Lewis7789 2002 Protege5 build thread (tons of pics)

[CheeseHelmet]

Ah, I didn't know that about the rad. In that case, I'd get the big fancy one

Heh, I get really anxious too when doing anything unfamiliar to me on my car. Luckily I have a patient brother who deals with my s*** when things aren't going smoothly. Regardless, take your time and enjoy it. If you rush, you'll never enjoy the work and you'll make mistakes. Luckily you have a bunch of awesome people who can help!

Oh, and take pics

 

[Lewis7789]

Luckily you have a bunch of awesome people who can help!

Damn skippy. Between all you cats helping out online, my local Team Ohio peeps and a roommate with 5 cars I'd be screwed if i was trying to do this alone. So a sincere thank you to you guys.

Wes will be taking lots of pics of the build. And my buddy Pablo will be helping me out with wrenching. He's one of the few cats i trust enough to touch my car. haha

And thanks for the info, Bull. I think I'll rock the single 12" fan and see how it works out, then add the 10" if necessary. speaking of fans, the 12" and 10" from Josh were used as pushers but I can just re-wire them as pullers right? Then again, since I won't have an A/C condenser I can just mount them to the front of the radiator and use them as pushers. Seems like a better setup especially for the thicker core of the radiator will put it closer to the motor/header. Hmmm...

Speaking of headers, the OBX headers should be here Thursday. Going to pick up some DEI wrap from Summit for them tommorow after work and wrap those puppies.

 

[CTt3P5]

Sweet....the big hand is about to hit twelve on this swap! I was going to suggest using Josh's CS rad but wasn't sure if the specs would be right since it was used with the turbo set-up but now know it's moot due to the reversal of the hose fittings.

I get anxious too, especially if it's something I've never done before and at this point, that's just about everything as the P5 is the first car I ever picked up a wrench to do my own work on. I read up online, see what you guys have done/suggest but it also comes down to my lack of the proper tools at time and no-one nearby that I know of who may have them...double the anxiety. lol

 

[eprx799]

Evan
I don't know anything about your p5 but using a fan as a pusher is much less efficient the using a fan as a puller. So if you have the room make the fan a puller, and all you need to do on a DC fan is switch the wires so it runs in the oppisite direction. good luck with the build if you really need a hand let me know I and I will clear some time.

 

[Joost27]

Just a little something i have briefly looked into but a miata radiator has similar outlets and inlets to the mx6/626/millenia and almost same dimensions as the protege. Also, you can find dozens of choices for upgrades if you go that route.

 

[PrinceValorum]

Oh, and take pics

Lol I got that covered.

Evan
I don't know anything about your p5 but using a fan as a pusher is much less efficient the using a fan as a puller.

That makes sense, I would assume the air can "squirt" out the sides instead of going through the radiator.

If you can seal all around the radiator (not sure with what, I probably wouldn't use expanding foam, lol), so any air that goes in through the front grill has to go through the radiator, it seems like it would make it pretty efficient, especially for track use. I guess that depends on if the radiator goes across the whole front, though. You could build one of those air funnel shields like Bill did on his Protege race car, too, if that's a problem.

 

[HKPRO5]

If you can try to stay away from the wrap. Get it Jet coated! (if possible) if not then go with the wrap. lol

Just from personal experience.

 

[Lewis7789]

Marc, thanks for the offer, mate. And I figured I could just switch the wires to make it a puller fan. But why are some fans labelled as pushers and some pullers? Wouldn't it just matter on how it is wired?

The reason I'm looking into a pusher fan is because I have a lot of room in front of the radiator for the fans. Not so much when the thicker core radiator is mounted and closer to the V6 front header. It will be a tight fit if it's a puller fan setup...

Justin, thanks for the heads up on the Miata radiators! There are tons of options out there for them and doing a quick search looks like you're right about the dimensions being very similar.

Wes, I'm looking for a radiator that will cover the front end well so I won't have the gap problem like Marlon and Bill have/had. Measure twice, purchase once. heh-heh

HK, why no love for header wrap? I'm not trying to start s***, just curious. It seems like no one likes header wrap. I can see if you wrap a header with thin walls it could heat up the welds/piping too much and make them crack. Or they can hold in moisture and rust them out. But I wrapped my header last summer and everything still looks good to me. I'll get a better look at it this weekend. But you're right, coating it would be the best thing. But I'm just going to wrap it until I find out for sure if I can run just 2 O2 sensors or will need 4 like the USDM Milly motor. I still have to find a definetive answer if the JDM KLK1 ECU only uses 2 or 4. If I need 4 then I'll have to have the bungs welded into the headers. PGT's and MX-6's only have 2 OBD1 O2 sensors...

 

[THE Phen]

Marlon and Bill's radiators are supposed to be like that thanks to the side mounted intercooler.

 

[Lewis7789]

Yeah, I know. My point was I want to find a radiator that fits well without much gap so there won't be any blow by.

Got my headers today and DEI header wrap last night from Summit. I'll wrap them tonight and take a pic.

 

[Lewis7789]

Well here's a pic of the headers and wrap. I got one header wrapped but decided to hold off on wrapping the other because of the EGR tube. I forgot my motor doesn't have an EGR so I don't need it so I cut that badboy off and Josh is going to weld the hole closed for me.

 

[Josue6WGN]

PURRDY!

where's that hole at?

 

[Lewis7789]

You can barely see it in the pic, it's the top left header, the bottom bung. But I cut the tubing off so it's just a small 1/8"-ish hole.

 

[HKPRO5]

Although its too late, going with the jet coat will protect not just the outside but the inside as well. Its also cleaner, and will give you more clearance for surrounding items as well as the thermal reduction and what not.

I didnt like the wrap because of working around it getting fiberglass shards everywhere sucked. Maybe you will have better luck than I did. lol

 

[Lewis7789]

Ahh, yeah, I can see that. I mean, ideally, that's the way to go. But probably pretty expensive.

I'm pretty good with header wrap, I've done 4-5 headers now and I think do a fair job at them. The trick is to get header wrap a little wet so it's easier to work with. I'll take pics once the other header is welded and wrapped.

 

[Josue6WGN]

a little wet so it's easier to work with.

Giggidy Giggidy!

 

[Lewis7789]

Haha! Nice, Josh. Giggitty-goo.

Well, so it begins. I parked the car in her spot for the last time with the FS-DE and the next time she's out of the garage will be with v6 powa. We had a little talk about how surgery will be okay and she'll be feeling much better with the new motor in. And I gave her a hug.

I'm going to change into my wrenching clothes and get to work. Woo-hoo! I'm excited.

 

[goodfornothing]

OMG OMG OMG this is going to be so epic! Good luck with it man! She'll be fine, her sister will be praying for her

 

[Alamo1]

Looks like fun! Good luck. She'll thank you in the end.

 

[ajkulish]

id be pumped. what are you doing with the header off the fsde? ill buy it if the price is right, pm me.