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Austin's RX-7 FB Turbo II Swap

Discussion in 'Project Cars' started by Lindahl#7, Jul 24, 2013.

  1. Lindahl#7

    Lindahl#7 New Member

    This will be a transplant of my original build thread on RX7Club.com found here: Austin's FB TII Swap - Details and Pics Aplenty. I'll keep this one updated as best I can at the same time I update my 7Club thread. This one will also be an abridged version because it would be 4 pages of just me copying pics and text of mine so I'll keep it short and to the point. Enjoy :cool:

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    Hey guys, I'll just start off with a few pics and details of the cars: as I promised.

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    1984 Mazda RX-7 GS
    1.1L 12a carburetor engine
    Stock engine, trans, rear end
    No ECU
    Complete burgundy interior

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    1987 Mazda RX-7 Turbo II
    1.3L 13b turbo engine
    TII transmission
    Stock ECU
    Interior partly gutted but should be complete

    Project description:
    I plan on swapping the TII 13bt engine and TII trans out of the 87 into my 84, along with all of the wiring and necessary parts.

    I will be posting up all of my links that have helped me in this post, then quoting a member's post that has proved to be extremely helpful in my considerations of what to do during this swap.

    Links I found helpful are as follows:

    Other Member's Build Threads
    Chronicles of a TII Swap
    Sean's TII 83 S
    Matt’s T2 FB Build (pic heavy)
    (TURBO) TII swap into GSL-SE
    Matt's Original Swap
    PeteyTurbo’s TII Swap

    How to notch the 12a for a 13b install
    How to Notch the 13b for install in a previously 12a car
    How to Notch the 13b for install in a previously 12a car another way

    FB FMIC?
    FMIC Installation into FB

    FC TII 5-lug conversion
    Write up - FC subframe swap (how I did it)
    Any one have 5 lug pictures of their First gen
    BBS vert wheels on 1st gen with big brake kit
    5 lug fc conversion on the rear of 1 gen

    Difference between 13b and 13bt
    13b NA and 13b Turbo engine differences

    Downpipe
    What did you use for a Downipe?(FC)

    TII Swap Questions
    TII swap couple questions

    Now, as anyone looking at this thread should know by now, I am a very open guy that likes to share info and things for others. I've provided my list of links so far to things that have helped me learn and move towards my goal.

    I'll keep posting here with pics, videos, and ideas and I'd appreciate those of you that are considering the swap and those I've featured above could help me out as well.

    Here's a short video of a walk around of my TII car that I'll be using for the swap.

    1987 Mazda RX-7 TII Turbo No Exhaust

    Here's the driving video I took.

    1987 Mazda RX-7 Turbo 2 II No Exhaust Short Drive

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    What I started with:
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    Still working on these:
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    Main ECU Plug #1 wiring harness and FEM-02 ready to be wired in:
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    Stupid snow.

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    12a picture at about 10:30am on Friday morning
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    after a few hours on a break getting family stuff done...

    12a engine and transmission removed at 8:00 Friday evening
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    Pics at 6:30pm of getting the engine out of the shed and out towards the car
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    First pics at 8:50pm of the 13bt resting on its own weight in the FB chassis - transmission mount yet to be modified but still serves it's purpose
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    TII ECU mounted under kick panel
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    Pic of knock control unit and pressure sensor plugs that need to be extended
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    In the middle of extending plugs
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    Extension of two plugs on harness finalized
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    Pressure sensor and knock control unit mounted
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    Fuse block mounted where stock FB fuseable links were
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    Final mounting of the ECU and components
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    Through the firewall we go!
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    Other side of the wall
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    Well, once I had that setup I had the fiance in the car turn it over and heard a suuuuper loud backfire and knew that it was probably going to work (whole UIM, TB, and intercooler weren't hooked up so it wouldn't have run right). Got it all hooked back up and BAM! - off she popped. Let it run for a bit and warm up, shut it down. Did it again, and once more. Then when we were going to leave I grabbed the GoPro and shot this:

    1st Gen FB RX-7 S4 Turbo II TII Swap First Startup

    Front shot of car without hood on its own suspension
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    An almost completed engine shot
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    Tokico Blue shocks that'll replace the 30yr old stock ones
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    Old rubber bushings in the control arms
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    Rubber bushings being burned out
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    Watts Links bushings replaced (didn't get a shot of the rear control arms - woops :blush: )
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    Driver's side shot of Blue shock and poly bushings
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    Pass side shot
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    Final shot of new rear end installed
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    Pictorial story of the day's progression:
    Got off of work a little late but wasn't too terrible. Ran to get new bolts, nuts and lock washers from Menard's for the driveshaft rear flange then went and got cash out for the shaft itself.

    Ran down to the shop making the shaft and was very pleased to get the new shaft, as well as the other two shafts I gave them for references. I'll try to sell these off to others that can use them more than I.

    New driveshaft versus the old FB 12a shaft directly underneath it, and the FC 13bt shaft below that. Shaft has greasable and rebuldable u-joints with a 1 year warranty.
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    Slip yoke side of the new driveshaft
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    Rear flange side of the new driveshaft with new Grade 10 nuts, bolts and lock washers for the whole rear end.
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    Got home and verified that I could drive the car without forgetting anything that would drag on the ground or be a safety concern. Got the IMSA spoiler installed temporarily as well as you can see later.

    After installing the shaft and cleaning out the entire car of all tools and hardware I decided to see if she'd go under her own power. I was ecstatic about the car being able to move itself I couldn't stand it! :biggrin:

    Then I figured out that the shaft on the clutch slave cylinder of the new FB was too long and pushing the clutch in constantly. My heart dropped in hearing and feeling that I couldn't drive the car the way it was.

    Until a thought crossed my mind...

    FB slave cylinder push rods side by side
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    Shaved off shaft that I'm using on the left in the car now. Has been shaved down even further by about 1/8" from this picture just with the feel in the car
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    So I put this in the car and wouldn't ya know it, she worked!! :biggrin:

    Re-bled the clutch system with some help from my dad and took him for a ride he won't soon forget :egrin:

    I drove the car for a total of about 8 miles in 2 mile stints up and down a road that isn't patrolled 364 days in a year. Only boosted it twice and man does it RIP now! Couldn't be happier with its performance and I can't wait to see how it progresses from this point.

    Driver's side view of the car after the night's activities
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    Passenger side shot
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    There's an end in site where I can reliably drive the car whenever I want.

    Well I have low oil pressure in the car upon partial rebuild.

    To get the TII engine to fit into the FB using the stock mounts I had to use a GSL-SE front cover and a GSL-SE oil pan. In doing this I removed the old TII front cover and oil pan and had to install a new gasket for the front cover, front cover o-ring, and FB pickup tube for the oil pan.

    On March 8 of this year I made my big order for the parts I needed from Atkins Rotary to build the engine up to put it in the FB. The issue I have is:
    1. I have an S4 engine (pretty obvious there)
    2. But I ordered a big hole front cover gasket from Atkins with a teflon o-ring
    3. The teflon o-ring didn't fit right so I just used a generic o-ring that we had in the shed at the time

    According to Aaron Cake at this post (pretty good thread about the issue): (2nd Gen Specific) new rebuild has low oil pressure
    "To clarify, using the Teflon ring has nothing to do with the front cover, it is dependant on the front iron you have. If there is room in the bore for the Teflon ring, you need to use it. If there is only room for the o-ring, then you don't use the Teflon ring. And you have to make sure to use the proper front cover gasket. The one with the big hole is to be used for the Teflon ring, but the small hole is for the o-ring only."

    Got this confirmed by reading about the issue on the Mazdatrix FAQ page found here: Mazdatrix FAQ: 86-92 Front Cover "O"-Ring

    So what I need to do is get a small hole front cover gasket or just use silicone (which seems to be the better, cheaper, more proven method on keeping the S4 o-rings in place), o-ring, and re-check everything in the front cover and oil pan again. Oh joy.

    While I'm at it I should check the oil pickup tube as well. I used a 12a oil pickup tube in the 13bt engine since the original one wouldn't fit with a GSL-SE oil pan. In doing this I didn't use a gasket since there wasn't one on the 12a FB pickup tube so I thought nothing of it. This can cause air bubbles in the vacuum that the pickup tube creates to the oil pump and air in the system can cause low oil pressure and severe engine issues in the future. So I will be installing a gasket in that part.

    So now it's lift the engine and take off the whole front cover again and redo it. Should have paid more attention to the order list, sucks to learn sometimes.

    I have this Saturday off and with some severe will power I should be able to get the whole system redone and checked out. Of course I'll have to let the material dry for 24hrs+ to ensure proper adhesion.

    The joys of learning..

    Here's the much requested walkaround video - be happy guys :bigthumb:

    First Walkaround of 1984 Turbo FB Mazda RX-7
    Well, here it is. 4 hours of video editing for 4 minutes of video.

    There will be more videos in the future, I guarantee that. I really enjoy using the editing software and it has been a blast comparing the two cars (I say two because they are separate now, a 12a FB and a 13bt FB using the same chassis).

    Enjoy :egrin:

    12a Vs. 13bt Should I Turbo Swap Comparison FB SA22C Mazda RX-7

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    That's completely current and up to date. I look forward to meeting some of you guys tomorrow and taking the car for it's longest cruise under turbo power yet!

    Thanks,
    Austin :D
     

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