Thursday 8/24
Big day for the build today-- much was accomplished.
First thing on my list for today was to remove the 1999 radiator and radiator fans. After it was removed, the msp radiator, radiator fans, and SMIC were mocked up before the install. I found out then, that there was not enough space between the front of the SMIC and the existing AC condensor on the 1999. So, the lines were purged and disconnected and the condensor removed, in addition to plugging the lines and the receiver to prevent debris from entering the system. Side note, I need someone to tell me if the msp AC condensor is only as wide as the radiator itself or if it spans the entire distance between the headlights like the 1999. If it it shorter I'll have to order the MSP AC condensor. If it's wider I'll just have to modify the brackets to make it sit up further in the frame.
With the condensor out of the way, the msp radiator, radiator fans and SMIC were installed and bolted into place. There were, however, two problems: The first major problem was that the passenger side radiator fan's electrical receiver was not compatible with the 1999 passenger side sender. So, the receiver (wires and all) from the 1999 passenger side radiator fan was swapped with the msp passenger side radiator fan receiver with some soldering. After that was complete, the sender/receiver hooked right up. The second major problem was that I didn't have the msp radiator/smic brackets. The brackets from the 1999 were not compatible because the msp radiator and SMIC sit flush with the frame (they are about an inch taller) whereas the 1999 radiator sat about an inch below the frame. The 1999 brackets accomodated this by arching downwards to bolt up to the radiator. This obviously wasn't going to work for the msp setup, so new brackets had to be fabricated. Templates were drawn and after about a half hour with the band saw, the grinder, the drill press, the belt sander, and the dye-grinder... the brackets were finished. They sat perfectly flush with the frame and fit excellently.
After the radiator, fans, and SMIC were mounted and the sensors hooked up, the lower radiator hose had to be reconnected and the upper hose had to be trimmed and turned to reach the msp radiator (about 2-3 inches taken off).
Once things were functioning the intake situation was tackled. After playing around with the n/a injen cai piping to find the best routed design, I settled on a design that is pretty similar to the injen cai design for the msp-- it flows nearly the same and the filter still sits under the driver-side headlight. The couplers and MAF were connected along with the intake-to-head line and the ambient air sensor. There is however, no bung location for the stock bypass valve, so a 3/4 inch hole was drilled and threaded in the intake, and a 3/4 inch barb was screwed in to make the bung for the bypass valve. The intake was cleaned to remove all the metal shavings and reinstalled. The stock SMIC-to-throttlebody pipe was installed and the radiator filled with coolant. The engine was cranked and it fired up like a charm. The power steering resevoir was filled with PS fluid and the wheel was turned slowly back and forth to drive out the airation that had built up-- that's what was making that nasty whining noise in the video. The motor sounds incredible. The 95 durometer motor mounts make the frame vibrate when the car idles/crankes along with the rumble of the turbo-back. When I gave it throttle it sounded amazing-- much better than tuesday's vid when neither the turbo, SMIC or the intake were hooked up. With wide open throttle and the turbo cranking you can actually see the turbo-to-SMIC piping expanding at the ribs from the air displacement-- I absolutely love it.
Tomorrow will be another busy day trying to get the remainder of the wiring issues solved. I'll keep you all updated.
Also I found out something interesting the other day. My car weighed in at about 2570 with the motor swap, that's about 275 lbs less than the mazdaspeed protege curb weight of 2843 lbs-- I believe that's a correct figure.
lol) next time i am in NY i want to see this car (june of 07 probally so u have time) 
