o to just do it.... sure it will manage fine and if not then at least you will have the 6 to play with till you put a manual in it

Some more pics of the new charger.

[img]http://mattjj21.co.uk/dump/219.jpg[/img]
^This is the casing after giving it a quick clean out just getting rid of all the oil. It's got a few scores in it but hopefully nothing too bad.

[img]http://mattjj21.co.uk/dump/220.jpg[/img]
^The inlet side of the charger is rather rough and has two rounded bits sticking out into it for no reason.

[img]http://mattjj21.co.uk/dump/221.jpg[/img]
^So they got removed and I've started trying to polish the inlet side smooth.

Got board and test fitted one of my alloys onto the back of my car while I had the wheel off checking how much pad was left in the rear drums.

[img]http://mattjj21.co.uk/dump/224.jpg[/img]

[img]http://mattjj21.co.uk/dump/225.jpg[/img]

I've also done some more ecu wiring but didn't take any pictures yet.
I've wired in two relays which are controlled by the piggy back ecu.
One connects and disconnects the primary lambda sensor signal wire so that that when not on boost the piggy back can give full control back to the stock ecu which should give better fuel economy off boost.
The second is going to be used to control the clutched pulley on the new SC, I'll be able to make a RPM vs Throttle Position map of when to engage and disengage the SC pulley.

Made a tiny bit of progress in trying to work out what is wrong with my brakes. Due to the intermittent ABS warning light I thought I'd start with the ABS system and do a resistance test on all the sensors.

Both front sensors and the rear offside sensor read around ~1,360Ω.
The rear nearside sensor had a reading somewhere around 20millionΩ.
So I guess there's an issue with that sensor lol

Hopefully this gets me somewhere nearer to fixing the brakes but so far I can't see a wheel sensor causing the peddle to be spongy but suppose it could cause the ABS pump to be doing something weird which might be why?

When last did you put fresh brake fluid in

[quote="AeroX"]Got board and test fitted one of my alloys onto the back of my car while I had the wheel off checking how much pad was left in the rear drums.

[img]http://mattjj21.co.uk/dump/224.jpg[/img]

[img]http://mattjj21.co.uk/dump/225.jpg[/img]

I've also done some more ecu wiring but didn't take any pictures yet.
I've wired in two relays which are controlled by the piggy back ecu.
One connects and disconnects the primary lambda sensor signal wire so that that when not on boost the piggy back can give full control back to the stock ecu which should give better fuel economy off boost.
The second is going to be used to control the clutched pulley on the new SC, I'll be able to make a RPM vs Throttle Position map of when to engage and disengage the SC pulley.[/quote]


WOW thats some skinny rubber you got there

nice wheels

[quote="eogbaker"]When last did you put fresh brake fluid in[/quote]
A few weeks ago, going to try bleeding again though as I bleed them in the wrong order (if that truly makes a difference).

[quote="cbreddie"]...
WOW thats some skinny rubber you got there

nice wheels [/quote]
Ha yeh I've only had the alloys nearly a year and still haven't bought tires for them
I just thought it best to check if they would fit in the rear arches as I never test fitted them on the rear before (only on front when I bought them).

The new ABS sensor arrived today and I've fitted it. No pics but swapping it over was pretty easy only took around half hour.
The ABS warning light hasn't showed it's self since changing it so far but as I suspected this isn't the only problem with the brakes.
I've ordered a pressure assisted easy bleed kit to try and help with the brake bleeding, my mate suspects that all the old fluid hasn't been flushed through the ABS distribution thing yet.

Well fingers crossed for you it's all sorted

[quote="eogbaker"]Well fingers crossed for you it's all sorted[/quote]I hope that after I bleed it with the easy bleed kit that it'll be fine (if not then I think I'll have to get my family's mechanic to look at it and get his opinion).


I don't think I said what happened with the fuel injectors I found on ebay. I ordered the £125 ones from Taiwan which fitted perfectly but turned out they only flow at 185cc and not 300cc so I'm in the process of sending them back to the seller for a refund.
I have however managed to find a set of 400cc denso injectors from a UK seller for £180 which come next day delivery and have a lifetime warranty.
I should be able to set them up to flow at 310cc by reducing fuel rail pressure to 2.3BAR which would make mapping easier as they'll be exactly double what the stock injectors should flow.

400cc Injectors fitted with some minor fuel rail modifications.
Will have more pictures tomorrow.

[img]http://mattjj21.co.uk/dump/239.jpg[/img]

Ok more pictures are ready.

[img]http://mattjj21.co.uk/dump/240.jpg[/img]
^Received the 400cc fuel injectors I ordered (Denso #195500-3920, apparently there used on the Subaru WRX)

[img]http://mattjj21.co.uk/dump/241.jpg[/img]
^I knew they where slightly shorter injectors then the standard Mazda ones (Mazda ones are 70mm and these are 58mm), now I found a company in Australia that manufactures adapters but there ~£50 and I don't know if they'll send to UK or how much they'll end up costing once delivered and through customs etc.
So I decided modifying the rail would be easier. I cut the mounting arms off of the fuel rail and cut a bit off of each and then tack welded them back on at a new lower height.

[img]http://mattjj21.co.uk/dump/239.jpg[/img]
^ This was where I was test fitting the rail back on after I had tack welded it to make sure it was lined up at the correct angle for the injectors (which it was). Now I know my welding skills are crap so I took the rail back off and took it to my mate (who can weld) to finish off the welding for me.

[img]http://mattjj21.co.uk/dump/242.jpg[/img]
^ So here's the welds he's done for me, much neater then anything I could do.

[img]http://mattjj21.co.uk/dump/243.jpg[/img]
^ And the other side.

[img]http://mattjj21.co.uk/dump/244.jpg[/img]
^ All fitted back in now, you can hardly see the injectors now underneath the fuel rail and wiring trunk.

The increase from 155cc to 400cc injectors is handled by the Emanage Ultimate as it has an injector scaling feature built in. I adjusted the FSE fuel regulator to lower the fuel rail pressure slightly so that it's at 2.5 BAR at idle and raises to 3 BAR on full acceleration.

Bought a pair of RX8 seats this weekend which I plan to fit into the 323.
The RX8 seats are much lighter then the BJ seats and also much more comfy.

[img]http://mattjj21.co.uk/dump/252.jpg[/img]
^Rails are similar but slightly narrower on the RX8 seats compared to the BJ ones. It might be possible to unrivot the brackets from the bottom of the BJ rails and weld them onto the RX8 rails but might be better to try and make some adapters so that neither rail is permanently modified.

[img]http://mattjj21.co.uk/dump/253.jpg[/img]
^ Both the RX8 rails and the BJ rails removed from the seats to compare size and fitment.

[img]http://mattjj21.co.uk/dump/254.jpg[/img]
^ Had the RX seat cushions lent up in the back while comparing the rails. Sat in it and it was rather comfy.

[img]http://mattjj21.co.uk/dump/255.jpg[/img]
^ Seat put back together and left sitting in the car (not bolted down).

looks like a much easier job to fit these to a BJ than into a BA

Excellent progress with the charger so far.

Fueling.

Have you changed the pump?

Higher flowing injectors and increasing the fueling via the ECU is exactly what you need to do, which is great that you've done it, the next weak link in the chain is the pump itself...

A 255lph Walbro unit will do the job nicely

[quote="AeroX"]Bought a pair of RX8 seats this weekend which I plan to fit into the 323.
The RX8 seats are much lighter then the BJ seats and also much more comfy.

[img]http://mattjj21.co.uk/dump/252.jpg[/img]
^Rails are similar but slightly narrower on the RX8 seats compared to the BJ ones. It might be possible to unrivot the brackets from the bottom of the BJ rails and weld them onto the RX8 rails but might be better to try and make some adapters so that neither rail is permanently modified.

[img]http://mattjj21.co.uk/dump/253.jpg[/img]
^ Both the RX8 rails and the BJ rails removed from the seats to compare size and fitment.

[img]http://mattjj21.co.uk/dump/254.jpg[/img]
^ Had the RX seat cushions lent up in the back while comparing the rails. Sat in it and it was rather comfy.

[img]http://mattjj21.co.uk/dump/255.jpg[/img]
^ Seat put back together and left sitting in the car (not bolted down).[/quote]

I've done this in mine, it was fairly simple; the time consuming bit was drilling out the rivets so you end up with just rails. So just used the rail adaptors from the 323 seats and put them on the Rx8 seats. Used grade 12.9 bolts to bolt them back in to keep it all safe.

The front brackets from the BJ fit, they just swivel in a bit. The rear brackets, the one on the bodywork side just needs the hole elongated a bit to fit, and the one on the central side just needs some shims on the bolt. I'll upload some pictures (and start a blog) sometime next week when I have a bit of time if you want to see.

The Rx8 seats are a bit lower, but not much (and a better fit for me, tall upper body but realtively skinny a**e) and very comfy. The airbag connectors are the yellow ones and the same in most cars. And don't forget to sort out the passenger occupancy sensor, which unlike what the workshop manual says - it is not a seatbelt clip but a pressure sensor built into the seat.

[quote="Zippy"]...

I've done this in mine, it was fairly simple; the time consuming bit was drilling out the rivets so you end up with just rails. So just used the rail adaptors from the 323 seats and put them on the Rx8 seats. Used grade 12.9 bolts to bolt them back in to keep it all safe.

The front brackets from the BJ fit, they just swivel in a bit. The rear brackets, the one on the bodywork side just needs the hole elongated a bit to fit, and the one on the central side just needs some shims on the bolt. I'll upload some pictures (and start a blog) sometime next week when I have a bit of time if you want to see.

The Rx8 seats are a bit lower, but not much (and a better fit for me, tall upper body but realtively skinny a**e) and very comfy. The airbag connectors are the yellow ones and the same in most cars. And don't forget to sort out the passenger occupancy sensor, which unlike what the workshop manual says - it is not a seatbelt clip but a pressure sensor built into the seat.[/quote]
If you've got pictures of what you've done that would be great.
My BJ is an early one which is pre OBDII, doesn't have seat belt or pressure sensors and only has 1 airbag (in steering wheel).

[quote="AeroX"]
If you've got pictures of what you've done that would be great.
My BJ is an early one which is pre OBDII, doesn't have seat belt or pressure sensors and only has 1 airbag (in steering wheel).[/quote]

Here's the only photo that I have online at the moment:

[url=http://www.flickr.com/photos/zippyonline/8625544504/][img]http://farm9.staticflickr.com/8104/8625544504_855a3db4bd_z.jpg[/img][/url]
[url=http://www.flickr.com/photos/zippyonline/8625544504/]Rx8-323[/url] by [url=http://www.flickr.com/people/zippyonline/]zippyonline[/url], on Flickr

If you PM me your email, I'll email back a few more photos I took, and I might even do a quick scribble diagram outlining what I did where

very very nice...

The problem with the brakes has been diagnosed as a faulty master cylinder. I've ordered a new one to try and fix the car, if that fixes the brakes the next thing is to try and get an MOT so it can go back on the road. This car hasn't got many chances left now, if it doesn't start all working soon it's been threatened with becoming cans.

[quote="AeroX"]Think I might have blown a piston ring.
Engine decided it doesn't like oil and has spat it all out via the crankcase breather

[img]http://mattjj21.co.uk/dump/282.jpg[/img]

[img]http://mattjj21.co.uk/dump/283.jpg[/img][/quote]
Since I posted this in the what have you done to your car today thread I've finally got round to doing a compression test on the engine and the results were not good.

Compression test results in BAR (nearest whole number by eye from gauge).
[code]Cylinder: 1 / 2 / 3 / 4
-------------------------------
Dry Test 1: 13 / 13 / 6 / 14
Dry Test 2: 13 / 13 / 3 / 13
Wet Test: 15 / 15 / 4 / 16 [/code]
Cylinder 3 has practically no compression on either the dry or wet test. So it's likely to be the rings that have gone.

What you gonna do!? Still got the love for a rebuild?

oooo that seriously sucks man

Best option I think would be to find a 1.5 engine on ebay and just direct swap!

Car is now in listed in the breakers yard...

[url]http://www.club323f.com/forum/viewtopic.php?f=69&t=58972[/url]

Most mods are available to buy (see below)...

[quote="The mods which are remaining to buy"]
[b]Engine, Handling, Etc.:[/b]
AWR front & rear replacement engine mounts
AWR side engine and gearbox mount inserts
Front mount intercooler
Front BJ sport strut brace
Rear MX6/Probe strut brace
Greddy E-Manage Ultimate ECU
Goodridge stainless steel brake hoses
Kerr Nelson HT leads
Stainless steel OBX sports exhaust header
Stainless steel Longlife 200cell sports catalytic converter
Stainless steel Longlife cat-back exhaust


[b]Styling Mods:[/b]
Air Deflectors on the front windows
Black tinted front indicators
Black tinted rear light clusters
Black tinted side indicators
Black Dyed roof lining
JOM noir series air/fuel gauge
JOM noir series boost gauge
JOM noir series fuel pressure gauge
JOM noir series voltage gauge
Single DIN gauge mount bracket (replaces clock)
Mazda 6 adjustable intermittent wiper stalk
Zxi front splitter (modified to fit BJ)

[b]Planned Mods:[/b]
Alloy mesh (wide enough to fit a BJ front bumper)
Mazda Sport20 headlights
RX8 Cloth Sport seats
[/quote]

Cool work dude!! Nice output also on the dyno

I'm with Hughie, surely it would be fairly straightforward to swap out for a new lump, especially after all the expenditure and hard work, alternatively, this is a good opportunity to beef up the internals to take the proposed 180bhp