How Kane and Ray build a Ceramic, Ported, Turboed Renesis!!!!

[Kane]

Welp - after some big big help by AZRR with a last minute save; it is time to start this thing....

Ok; so here is my story.

May 2009 - I'm getting some misfires from the BHR coils - Ray flies to HI to install a NOS kit in another car; and looks at my misfire issue; thinks maybe one of the wire connections is soft; mails me a new one..... I install new wire - still have some misfiring at high RPM and high Load; Ray tells me that one of the other wires may be bad.....and to take it easy until we see the issue. I think it may be the dwell... but am unsure.

Driving from a flat surface to an extreme uphill with BC settings at 10 PSI to redline and the same PPO2 tune I've been running for about 3-4 months.... I hear a very loud misfire followed by a catastrophic banging sound (uh-oh).... I let off the throttle and my vacuum is all over the place and I'm boosting 10 PSI to maintain 60MPH uphill..... well ****; there goes the motor. I happened to be logging at the time; which was nice.

http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/KaneBlownMotor.gif

Here is the datalog of my motor going bang.... the redline is the moment she went out. It makes more sense when you can see the whole thing - but whatever.


Now - Ray TOLD me to take it easy; and I was; but the BC should have been off and maybe I would have avoided this situation (my bad) - hard to say...... rotaries love turbo's and that ***** spools quick. But then again at that time we weren't sure that dwell was an issue.... **** happens.

I called Ray that morning; he made fun of me.... I called him fat - the norm; LOL and Erick laughed at me too I think. Turns out that weekend is when Jeff and Ray had started to see dwell issues for the big power boys on the BHR coils..... a day late for me!!!! HAHA.

Soooooooooooooooooooooooooooooooooooooooo

If you give a mouse a cookie

After talking to Ray; my choices were - new OEM motor; rebuilding mine assuming both housing were good; or super secret option number 3. This is where BHR customer service comes into play.

Ray had a motor in his shop; awaiting his experimentation.... it was blown but had low mileage; I had a dead motor in my car - and the desire to get my car rolling so I could PCS from Hawaii....... we decided on a trade; he gets mine and he rebuilds his for me n AZ and ships it to HI; flys here and helps me install it. Basically; Ray said "yeah that is cool man; I've been wanting to play with this thing anyway but just haven't had the time and parts." Now call ****in' Edlebrock and try to work that deal if a bad fuel pump kills a 350.

My next phone call; was back to Ray..... "hey man; since we are building this thing anyway - how crazy can we get with this thing?" We both made a few dozen phone calls to various experts like Kevin (Rotary Resurrection), Sven (NRS Rotorsports) and Brian (BDC) among many others; and settled on.

Hand cut side seals and hand built ported motor with everything documented (courtesy of Ray); Ceramic 1 piece 2mm apex seals with FD corner seals (NRS); the rotors had to be machined to accept the taller seals and springs. Ray is also hooking it up with a BHR stage 2 Clutch.

I then did my part; first spent a lot of money then custom built air intake based of the AEM; took old motor out; flow tested and balanced all of my injectors, Mazmart water-pump, power-coated EVERYTHING; Elite Series fuel pressure gauge; refinished my sub-frame; and got a set of Prototype Motormounts from Old Dragger. On top of obviously doing the tuning; however the MAF vs injector scale issue is much easier when you have your injectors flow tested. And while the engine was out I redid all the engine bay wiring cause I could.

From Arizona!

http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/DSC04141DesktopResolution.jpg
http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/DSC04144DesktopResolution.jpg
OOPS new housing time....
http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/DSC04155DesktopResolution.jpg
http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/DSC04163DesktopResolution.jpg


And from Hawaii
http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/Day5001.jpg
http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/Day5002.jpg
http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/Day5003.jpg
http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/EndofDay2.jpg
http://i229.photobucket.com/albums/ee222/kanetomlin/New%20Motor/EndofDay3.jpg




Coming up live streaming video of the re-install from BHR / BBQ; live tuning from Kane and PPO2 and all in time ( I Hope) to get me out of Hawaii on Nov 13th.


Now - who wants to question BHR's customer service reputation...... hmmmmm?


Now - for the first ever hand built, ceramic sealed; GT3071R turbo-ed, ported Renesis engine to show it's stuff!!!!!!


So far..... BIG BIG thanks too:

Ray Hill @ BHR
Erick @ BHR
Sven @ NRS Rotorsports
Kevin @ Rotary Resurrection
Brian Cain @ BDC
Yoshi @ Ron's Performance
Bobby aka PunisherRX8
Richard aka JudgeGTO2005
Mazmart
AZRR

[Kane]

The engine we built last night came to us by way of "Slidewayz" as it was his old engine and it popped a couple apex seals. The engine ran but rough and with only 13 in./Hg.

When I tore it down the bearings all looked immaculate, as did the housing that was not damaged from apex seal schrapnel (rear apex popped, as usual).

I then measured all of the internal clearances and they were smack dab in the middle of spec, which was why I casually referred to it as a "semi-blueprinting". Had I adjusted the clearances manually I would have set them where this engine's clearances already were. I became jealous as this engine was going to be my own "Monster Renesis" build and now this jar-headed prick, Kane, gets it for his own use! :lol2:

All engine clearances have been documented and recorded for Kane's future use.

Anyway, since Kane decided to use NRS's Ceramic Apex Seals (after talking with Kevin from Rotary Resurrection and getting some suggestions) I decided to send the rotors to SpeedSource (since they use them, as well) for ceramic seal prepping. They cut the apex grooves deeper to accept the taller seals and their price was damned-reasonable.

I got the rotors back and took the housings and side plates to UMS in Phoenix for hot-tanking. They cleaned up real nice.

When Easy and I got back to my house we started with Erick painting the side plates while I prepped the side seals and custom-set the gaps.

Then, since I could not access my Mazda FSM on CD I had to look at all these parts and try to remember which springs went where as they have specific grooves into which they must be placed. Luckily, I remembered....... ;) BTW, those of you who may be familiar with the dynamic Erick and I engage in when teaming up on our installs (sarcasm and such).... none of that was present this time. I guess we wanted to be careful with $900 apex seals laying around. :dunno:

That which I could not immediately recall, Easy remembered and I am grateful for his help as he cut the build time in half.

We buttoned that ***** up at 7:30 this morning, packed it on a palate for shipping, and it now sits in my garage shrink-wrapped and sealed up for shipment to Hawaii.

From the Build Team

http://i59.photobucket.com/albums/g307/Easy_E1/Kanesrerbuild11042009024.jpg

[zoom zoom maz6]

that makes me happy in my pants