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post #151 of 159 (permalink) Old 05-24-2016, 02:27 AM Thread Starter
chris_top_her
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My new (smaller) turbo came in, and fab started. The turbo fits behind the motor just by removing the compressor housing. Disassembled it, removed any factory oil/residue etc, replaced the exhaust side piston ring with a gapless type, heavily oiled it and put it back together. The exhaust manifold mid pipe flange is an odd spacing (which I can't seem to find as aftermarket), and the exhaust side of the flange is threaded as well. So I had to widen the holes on the flanges I bought, and see if these bolts I got from home depot will fit in the thread. The up pipe I have started will be a u shape to the left, up into the engine bay, then a right over the manifold. The manifold has some screw holes for the aluminum shield, which I will repurpose to attach a support bracket off the pipe. I may make a little bracket with a stiff spring welded in the middle to attatch to a stud on the firewall. The little t25 to 2.5" exhaust inlet flange I got has some conflicts with the bolts I bought (head is too wide), so I'm going to grind/cut the washer part down a little so the bolt clears the pipe opening. If not I'll just buy some that dont have a washer built in. Now that I got under the car, I may actually be able to get a 2.5 pipe through with clearance on the right side, meaning I can have a 2.5" downpipe, vs. a smaller sizing or split pipe for the exhaust. In order to avoid buying a bunch of pipe/hangers to replace the mid pipe, I'm just going to cut it aft of the 2nd cat in the stright area, and replace that short travel with either a stright pipe, or cheap cat with an 02 bung welded into it. Our 2nd o2 sensor is pre 2nd cat, so I don't have to worry about buying a cat with a bung hole. At least this way, I can utilize the oem exhaust hangers etc and save myself a bunch of fabrication. If I need to return it to stock, all I have to do is buy a 2.5" coupler and weld the OEM section back on. That would be the last thing to do anyways, since I don't need that to test the turbo. For trials, I'll probably jsut lower the exhaust enough to get the upipe by, or just remove it.







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post #152 of 159 (permalink) Old 05-24-2016, 03:54 AM
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If you're going to tie a bracket into the firewall, my vote would be go full hog and make that an extra motor mount to keep the engine from moving around as much. I would NOT be comfortable long-term with any spring directly attached (let alone welded) to anything that enjoys that much heat.


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post #153 of 159 (permalink) Old 05-24-2016, 04:59 PM Thread Starter
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The thing about that is the FW studs are about 10mm, and the little bracket I have in mind is mainly extra, not so much a main component. the spring itself will be down the bracket a bit so it'll be in an open area, basically pipe ------- spring ------ FW stud. If I decide it's practical, I'll be looking at high temperature springs like clutch springs and the like. The exit flange is after the OEM flex pipe, so between that, the brackets and the charge piping/down piping it should be pretty secure, without too much movement to hit stuff, and enough to take stress of welds under movement (the turbo will be on top the pipe). If I can find a good hole (there are plenty unused, some tapped for the diesel) I may add an exhaust hanger type bracket as well. Once I have the pipe in place it'll be easier to see what will work and how. I bought some steel sheets to cut up for that stuff.


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post #154 of 159 (permalink) Old 05-24-2016, 10:42 PM Thread Starter
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@color0 like this. That spring came from an exhaust mani bolt. I need to work on a better way to weld it though. It's hard to seat, and it pops easily. As bad as that looks, its actually pretty solid. Basically thats the middle then i would weld a strip on each end (90 degrees) with a hole to on one end for the fw stud and a hole on the other side to put a bolt and nut through to attatch to a small tab welded onto the pipe. I jave to be able to get it in and out so a long welded bracket won't work. Im going to have a vband on the up pipe for the same reason.


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post #155 of 159 (permalink) Old 05-24-2016, 11:24 PM
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post #156 of 159 (permalink) Old 06-03-2016, 03:39 PM Thread Starter
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post #157 of 159 (permalink) Old 06-10-2016, 02:28 PM Thread Starter
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post #158 of 159 (permalink) Old 07-08-2016, 04:40 AM
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Every day I look at this thread and I get closer and closer to convincing myself that I will turbo my 2015 2.5L mazda 3

Only thing stopping me is figuring out how to get it smog legal in cali.

Keep up the good work Chris
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post #159 of 159 (permalink) Old 07-08-2016, 07:40 AM
Bruns
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Man, i really wish I had the balls to turbo my AWD 2014 '3'


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