mx5cartalk.com

Well I've owned my Velocity Red SE since October 2005 and soon it will cease to be my daily drive and retire to a life of luxury. By luxury I mean sitting in the garage and getting some nice new shiny bits. I haven't posted much but have used this forum ever since my first 1999 MX5, it has been invaluable so as best I can I will try and give a little back during my upgrade journey.

So...here are my plans for the next several months.

Stage 1
Turbosmart Manual Boost Control
Autometer 4301 Boost Gauge
FM Intercooler upgrade

Stage 2
Mazdaspeed Throttle Body Inlet and Kompact By-Pass Valve
AEM Intake

Stage 3
Full Exhaust (probably SMB)

Stage 4
Engine Management

Stage 5
Bilstein PSS9 Kit

Stage 6 (Maybe)
Garage Vary - Bumper, Side Skirts, Rear Skirt

A large part of this plan was gleaned from pages and pages of threads from here and Mazdaspeed and my good friend from Motec. I'm looking forward to pulling my experiences together in one place, so the next SE owner doesn't end up needing glasses from hours of reading on an iPhone.

I will post some photo's soon but you all know what a Velocity Red SE looks like and at the moment it is factory except for a Quick Shifter. I will also try and get it Dyno'd before I start any performance bits so there is a base line to compare with.

My goals are simply to have some fun and learn on the way. I'd appreciate any advice, warnings and/or support along the way.

While I'm here, a hat tip to Alf who did warm me about the soft wheels on the SE...unfortunately it was unheeded and at least 2 are wobblier than my Darth Vader Bobble Head. Something that will need to be fixed as part of my cars semi-retirement.

Stage 1 is due for completion at the end of November. Here we go.

Regards
Mentalpopcorn

That's going to become one very sweet ride; kudos

>Stage 1
>Turbosmart Manual Boost Control
>Autometer 4301 Boost Gauge
>FM Intercooler upgrade

S&H for the FM intercooler will be VERY expensive and probably come close to the cost of the intercooler itself - all up it will cost you about US$1,000 at least. I know this because I bought the FM Midpipe and exhaust upgrade in a Group Buy and it cost almost as much in S&H. FM do package the items well though.

Consider MX5 Mania's intercooler instead: http://www.mx5mania.com.au/product1264.htm
This will come with all hoses and mounting brackets (approx A$600). I bought this as my first major upgrade.

Alternatively, purchase a Cooling Pro intercooler from eBay.com.au, just type in "+mx5 +intercooler" in the eBay search criteria and you'll see a lot of them pop up for A$130. You will need to manufacture a mounting bracket (many people simply make these out of two pieces of aluminium and bolt them to the top existing intercooler bracket mounts - you don't need to worry about the bottom bracket mount since the intercooler is held securely there by the existing intercooler "barbs" and the car's intercooler pipes). You will also need to purchase hose adapters to connect the intercooler to the existing intercooler pipes (these are cheap from most car places such as Supercheap). All up, you're looking at approximately $250 and some effort on your part. If I was to do it today, this is the option I would choose - the MX5 Mania intercooler is the same Cooling Pro radiator.

Whatever option you decide, it will require cutting of the existing intercooler pipes. I did this with a hacksaw and the tricky bits with a hacksaw blade mounted in a blade handle. Unfortunately my cuts weren't straight and I spend hours getting it straight with a file. I recommend using/hiring a reciprocating saw for this job, you'll get a straighter cut and it will be MUCH quicker.

Your initial upgrades are a litlle out of order though. Consider this order instead:

Autometer 4301 Boost Gauge
Turbosmart Manual Boost Control
AEM Intake (very easy DIY install - purchase from the US, MUCH cheaper, even allowing for S&H)

Full Exhaust (probably SMB)
Mazdaspeed Throttle Body Inlet and Kompact By-Pass Valve

FM Intercooler upgrade

ie. The intercooler upgrade isn't really necessary unless you're thrashing your car.

If you can, do these upgrades yourself (I didn't do the full exhaust due to the hassles I've read from others and Midas did it for $80 so that was definitely worth it), you'll save yourself a bundle and appreciate the car more.

Thanks Lokiel.

I admit finding it very difficult finding some concrete information on installing a Cooling Pro or the difference between that and the Mania. Makes sense now though. Currently I'm waiting on S&H info from FM so expect as you say it will scare the bejesus out of me. Will probably compromise in the middle and go for the Mania, as this is still a daily driver for now I want to minimise installation time (and as my first time any brackets, pipes or instructions will help)....I have an outstanding query with Mania on price and availability on some bits which I'll chase up next week.

Turbosmart Boost Controller and Autometer Gauge are on their way.

I've been emailing Brian at Goodwin Racing regarding the Intake which are due in soon. Unfortunately the girlfriend will be holding this for ransom until Xmas. This has dictated the order of the upgrade, as did the exhaust which I've squeezed out of my parents for Xmas too. Still, the timing between Stage 1 to 3 will only be 4 to 8 weeks.

My expectation is all the upgrades will be completed by me to save costs although they will cost mate points. One friend who works for Motec and regularly races will be helping with Stage 1 & 4, and my best mate (mechanic of 23 years) will be helping with Stage 2, 3 & 5.

Been doing some more investigation into suspension today. Still appears Bilstein PSS9 is top of the list, particularly considering price via Shox and Aussie dollar. Ohlins DFV has peaked my interest by I think price will be deciding factor. At the end of the day it will never be a track car so I shouldn't go overboard.

Might post elsewhere to get some assistance on the exhaust, as I'd love to hear an SMB before proceeding or finding someone with Town & Country as a comparison (it seems these are popular of late, but not sure on their experience with an SE). I'm renewing my MX5 Club membership now so I'll try and get to the next event.

I think that is all the latest info and action.

The Turbosmart Manual Boost Controller was received today...very exciting.

Here are some photo's of the unboxing.


Pretty straight forward contents...controller, mount, Turbosmart sticker and CD installation instructions.

Here is a close up of the controller.


In other news today....following advice from Lokiel I opted for an Intercooler from MX5 Mania. I think it will be a nice compromise to fabricated mounts etc. It is on its way.

Did some more reading on exhausts mainly around size 2 1/2" vs 3". Broadly speaking several posts suggested once you go beyond bolt on improvements and into ECU/Injectors (hence more significant kw increase) that a 3" system may provide additional power. Went to the professionals and shot of an email to SMB to ask the question. Grant from SMB came back straight away and explained "for the SE due to a combination of the standard cast dump and the size of the original turbo, our system changes diameter to get the best of performance and noise.

SMB come off the cast dump at 3” into a 3” high flow converter (metallic 100 cell) then after the converter they transition down to 2 ½”, this keeps the gas velocity reasonably constant, and makes for a smoother power delivery, and the other major benefit is noise levels are only increased slightly from original with a deeper note.

To go to 3” from the converter back ( because of the turbo and cast dump) there would be no increase in performance just an increase in noise"

This is probably information many of you already know, but I found this explaination made sense and was very clear.

Renewed my membership to the MX5 Club of Victoria (after 4 year absense) and joined up my girlfriend. Plan to go on "A run through the trees to Strath Creek" on 7th November. Looking forward to it.

Grabbed a photo of my car from 2005. Basically the same except for the plates, now MX5SE.


All the best

Nice ride man, thanks for the information about your turbo set up, interesting to read and informative keep it coming

... Man I need some SE headlights!

Not too much new to report...waiting on parts is not as much fun as investigating what to get.

So we need to spice things up while I wait and that means......Dyno.

Saturday morning I will be getting some benchmarks results before starting modifications. If the Boost Gauge arrives tomorrow (cross fingers) I will also install the boost controller and gauge, and retest. Expect some photos and videos on the weekend.

Intercooler is also expected and with a four day holiday I might get that in as well. Everything is dependant on Australia Post and Couriers!

More soon.

Well, its all happening for you now.
After nearly 3 yrs of ownership and modding, I am still waiting for new parts also.
(6ULS and BCs)

As the saying goes, Once you pop, you cant stop!

mentalpopcorn wrote:Not too much new to report...waiting on parts is not as much fun as investigating what to get.

You mean you're not into hitting refresh on the parcel tracking websites? One of my favourite pastimes.

All the best with the mods. Will be keeping an eye on this thread for ideas.

The Autometer Boost Gauge has arrived! Thankfully I was in meetings all day, away from my PC and the temptation to track my packages. Unfortunately the Intercooler didn't make it today so hopefully I will see it Monday or Wednesday. Might still allow for installation this weekend as I have Monday off and Tuesday is public holiday.

Lets focus on the gauge which will certainly be installed this weekend. Here's what came in the box.


Although it came with a red light cover, I'd prefer a red LED, so I'm going to check with the local Autobarn and see if they have any. Might have to order online. Funny story here...found the LED at Amazon.com for around 10 bucks. When I checked the freight it showed $78 US.....hhmmmm....didn't realise LED's were so heavy.

Here is a close up of the gauge from front and rear.




Will be installing in the right vent. These are the best instructions I have found from the Mazda-Speed forum. Thanks to CanyonFive.
http://www.mazda-speed.com/forum2/index.php/topic,3109.0.html

Tomorrow is going to be huge....boost controller, gauge and dyno! Exciting.

As mentioned I'll take photo's and video tomorrow and document the installation as best I can.

Well here it is...dyno results for my completely stock Mazda MX5 SE.



Here's a video of the car on the dyno.



So the result was as expected. 94 kw and around 7psi boost I think is pretty standard for stock SE. After the first couple of runs we then installed the Boost Gauge and Manual Boost Controller.

It's a mechanical gauge so we had to run a tube from engine bay to cabin. My plan was installation into the right vent, so wanted to get close to there. We ended up threading it into a grommet right near the bonnet release.



The controller isn't mounted in the best location, but it is accessible.



Initally we just hung the gauge in the cabin so we could check it was working and play around with the boost. We completed several runs adjusting the boost to try and get it to the best position (before boost cut off). Ultimately it will change due to prevailing conditions but we got it pretty right. You see in the next dyno result a lot higher boost compared with the first run. Kw remains unchanged as the extra boost isn't sustained throughout the top end. Someone smarter than me can confirm this but I expect this is simply a restriction of other components i.e. Exhaust, Recirc Valve etc. The controller is just a means to an end, so will come into play more significantly later. You'll also see kw drop off which we believe is result of engine etc heating up after several runs.

The purple line was where we left it.


On the road, you certainly notice a kick at around 5000/5500 rpm from 1st to 2nd, and maybe a little earlier in 2nd to 3rd but it is more minor. This is similar to the experience of other posters. On the way home it got a lot cooler and started raining so starting hitting 10psi on boost gauge and experienced some boost cut out. Adjusting down a little to accomodate and expect will be playing with this a bit over the weekend.

So....the gauge install was fun. Plenty of instructions available which helped immensly.

How to remove a dash vent from MazdaSpeed
http://www.mazda-speed.com/forum2/index.php/topic,479.0.html

My previous post can direct you to install instructions as well. Below are some photo's on the gauge install. Happy to answer any questions anyone might have. A couple of things to note...

-Using credit cards or equivilent to get the vents out works really well. The clips you are aiming for are at 3 and 9 o'clock.
-I used string to pull the vent out, it did break, but just in time. Used the air con to blow the string end back through.
-The gauge is a tight fit, so make sure you line it up for installation. There are two divots at 3 and 9 that it clips back into so ensure it level.
-I purchased some aftermarket LED's at Autobarn rather than Autometer LED's. Reason was it had actually 5 LED's and provided better coverage...problem was it was too big and hit the gauge needle...be careful! Opted for the standard globe with red cover for the time being.
-Take care when putting the vent/gauge back in as it is very hard to get the air vent back out without the ability to pull it from the centre. Line everything up before clicking it in.
-The dimmer switch is inverted, so my first connection to it dimmed when the dash was bright and visa versa. Ended up connecting my White connection to Red/Black and Black connection to Red/Grey. This dimmed correctly. Here is some info on the MX5 dimmer that helped. http://forum.miata.net/vb/showthread.php?p=4328260

Smarter men than me fitted off the Manual Boost Controller, so I learnt a lot during the process, but not too comfortable given any detailed instructions here. Suffice to say the Turbosmart instructions were pretty good.

Now..photo's.

LED light test. See the multiple lights. Too bad it didn't fit.


Vent coming out with card and string.


Vent no more.


Press in the side clips to get the silver surround off the backing. This will allow inner vent to come out and gauge to go in.


Gauge in and surround back on


Plug the light in, screw in the boost tube and push the gauge back in. Don't crimp it! This was awkward, but ended up using the excess tube and curled it behind the gauge in the vent. It appears OK. Also put some old Towel into the vent so hot air doesn't heat up the gauge.


And in the dark


Well that is it for this weekend. Pretty happy with the result. Gauge is an excellent match to standard instrument cluster. Whether I miss having the vent, only time will tell.

I doubt the Intercooler will arrive Monday...who works in Melbourne on Monday! So that may be a job for next week. Ordered and paid for the Inlet replacement and blow off from Flyin Miata, so that will be on it's way next week. Exhaust should be ordered in the next two weeks.

Happy to answer any questions on gauge installation and process so far, or hear your feedback.

All the best.

Looks Great

Thanks for posting the dyno results, I always wondered what the OEM car actually produced at the rear wheels - no wonder the car felt so dramatically different after I installed the AEM CAI (the PO had installed the FM downpipe but the car still felt pretty "ordinary" for a car with a turbo).

Supposedly the OEM car's engine produces 121kw which means yours lost 27kw (ie. 22%) down to the rear wheels - isn't that way too much, or were the original engine specs a little inflated? Surely that doesn't happen

In future, here's a safer Eyeball Vent Removal guide:
http://forum.miata.net/vb/showthread.php?t=396304

Please continue to post your excellent installation pics and notes, I've learned from others doing this and create them myself - we can never have too much information and it's always good to be aware of the "gotchas" involved during installations since they can bring DIY installations to a screaming halt (and since I only have one car, that makes things quite difficult if I need a few more parts/tools).

Thanks Lokiel for the encouragment. I agree that losing 22% from flywheel to rear is too much to bear. I guess that's why we do what we do. Also thanks for the additional info on the eye ball vent. I actually ended up using one card that was equivilent to credit card thickness and another that was a bit thinner...I think it was my old gym membership (at least it was good for something!).

Not much to update today...the boost controller is working well. I did dial it down a little this morning and now I'm hitting close to 10psi without hitting boost cut. I think if I was to do the gauge again I would probably get one that you can lock the highest boost position so you don't have to stare at the gauge...I find my eyes being draw to it...cannot be good for safe driving. I might just pencil that in for an upgrade in the future.

SMB Exhaust has been ordered and paid for. It can now officially be called and "early" Xmas present...it will be installed as soon as it is received and I cannot wait!

If the weather is good Sunday I will probably be heading out for my first club run "A run through the trees to Strath Creek".

So as far as all the bits are concerned, the summary is:

SMB Exhaust - Ordered, expect late this week or early next week
Mania Intercooler - Due this week
AEM Intake - Back order expect Mid/late November
Inlet and Recirc Valve - Back order expect mid November

Big update today as lots of stuff has arrived. But first, just a quick word on my first run with the MX5 Club Vic. Completed the "Run Through the Trees to Strath Creek" passing through Hurstbridge, Arthur's Creek, Kinglake, Healesville, Flowerdale and Strath Creek. There were around 30 cars from NA to a just purchased NC. It was also nice to see a couple of Velocity Red SE's. The people I met were fantastic and very welcoming. I highly recommend anyone who hasn't joined the club to do so and come for a drive. It was a great day. Here's a photo.



Now, to the unboxings. Over the last several days I have received: SMB Full Exhaust, Mania Intercooler Kit and FM Throttle Body Inlet and Turbosmart Kompact Recirc.

The SMB Exhaust came very well packaged. It took me 20 minutes just to take off all the bubble wrap and plastic wrap. They must have used gloves when wrapping it as I couldn't even see finger prints in the shining surface. They also threw in a few hats and stickers which was a nice surprise. I am soooo busting to get this in!!



The Mania Intercooler Kit was well wrapped with each side of the cooler covered by a piece of card. It came with the mounting bracket, reducers and 4 brackets. There were also fitting instructions.

Intercooler with protective card and bracket


Intercooler uncovered


Reducers and brackets


The Flyin Miata Throttle Body Intel and Turbosmart Kompact Recirc Valve came boxed and well padded with newspaper. Instructions were included. Although there was some delay with backordered parts, once sent, it only took 4 days to arrive from the U.S.



So what now.....

Well, unfortunately the weekend is finite, so I need to make some choices about what gets fitted now or later. I don't think I will be able to resist getting the exhaust in so that will be a job for Saturday. If quicker than expected I may then go for the Throttle Body inlet. Then leave the intercooler for the following week.

Lots more to come so stay tuned.