COMPLETED [MERAH]

some ppl might know it already.... but i guess its about time for me to post about it

mazda3 SP23 has been a great car too me.... its just the gearbox and the engine mounts problem that happened more than once.... i just dont want to wait for the next time it happens again... so i decided to fix everything then sell it...

at the moment has been returned to stock form and most of the parts has been sold....

FINAL SPEC: MERAH
march2004 - august2006



PERFORMANCE

0-100km/h (sec):
6.7 sec (tested with G-Tech, mod: header, intake, catback)

BEST QUARTER – MILE:
15.07sec @ 108.88* mph on Heathcote Raceway. (mod: header, intake, catback)

BEST TRACK RESULT:
1:51.5 at Winton Raceway long track (3km)
Mod: bridgestone RE070, coilover, intake, catback, F&R strurt and sway bars
Haven’t done one with the current mods

POWER OUPUT:
109.7KW ATW @ 6900 RPM (mod: header, intake, catback) @ Dynamic Dyno.
DYNO PLACE / CONTACT WORKSHOP & NAME: Pro-Tek automotive: 03 9484 3117

*the trap speed on my best run is inaccurate. my other run on that day only ranging from 97-100mph

AUXILIARY PARTS

ECU: Microtech LT10 (in development)
AIR FILTER: AEM cold air intake
EXHAUST PIPE: 2.5inch mandrel bent
MUFFLERS: Magnaflow with 4inch Aluminium SE Magnaflow tip
EXHAUST MANIFOLD: Custom 4 – 1 setup. 1 7/8inch primary & 2.5inch collector. Ceramic coated
OTHER: Oil Catch Tank


TRANSMISSION

FLYWHEEL: EXEDY lightweight
CLUTCH PLATE: MAZDASPEED
PRESSURE PLATE: MAZDASPEED
GEARBOX FITTING/MODS (in progress):
- MTX75 conversion
- Torsen 1.5 LSD
- 4.06 final drive
- Nitride Treatment
- TWM short shifter
- Redline MT90
- Billet Driveshaft
- Custom mounts
- Adapter plate

HANDLING AND SUSPENSION

COILOVERS: TEIN Superstreet (front 45 mm rear 40mm)
FRONT SWAYBAR: AUTOEXE 22mm
REAR SWAYBAR: AUTOEXE 22mm
FRONT STURT BAR: AUTOEXE Front 3 points
REAR STURT BAR: AUTOEXE Rear 4 points Sturt Bar
ENGINE MOUNT: AWR rear Engine mount
OTHER: TEIN Electronic Damping Force Controller


BRAKES - FRONT

CALIPER:
WILWOOD 6 piston calipers - Forged SuperLite

ROTOR:
HD 13" x 1.1" wide, vented, directional rotors.
Gas slotted, zinc plated.
Aluminum rotor hats.
Steel mounting brackets.

PADS:
Wilwood BP10 pads.

OTHER
Stainless steel braided hoses.


BRAKES - REAR

CALIPER:
Stock BK3P rear caliper

ROTOR:

Direct replacement 11.75" non vented rotor for stock caliper, retaining parking brake.
Gas slotted and zinc plated.
Aluminum rotor hats.
Steel Caliper mounting brackets.

PADS:
EBC Green stuff

OTHER
Stainless steel braided hoses.


WHEELS & TYRES

STREET:
WHEEL BRAND: KYOYA MODEL: CE28 copy
DIAMETER & WIDTH (FRONT & REAR): 18x7.5 +42
TYRE BRAND (FRONT & REAR): Goodyear Eagle F1 GSD3
SIZE: 225/40/18

TRACK:
WHEEL BRAND: ROTA MODEL: ??
DIAMETER & WIDTH (FRONT & REAR): 17x7 +40
TYRE BRAND (FRONT & REAR): Bridgestone RE070
SIZE: 225/45/17


EXTERIOR BODYWORK

‘Carbon Products’ – Vented Carbon Fibre Bonnet
Custom Bonnet paint
Valiant Front Lip
Valiant Front Grill
Valiant Rear Roof Spoiler
Custom paint Engine cover


OTHER BODY MODS:
JDM slimline Visor
Satin Fuel Door
SUNROOF - Webasto Holandia 700


INTERIOR

SEATS: WRX 2004 conversion Seats
PEDALS: RAZO – G speed 4 Piece
MISC:
Pivot 3 stages Shiftlight
DIY painted interior plastic stripe
DIY painted Caliper
DIY Painted engine cover
DIY center dash 3 gauges holder
Door sills
Leather shift boot cover

yay! 90% completed... MERAH is almost complete

FINALLY.... MERAH is running again... habbah habbah.... few minor things to do still.... replace the driveshaft and fix the door... but apart from that, the car is running and test drove it with desmond few days ago, and it was fine, except ofcourse the driveshaft grinding....

updates on MERAH:

progress: 90%
Duration: 24 hours (5 nights)

night 14 (3 hours)

1. install stock front sway bar
   
2. putting the engine back in the engine bay
   
3. install all engine mounts
   

night 15 (4 hours)

1. repositioned the engine to sit correctly
   
2. install stock header
   
3. install fan shroud
   
4. install stock header
   
5. install catback
   

night 16 (5 hours)

1. rewire everything back
   
2. reconnect all the hoses including fuel line
   
3. install battery holder
   
4. install plastic front cowl
   
5. install the AC compressor and belt
   
6. fill the coolant tank
   

night 17 (5 hours)

1. install suspension and control arm
   
2. return the caliper and rotor to stock
   
3. install the driveshaft back
   
4. install headlight
   

night 18 (7 hours)

1. install the seats back
   
2. compress the rear brake caliper piston
   
3. bleed the clutch
   
4. bleed the brake
   
5. install the interior trim back
   
6. return the hood to stock
   
7. refit the bumper
   
8. refit the wheels
   
9. test drive! wohooo... wash the car too
   

the next day, i was driving to thao's work place and the drive shaft came loose... lol.... oh well, as long as i dont drive over 60kmh, its fine....

thx to: kenny/kthl, mark/cully5, jason/unco, desmond/nismo14 for the help and the support.... as i always said.... i couldn't have completed it without any help from all of you.... thx guys...

damage report during the process: snapped brake hose, rear brake piston dust seal, crank sensor, drive shaft clip....

another progress - 60% completed

sorry guys, i've been abit busy lately.... i'll try to finish and get back as soon as possible....

updates on MERAH:

progress: 60%
Duration: 32 hours (9 nights)

night 5 (3 hours)

1. take off the left drive shaft
   
2. take off the left coilover
   
3. take off the left endlink
   
4. take off the left braided hose line
   

night 6 (3 hours)

1. take off rear engine mount
   
2. take off headers and O2 sensor
   
3. take off 2 underbody braces
   
4. take off exhaust connection
   

night 7 (4 hours)

1. take off all the wiring and loom
   
2. take off main switch
   
3. take off the radiator mount
   
4. take off fan shroud
   
5. take off coolant reserve tank
   
6. take off the hoses
   
7. take off fan shroud
   
8. take off shifter cable
   

night 8 (6 hours)

1. take off the right drive shaft
   
2. take off the right coilover
   
3. take off the right endlink
   
4. take off the right braided hose line *broke it *
   
5. take off the joint shaft bracket
   
6. take off the radiator main hose
   
7. take off the main engine mount
   
8. lift off the engine and gearbox... FINALLY....
   

night 9 (2 hours)

1. disconnect all gearbox wiring
   
2. take off the starter motor and wiring brackets
   
3. take off the gearbox
   
4. take off the clutch
   

night 10 (4 hours)

1. take off flywheel
   
2. install stock flywheel and clutches
   
3. take off the right swing arm
   
4. take off the front sway bar
   
5. take off the rear sway bar
   
6. take off the 3 autogauge
   
7. take off the jointshaft from gearbox
   

night 11 (4 hours)

1. take off the WRX seats
   
2. take off unco's seats
   
3. install WRX seats to his car
   
4. take off rear sturt bar
   
5. take off the seatbelt harness
   

night 12 (2 hours)

1. install front swaybar
   
2. install the gearbox
   

night 13 (4 hours)

1. degrease and clean the engine bay
   
2. thighten all gearbox bolt
   
3. install starter motor
   
4. install gearbox wiring
   
5. install joint shaft n bracket
   

thx to: jason/unco, kenny/kthl, mark/cully5 for the help and company.... much appreciated.... special thx for irawan/visage for the help and supervision... without you, i will never get those driveshaft and hoses out! geeeez.... thx man....

can wait to finish it.... this things supposed to take far less amount of time... but i'm not a mechanic and this is my first time pulling car appart.... the hardest part is about to come.... putting everything back together...

oh well... wish me luck...

few pics of the process

so here is the handsome gearbox, the famous MTX75 with 4.06 final drive... woohooo...


here is the pics of my intake *jase, i dont thing you would want it anymore * it got dent in it caused by hitting the chasis when the engine dropped on angle


the hole one the gearbox is cause by the engine mount... the mount actually holding at where the hole at


and this is the poor engine mount snapped into 3 pieces... the other pieces still stuck on the gearbox....


the right driveshaft also broken and get pulled off from the connector boot when the engine mount snapped....


hanging by the crane

healing process begins

refunded the ford shifter... i found a way to just use and modify the mazda3 shifter.... all i need is a welder....

anyway.... updates on MERAH:

progress: 10%
Duration: 14 hours (4 nights)

night 1 (2 hours)

1. Received the engine crane from Adelaide
   
2. assemble the crane base and wheels
   

night 2 (4 hours)

1. assemble the crane top
   
2. assemble the engine stand
   

night 3 (4 hours)

1. Jack up the car, hold the car with axle stand
   
2. take of all the wheels
   
3. take off the front bumper
   
4. take off the hood
   
5. use the crane to lift the engine abit and hold it (2 out of 3 engine mounts are broken, so engine was on angle)
   
6. take off the intake pipe
   
7. take off the oil catch can
   

night 4 (4 hours)

1. take off the 2 main fuel lines
   
2. take off the strut bar
   
3. take off the wiper and plastic cowl
   
4. take off the battery and ECU
   
5. take off the accelerator cable and cruise control
   
6. take off the under body splash guard
   
7. take off TOP LEFT engine mount (it was in pieces)
   

thx to: mark/cully5 for sitting around, smoking, finish my coke and calling me stoopid... jk bro.... thx for the help...