Bosswagon Ver 7.0 beta1

[rodslinger]

Do you still have your intake tuba in place or have you removed it? That looks satisfyingly faster than a stock 5 thats for sure!

I've removed all the stock intake tubing, box, etc... The air filter is in the lower front corner behind the bumper cover. Pulls air from the same area the stock intake did. 3" pipe comes up from that area and leads directly to the turbo inlet. MAF sensor is mounted in that 3" pipe. In one of the photos you see two polished pipes in the engine compartment. The larger is the 3" unit that runs from the filter to the turbo inlet. The smaller 2.5" is the charge pipe that runs from the intercooler to the throttle body. The charge pipe from the turbo to the intercooler runs underneath the engine.

 

[phunky.buddha]

6000 miles later.....

The only issue I have now is a light rattle in the exhaust pipe. I installed a high flow catalytic converter and the hanger is tweaked a little. It doesn't rattle all the time so it hasn't bothered me enough to pull it out to fix. You have to be accelerating at just the right load for it to rub so I usually only hear it once a day. No biggie at this point. I may wait to fix it until I have to go to Miami again next time. There is a exhaust shop down there that does mandrel bending and fairly reputable (Miami Muffler). They've done some work for me before and I may just let them run a new cat-back and fix the converter hangar.

Catalytic converter heat shield?

Just put an smaller diameter tube in the MAF sensor area to reduce the intake size to the same as the stock air box. MAF signal is perfect and no need to tweak it.

Good old MAF hack!

 

[rodslinger]

Decommision has begun...

I didn't start until today. I actually struggled with the thought of selling it. I REALLY like the way it drives. Finally took her for one last spin around the block this afternoon before starting. Rear end is back to stock. Tri-point bar removed, Koni's out and H&R springs out. MS3 wheels back on. Starting on the front suspension shortly. Pulling the snail off tomorrow.

I'll be leaving the MS3 brakes on it. It is a worthy upgrade even for a non enthusiast. Just feels better, more responsive and progressive. Next owner deserves a good set of brakes.

 

[rodslinger]

Catalytic converter heat shield?

Would you believe it ended up being the intercooler? I fixed it way back but didn't update. The engine would torque and the IC tubing would push forward just enough to make the end of the intercooler lightly contact the radiator support. The noise transmitting through the metal sounded just like an exhaust rattle at your feet.

 

[Rally Man]

Please do let us know when you put the parts for sale. Really interested on the springs. BTW, will you be sticking around after the part out?

 

[twintrbo]

How much are you asking for the turbo kit?

 

[rodslinger]

Will be selling the kit complete for $2500. That includes entire Tri-Point kit as it was delivered to me + AEM failsafe gauge. I've also installed a hi-flow 49-state catalyst in the downpipe. As long as you dial in the tune for your 5 you should have no issues passing visual and plug-in emissions checks outside of California. I'm not having to use any O2 tricks, hacks or anti-foulers on the sensors to get them to pass checks.
-$200 without the FIC if not wanted or needed.
-$200 without the AEM gauge setup if not wanted or needed.

I'll be sticking around. Will likely hang out to see what Mazda does for the next generation and decide if I want to go with that or go back to a 1st or 2nd gen instead.

 

[sac02]

Any interest in selling the AEM gauge separate at this point?

 

[rodslinger]

Any interest in selling the AEM gauge separate at this point?

Not yet. I'd like to give whoever is interested in the kit first option on it. It isn't a cheap item and has been invaluable in assisting in setup and making sure everything works as it should at all times. It can also integrate with the FIC. If the A/F gets out of a desired range it can have the FIC trigger an alternate fuel map for safety. Extra timing retard, +10% fuel, etc...

I think that is actually one advantage the FIC setup had over trying to get the ECU programmed. I would have lost that safety net.

 

[Rally Man]

you should have no issues passing visual and plug-in emissions checks outside of California.

And that's why I'm not even want to get interested

Damn California hippies!

 

[rodslinger]

Damn California hippies!

Jeez... Cali does suck.

New California Aftermarket Catalytic Converters
As of January 1st, 2009, What You Can and What You Cannot Sell/Required:

*Please Note - Installers may not install a new aftermarket catalytic converter in a vehicle unless all of the following conditions are met:

(A) The vehicle is specifically included in the vehicle application list for which the new aftermarket catalytic converter has been exempted;

(B) The vehicle is more than 7 years old or has more than 70,000 miles on its odometer;

(C) The vehicle is beyond the coverage of the OEM catalyst warranty period (which can vary from 7 years or 70,000 miles to as high as 15 years or 150,000 miles).2 Installers may reference the vehicle owner’s manual/warranty booklet or contact the vehicle manufacturer or its representative to verify the applicable OEM catalyst warranty;

(D) The vehicle has a legitimate need for replacement of the existing converter that has been established and documented by the installer on the repair invoice. If the OEM converter is present, the installer must make a determination that it is not functioning properly before acting to replace it;

(E) The exempted new aftermarket catalytic converter is installed in the same location as the OEM catalytic converter it is designed to replace. The front face of the installed catalytic converter shall be no more than three inches further upstream or downstream in the exhaust from where the front face of the OEM catalytic converter was located. The installation may not alter the location, position, or orientation of oxygen sensors upstream and downstream of the catalytic converter(s);

(F) The exempted new aftermarket catalytic converter is installed on a one-for one catalytic converter (not substrate) basis;

(G) The exempted new aftermarket catalytic converter is installed with all other required catalytic converters (no consolidation of catalytic converters, nor addition of extra catalytic converters is allowed); and

(H) A warranty card has been filled out by the installer, signed by the customer, attached to the repair invoice, and a copy returned to the manufacturer.

(I) Installers shall keep documentation regarding the installation of the new aftermarket catalytic converters including all of the above information. This documentation shall be made available to ARB or its representative as provided for in title 13, section 2222(b)(8). All such records shall be maintained for four years from the date of sale or installation of the catalytic converter.

 

[Silentnoise713]

Will be selling the kit complete for $2500. That includes entire Tri-Point kit as it was delivered to me + AEM failsafe gauge. I've also installed a hi-flow 49-state catalyst in the downpipe. As long as you dial in the tune for your 5 you should have no issues passing visual and plug-in emissions checks outside of California. I'm not having to use any O2 tricks, hacks or anti-foulers on the sensors to get them to pass checks.
-$200 without the FIC if not wanted or needed.
-$200 without the AEM gauge setup if not wanted or needed.

I'll be sticking around. Will likely hang out to see what Mazda does for the next generation and decide if I want to go with that or go back to a 1st or 2nd gen instead.

So tempting! I have so much cr*p that I absolutely need to install first, I can’t possibly take this on at this time. I’m sure you’ll find a buyer, if not I may be interested in the whole kit come summer. GLWS.

 

[TonyC]

I'll be leaving the MS3 brakes on it. It is a worthy upgrade even for a non enthusiast. Just feels better, more responsive and progressive. Next owner deserves a good set of brakes.

you're a nice guy. that's good karma right there.

 

[Rally Man]

Jeez... Cali does suck.

Yes sir, a big one too!

New California Aftermarket Catalytic Converters
As of January 1st, 2009, What You Can and What You Cannot Sell/Required:

*Please Note - Installers may not install a new aftermarket catalytic converter in a vehicle unless all of the following conditions are met:

(A) The vehicle is specifically included in the vehicle application list for which the new aftermarket catalytic converter has been exempted;

(B) The vehicle is more than 7 years old or has more than 70,000 miles on its odometer;

Got that covered.

(C) The vehicle is beyond the coverage of the OEM catalyst warranty period (which can vary from 7 years or 70,000 miles to as high as 15 years or 150,000 miles).2 Installers may reference the vehicle owners manual/warranty booklet or contact the vehicle manufacturer or its representative to verify the applicable OEM catalyst warranty;

Don't give a damn what the warranty period is.

(D) The vehicle has a legitimate need for replacement of the existing converter that has been established and documented by the installer on the repair invoice. If the OEM converter is present, the installer must make a determination that it is not functioning properly before acting to replace it;

I have not idea how that large screw driver penetrated the catalytic converter.

(E) The exempted new aftermarket catalytic converter is installed in the same location as the OEM catalytic converter it is designed to replace. The front face of the installed catalytic converter shall be no more than three inches further upstream or downstream in the exhaust from where the front face of the OEM catalytic converter was located. The installation may not alter the location, position, or orientation of oxygen sensors upstream and downstream of the catalytic converter(s);

Screw you (E)!

(F) The exempted new aftermarket catalytic converter is installed on a one-for one catalytic converter (not substrate) basis;

(G) The exempted new aftermarket catalytic converter is installed with all other required catalytic converters (no consolidation of catalytic converters, nor addition of extra catalytic converters is allowed); and

(H) A warranty card has been filled out by the installer, signed by the customer, attached to the repair invoice, and a copy returned to the manufacturer.

HA! Fat chance any of the exhaust shops do that (at least I don't think).

(I) Installers shall keep documentation regarding the installation of the new aftermarket catalytic converters including all of the above information. This documentation shall be made available to ARB or its representative as provided for in title 13, section 2222(b)(8). All such records shall be maintained for four years from the date of sale or installation of the catalytic converter.

Sure......

 

[rodslinger]

Got my 4WD Mazda back. It honestly feels like a 1970's Cadillac with the stock suspension back on it. I hit a small pothole and didn't notice it. Kinda freaky.

 

[hchia29]

Dude. I want to install a turbo on my 2010 mazda 5, but my wife will kill me trust. She made me get rid of my xbox when my second child was born.

 

[Rally Man]

^^^ wiped.

BTW, I'm in the same club.

 

[tuanies]

I'll get to a turbo eventually. My wife doesn't say anything about the 5, its my official project car for stories and such, which gets me paid lol

 

[twintrbo]

I brought it up last night, she didn't seem very into it lol. "Does everything we own need to have turbos?" Not sure how much time I have left with this platform honestly, my recent road trip to Florida brought some things to light if we are to continue using this car for road trips. I'm sure someone will pick this up from you, its well worth it.

 

[DougNuts]

I'd be interested in the suspension, well, except for the rear shocks because I already have them. Let me know if you want to sell and ship to KY.