harness. Another day, another dilemma.

 

[khaosman]

Machine shop said to try welding a rod to the tap and trying to get it out like that. Drilling into that would be tough like you said. It'd just "walk" off

All the guys at Mazda are probably laughing at me. I had to pick up a gasket there so I asked them what they thought. One guy said "JB weld it and sell it" lol Another guy had a decent idea of trying to score the tap like a slot "-" and fitting a screw driver in there and getting out.

I'm putting it up on the stand here in a moment and will check it out.

 

[GMalatrasi]

I doubt the screw driver idea will work, it'll probably just strip it.
But hey you wont loose anything for trying... except maybe a lil time.

 

[khaosman]

Time to torch the garage

 

[khaosman]

Time to torch the garage

So for whatever reason, I tried to use one of those reverse-out screw extractors. I put about 12oz of Liquid Wrench on the bastard, followed by at least 60 seconds of heat gunning.

Obviously, this didn't work. Now I have two tap things broke off in my oil pressure sender port. (fu) http://www.khaosman.com/gallery/whygodwhy

Oh and my iPod is such a piece of junk. 2 second battery life, sporadically stops playing music, and other cool things. It took all my self-restraint to not smash the hell out of it with a hammer after this happened.

 

[GNO]

Hey, I just PM'd you asking about progress on this and then decided to do a search. DAMN!!!

I have a lot of broken bolt experience from my supercharger pulley swap days. Hardened bolts would break off in the snout and a wide variety of bits would not work. As mentioned in earlier posts, they wander or if I did get them started, the bit would get dull and stop cutting after getting about 1/16"-1/8" deep. A friend at work gave me some carbide bits. Titanium bits suck big donkey balls. After only a few turns, the carbide bits would cut more than all the others after hours of trying.

Try a carbide bit. The only carbide bits you'll find at are hardware store are for masonry. You'll want to try an industrial supply shop, or search online. The problem is that they are fairly expensive and extremely brittle. The ones my friend gave me shattered a few years back, otherwise, I'd drive over and extract that broken tee for you.

Once you get those extractors out, drill into the brass and bore it out a bit more, the rest will crumble and come out easily. Afterwares, clean it out with a tap.

I'll try to get a hold of you later this week to see if I can help with anything.

 

[khaosman]

IT IS OUT!!!!

Woohoo (cool) (bowdown) (birthday) (nana) (cabpatch)

Thanks to Bill, a family friend who is a mechanic. He had some nice drill bits and other assorted tools, including this awesome Mac magnet that is the size of a pencil but super strong. Anyways, much drilling, cussing, and tapping later, it is out.

We rethreaded it 1/8" NPT and the fitting went in like a dream. Using the magnet, compressed air, and carb cleaner we were able to flush out 99% of the stuff out. We took off the head to further flush it but there was a restrictor port that we didn't want to mess with. I'm not sure if it was replaceable or not, so we left it alone.

Anyhow, I'm going to get a new head gasket while I'm at it, maybe one of those thicker Cometic ones. Also some new head bolts, timing belt, and tensioner. Just gotta get this wiring figured out and then drop her back in... get the damn IC piping done and call it a day! phew

One MASSIVE f'n obstacle = overcome. I feel so relieved now.

 

[Kansei]

so it's almost done sorta? Engine back in the car? I hope not since you mentioned the timing belt.. with engine out, crazy, crazy easy, 15 minute job tops.. with it in.. zomg so freakin painful to get at everything.

 

[khaosman]

so it's almost done sorta? Engine back in the car? I hope not since you mentioned the timing belt.. with engine out, crazy, crazy easy, 15 minute job tops.. with it in.. zomg so freakin painful to get at everything.

Nah engine is out still. That should make installing that belt easy, along with the intake manifold and whatever other junk I need to put on.

I'm not too stressed about getting this done like omg right now!!! kind of thing, but some time soon would be nice Sunday marks 3 weeks of down time.

 

[Egprotege5]

Don't worry, mine's going under the knife this weekend. Already have all the internals, just waiting for the gasket set. Then break-in while obtaining the turbo components. (drinks)

 

[bazooka joe]

IT IS OUT!!!!

Woohoo (cool) (bowdown) (birthday) (nana) (cabpatch)

Thanks to Bill, a family friend who is a mechanic. He had some nice drill bits and other assorted tools, including this awesome Mac magnet that is the size of a pencil but super strong. Anyways, much drilling, cussing, and tapping later, it is out.

We rethreaded it 1/8" NPT and the fitting went in like a dream. Using the magnet, compressed air, and carb cleaner we were able to flush out 99% of the stuff out. We took off the head to further flush it but there was a restrictor port that we didn't want to mess with. I'm not sure if it was replaceable or not, so we left it alone.

Anyhow, I'm going to get a new head gasket while I'm at it, maybe one of those thicker Cometic ones. Also some new head bolts, timing belt, and tensioner. Just gotta get this wiring figured out and then drop her back in... get the damn IC piping done and call it a day! phew

One MASSIVE f'n obstacle = overcome. I feel so relieved now.

(cool)

 

[khaosman]

Don't worry, mine's going under the knife this weekend. Already have all the internals, just waiting for the gasket set. Then break-in while obtaining the turbo components. (drinks)

That's a good idea--if I had a turbo on there during break in period, I don't know if I'd be able to resist giving it the beans...

 

[mspeedP5]

That's a good idea--if I had a turbo on there during break in period, I don't know if I'd be able to resist giving it the beans...

Just program your EMS to keep you in line...

 

[djarkitek]

IT IS OUT!!!!

Woohoo (cool) (bowdown) (birthday) (nana) (cabpatch)

Thanks to Bill, a family friend who is a mechanic. He had some nice drill bits and other assorted tools, including this awesome Mac magnet that is the size of a pencil but super strong. Anyways, much drilling, cussing, and tapping later, it is out.

We rethreaded it 1/8" NPT and the fitting went in like a dream. Using the magnet, compressed air, and carb cleaner we were able to flush out 99% of the stuff out. We took off the head to further flush it but there was a restrictor port that we didn't want to mess with. I'm not sure if it was replaceable or not, so we left it alone.

Anyhow, I'm going to get a new head gasket while I'm at it, maybe one of those thicker Cometic ones. Also some new head bolts, timing belt, and tensioner. Just gotta get this wiring figured out and then drop her back in... get the damn IC piping done and call it a day! phew

One MASSIVE f'n obstacle = overcome. I feel so relieved now.

dude that's awesome man. good job and good luck, and dont ovetorque anything ever again , lol.

 

[GMalatrasi]

That's a good idea--if I had a turbo on there during break in period, I don't know if I'd be able to resist giving it the beans...

Hey I got the DP and the studs and the gasket!
Thanks alot... Now on to the new GT25R

PS: what are the studs for? the turbo and DP or what?

 

[khaosman]

Hey I got the DP and the studs and the gasket!
Thanks alot... Now on to the new GT25R

PS: what are the studs for? the turbo and DP or what?

S-pipe to J-pipe I believe. The ones that were in it work but they look pretty crusty, so just put those nice new studs and nuts in

 

[khaosman]

Slight updates...

Got my Protege Garage intake manifold, woohoo!

Now I am just waiting on head bolts and the Cometic head gasket before putting the motor back together. I'm afraid of waiting for the Cometic head gasket, so if it won't arrive here this week I'll just get a stock one

Today I plan on finally finishing up the Microtech wiring.