Pinkcheese's Conversion Borgwarner S256 BT Build

[pinkcheese]

Starting a build thread as my car keeps getting more and more involved and like a speed 3

Pinkcheese AKA Logan
I have a 2009 mazda 3 GT Sunlight silver Modification's listed below.

Performance

•AEM 96" Universal wiring harness
•AEM Boost Control solenoid
•AEM Coolant Temp sensor
•AEM EMS-4
•AEM Intake Temp sensor
•AEM Fuel pressure regulator
•AEM TwinFire ignition system
•AEM UEGO
•ARP Head Studs
•ARP Main Studs
•ARP Cam bolts
•ARP Crank bolt
•ARP 2000series Rod Bolts
•Autolite AR 93 6step colder Spark plugs
•Borg Warner S256 turbo
•Borla 3" Straight exhaust
•CFM 67MM throttle body
•Cosworth heavy Duty Main bearings
•Cosworth Heavy Duty Rod bearings
•Cosworth crankshaft keyed sprocket
•Cosworth camshafts
•Crower titanium springs
•Crower titanium retainers
•CP-E center dash gauge pod
•Crower Stage 2 FI Cams 280/280 (Should be labled as stage 4 with as much overlap they have) Soon to be installed
•Custom keyed ranger crank
•Custom Fuel basket with return
•Custom intake manifold spacer
•Custom built intank fuel surge pot
•Derale Oil Cooler
•Derale Oil Thermostat
•Eagle H Beam Rods
•GodSpeed intake Manifold
•Focus SVT re-Manufactored 255LPH fuel pump (BAP, Compatible)
•Ford GT green top 300 LPH pump
•Megan Racing Oil Catch can
•Modified Reactive racing turbo kit
•MSD Blaster II coils (150,000V)
•PCS XFC
•Silicone vacuum hoses
•Siemens Deka 1000cc/min high impedance injectors
•Supertech lash caps
•Supertech shims
•Suptech valves Stainless steel Intake Black Nitride coated.
•Suptech valves Inconel Exhaust
•Suptech valve seats
•Supertech valve seals
•Supertech pistons 9.5:1 compression With custom valve reliefs
•Summit Racing braided stainless oil feed line -3an
•Summit Racing braided stainless oil return line -10an
•Summit Racing braided stainless fuel feed lines -6an
•Summit Racing Route around check valve
•TurboSmart 38mm wastegate
•TurboSmart E-boost street 40PSI
•Throttle body adapter
•Valveoline Full race synthetic 20w50 (The illegal stuff)
•2.0 oil conversion plate
•2.5" stainless down pipe

Drivetrain

•ACT G6 sprung clutch kit
•ACT flywheel
•ACT Heavy Duty pressure plate
•Mazdaspeed 3 6speed transmission
•Protege Garage shifter weight
•Street Unit 90 duro tranny
•Street Unit 90duro passanger side engine mount
•Street Unit full race main engine mount
•Street Unit shifter bushings
•Royal purple MTX fluid 75w-90

Machine work

•Balance shaft feed line welded shut
•Balanced Crankshaft, Pistons and Rod assembly to .05grams for 9000RPM
•Custom keyed crankshaft
•Custom keyed pulley
•Decked block
•Honed cylinder chambers
•Oil pan welded for return line
•Pinned main bearings
•Pinned Rod bearings

Brakes

GoodRidge Stainless Steel lines
Mazda 5 rear brake conversion
Mazdaspeed 3 Front Calipers
Stoptech Rotors Front
Stoptech Rotors Rear

Suspension

•AWR endlinks (aftermarket style) Fronts
•AWR endlinks (aftermarket style) Rear
•Hotchkits sway bars Front and Rear
•Megan racing coilovers 10kg front 12kg rear
•2"drop Front
•1.5" drop rear

interior

•COBB short throw shifter
•Dome light LED blue
•Glovebox light LED blue
•Greddy turbo timer special edition black
•Mazdaspeed 3 shift knob
•Mazdaspeed pedals
•Map light LED blue
•Modified advanced warning features to include boost cut through Turbosmart E-boost street
•Modified Zeitronix Datalogger
Water temp
Fuel pressure
O2 sensor
Oil temp
Oil pressure
EGT sensor
Map sensor
•Schroth 4point harness

Exterior

•Anodized valve stems
•Engine hood spacers
•Enkei RPF-1 17X9 +45
•kumho ecsta XS 245/45/17
•Street Unit sponsor vinyl
•Zoom-ZOOm 3rd brake light





















Running off AEM EMS-4

- YouTube

- YouTube

[forcedinduktion]

Damn looks like a badass build! And a lot of $$$

[Ski82]

Can't wait to see the results from this build

[SLOWHATCH]

Bad ass man. If I may suggest, loose the mazdaspeed banner up front. Other than that, car looks great and that is one awesome build.

What kind of power is it putting out?

[pinkcheese]

It was putting out around 350-375WHP before switching over to the standalone.
Once I finish up the standalone there will be nothing stopping it at this point. Before I was running a piggyback which limited me on how far I can take the car due to lack of timing control. Now the only limitation is the clutch.

I am shooting for 450+ WHP in Dec. When I go to get it tuned. Then a few months after that aiming for 500+ WHP, Once I have done a direct port meth injection aswell as a more efficient intercooler.

Still have lots more to upload to this thread quite a bit missing from what is actually done to the car.

Originally Posted by SLOWHATCH Bad ass man. If I may suggest, loose the mazdaspeed banner up front.

^^ That banner is part of MazdaSpeed Motorsports program, has nothing to do with MazdaSpeed 3

[Chimmike]

nothing stopping? that 255lph in-tank pump gonna stop ya!

Holy $$$ build batman.

Good luck

[Monotonous ONE]

Awesome

I can actually say i have seen this car in person...which makes me cool

[DONOTBUGME]

wouldnt it be cheaper to get a speed and put in a bt.

[Tomas]

Guess you're only gonna do a few pulls here and there. Cuz with the stock radiator your shit's gonna get mucho caliente if you ever do more than 5 or 6 WOT pulls at a time.
Nice red line. 9K rpm. Wheeew! Does your rpm gauge do more than one full turn? lol. Did not see an rpm gauge in your interior mods.

[pinkcheese]

You guys would be surprised I have less in this build than most of the big turbo guys here do. Doing all the work myself.


That fuel pump is rated for 255LPH at 12v I'm pushing 14.3v through it and BAP on the way just in-case the added pressure is there. It is a remanufactored SVT focus pump which was built for boost a pump applications. This is one area I am not worried about in this build.

[DONOTBUGME]

what about all the other parts like brakes, axles, tranny, and other stuff the speed has upgraded compared to the mz3...or do they?

[pinkcheese]

Originally Posted by Tomas Guess you're only gonna do a few pulls here and there. Cuz with the stock radiator your shit's gonna get mucho caliente if you ever do more than 5 or 6 WOT pulls at a time. Nice red line. 9K rpm. Wheeew! Does your rpm gauge do more than one full turn? lol. Did not see an rpm gauge in your interior mods.

Stock radiator holds up very well I have been to several track days and it has maintained coolant temp very well. Oil on the other hand has gotten pretty hot I have 20"X12"X2.5" tubular oil cooler on the way with a thermostat. The 20w50 does a pretty decent job of not breaking down especially with the fortified zync-phosphate but still don't want to take the chance and destroy another turbo.

Originally Posted by DONOTBUGME what about all the other parts like brakes, axles, tranny, and other stuff the speed has upgraded compared to the mz3...or do they?

^^ I have a 6speed tranny this includes the axles. Brakes I am running MS3 fronts and Mazda 5 rears. Yellow stuff pads, and good ridge lines. This isn't just a power build everything that could possibly break has been changed out and all the weak links as far as suspension and braking goes.

[Tomas]

Originally Posted by pinkcheese Stock radiator holds up very well I have been to several track days and it has maintained coolant temp very well. Oil on the other hand has gotten pretty hot I have 20"X12XX2.5" tubular oil cooler on the way with a thermostat. The 20w50 does a pretty decent job of not breaking down especially with the fortified zync-phosphate but still don't want to take the chance and destroy another turbo.

Are you in Florida? what tracks and with what clubs?

[pinkcheese]

In Virginia, local autocross chapter rents out places time to time for track day events.

I missed VIR this year but hopefully next season I'll get out for some NASA events.

[kmac]

Nice build . U got my attention

[Karmat]

Funny bit is you will probably make more power than any MS3 here since you aren't crippled by DISI and won't run out of fuel like we do.

[forcedinduktion]

^^this. but i wouldnt go as far saying "any"

[Manny]

Originally Posted by Monotonous ONE Awesome I can actually say i have seen this car in person...which makes me cool

damn you're soo cool, I wish I could be just like you.

[pinkcheese]

Originally Posted by Tomas Nice red line. 9K rpm. Wheeew! Does your rpm gauge do more than one full turn? lol. Did not see an rpm gauge in your interior mods.

The engine is capable of 9,000rpm but I don't push it that far most I will ever push it will be 8,500rpm's. I wanted the capability to go higher and also to allow for a margine of error. These engines really shouldn't be pushed past 8,600RPM without quite a bit of work more than I have into it atleast.

Also The crower cams I am putting in peak power around 8,000rpm and drop off around 8,500rpm. so this gives me some shifting room and won't stress my components inside the engine to much with harmonic instability.

YEs the needle will go past the gauge it stops just before hitting the inner edge of the gauge. I do not plan to mod it because I rarely will get that high in the rev range.


Added a few pics of the keyed crankshaft surprised some of you haven't switched over to this yet atleast I would have expected some of the big power guys to.

[mason]

seems like there are a few things us speed 3 guys can do that you 3 guys are doing, build looks sick man!

how different is the speed 3s head compaired to the 3s head? iv never looked into it. 9000 rpm red line! bad ass!

[Chimmike]

Originally Posted by pinkcheese You guys would be surprised I have less in this build than most of the big turbo guys here do. Doing all the work myself.

how do you figure after just adding up the cost of parts alone?

I mean, I know Erich's build probably cost a lot, but I'm guessing he didn't reach the parts expense you have by a long shot, and he's at over 500whp

[dsmluck]

Originally Posted by chimmike how do you figure after just adding up the cost of parts alone? I mean, I know Erich's build probably cost a lot, but I'm guessing he didn't reach the parts expense you have by a long shot, and he's at over 500whp

That's what I was thinking. I am willing to bet my BT build cost less than half that parts list. Either that or OP is ultra Jew and got the parts for next to nothing.

[802MS3]

damn this shit is legit. nice job. bet youre gonna surprise some much fast cars out on the track.

[bmylez]

Erich has a built block. Let's talk about kmac. 494whp, stock motor. There's no way he spent even 1/3 of what the OP's parts list is. Turbo manifold, turbo, intake manifold, water/air intercooler, custom meth setup, clutch...and then all the other miscellaneous things, but nothing super expensive.

[Monotonous ONE]

this build is cool and all but i think you should answer the obvious question on everyones mind




what kind of gas mileage do you expect to get?

[Chimmike]

Originally Posted by bmylez Erich has a built block. Let's talk about kmac. 494whp, stock motor. There's no way he spent even 1/3 of what the OP's parts list is. Turbo manifold, turbo, intake manifold, water/air intercooler, custom meth setup, clutch...and then all the other miscellaneous things, but nothing super expensive.

even with Erich's built block, his pistons/rods didn't cost as much as OP's entire engine management system, let alone his extensive list of Cosworth parts, etc.

I'm betting the overall cost for this thing in parts alone exceeds what most guys here with built motors have spent, and with something simple like port FI, I'm betting 550whp isn't going to be hard to reach on the DISI.

[J-Liss]

hey logan didnt know you had a build thred here.

<3 you.

Originally Posted by chimmike even with Erich's built block, his pistons/rods didn't cost as much as OP's entire engine management system, let alone his extensive list of Cosworth parts, etc. I'm betting the overall cost for this thing in parts alone exceeds what most guys here with built motors have spent, and with something simple like port FI, I'm betting 550whp isn't going to be hard to reach on the DISI.

eh not really i got him those parts and it wasnt bad at all what he spend for the system. MAYBE a alittle more than a AP.

[pinkcheese]

Gas milage isn't bad even with speed density tunning and no maf it's around 20milea to the gal. Aslong as I keep my foot out of it there isn't real issues. No highway numbers yet because I don't drive to far with the far till it's all sorted out. Lasttime I drove it on a long trip it was around 35-38mpg

The speed 3 head and the 2.3l and 2.0l head one I'n the same are about $1200 of machine work from fitting together mainly the oil and coolant passages only thing that lines up is the headstuds. I am going to start building a frakenstien block here around tax season with a speed bottom end and a mz3 head. As a backup block.

I can tell you guys that only about 2-3 of the listed parts were bought at retail cost. And none of them big items.

[J-Liss]

if anyone can do it logan you def can.

[AtTheDriveIn]

Logan. Which shop is doing the machining for you?


Oh and fuck you and your port injection...

[pinkcheese]

Originally I used L&W and Melvins for a few oddball jobs. But I will more tha likely use this place in Ashland VA for the Frankenstein block sense they have quite a bit of expierence with this and other work I want done.

There has been quite a bit of headway recently with the new skiactive engines mazda came out with. I expect to see some more 500+ speeds now that you have a new fuel rail, Injectors and 2900PSI to work with.

Port injection is ok but I will miss the little bit of high pressure (175-220PSI) I was running there. Nothing like having a smooth idle, and being able to ramp the injectors with fuel pressure to change the flow characteristics for high power. Only thing port injection really has is simplisitic proven design with a lot more aftermarket stock for stock I'd Take DISI anyday.

Thanks for the vote of convidence Josh.

[dsmluck]

Originally Posted by pinkcheese Originally I used L&W and Melvins for a few oddball jobs. But I will more tha likely use this place in Ashland VA for the Frankenstein block sense they have quite a bit of expierence with this and other work I want done. There has been quite a bit of headway recently with the new skiactive engines mazda came out with. I expect to see some more 500+ speeds now that you have a new fuel rail, Injectors and 2900PSI to work with. Port injection is ok but I will miss the little bit of high pressure (175-220PSI) I was running there. Nothing like having a smooth idle, and being able to ramp the injectors with fuel pressure to change the flow characteristics for high power. Only thing port injection really has is simplisitic proven design with a lot more aftermarket stock for stock I'd Take DISI anyday. Thanks for the vote of convidence Josh.

What fuel rail and injectors?

[Chimmike]

he's referring to the skyactiv injectors, but as speedsixkillah mentioned, they do not directly fit the MZR, however he's sending them off to see if the internals will work in our injector housing

[harryclay]

damn logan didnt realize you had so much in the car. I gotta go for a ride in that thing sometime haha looks sick

[pinkcheese]

You'll have to wait till the beginning of the year. I'm driving around on 7psi right now. Not pushing it till I get some more time been so busy with work and school 7days a week. But once it's fully tuned and running good I'll give you a ride.

Most of the work is I'n the engine which can't be seen and the engine bay looks somewhat stock with everything hidden. nice sleeper effect.

[dsmluck]

Originally Posted by chimmike he's referring to the skyactiv injectors, but as speedsixkillah mentioned, they do not directly fit the MZR, however he's sending them off to see if the internals will work in our injector housing

How did I miss this? What are the chances the internals would fit?

[pinkcheese]

Unfortunately my tune date is getting pushed back, I have to send my EMS back to AEM for awhile voltage regulator is for the coms is going out do I cannot connect to it half the time with my laptop. Apparently this is a known issue bad batch of regulators, that AEM recieved. Pushed back 2 weeks. This gives me a chance to properly seal up the wiring with slmething more permanent now that I'm happy with the mock up I choose.

[Tabasco69]

You know Logan I was seriously considering resleeving my block with some Darton mids, hell of a lot better then the 2mm liner we have to work with, $660, probably another 300 for the machine work involve, can't say for sure I haven't really looked into it yet, also I think I found a reinforced main girdle assembly though you wouldn't think a one piece girdle could walk especially when using arp studs.

Mid december I' am headed back to PRE and do another dyno session since I will have the new ewg installed with the 18" screamer dump, and the new 386lph intank walbro...maybe just maybe might hit close to 400whp...we will see.

and I 'll get the final word on that halltech platinum 1000 mzr setup, pretty sure the oe ecm will still need to be ran parallel for ancillaries just like you are going to have to do with the AEM unit.
look good man, keep up the progress

[pinkcheese]

Originally Posted by Tabasco69 You know Logan I was seriously considering resleeving my block with some Darton mids, hell of a lot better then the 2mm liner we have to work with, $660, probably another 300 for the machine work involve, can't say for sure I haven't really looked into it yet, also I think I found a reinforced main girdle assembly though you wouldn't think a one piece girdle could walk especially when using arp studs. Mid december I' am headed back to PRE and do another dyno session since I will have the new ewg installed with the 18" screamer dump, and the new 386lph intank walbro...maybe just maybe might hit close to 400whp...we will see. and I 'll get the final word on that halltech platinum 1000 mzr setup, pretty sure the oe ecm will still need to be ran parallel for ancillaries just like you are going to have to do with the AEM unit. look good man, keep up the progress

If you are going to want to push more than 25-28PSI you really will need sleeves the MZR 2mm doesn't handle higher boost levels well this comes from the guys up at PCS when I spoke with them. This is why I am currently in the process of building a frakenstein block like they use on their drag cars disi/MZR block with port injection head. Shoot me a pm if you are really interested in sleeving a block. I have quite a bit of research on the matter

Sense you can pull timing and alter injection pulse width, you will make 400 only thing is that the stock computer does have limitations. I would suggest you really look into that haltech, You will have to upgrade your ignition system at a point to make those types of numbers aswell as need some full control in areas it isn't offered that and the peace of mind. The stock computer has to control the ancillaries, the power steering isn't belt driven and the alternator is a pain.

[pinkcheese]

Fuel system is finished and ready for install. Pressure tested it for 80PSI and it works.
Includes factory form and function. Removed the restrictive check valve, as well as ported out the fuel passageways from 1/4" to 3/8"
Also modified the factory feed so it acts as a return line now and feeds the fuel into the surge pot. This will help for high speed cornering. Finally replaced the factory fuel pump with The Ford GT 300lph pump at 14.5V