Lewis7789 2002 Protege5 build thread (tons of pics)

[Lewis7789]

I are happy. I found a Mazda service manual and Mazda wiring diagrams for a 1996 Milly (which is my setup and year). That helps extremely! Just in case anyone else needs them in the future.

http://docs.milleniatech.net/

 

[Lewis7789]

Well, the radiator is probably the next issue to tackle. The default radiator would be a standard Millenia radiator and a slim fan. But I just found these on Summit Racing's website. hmmmm...

http://www.summitracing.com/parts/SUM-CSUM3804/

$375 for an aluminum radiator, and fan/shroud and mounting brackets sounds pretty good to me. My friend is coming over to wrench so I'll have to research it more tomorrow. But they have different radiator dimensions available, I'll have to cross reference the Protege/Milly radiator sizes with the Summit sizes.

 

[Perro del Sol]

Well, the radiator is probably the next issue to tackle. The default radiator would be a standard Millenia radiator and a slim fan. But I just found these on Summit Racing's website. hmmmm...

http://www.summitracing.com/parts/SUM-CSUM3804/

$375 for an aluminum radiator, and fan/shroud and mounting brackets sounds pretty good to me. My friend is coming over to wrench so I'll have to research it more tomorrow. But they have different radiator dimensions available, I'll have to cross reference the Protege/Milly radiator sizes with the Summit sizes.

talk to the guys @ Big 3 on Saturday, they maybe able to help a brother out!

 

[THE Phen]

Well, the radiator is probably the next issue to tackle. The default radiator would be a standard Millenia radiator and a slim fan. But I just found these on Summit Racing's website. hmmmm...

http://www.summitracing.com/parts/SUM-CSUM3804/

$375 for an aluminum radiator, and fan/shroud and mounting brackets sounds pretty good to me. My friend is coming over to wrench so I'll have to research it more tomorrow. But they have different radiator dimensions available, I'll have to cross reference the Protege/Milly radiator sizes with the Summit sizes.

Or, you can save $200+ and go with an OEM style that will be more than enough for your application...

 

[Lewis7789]

Well the big thing is the Milly OEM style fan will need mounting brackets. And I don't want to fabricate some half-ass brackets out of zipties. If I get the Summit kit it comes with their mounting brackets so I'll just drill/tap and bolt them onto the car and won't need to worry about them.

The OEM route is still an option.

 

[THE Phen]

Gotcha. I'm trying to think of who I know locally who has done some fab work with metal so that you don't have to go the ricer-drifter route.

 

[PrinceValorum]

Wait, I know someone that welds, but who has a welder?

 

[jri4]

I've got one of each:

Bear in mind I know nothing about welding. My uncle a few houses down does, though, and would be able to help out.

 

[Lewis7789]

WHAT!? Chipmunk, you have a mig welder? Niiiiiiice. I'll probably be hitting you up on that offer. I haven't welded in about 8 years but Wes seems to be pretty good at it.

And I think I'm going to push the install date further back a bit so I can get the LSD. I'm still shooting to have the motor in, and running flawlessly by May 1st for The Mitty. Plus I know it will be tough to have friends help with the swap when it's 25degrees outside. I just figure if I'm going to build this motor, I might as well do it right.

 

[Perro del Sol]

WHAT!? Chipmunk, you have a mig welder? Niiiiiiice. I'll probably be hitting you up on that offer. I haven't welded in about 8 years but Wes seems to be pretty good at it.

And I think I'm going to push the install date further back a bit so I can get the LSD. I'm still shooting to have the motor in, and running flawlessly by May 1st for The Mitty. Plus I know it will be tough to have friends help with the swap when it's 25degrees outside. I just figure if I'm going to build this motor, I might as well do it right.

So, are you driving trhe Audi @ Mid-Ohio in April?

 

[Lewis7789]

Hahahahaha! no. (but I wish. The TT is a bit tempermental...)

I'm driving the P5 with the FS-DE! She's still running like a champ and this time I'll push her harder since if the motor does pop, I've got a back up. I was still taking it easy on the motor at the last Hyperdrive and not really pushing it, short shifting and staying away from the high RPM's. But I'm going to give the old girl one last wringing before the new motor gets swapped. Then I plan on making it to the other Hyperdrives out of state too.

 

[THE Phen]

Surprise there... it is a Volkswagen after all...


I wouldn't be too afraid of your engine man. It's a good running engine. It's good to be cautious, but I would be confident with yours.

 

[Lewis7789]

Well yesterday I picked up a digital tach interface ($90) so my OEM tach will work with the V6. I got it from Summit Racing. I was looking at the tach's on display and was thinking of going that route with a smaller one because the huge ones just look ricey, even I know they aren't because they're functional, but still. And my buddy was like "Then your tach won't work in your car.". And that would drive me coo-coo-banana-crackers. So I went with the interface and kept my dash looking OEM.

I did buy a steering colomn gauge pod for a wideband a few weeks ago. I'm still debating on which brand for the wideband though. I was going to get an AEM but heard they aren't very accurate. Moooooore research...

And I just ordered my clutch and flywheel. I'm poor once again. haha

 

[Perro del Sol]

Well yesterday I picked up a digital tach interface ($90) so my OEM tach will work with the V6. I got it from Summit Racing. I was looking at the tach's on display and was thinking of going that route with a smaller one because the huge ones just look ricey, even I know they aren't because they're functional, but still. And my buddy was like "Then your tach won't work in your car.". And that would drive me coo-coo-banana-crackers. So I went with the interface and kept my dash looking OEM.

I did buy a steering colomn gauge pod for a wideband a few weeks ago. I'm still debating on which brand for the wideband though. I was going to get an AEM but heard they aren't very accurate. Moooooore research...

And I just ordered my clutch and flywheel. I'm poor once again. haha

Once again my son, you show much respect for the Flying M, and the zoom, freaki' zoom lifestyle.......

 

[blackdragon0731]

I just read like all 45 pages of this because I've wanted to keep up with a KL swap in a 3rd gen for the longest time. This is awesome! Also, check out ClubProtege.com, you'll get info on all sorts of Protege's from all years, and they'll be able to help you with the KL stuff just the same as the Probetalk guys, some of them are probably on both. Kudos on your work ethic as well, labeling and taking your time is the way to go!

 

[justanothermp5]

who says the AEM isnt accurate? mine is pretty accurate

 

[PrinceValorum]

I'm interested to see how much your LSD actually gets used. I was planning for more power and wasn't planning on one. Even on the track (not strip), it seems kinda pointless because you can easily modulate the throttle with your foot, it's not an on/off switch. I think if I was on the track it would be for me, not to set some records, but you're probably going for records. (evil)

 

[roy obanion]

With that power, you'll notice a difference at the track too. Hell, my 20 whp less P5 spun RT-615's around turns with no effort. I did a ride along in an Mk2 GTI with no LSD and he would break a tire loose on R-comps at Mid-Ohio. Just keep it in mind. It's not like it would hurt at all.

You want an LSD man. The P5 needs an lsd stock, with 43 whp. It's a combination of stiff chassis and the arrangement of the axles. you will hate yourself if you do not. the msp has less power than you'll have and even mazda, who ****** up most of the bj, recognized the need.

I think these guys know about LSD...but what do I know, I drive a hairdresser car

 

[Lewis7789]

Simon, I read somewhere that their AEM wasn't as accurate as their friends brand. I'm not saying that AEM's aren't accurate, that's just silly. AEM makes good stuff. I was about to pull the trigger on an AEM since they dropped the price but read that so I'm looking into Innovative as well. I'm sure yours is accurate, as are most of the AEM widebands, just gotta do more research is all.

Wes, I'm thinking the same thing and totally agree with you. It's not like it's impossible to drive on a track without an LSD. Hell, I'm sure there are tons of cars on track with 160+whp without LSD's. But again, it comes down to my plan of "doing it right". I have the transmission already out and am in no rush to get the swap done (other than wanting to feel some more power already, jeez!) and I might as well swap in an LSD now while it's easier to do and I have the spare cash. Than waiting until later in the summer, pulling the tranny out, dropping it off at a shop and waiting a week without a car.

I saw a video (I think here on 247) of a Mazda3 with before and after video of the MFactory LSD on an auto-x track and it really does make a big difference. Well worth $650+install. I'm not saying it's absolutely necessary like Phen and Rob are saying, but I agree with them that it is well worth it. Those Miata guys, pffsht... (you're in that group too, Ryan. haha)

 

[HKPRO5]

Post link? Glad to gear everything is going well. Where are you getting the LSD from?