Quest for More Power and More Traction! BP+T + AWD Build Thread

[Nerd Racing]

EDIT: disregard the cigarette butts... my brother in law throws them everywhere... I'm surprised he hasn't burned the garage down yet...

I want to use off the shelf axles. can't do that if i do hybrid axles, plus i want the wider wheel base... remember the old mazda commericals "wider is better" well there is something to that... AND the miata rear end is wider than the festiva wheel base too, I'd like it to match.

I'm dumb enough to try... and too stubborn to quit... lol

As far as the B3 goes, I would rather have things situated similar to stock if I can when it comes to engine and trans mounting. I will be using a GTR intake manifold so firewall clearance shouldn't be an issue there.

[Damkid]

i figure the FWD G series always locates the engine more forwards with BP/B6T swaps and since your GTX trans is still a G series, i figure it may do the same and want to locate the B3 further forward in the engine bay, possibly causing you some grief by still having it in there

[Nerd Racing]

I will look out for that, I did some comparing when i first got it in my head to do the awd swap (probably a good 6 years ago) and the AWD trans was actually smaller around the front diff housing area that usually gets close to the steering rack. This was comparing to a KIA Sephia G-series I pulled to sell. I need to look up in my FSM about how to remove the diff lock motor. If I can get that off tomorrow I should be able to bolt the trans to the B3 and start jacking it up into place and see how things look. I'll try and take plenty of pics for sure.

[kellen302]

That new tranny sure don't look like anything I've ever seen. lol. Great Job, can't wait to see it launch on some subies

[Damkid]

I will look forward to pics

[Nerd Racing]

I don't plan on doing any hard core launches, unless I have a backup trans or two... lol. I don't even launch my 4wd protege NA BP. The thing still moves pretty well for being as heavy as it is though and it handles pretty well for having 4 blown struts. I can't imagine how the festiva will feel when its done and the turbo setup is in and tuned.

[tls_zx3]

i look forward to seeing the finished project. i hear tons of talk on the focus forums about people wanting to do or saying they are going to do a awd swap. nice to see some one who actually has the balls to try it.

i do feel sorry for you trying to get the alignment correct on that front end. even mounting that rear bushing on the control arm a little off with mess with your caster and make that thing pull, or the tie rod length or camber from those struts being incorrect making it drive like a walmart shopping cart... good luck

[Nerd Racing]

believe me, the alignment is a major concern. I will be building my mounts and doing my measuring to the thousandths of an inch. Being a mechanical engineer comes in handy for the parts I have to design. The rear sub frame was not really that critical so it was crude, it will be redone eventually.

Then I have access to a great alignment shop once I'm done. The thing will be in line for sure. I'm also considering getting a ZX2 sub frame to hack up and make two half sub frames out of so the mounts will be positioned properly. I haven't really put much into that portion yet. I just slapped it together for a quick pic and to see what I was up against. As far as making engine and trans mounts, I've done that to death with aspires, the festiva will be well set as far as those are concerned.

[Rocketman]

You can use a different balljoint to move the knuckle out more... I think the BF guys used to use RX7 balljoints to get more track width for BG swaps, it might be a happy medium?

[Nerd Racing]

Yeah FC ball joints do increase the track width. I already bought ZX2 ones new though. I'm swapping arms out tomorrow with a guy from the protege forums.

Managed to get the engine and trans bolted together without removing the diff lock motor. Here are a few clearance photos:









Axle alignment looks decent where its at:



The engine will have to move forward some just like a fwd swap. I was hoping to avoid it oh well.





I picked up some 1/4" plate to start making my mounting brackets out of. Hoping to have her mounted up by the end of the week.

[Nerd Racing]

If you look at the first pic in the post above, I will be making a tail mount that bolts to those three studs. I'm starting there first. Hoping i can get it laser cut at work.

[Nerd Racing]

not much progress, just ordered an energy suspension motor mount bushing kit, some seamless tubing, and a couple energy suspension Jeep style transmission mounts. The engine should be nice and stiff, without a lot of pass through vibrations.

[Nerd Racing]

SRT-4 Intercooler:



Bushings arrived along with mount materials and Protege control arms:



Couple more shots before I shifted some things around:





I decided to put longer bolts in the passenger mount bracket to move the engine forward:



rack clearance:



Passenger side clearance:



Wheel with the protege arms and caster adusted:





Some clearance shots after the engine is centered front to back:







As you can see I will need to roll the engine forward angle wise but that won't be an issue.

an idea of where I am going with the tail mount:





I have to get some plates cut, hopefully at work...

I had to cut the crossmember up, front piece in there... I will be moving the mount closer to the radiator support than it was:



and another rack clearance shot:



I will be going down slightly with the trans from what the pics show (to level out the engine) and the engine gets angled forward slightly. Things will clear nicely without bashing or cutting underneath. I may put a little clearance in the driver's frame rail for comfort.

I know how I am going to do 2 of the 3 transmission mounts and I have an idea of how do the 3rd, just have to get stuff cut.

[Nerd Racing]

Some more progress on the tail tranny mount. This one will be crucial because I need it to locate the trans so I can take and tip the engine into the angle I need to make the other two mounts.

Base plate:



Cut up some tube and sunk a couple holes:





I am using a couple wheel studs to mount the base plate to the tube connecting to the frame and mount. I needed a different drill bit size so I have to wait till tomorrow to final assemble the mount... and I have to get some fine thread nuts for the threaded studs on the trans.

I am looking into using some rivet nuts, they are threaded inserts you drill a hole for, then use a rivet gun style thing with a threaded mandrel. then you pull them up like a rivet. they are ridged so you don't spin them either. I'm ordering a pack and the bit I need so I can add threaded inserts without drilling all the way through the unibody. Should be just as strong as the OEM captive nuts and I won't promote internal corrosion due to welding heat.

[Nerd Racing]

Well I ripped the B3 out with the trans.

Pulled the BP and GTX trans from my protege so it could be picked up:





Going to try and put it in some time this week.