Got the races mixed up. I know a company caled AK Automotive who ran a 1.6 in the Northern Sports and Saloon Car Championship that had been tubocharged to 250 bhp. they have now put in a 2.0 turbocharged engine and it has 350bhp. the car they run in the Ma5da races car no 90 which is a different car.

I would say 250bhp out of a 1.6 would make it fairly unreliable!

Go for a 1.8 john ;)

I would have thought so too, but lots of people seem to manage to get that sort of power out of the 1.6 (or at least claim they do!).

I think I'm just going to rebuild the 1.6, then possibly think about adding a small turbo. I won't be trying to get anything like 250bhp out of it though!

Almost ready to get the engine out by the way James. Just need to undo the gearbox and engine mount bolts, so the sooner I can borrow your crane the better ;)

Are to going to decompress the engine or just run really low boost?

I best get a wriggle on.....:rolleyes:

There's no need to decompress unless you're going for silly boost.
Mazda used a slightly modified engine from the 323 turbo for the early MX5's, so they're already fairly low compression, and ideal for bolting a blower on :cool:

Don't worry about rushing, I've got plenty of other things to be getting on with!

You make it sound so easy;) :D

Only because I've never done it before, and I'm still blissfully unaware of what's really involved :D

:D how hard can it be!?!??

Harder than I thought - just spent an hour trying to get a broken stud out of my turbo and I still haven't got the c**t out :mad:

https://www.youtube.com/watch?v=vUKg...0U5 9RxFKwHWq
aussie boys run you through the process
john

That Turbo Manifold design looks great, cheap and easy. I'm already browsing ebay for a TD04 turbo! :D

I had something very similar in mind for the manifold :D

Just been offering up the turbo to the side of the engine. It's looking a bit tight!

What turbo have you got again? That manifold is tiny though, surely with something like that you could make it work.

I didn't say I couldn't make it work :D

I've got a TD04L-12T off a Volvo:

That looks fine! There's loads of room! ;)

What is the melting point of fibreglass again?? :D

Tidy job. That you tube video is going to get us all divorced, & bankrupt ! :D well done for this skov, pioneering the way for us mx5 boys. I smell competition with the fix or repair daily boys !:D :D

I smell brown trousers :p

Have you not got the turbo upside down in the pic john?

Mine went the other way up:confused:

Erm sort of... but if I put it the other way round the exhaust comes out the wrong side :rolleyes:
I have however removed the locating pegs in the housings so I can rotate the centre section round 180 degrees so it's the right way up.

its called "clocking" when you turn the cartridge....ideally you want oil feed at the top and drain at the bottom...drain usually goes straight into the sump. things look like they are going to be tight in there use plenty of that heat shield stuff on the back of any fiberglass near hand.

I nearly bought a TD04 this week! Fortunately I came to my senses and bought some aluminium sheet! :rolleyes:

What engine management are you thinking of using John?

There's no point resisting, you know it's inevitable :D

Haven't quite decided on engine management yet. I've got a half baked plan to modify/enhance the OEM ECU, but chances are I'll get stuck or lose interest and buy something instead!

In other news, the turbo project's on hold whilst I rebuild the engine.
Stage 1 is complete - got the engine out this evening:



Thanks for the loan of the crane James :cool:

You have been a busy boy this week! ;)

Glad to help mate :)

I suspect the rest of the week will be somewhat less productive.
I woke up with a severe case of man-flu this morning... :(

Funny you should say that I can feel the onset of the dreaded man flu!!:(

Oh no! Apologies if it was me that infected you :o
Hope for your sake it wasn't - this has got to be the worse case I've had in years :(

I used to have a load of TD04-HL15G's when I had my T5...

All long long gone now...

TT

Look at this!

http://www.homemadeturbo.com/fabrica...flange-120190/

I'm still looking at turbos on ebay! :D

It was a bit touch and go at times, but it looks like I somehow survived the dreaded man flu!
Managed to drag myself out in the garage the last couple of nights and got the engine stripped down.
The block's currently waiting to be picked up for a honing before I treat it to a new set of piston rings and bottom end bearings:

Doing a proper job! Which TD04 did you get 12T 16T 15G etc?

Doh. Nevermind. I have manful this week and it's affecting my mind!:(

edit: *manflu! See what I mean!

Ha ha, I know the feeling Chris.
My head's only just about back to normal. In fact I'm not sure what I was thinking when I decided to do a proper job on the engine rather than my usual half ar5ed approach :D

Got my block back yesterday - it's looking much nicer now the bores have been honed.
Ordered a set of ACL race series bearings but currently struggling to find any sensibly priced piston rings - mazda wanted £216+VAT for a set :eek:

crikey:eek: for not a lot more you could get forged pistons that would come with rings... if you google mazda tuners in the uk there are a few to whom you could ask

:eek: That's really not so good!

That's going to be one quick car when it's done. Have you had your turbo rebuilt ? I changed my mates turbo on his laguna 1.9 dci, and it was knackered ! The turbo veins had been hitting the casing, and had completely lunched the veins ! Just check the end float in the turbo, & make sure that you have no play at all, otherwise it could cost you your engine when bits fall into the block, as it did with my mate. I will put pictures up on here in a bit. Turbo clinic are really good, they will completely rebuild it for about £250, or if you are feeling really brave, you can buy a replacement cartridge for about £160 on the net. Good luck !:D

To be fair there is a bit more play in the turbo than I would like.
The blades just touch the housing....
My current plan is to buy a rebuild kit and rebuild it myself. How hard can it be :D

Regarding the piston rings, after hours of googling and cross referencing I managed to order a set of aftermarket ones from the states for just under £50.
Fingers crossed they turn up and they're the right part!

I would get that turbo rebuilt to be on the safe side. The two faces should not touch. I know that the tolerances are very fine, but if that thing touches, your rebuilt engine will be in a bit of a bad way.

If you are planning a re-build then invest in the best circlip pliers you can and a pair of needle nose pliers......you will defo need them;)