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Turboing my MZ3

4.1K views 39 replies 11 participants last post by  Marne_Aeok  
#1 ·
Hello everybody,
My name is Sonny and I am currently looking for parts to turbo my 2004 Mazda 3 sedan. I already have planned everything out to include the shop which is going to work on my car. While reading the posts and many praises I have decided to send it to Reactive Racing. Yes I am getting their turbo kit as well. Thing is, I am currently in Iraq "sandbox". I dont have much time when I get home, so I have decided to send my car from SA, TX to VA and have the work done while I am here in Iraq.... to maximize the time I can enjoy my car. I am going to order parts and ship them to Dees shop for install. Dee tells me the car will be done in 3 weeks, but I am going to give him 5 weeks because of the other stuff I want to get installed. Since I am here, I dont have enough time to extensively search threads and look for answers to my questions, let alone call Dee during his working hours. So I am relying on this forum to answer my questions....

To save forum and page space, I am going to break it down to one general question. What parts from the MS3 side are going to be available to use for my car during my build (i.e. exhausts, turbo manifolds, intake elements, ignition amplifiers, suspension parts, intercooler upgrades, hoses, metal exhausts gaskets..... etc). I already know engine internals are not an option, so I am going for parts around the engine. I am trying to stay away from custom parts because I know it will take a lot more time. Any help would be greatly appreciated. Thanks....
 
#2 ·
How much are you paying for the kit, installation, and tuning?

To answer a few of your questions:
The exhausts, suspension parts, gasket, and engine internals can be used. The turbo manifolds, intake elements, intercooler upgrades cannot be used.

We already have our own suspension parts, gaskets, and engine internals so we can just use those. For the exhausts go for the mazdaspeed3 aftermarket exhausts because they usually are 3in piping, however I believe Dee uses a 2.5in DP. Dee will provide you with the turbo manifold, intake piping and the front mount intercooler.

Also Ricardo at F2 has a lot of parts for our car. He sells pistons, rods, and anything else the 3 needs.
http://www.f2usa.com/index.php?main_page=index&cPath=3&zenid=c62b82d516a78affc6f4ef79a8f139bc
 
#3 ·
I am still awaiting for an estimate because I am getting the internals done. The engine and tranny are gonna be built up as well, but for R&D and taking the engine out it was $1700 labor + parts. I know the kit is $4150 and $250 for a stage two. This is just a rough estimate.
 
#5 ·
Sorry.....I used to live in the DC area (Largo/Landover) when I was stationed at Andrews AFB. I loved it there alot. Currently my car is in San Antonio TX and that is where I am going to be until I recieve orders somewhere in the states (hopefully Va Beach). I am getting my car shipped to Ashland though for the work and driving it down to San Antonio when it is complete. I should be home by then. I havent talked to Dee in a bit as well, but I am going to try later on tonight (Iraq time) and afternoon (US time). I really appreciate the offer for the ride and all.

As well, more MS3 parts that are usable for the MZ3 after turbo would be great to know. Thanks again everybody.
 
#6 ·
well there arent that many actually....like i have the hks hi power exhaust made for the speed but its not a direct bolt on you need to get an extension pipe made up cause its 13in short.

um intakes wont work, nothing intercooler wise will work, um the ms3 specific bov wont work, i mean i dont no why you would really want anything other than like a 3 in cat back. i mean you get a new engine mangagment and injectors.

dee is a really nice guy, i ve seen his work and i like it alot, he is currently building my motor which should be done this week
 
#7 ·
Aminzer,
He is building your motor? Great!!! because that is what I am having done as well. I plan on shipping mine in July and Dee is gonna take over the project from there. I think I need to contact him on parts. I told Dee I am willing for him make suggestions if it will better the overall performace or longetivity of the engine (of course if it is under my initial budget).

As for the exghaust, I am looking from the turbo on back. I am just a stickler for details like that, in which I need full sections replaced from specific parts. If I was going NA I would go for a full exhaust system with the header on back (for example). So the CPE system would be great because it is 3in as well.

When you get your engine back, can you send me the feedback on what was replaced and upgraded? That would be greatly appreciated.
 
#8 ·
well i can tell u everything i had him do already,

custom arias pistons
custom eagle rods
custom billet crankshaft
crower cams
over sized valves
titanium valvesprings and retainers
keyed the crankshaft
adj cam gears

but i mean im going big with my set up....this will hold up to 600whp, so i mean you can do with out some stuff and especially what kind of budget your on, because stuff like the billet crank is $1800 by itself, plus you dont have to build ur head like i did.
 
#9 ·
[quote author=aminzer link=topic=111463.msg2304820#msg2304820 date=1210549975]
well i can tell u everything i had him do already,

custom arias pistons
custom eagle rods
custom billet crankshaft
crower cams
over sized valves
titanium valvesprings and retainers
keyed the crankshaft
adj cam gears

but i mean im going big with my set up....this will hold up to 600whp, so i mean you can do with out some stuff and especially what kind of budget your on, because stuff like the billet crank is $1800 by itself, plus you dont have to build ur head like i did.
[/quote]

yeah, this guy ^ doesnt play around trust me :p
 
#10 ·
you will have a very good experience with dee. and the thing is that you won't really need to pull parts from the ms3 world once you have dee's kit. even if you want internals we have those not from the speed3. you will have a fmic, pretty nice manifold, good turbo, great bov, great wastegate, custom intake and so on.

as far as the exhaust, you get a custom catless dp from dee and from there you can get a 3" trubendz that will bolt up to it.

dee is a great guy. there is no way my car would be running right now without him. he helped me fix SO MUCH stuff that i wouldn't have thought of that was flawed form the hiboost kit. i won't repost anything, but you can look here for all the stuff that happened and the experience i had with him. great guy, great kit. happy boosting!!

oh, and here's the link to my thread:
http://www.mazda3forums.com/index.php?topic=109312.0
 
#11 ·
Yeah that was my reason on choosing Dee and his kit for my build (all the problems some people were experiencing). As for all the parts, I am going with Dee's internals and all the other parts as well. I am still unsure if I want to get the crankshaft though. I am looking to get it for preventative maintenance for if I want to boost higher. I am looking to get withing the 400-450 whp daily driving and 500+ whp max. So that is why I am in a predicament to get the crankshaft. Any thoughts would help about getting this part. Plus I have to incorporate upgrading my bottom end in which Dee is going to do as well. Money is there and put aside for this build so I really cant wait.
 
#12 ·
wow nice!!!!...im more or less just subscribing to the thread...i want to see how this turns out.
 
#14 ·
one thing that you will need to factor in to all of these expenses is gears, a clutch and a limited slip. that always catches people by surprise. good luck reaching those numbers though! if there's anyone in the states that can help you do it, its dee
 
#16 ·
ya you will need a built trans for that kind of power, even a built head and a bigger turbo that comes with a dee's kit which means he would need to make a tubular manifold aswell instead of the cast and prolly a bigger intercooler that will flow enough air and you would also need an ecu with ingnition control aswell. so i mean at that point you might even want the billet crank for saftey but than you just put out a shit ton more money
 
#17 ·
[quote author=aminzer link=topic=111463.msg2306210#msg2306210 date=1210604804]
ya you will need a built trans for that kind of power, even a built head and a bigger turbo that comes with a dee's kit which means he would need to make a tubular manifold aswell instead of the cast and prolly a bigger intercooler that will flow enough air and you would also need an ecu with ingnition control aswell. so i mean at that point you might even want the billet crank for saftey but than you just put out a shit ton more money
[/quote]

lol why do we do this to ourselves?
 
#21 ·
All those parts have been accounted for as well (research sucks but it is well worth it). I gave a list to Dee with parts that I researched over the net also to how much it will cost w/o tax and labor. This took a long time to look up (due to lack of time, internet wise and freetime). But I gave him the flexability to change what he wanted in the list. It is a large sum of money, but I plan on doing this the first time right and not be afraid of anything breaking down. It is my 8th yr in the Marines present to myself.... and i have to include my wife... damn... LOL!!! I was able to talk to Dee today to discuss some stuff. He will be giving me an estimate on everything shortly, hopefully it is under my budget. I dont mind an extra thousand above though. It looks like I will be getting the billet crank (which will have to change to custom everthing from what Dee said). I am doing it for preventative maintenance ($1850 worth lol....).

Upon my coversation with Dee, the MZ3 trans (manual) can hold up to 600 hp, which is not that bad. I inquired about upgrading the gears and trans but Dee said it will cost more than just doing a MS3 tranny sway (which can take approx 800-900hp). Dee said he contacted the MS3 lead engineer and this is what he said. So a tranny swap will be in effect after a couple of years.

The turbo is not issue, I will be getting the stage 2 turbo and whatever else is included from Dee. As for the manifold and intercooler, i will let Dee handle that. I also talked to him about my exhaust as well. Dee said it will be no problem about increasing the diameter to 3". That just shows how much Dee is willing to work with people. Havent seen customer service like that.

I have also accounted for the clutch. I was going to get a SPEC Stage 3+, but that wont be able to handle the power I will be getting. Dee is inquiring about the multiplate clutch disc from Fidanza (which will be sweet). Has everything you need, the driveablility of a 3.2 but the clamp load of a 5.4 or more. The LSD is something I am going to wait a little bit for. I am looking towards the Quaife (any other suggestions will be great).

So basically this is it: I will be getting all my engine internals from Dee. What ever parts he does not have or cannot obtain, I will order them and have Dee install it.

I really cant wait until this project takes off. A short month and a half till it all begins.

I'm like a fat kid in a candy store right now just writing about this.

One question though and maybe some suggestions as well. I am stuck on the coilover set up I want to get. The two that I want are the BC Racing and the Tein SS Dampner. I like the BC Racing for its adjustability (camber plates and arms, have to pay extra but well worth it). Then I like the Tein for the EDFC. I like just having the ease of adjusting my dampning force with the push of a button. But with the Tein (with the exception of www.therpmstore.com) all the other places dont provide pillow ball mounts...mmmm.... That is something I want. Also for the same price as the Tein I can get the BC Racing with adjsutable camber plates and arms for just a hair less. But the thing is I have not heard of BC Racing until I saw the Suspension forum. So my concern is about the quality. Any posts that can ease this issue will be appreciated.

Ok this is a long post so I am gonna end it. I have more to say but will save it for later.
 
#25 ·
In general what will these gears do? Will it change the gear ratio? Will it change the longetivity of the gears?

How did you break 10 gears?

Wondering about that last one. Tranny's are not my specialty and I'm researching turbo's and engines. Screw tuning, I will leave that to the pros.
 
#26 ·
they just can't handle the power we put through...i'll just be driving and SNAP...time to call a tow truck....the last time it happened it was still driveable but i just skipped 3rd gear. the worst was the first time. i shattered / sheared every tooth off the gear and they got stuck in everything so we couldnt even push the car...had to put it on rollers to get it on the flat bed....

i'll take pics later i have the gears downstairs in a closet as memorabelia haha