Lewis7789 2002 Protege5 build thread (tons of pics)

[Lewis7789]

Justin, yup, that's the gasket I was referring to. Bull, did you install that monster gasket thing or just run without?

 

[Josue6WGN]

My seats bracket? I know you said you have a busted one but I have Recaro's with custom brackets so they won't help much. I'll check the garage for some spare parts tonight though.

HA! That didn't even occur to me. Yea, let me know if you've got one laying around.

Fark it. The swap begins next weekend, April 22nd. I just need to order some bolts, hoses, and radiator. Then Josh can pick up my motor, Rob can pick up my trans and Chris can pick up my MP3 ECU. Then I can sell off some other FS-DE parts to fund any unforeseen expensenses. My P5 might not make it to the Mitty but I need to stop dragging my feet and get wrenching. heh-heh

Josh, did I see a welder in your garage?

You sure did! My garage is always open whenever you need to use it.

And if you were wanting those steelies gone asap, you can bring them if you come over on sunday.

 

[bullshark524]

if you're talking about the outlaw engineering spacer then yeah i have them on

 

[Lewis7789]

Josh, I'll need my midpipe welded once the new motor is in to mate the midpipe from the OBX headers to the CorkSport midsection. If you can weld it up I would owe you big time, buddy. And I'll bring those steelies Sunday, fo sho.

Bull, I meant there is a large metal thin gasket sometimes between the tranny bell housing and the motor. My motor nor did my tranny came with one (though I do have the little dust shield on the bottom like you have, Justin). After looking through the Mazda manuals for the Protege and 626 it doesn't seem they have them. But I could've sworn my friend 1.8 FP had one when we swapped them. hmmm... I'm sure it's not vital, just curious.

 

[bullshark524]

no mine didnt come with one and i am pretty sure i didnt have one on the 1.8L. i dont even have that dust shield at the bottom

 

[Josue6WGN]

Josh, I'll need my midpipe welded once the new motor is in to mate the midpipe from the OBX headers to the CorkSport midsection. If you can weld it up I would owe you big time, buddy. And I'll bring those steelies Sunday, fo sho.

Sure can. It might not be as pretty as a TIG line or anything, but it'll be strong! haha

 

[THE Phen]

Hmmm.... I may have to utilize your services good sir. The transmission mount on my Civic is kinda goofed up. I've figured out a solution, but it requires a little welding.

Evan, if you can arrange this, consider it payment for using the Civic. Haha.

 

[Josue6WGN]

Happy to help! He can roll it over on sunday when he comes, or you can roll over before then if you want. I'm free after 5 on weekdays. lmk

 

[THE Phen]

Work has been ridiculous for me lately so by the time I get home, I just want my beer, a bite to eat, and to crash. I can't wait until next week is over.


/threadjack.

 

[ajkulish]

Why do you guys not know how to weld?

 

[Lewis7789]

I know how to weld, I don't have a welder. Big difference.

 

[CheeseHelmet]

Why do you guys not know how to weld?

Teach me!

I tried welding last summer with a stick welder and it really didn't work very well. The best I managed to do was to weld a brake rotor to a piece of angle iron. But the welds were weak, I was able to break them with a hammer

 

[Lewis7789]

AJ, I've seen your welds for your supercharger.

I learned how to Mig weld from a welder at my old work. Then just kinda learned as I went. Then got more practice when I was at the powder coating shop and racks would break, but that was about 8 years ago since I've touched a welder. So I would rather have someone with expertise do my welds for me. It's like painting and soldering. I can solder like champ and can paint, but welding is tricky and takes time to perfect, just like everything else.

 

[ajkulish]

I mean yeah my welds originally were bad, kinda spotty, but I found the problem there was a bunch of s*** on the teeth of the neg clamp and I didn't have the power high enough. Since I fixed that, the welds are MUCH. Bettter. A world of difference

 

[PrinceValorum]

Sooo excited for this to start!

 

[Lewis7789]

Well I'm back to weighing my options on a cooling system again. My philosophy is if I'm going to buy parts, I might as well upgrade them while I'm buying them new. So a used radiator is out of the question. I just don't trust them for something as crucial as cooling my new motor, ya dig? And I'm not the type of cat who just buys the cheapest stuff I can find.

So while hunting online I've found OEM-style replacements are about $200 from Autozone. So I'm leaning more towards a universal aluminium radiator from Summit Racing again. Simply because I only want to buy a radiator once. Why buy an OEM one now just to upgrade it in a year when the P5 will be spending more and more time on track?

So the dimensions for the radiators are;
Milly; 26" x 15-11/16" x 1/2" inlet/outlet: 1-3/8"
P5; 26-11/16" x 12-13/16" x 5/8" inlet/outlet: 1-1/8"

So I need to find a radiator with similiar dimensions to the P5 (so it will fit in the confines of the chasis) but with the inlet/outlet of the Milly. And I'll need to fab up some brackets to hold the radiator. Summit wants $80 for them, ouch.

Something like this radiator might work and it's $145.

I'll know more if it will fit for sure or not once I have everything removed and can take measurements. It might be a little tall. And the inlet/outlet will need an adaptor.

And I'll need to find a cooling fan solution. I can snag a 12" and 10" SPAL fan from Josh from his turbo de-mod. But I'm thinking since I will be deleting the A/C condensor only one 12" fan would work, right? I mean if bigass V8's run aluminium radiators with just one fan my pesky 2.5l V6 should be okay. But alas, more research needs to be done.

 

[CheeseHelmet]

What's wrong with your current rad? Without the A/C rad and a big fan I don't see why it wouldn't work. Just keep an eye on the temperature gauge (you might want to invest in a proper coolant temp gauge) and if it gets too hot for your liking then buy a fancy rad.

The big day is fast-approaching

How are you doing with the wiring harness?

 

[bullshark524]

last i knew justin was only running one fan

 

[Lewis7789]

The P5 radiator has the inlet/outlet on the opposite ends of the tanks for the KL. The KL rad has passenger top/ driver bottom inlet/outlets. If that makes sense.

I am going to wrestle with the wiring harness(es) tomorrow after work. They've been lurking in the basement waiting for me like a scary clown. not looking forward to all of that. But I think it will be easier to figure it all out with the motor/trans sitting in front of me in the garage tomorrow. I'm kind of lucky I've got a complete engine bay harness froma 1996 Milly with a KL, disty, ECU and O2 sensors. I'm hoping that with keeping all the same year/make/model will pay off. And I've still got the JDM KLK1 ECU and partial engine harness if things get messy. As well as a 94 engine/manual tranny harness. And the JDM MX-6 trans has all the plugs still on it so I can re-solder those to the harness as well. So I think I've got all the mechanical electrical bits/pieces. I just need to figure out what I should solder to what.

And honestly, I take meds for anxiety so this week has been rough. But I'm really looking forward to getting my hands dirty friday and finally working on the bloody car. I've spent more time on the computer than in the garage on this swap.

 

[bullshark524]

just took another look in justins thread and found this

yeah i only run one mx6 fan. Its a two speed fan low speed I have set for normal cooling operation, and the high speed is set for a/c operation.

edit:
also found this

And I run my cooling fan on a universal relay setup from advance that has a thermo-switch that slips in between the rows in the radiator.
QUOTE]