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Subject SZR, wanted to share this little project with you guys >
     
Posted by Ash's Z on December 18, 2016 at 11:28 PM
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Message 1987 Mazda B2200 I've had since highschool.

Over the course of the past year and a half I've put some time into doing something fun. Let a buddy borrow the truck at 380K miles and a small coolant hose blew, he kept driving it until it was puking oil out of every orifice. So just naturally, a VG conversion seemed fitting... for me, at least.

Setup on the engine test stand to fire off and check vitals.

VG30DE 10.5:1 OEM 0.020" over pistons w/30P heads.
Bowl work, port matching to the AshSPEC Ex. Manifolds
5spd cams
2.5" turbo inlet pipes
2.5"/3.0" charge pipes
Mitsu DSM SMICs, modified for fitment
3" divorced downpipes
3" midpipes converged to 3.5" and borla turbo muff at the back
SZ High-5 clutch
Stock turbos, 360-degree thrust bearings
Nismo 740cc injectors
Z32 AC Compressor fitted to the Mazda AC components. (YES, AC! :)
Ford blow-through MAS system

Stock turbos, disassembled, bead blasted housings & center housing, chem dipped rotating bits, new journal bearings and 360-degree thrust bearing groups installed for high-boost wear resistance.

Engine bay prepped and painted with modified Nissan AH3: instead of #3 pearl flake at 50g per gallon, #2 (thicker pearl chip) at 100g per gallon, high solids urethane clear coat.

AshSPEC LPHF Cast Iron manifolds fitted and turbos hung.

Engine mounts fabricated to use OEM vibration isolators to mate with the Mazda's original engine mount points.

Engine fitted. Wiring harness was hand-built from several old OEM EFI harnesses that were stripped down for wiring and connectors and lines made to lengths for good fitment.

The transmission mounting point difference between the OE Mazda location and the new location with the VG and Z32 trans was literally about 1" difference longitudinally and about 3/4" horizontally from center between the two fasteners. A 5/8" plate of 6061 aluminum was used to make an adapter plate to allow the Mazda trans vibration isolator to bolt up to the Z32 trans.

The Mazda driveshaft was modified to put the Z32 trans' output yoke at the head end. This was done in-situ with a dial gauge, tacked at two points and with the rear wheels off the ground, rotated, "tapped" with a mallet to eliminate runout, more tack-inspect sequences to build up a full 360-degree array of tack welds, then removed and fully seam welded.

Divorced downpipes fabbed. The turbine and wastegate pipes are merged into a 3" tube with mandrel bends leading to the 3-bolt flanges.

Midpipes and cat-back fabbed. This was later modified and the twin 2.5" pipes after the merge were replaced with a single 3.5" tube all the way to the back, through a borla muffler with 3.5" inlet and outlets.

Mitsu DSM sidemount intercoolers were modified to add a 2.5" inlet pipe and a new endtank on the discharge side was fabbed and incorporated 3" discharge mandrel bends.

Ford Mustang cartridge MAS were added in just downstream of the ICs to function as blow-through sensors. A voltage averaging circuit was built to combine the signals and then the ECU's VQ table was modified to suit the response of these sensors.

This is what the frame looked like from the factory:

Adding the TT Z32 1994 rear subframe assembly:

Fabbing the F1 style shock/spring rockers so the assemblies can be mounted horizontally rather than protruding vertically trough the bed. Honda Accord front springs were used to stiffen the spring rate. This was necessary given how this new geometry "leverages" the spring compared to how it works in the Z32.

Z32 Double-Race timing belt idler bearing used for the pivot arm:

Left-Right hand thread turnbuckles machined on the lathe:

Parts complete:

New lower control arms for the front were fabbed along with modifying the upper arms so that the Z32 spindles can be used.

The turnbuckle arm had to be modified from its base angle to correct for bump-steer when attached to the Mazda’s steering bar. The Mazda uses a Pitman arm system which moves on an arc from left to right so some mod was necessary to keep the steering geometry in check.

The front anti-sway bar was beefed up to better cope with the additional weight of the front end and to better suit the anti-sway properties of the Z32 rear end underneath this lighter-weight chassis.

A SS fuel tank was fabbed using 22ga 304.

Fuel pump baffle:

The OE Mazda tank bulkhead was used with the level sender to feed the gauge. Isolated terminals were fabbed to provide electrical power to the pump.

AshSPEC 13” Big Brake Kit Installed:

Z32 Seats installed:

Put her up on some 20” wheels: 20X10 rear with 285-30s and 20X8.5 with 245-35s.

Fabbed some injector adapter components to install Nismo 740cc squirters:

If you want to make your own:

The setup was tuned to run on E85 which we have locally here now. Literally installed the injectors yesterday and then tuned the setup on the way from Ormond Beach down to Orlando Speed World. She’s peaking 28.5psi on the stock turbos. Running 12:1 through the powerband and pushing 23 degrees of timing in the maps from about 20psi up.

Coming out of the hole on the maiden run:

Video:
https://m.youtube.com/watch?v=SR9xLxA69xI

Timeslip:

Second run Video:
https://www.facebook.com/ash.spec/videos/1513986251963484/

Timeslip: I launched her a bit harder on the second run and pulled a 1.884 60' and still wasn't spinning. Surprising given these are just Sumitomo tires. She could do even better.

I know it looks like a 1987 Mazda pickup... But to me, it feels like a very lightweight, very responsive and peppy Z32. She’s a hell of a lot of fun to slide as well. :) Next year will be the 25th year I've owned her...

Going up to Gainesville soon and put her up on the rollers to see what she’s putting to the wheels. Already planning to go to some GT2554R turbos. I wanna see 11's and then I'm done.

Some of the widebody modeling I've been playing with to figure what I want her to look like when finished:

I know it isn't a Z32 but it is my "other" Z32. :-D

Enthusiasts soon understand each other. --W. Irving.
Are you an enthusiast?

If you are out to describe the truth, leave elegance to the
tailor.
Albert Einstein

     
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