Freds FE3 into the ute swap DONT POST HERE. - Mazda MX-6 Forum
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post #1 of 188 (permalink) Old 3-3-07, 16:25 Thread Starter
 
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Freds FE3 into the ute swap DONT POST HERE.

Hello all,

it has been a long time coming, but at last, the progress is happening thick and fast. I'll be chucking my story and some supporting pics in here to keep you entertained. Hopefully this will inspire some of you to post up your projects and stop this forum from being completely dead.

To keep this thread contiguous and tidy, please DO NOT POST HERE. I have asked the mods to delete posts in this thread for that reason. Save them the work please.

If you are reading this, you may as well let this page load and read through it, but for the subsequent pages, unless you havent seen it before and have dsl, i recommend searching for what you want to see in this thread :

https://www.mx6.com/forums/fe-dohc/19...ml#post1918523

That thread contains every post directly linked and indexed so you can search for anything you are interested in without opening extremely large slow to download pages of this thread. It also contains a full listing of everything of interest to an fe3 owner/modifier. It should be your first port of call anytime you need to know anything.

here is the comments thread :

https://www.mx6.com/forums/showthread.php?t=182352

enjoy!

Fred.

Last edited by fredio54; 12-2-07 at 9:14.
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post #2 of 188 (permalink) Old 3-4-07, 3:43 Thread Starter
 
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I guess the first post should be a collection of links to all my threads from all the years. they make up the balance of this project. So this post will be for that. I'll edit it as i find them.

List of threads about my project :
The bell housing find (note this is only good for one type of R box, there are twisted and straight) :
https://www.mx6.com/forums/showthread.php?t=134392
Max lift on stock bits :
https://www.mx6.com/forums/showthread.php?t=133181
Different intake manifold discovery :
https://www.mx6.com/forums/showthread.php?t=153444
FAQ revamp suggestion (still needs to be done. if i could edit it i might give it a go.) :
https://www.mx6.com/forums/showthread.php?t=158607
The beginning of the end (the truck drives again after a long long hibernation, and a LOT of welding) :
https://www.mx6.com/forums/showthread.php?t=159350
The intercooler purchase :
https://www.mx6.com/forums/showthread.php?t=177011
Where I found my motivation to get stuck back in after working too much for too long :
https://www.mx6.com/forums/showthread.php?t=178953
Turbo and bits :
https://www.mx6.com/forums/showthread.php?t=179272
Wastegate problem :
https://www.mx6.com/forums/showthread.php?t=179342
The sump mods :
https://www.mx6.com/forums/showthread.php?t=178777
VR6 springs dont fit without mods!! :
https://www.mx6.com/forums/showthread.php?t=133131
Manifold design files (stopped working, if you wanna host em on mx6.com or somewhere, let me know, i still have them.) :
https://www.mx6.com/forums/showthread.php?t=177570
What not to do when swapping springs on a whole engine :
https://www.mx6.com/forums/showthread.php?t=180707
Bottom end factory torque with link to head torque (Thanks a million dutch) :
https://www.mx6.com/forums/showthread.php?t=181997
The telstar purchase :
https://www.mx6.com/forums/showthread.php?t=179774
How to clean your HLAs (the original one and only) :
https://www.mx6.com/forums/showthread.php?t=106184
The gearbox :
https://www.mx6.com/forums/showthread.php?t=154476
The first fe3 smokey :
https://www.mx6.com/forums/showthread.php?t=182313
temp sensor resistance/temp graph :
https://www.mx6.com/forums/fe-dohc/14...sor-table.html
turbo flywheel and clutch in an na tranny/bell housing :
https://www.mx6.com/forums/1g-mx6-gen...-n-tranny.html
fuel system thread :
https://www.mx6.com/forums/fe-dohc/19...n-diagram.html
antilag thread :
https://www.mx6.com/forums/fe-dohc/19...ggestions.html
megasquirt thread :
https://www.mx6.com/forums/fe-dohc/19...fo-thread.html
build thread post :
https://www.mx6.com/forums/1756303-post7.html
crank case vent pcv
https://www.mx6.com/forums/fe-dohc/18...rt-survey.html
fe3 humour AKA take the piss out of myself and fraud :
https://www.mx6.com/forums/fe-dohc/19...e3-humour.html

will edit as i create new threads about different aspects.

enjoy :-)

Fred.

Last edited by fredio54; 11-2-07 at 19:08. Reason: Add links in.
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post #3 of 188 (permalink) Old 3-4-07, 3:49 Thread Starter
 
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Yesterday and today were big days for the ute project, yesterday i took the old engine and trans out, and then slipped in the new box. I bolted a spare block and head up with the sump thermo housing and CAS on it, and found that i needed to beat in the firewall a bit to make the CAS fit. I went ahead and did that and also whipped the bottom corners off of the sump to clear the chassis in a place where i had forgotten i had left less than the average amount of clearance. here are the pics :

placeholder to be posted.

Fred.
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post #4 of 188 (permalink) Old 3-5-07, 4:10 Thread Starter
 
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i'm going to keep the story rolling and add pics later.

this morning i dropped into abc in taka and ordered my clutch.

1900lb pressure plate (stock is supposed to be 1300 or so for the f2t)
luk friction disk with large dual springs and normal organic material
new bearings.

i also ducked into bnt and picked up a large simota air filter cheap, good, pretty. what more could you ask for. 190 across the base, 150 neck and 120 across the top. dual cone type.

this evening i seperated the motor from its auto box and removed the torque converter and flex plate.

i also tried the filter in the place it will sit. good clearance all around to suck nice cool air from all directions.

just need the flywheel modifying before the engine can go in!!

fred.
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post #5 of 188 (permalink) Old 3-6-07, 2:15 Thread Starter
 
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so, this morning i ducked out and did a couple of things to the engine. i forget exactly what. this arvo i picked up the pressure plate and brought it home. i cut the ring gear off of the flex plate ready to fit and weld to the f2t flywheel as soon as it gets turned down for it. i went to a mates with a BIG air compressor and sand blasted my sump welds ready for a lick of paint. i organised some parts from my cous at mazda, and sand blasted the trailing arms i got out of a townace van that i need for cert because i have used 60mm lowering blocks. i also came up with a cunning idea :

having been unable to find a weld on flange for the vband outlet on the holset, not here, not on ebay, not anywhere... i realised that a machined pulley off of some engine or other will be correct or close to the right diameter, and i can cut it down and bore it out for the 4" down pipe. have to go looking this weekend.

off outside now to put some primer on all the sand blasted bits... before they rust.

fred.
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post #6 of 188 (permalink) Old 3-6-07, 5:57 Thread Starter
 
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ok, so i painted all the bottom end gear with high temp primer, and the trailing arms with ordinary zinc primer, i measured the bell, pressure plate, flywheels, ring gears etc, counted, and measured the bolts/threads for the sump considering its all different on mine now... and will go looking for bolts and bits in the morning before work.

the thead that isnt mine, that i posted in ever so long ago about the flywheel and bell mod is this one :

https://www.mx6.com/forums/showthread.php?t=156505

i'll update and add pics when i do the mod this week or early next.

fred.
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post #7 of 188 (permalink) Old 3-6-07, 17:59 Thread Starter
 
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got up before the alarm at 7am this morning, headed out the back and put some black hi temp enamel on the sump flange, and wiped the primer off the mating surfaces of the mains braces with some thinners, went out to the engine and filled the ports with socks and whipped off the intake manifold. went and bought and ordered bolts and cap screws to hold the sump on with, picked up a section of 4" pipe to size my turbo outlet fitting to. time to sit and work for X hours until i get home and do some more "ute" work.
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post #8 of 188 (permalink) Old 3-7-07, 3:34 Thread Starter
 
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bought a 35mm mandrel U tonight and started work on coolant plumbing. also diced up a U for the manifold, and modified the alternator bracket to not be an engine mount and to be a coolant pipe mount. i'll pickup another U and a straight bit tomorrow and start some welding and mounting. i have a nice genuine two valve thermostat on the way along with some other genuine parts from mazda. tomorrow night along with that i'll be painting the sump and fixing some rust in a fucked old corolla wagon for a mate that did 162kph on skis and crashed on one run at about 120kph and broke a few ribs and a thumb. looking forward to the weekend, i'll have the motor ready to go in bar the flywheel that i'll be turning up on a mates lathe on monday night to match the small ring gear.

i promise, i'll put up some pics soon :-) soo much to do, no time...

fred.
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post #9 of 188 (permalink) Old 3-7-07, 18:32 Thread Starter
 
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grabbed some more U bends and pipe today, and picked up a new rear main seal, new thermostat from a bp, new shifter boot, two oil pump pickup gaskets, and an O ring for the CAS. staff price at maz = 1/2 retail, but still pricey for what i got. the correct thermostat has rolled over to a f201 part number, the old ones have been superceded. the only difference is in the brass bit that comes out to touch the sensor, but as i wont be using that anyway, it is irrelevant. it has the double valving like the one dutch pictured. both do. it was my suggestion to check the other dohc motors. and its worked out to save me about 15 bucks.

i'll take and post some pics tonight if i get enough done. thing is i forgot a work meeting, and have the roller to do, so may not get a lot done before its too late to make too much noise...

fred.
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post #10 of 188 (permalink) Old 3-8-07, 5:40 Thread Starter
 
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ported out the thermo housing a little to ensure the thing can open 100%

the bp05 part is slightly longer in the back and thus will not quite clear the housing when fully open. strangely its even worse in the fe3 housing, and even though the fe3 one is shorter, there is no way it would open all the way in there...

i also radiused the edges while in there for more coolant flow :-)

i painted the alt/coolant mount with black engine enamel tonight too.

not very productive, but got the corolla done, and got home at about 7:30...

tomorrow night will be better!

i guess i better chuck up a photo or 10, so heres an air filter and other gear... ok, i went a bit nuts and put most of them up... so in the next post.

fred.
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post #11 of 188 (permalink) Old 3-8-07, 6:15 Thread Starter
 
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yay, pics at last.

all ready to pull


pulled


empty


a sight for sore eyes :


sump etc in to fit


doesnt fit so well, oops i forgot...


THERMO HOUSING DOES THOUGH :-P (i'm so childish ;-))


new engine pulled and ready for final lift.


sump rework begins look at that penetration


how it looks sliced


more in next post if conn holds out and my patience with it...

fred.

Last edited by fredio54; 7-22-07 at 11:49.
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post #12 of 188 (permalink) Old 3-8-07, 6:28 Thread Starter
 
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the sump welded up again






coils and wires and igniters


big arse air filter with 150 mm inlet/outlet


donor flex plate that surrendered its ring gear


clutch friction disk with four rivet per post attachments.


and some more, wiggling the lines under the house helped the conn no end...

fred.

Last edited by fredio54; 7-22-07 at 11:59.
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post #13 of 188 (permalink) Old 3-8-07, 6:35 Thread Starter
 
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final post for tonight :

flywheel with new small ring gear on top


pretty exedy hd 1900lb pressure plate




sump sand blasted to make sure paint sticks well


primed with high temp zinc


primed toyota trailing arm


fu.ck this i'm off to bed.

Last edited by fredio54; 7-22-07 at 16:31.
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post #14 of 188 (permalink) Old 3-8-07, 14:30 Thread Starter
 
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clutch barely fits into the bell housing, but will be ok with 2mm machined off the outside edge.


primed braces


enameled gasket surface


alternator bracket was engine mount now coolant mount






stock and f2 thermo housings with thermostats and seals etc


thermo ported slightly


these are the last pics you get till sufficient comments roll in :-)

fred.

Last edited by fredio54; 7-22-07 at 12:31.
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post #15 of 188 (permalink) Old 3-10-07, 5:42 Thread Starter
 
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got quite a lot done today, no time for pics, but will get down and do a write up tomorrow night. have to go paint something now.

fred.
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