Mazda 323F BA - 1.8 Turbo

JapCarForum Cars, Cars, Cars! Project Cars Mazda 323F BA - 1.8 Turbo

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323F Rock
Junior Member

27-08-2019, 10:28 PM

Lee Stephens & Nathan Stephens (Son) (username: 323F Rock)
1.8L 323F GTR 1997 UK Birmingham

The modification list 06/08/12

Engine and Transmission:
Original 1.5l engine 90BHP change to 1.8l BPD now at 275BHP - 205% power increase!
Mazda 323 GTR 1.8L BPD Turbo engine
IHI VJ23 Turbo RHF6
Tial F38 External Wastegate
A’pexi air filter
Grayson Thermal Systems Custom Charge Air Cooler (CAC)
Tubular stainless steel exhaust manifold
SARD fuel pressure regulator (69010 G)
GATES Racing timing belt (T179RB)
Link G4 Storm Stand alone ECU
Kerr Nelson Red Ignition leads (For 323F BG GT)
Walbro 255l/h fuel pump (ITP253)
550cc SARD injectors
Competition Clutch Stage 4 sprung clutch, 6 pad ceramic disc (10045-1620)
Competition Clutch lightweight flywheel 4.95kg
Toda Cam adjustable pulleys (14210-NB0-001)
323F 1.8 BA G series Gear box
Titan Race 75W90
Forged internals (Pistons - WI-K553M835)
TWM short shifter
HKS SSQV dump Valve with Gold fin
2 x 11” SPAL radiator Fans (VA10-AP9-C-25A)
Grayson Thermal Systems Oil Cooler (HP-2412-210)
Greddy Boost Controller - Profec - B-Spec. II
Greddy Turbo timer - FATT2
Custom-made s/s exhaust twin pipes either side of the car
Gulf Competition 5W40
K&N oil filter (HP-1010 might try a HP-4001 next time as its even bigger!)
Mocal Oil Thermostat (OT/1 - 1/2" tails)

Suspension:
FK silverline Coilovers (FKXMA28)
Whiteline Front strut tower brace (KSB563)
Whiteline Rear strut tower brace
Whiteline uprated anti roll bar (BMR53)
Ultra racing room brace (UR-RO2-555)
Ultra racing rear body brace (UR-RU2-552)
PU Front Antiroll Bar Bushes (SPF1406-24K)

Brakes:
2 pot calliper upgrade using Subaru Legacy (92-94 Turbo) callipers
Mazda 626 GD calliper hangers
Mazda 323f BA V6 front hub carriers
Mazda MX-5 2008 2.0l sport EBC ultimax discs
Goodridge braided brake lines (for Mazda 323F BJ with rear discs)
Mazda 626 GD EBC Green stuff brake pads
Rear drums replaced with disc brakes from a MX3
"Pudding bowl" scoop cooling ducts to front brakes from front bumper

Wheels:
WOLFRACE KATANA Shadow Chrome 18” alloys

Body and Chassis:
Pakfeifer side skirts shaped into front mud flaps
Rear Pakfeifer spoiler - Aero style (044TAMA323F5)
Der-tuner Front bumper (PP25071)
De-badge front
Painted brake callipers (RED)
Headlight protectors tinted
Blacked out indicator units
Rear lights tinted and stencilled with Japanese Kanji symbol for 'Speed'
Rear fog and reverse lights replaced with white Type R units
LED Rear fog light bulb
Clear side repeaters
Under car LEDs (RED)
Club stickers on side skirts
Tinted windows
Custom one off rear diffuser
Real Carbon-Fibre bonnet (10104600)
Real Carbon-Fibre canards
Twin red Sickspeed horns

Interior:
Black mats with red piping
Smiley face air freshener
Chrome with red pedals
Aluminium and red leather handbrake cover with
Custom red hand stitched leather gaiter
MOMO Trek 350mm Steering wheel with snap off boss kit
Red and black front bucket seats
Rear seat trimmed to match front seats
Red Sparco Safety Harness both front seats
Solid stainless steel 'Garath style' gear knob
Mazdaspeed head rests

ICE:
7” flipout DVD player
JVC head unit with a JVC 12 disc changer in boot
VIBE CBR 12” Active
Infinity component speakers and tweeters in front doors with external crossovers
Custom parcel self including infinity 6x9’s with external crossovers and Kenwood 400W Amp

Planned Mods:
Digital dash - Race Technologies DASH2
1" Mazda Xedos 9 OR 1 1/16" Subaru Legacy 2.0L TT 95-98 brake master cylinder
V6 Proportional valve maybe?
Standard GTR manifold to replace the knackered tubular one!
Yellowstuff pads
Variable intermittent wipe wiper stalk (to be installed)
Link G4 knock link (to be installed)

Here's how she stands today:
[Image: JAE2011213.jpg]

[Image: 300867_819463029598_223702967_12679672_1818683989_n.jpg]

:cheers:

Lee (father)
&
Nathan (son)

Edited 08-10-2012, 11:07 AM by Bandit.

323F Rock

27-08-2019, 10:28 PM #1

323F Rock
Junior Member

27-08-2019, 11:13 PM

Whoops could someone edit that post and delete the massive text about my old clutch please? thanks Big Grin

323F Rock

27-08-2019, 11:13 PM #2

Whoops could someone edit that post and delete the massive text about my old clutch please? thanks Big Grin

323F Rock
Junior Member

27-08-2019, 11:45 PM

Here's how we got there:

in an industrial unit far far from home (well about 45mins actually )
[Image: DSC02023.jpg]

a 323f was parked
[Image: DSC01986.jpg]

Which was being shared with a tasty red DC5 (bad pic )
[Image: DSC01987.jpg]

And let the modding begin

we started with some carpentry... we used wooden blocks on the lift to help clear the side skirts
[Image: DSC01985.jpg]

old stuff to be removed
[Image: DSC01989.jpg]

Ooooooo nice new parts to fit
[Image: DSC01988.jpg]

mmmmm red hoses
[Image: DSC02014.jpg]

behold the worlds MOST stubborn drive shaft stuck in the hub....
[Image: DSC02000.jpg]

We tried for many long hours, breaking in total i think 6 different hub pullers by shearing bolts, leaking hydraulic rams and actual failure of forged steel causing shrapnel spearing off and hitting me twice!! In the end Nathan took the shaft and hub to work where he heated the hub whilst being under 30 tonnes of pressure on a bearing press and nothing happened so, we gave up and bought new bits from a scrap yard!

10 tonne hydraulic ram on said drive shaft
[Image: DSC02027.jpg]

bit of an interesting shot lying on the floor after a long day
[Image: DSC02002.jpg]

new cool tools
[Image: DSC02051.jpg]

probably the most important tool required Lateral link bolt insersion tool
[Image: DSC02046.jpg]

One of the many inncorrect drive shafts that we were supplied and the reason we didnt make it to JAE!!! Grrr!!
[Image: DSC02138.jpg]

when pressing the front hub out of the hub carrier the inner race of the bearing tends to stick... to get it off Nathan filed two flats (using diamond files; normal ones won't touch them; angle grinder works well too but didn't trust myself enough to grind so close to bits we wanted ) on the race opposite each other and used a two leg hub/gear puller to pull it off.
[Image: DSC02126.jpg]

we painted the inside of the strut towers with hammerite as they were starting to show some slight surface rust...
[Image: DSC02015.jpg]

this one wasnt too bad but we did it any way
[Image: DSC02026.jpg]

look ma no legs!
[Image: DSC02016.jpg]

323F Rock

27-08-2019, 11:45 PM #3

Here's how we got there:

in an industrial unit far far from home (well about 45mins actually )
[Image: DSC02023.jpg]

a 323f was parked
[Image: DSC01986.jpg]

Which was being shared with a tasty red DC5 (bad pic )
[Image: DSC01987.jpg]

And let the modding begin

we started with some carpentry... we used wooden blocks on the lift to help clear the side skirts
[Image: DSC01985.jpg]

old stuff to be removed
[Image: DSC01989.jpg]
[Image: DSC01990.jpg]

Ooooooo nice new parts to fit
[Image: DSC01988.jpg]

mmmmm red hoses
[Image: DSC02014.jpg]

behold the worlds MOST stubborn drive shaft stuck in the hub....
[Image: DSC02000.jpg]
We tried for many long hours, breaking in total i think 6 different hub pullers by shearing bolts, leaking hydraulic rams and actual failure of forged steel causing shrapnel spearing off and hitting me twice!! In the end Nathan took the shaft and hub to work where he heated the hub whilst being under 30 tonnes of pressure on a bearing press and nothing happened so, we gave up and bought new bits from a scrap yard!

10 tonne hydraulic ram on said drive shaft
[Image: DSC02027.jpg]

bit of an interesting shot lying on the floor after a long day
[Image: DSC02002.jpg]

new cool tools
[Image: DSC02051.jpg]
probably the most important tool required Lateral link bolt insersion tool
[Image: DSC02046.jpg]

One of the many inncorrect drive shafts that we were supplied and the reason we didnt make it to JAE!!! Grrr!!
[Image: DSC02138.jpg]
[Image: DSC02118.jpg]

when pressing the front hub out of the hub carrier the inner race of the bearing tends to stick... to get it off Nathan filed two flats (using diamond files; normal ones won't touch them; angle grinder works well too but didn't trust myself enough to grind so close to bits we wanted ) on the race opposite each other and used a two leg hub/gear puller to pull it off.
[Image: DSC02126.jpg]

we painted the inside of the strut towers with hammerite as they were starting to show some slight surface rust...
[Image: DSC02015.jpg]

this one wasnt too bad but we did it any way
[Image: DSC02026.jpg]

look ma no legs!
[Image: DSC02016.jpg]

323F Rock
Junior Member

27-08-2019, 11:50 PM

Lee, puting some bolts in
[Image: DSC02043.jpg]

hose run looked a bit funny to us but decided it was fine with some reassurance from Andy
[Image: DSC02032.jpg]

Handbrake cable... Grrr!! we bought a 'Blue print' one rather than a mazda one is the right length but the fittings on the caliper end need filing to fit in the bracket!!
[Image: DSC02019.jpg]

bit of work and it fits!
[Image: DSC02036.jpg]

new leg

new parts pile going down
[Image: DSC02033.jpg]

we bought 270mm discs as advised in the guide however these are veryveryvery close to the calipers so i had them turned down to 263mm just to make sure! pics are before they were turned down.
new and old discs comparison.
[Image: DSC02010.jpg]

much happier with that clearance
[Image: DSC02122.jpg]

front bolted up and ready to go
[Image: DSC02116.jpg]

brake fluid required thought we'd better put some good stuff in as recommended by Andy and Stu
[Image: DSC02130.jpg]

Wheels on! quite like these pics show all the goodies behind the wheels
[Image: DSC02257.jpg]

(for the worried eagle eyed members the rubber collars are temporary till we get some more metal hose clips )

[Image: DSC02252.jpg]

323F Rock

27-08-2019, 11:50 PM #4

rear end all fitted up after having to cut and shut the brake line on the drivers side as the brake pipe nut rounded off so we cut it, re-flared it and bent the pipe up and around so we didn't have to add more pipe in (more special tools bought)
[Image: DSC02135.jpg]
[Image: DSC02119.jpg]

Lee, puting some bolts in
[Image: DSC02043.jpg]

hose run looked a bit funny to us but decided it was fine with some reassurance from Andy
[Image: DSC02032.jpg]

Handbrake cable... Grrr!! we bought a 'Blue print' one rather than a mazda one is the right length but the fittings on the caliper end need filing to fit in the bracket!!
[Image: DSC02019.jpg]
bit of work and it fits!
[Image: DSC02036.jpg]

new leg
[Image: DSC02037.jpg]

new parts pile going down
[Image: DSC02033.jpg]

we bought 270mm discs as advised in the guide however these are veryveryvery close to the calipers so i had them turned down to 263mm just to make sure! pics are before they were turned down.
new and old discs comparison.
[Image: DSC02010.jpg]
[Image: DSC02009.jpg]

much happier with that clearance
[Image: DSC02122.jpg]

front bolted up and ready to go
[Image: DSC02116.jpg]
[Image: DSC02115.jpg]
[Image: DSC02117.jpg]

brake fluid required thought we'd better put some good stuff in as recommended by Andy and Stu
[Image: DSC02130.jpg]

Wheels on! quite like these pics show all the goodies behind the wheels
[Image: DSC02257.jpg]
[Image: DSC02259.jpg]

(for the worried eagle eyed members the rubber collars are temporary till we get some more metal hose clips )

[Image: DSC02252.jpg]
[Image: DSC02253.jpg]

323F Rock
Junior Member

27-08-2019, 11:51 PM

ride height set to a sensible level Smile

(wood needed under the wheels to get it off the lift Wink

)

Drove her home sunday with only a couple of niggles:
Handling is awful... not been 4 wheel aligned yet and the front wheels are noticeably toeing in :?
and the rear brakes were dragging slightly so we just need to adjust the hand brake.

It's safe to say we are very happy with the outcome Big Grin

just gutted it wasn't ready for JAE 2010!! Sad

Big massive thank you's to:
Paul for letting us steal his lift for soooo long
AndyM for coming and helping us out on a number of occasions and for the loan of the 'Book of Knowledge'
Matt for caliper hangers and loads of information
Stu for information on his rear brake conversion and hand brake cables
FPS for supplying a fair few parts
Matco Engineering - http://www.matcoeng.com machined the discs down for us (a veryveryvery good machine shop!)
Grayson Thermal Systems http://www.graysonts.com (where Nathan works) for letting him miss a fair bit of work so he could use the machines when we were trying to get it finished for JAE.

There are probably people we have missed and if we have we're soooo sorry please let us know!!

323F Rock

27-08-2019, 11:51 PM #5

ride height set to a sensible level Smile
[Image: DSC02255.jpg]
[Image: DSC02256.jpg]
[Image: DSC02254.jpg]
(wood needed under the wheels to get it off the lift Wink )

Drove her home sunday with only a couple of niggles:
Handling is awful... not been 4 wheel aligned yet and the front wheels are noticeably toeing in :?
and the rear brakes were dragging slightly so we just need to adjust the hand brake.

It's safe to say we are very happy with the outcome Big Grin just gutted it wasn't ready for JAE 2010!! Sad

Big massive thank you's to:
Paul for letting us steal his lift for soooo long
AndyM for coming and helping us out on a number of occasions and for the loan of the 'Book of Knowledge'
Matt for caliper hangers and loads of information
Stu for information on his rear brake conversion and hand brake cables
FPS for supplying a fair few parts
Matco Engineering - http://www.matcoeng.com machined the discs down for us (a veryveryvery good machine shop!)
Grayson Thermal Systems http://www.graysonts.com (where Nathan works) for letting him miss a fair bit of work so he could use the machines when we were trying to get it finished for JAE.

There are probably people we have missed and if we have we're soooo sorry please let us know!!

323F Rock
Junior Member

28-08-2019, 12:00 AM

The start of the wiring nightmare:
[Image: DSC02351.jpg]

New Gates Racing timing belt:
[Image: DSC02439.jpg]

323F Rock

28-08-2019, 12:00 AM #6

Then early 2011 we started the engine swap with the plan to be finished in time for Japfest! haha

We bought another members car that had already done the engine swap from a 4 wheel drive 1992 Mazda 323 GT-R! his install left much to be desired so we were happy to pull the engine and put our spin on it!

Pictures speak louder than words… any questions comments etc. go right ahead!
[Image: DSC00015.jpg]
[Image: DSC00033.jpg]
[Image: DSC02349.jpg]

The start of the wiring nightmare:
[Image: DSC02351.jpg]

[Image: DSC02373.jpg]
[Image: DSC02385.jpg]
[Image: DSC02388.jpg]
[Image: DSC02389.jpg]
[Image: DSC02390.jpg]
[Image: DSC02403.jpg]
[Image: DSC02404.jpg]
[Image: DSC02406.jpg]
[Image: DSC02408.jpg]
[Image: DSC02409.jpg]
[Image: DSC02410.jpg]
[Image: DSC02426.jpg]
[Image: DSC02432.jpg]
[Image: DSC02433.jpg]

New Gates Racing timing belt:
[Image: DSC02439.jpg]
[Image: DSC02440.jpg]

323F Rock
Junior Member

28-08-2019, 12:02 AM

Eeek at that welding! Definitely saving for a new manifold!
[Image: IMAG0009.jpg]

Out with the old:
[Image: IMAG0035.jpg]

Wiring **shudder**
[Image: IMAG0038.jpg]

323F Rock

28-08-2019, 12:02 AM #7

[Image: DSC02441.jpg]
[Image: DSC02444.jpg]
[Image: DSC02443.jpg]
[Image: IMAG0005.jpg]
[Image: IMAG0008.jpg]

Eeek at that welding! Definitely saving for a new manifold!
[Image: IMAG0009.jpg]
[Image: IMAG0010.jpg]

[Image: IMAG0024.jpg]

[Image: IMAG0028.jpg]

[Image: IMAG0029.jpg]
[Image: IMAG0034.jpg]
[Image: IMAG0033.jpg]

Out with the old:
[Image: IMAG0035.jpg]

[Image: IMAG0037.jpg]

Wiring **shudder**
[Image: IMAG0038.jpg]

[Image: IMAG0040.jpg]
[Image: IMAG0044.jpg]
[Image: IMAG0045.jpg]
[Image: IMAG0046.jpg]
[Image: IMAG0048.jpg]

323F Rock
Junior Member

28-08-2019, 12:03 AM

Custom install for the boost controller, really pleased with how this turned out!

[Image: IMAG0058.jpg]

ARP bolts

Few measurements for new fans:
[Image: IMAG0142.jpg]

Ready for engine:
[Image: IMAG0146.jpg]

She’s in:

Ceramic coated exhaust bits:
[Image: IMAG0149.jpg]

Hand fabricated custom brackets 16 in total
Template:
[Image: IMAG0152.jpg]

Tools:

323F Rock

28-08-2019, 12:03 AM #8

[Image: IMAG0057.jpg]

Custom install for the boost controller, really pleased with how this turned out!

[Image: IMAG0058.jpg]
[Image: IMAG0059.jpg]
[Image: IMAG0060.jpg]
[Image: IMAG0061.jpg]
[Image: IMAG0065.jpg]

[Image: IMAG0115.jpg]

[Image: IMAG0116.jpg]
[Image: IMAG0117.jpg]
[Image: IMAG0127.jpg]

ARP bolts
[Image: IMAG0133.jpg]

[Image: IMAG0131.jpg]

Few measurements for new fans:
[Image: IMAG0142.jpg]

Ready for engine:
[Image: IMAG0146.jpg]

She’s in:
[Image: IMAG0147.jpg]

[Image: IMAG0148.jpg]

Ceramic coated exhaust bits:
[Image: IMAG0149.jpg]

Hand fabricated custom brackets 16 in total
Template:
[Image: IMAG0152.jpg]

Tools:
[Image: IMAG0153.jpg]

[Image: IMAG0154.jpg]

323F Rock
Junior Member

28-08-2019, 12:04 AM

Custom brackets for the coil pack:
[Image: IMAG0180.jpg]

Brand new front bracket: (old one was cracked and had a hole torn out...)
[Image: IMAG0187.jpg]

2 Brand new SPAL radiator fans mounted by more custom brackets.
[Image: IMAG0198.jpg]

Custom wiring loom for the turbo timer and gauges using an RX7 FD3 turbo timer harness:
[Image: IMAG0199.jpg]

Fluids:

Not just cleaned, sterilised coolant tank!
[Image: IMAG0227.jpg]

323F Rock

28-08-2019, 12:04 AM #9

[Image: IMAG0156.jpg]

[Image: IMAG0226.jpg]

Custom brackets for the coil pack:
[Image: IMAG0180.jpg]

[Image: IMAG0184.jpg]

[Image: IMAG0182.jpg]

Brand new front bracket: (old one was cracked and had a hole torn out...)
[Image: IMAG0187.jpg]

2 Brand new SPAL radiator fans mounted by more custom brackets.
[Image: IMAG0198.jpg]
[Image: IMAG0220.jpg]
[Image: IMAG0230.jpg]
[Image: IMAG0231.jpg]

Custom wiring loom for the turbo timer and gauges using an RX7 FD3 turbo timer harness:
[Image: IMAG0199.jpg]
[Image: IMAG0214.jpg]
[Image: IMAG0216.jpg]
[Image: IMAG0217.jpg]
[Image: IMAG0218.jpg]

Fluids:
[Image: IMAG0223.jpg]

[Image: IMAG0224.jpg]

Not just cleaned, sterilised coolant tank!
[Image: IMAG0227.jpg]

[Image: IMAG0228.jpg]
[Image: IMAG0229.jpg]

323F Rock
Junior Member

28-08-2019, 12:04 AM

#10

Custom oil cooler piping and oil cooler which was actually completely designed from scratch by Nathan at work:
[Image: IMAG0265.jpg]

Silicone hoses:
[Image: IMAG0266.jpg]

Braces:

Genuine Apexi air filter not a fake one like I bought first….. and more custom brackets:
[Image: IMAG0275.jpg]

Custom one off CAC with baffle plate to direct air flow across the core
[Image: IMAG0279.jpg]

Custom air ducting at front to force air through the CAC then through the radiator (need painting) Space for new horns…. Sick speed possibly.
[Image: IMAG0285.jpg]

Temporary decat to get to the exhaust fabricators.
[Image: IMAG0271.jpg]

323F Rock

28-08-2019, 12:04 AM #10

Custom oil cooler piping and oil cooler which was actually completely designed from scratch by Nathan at work:
[Image: IMAG0265.jpg]
[Image: IMAG0291.jpg]

Silicone hoses:
[Image: IMAG0266.jpg]

Braces:
[Image: IMAG0268.jpg]
[Image: IMAG0269.jpg]

Genuine Apexi air filter not a fake one like I bought first….. and more custom brackets:
[Image: IMAG0275.jpg]
[Image: IMAG0270.jpg]
[Image: IMAG0274.jpg]
[Image: IMAG0276.jpg]
[Image: IMAG0277.jpg]
[Image: IMAG0278.jpg]
[Image: IMAG0289.jpg]

Custom one off CAC with baffle plate to direct air flow across the core
[Image: IMAG0279.jpg]
[Image: IMAG0280.jpg]

Custom air ducting at front to force air through the CAC then through the radiator (need painting) Space for new horns…. Sick speed possibly.
[Image: IMAG0285.jpg]

Temporary decat to get to the exhaust fabricators.
[Image: IMAG0271.jpg]
[Image: IMAG0272.jpg]
[Image: IMAG0273.jpg]