My coldside mods.

[99mx5]

Ill post pics and how I modded my kit here
-Ari

Heres a pic of the ported blower intake and TB adapter.

I mated the TB adapter to the blower and marked the part where the joint didnt match. I sealed the outlet port with tape and sealed the chamber with foam cut to match the opening for the rotors and bypass. The foam sealed nicely, no particles entered. I dremeled the intake smooth and rounded the edges of the bypass port. I shaped the surface and smoothed the mold lines. I vacuumed the ports after grinding and smoothing. I then wet sanded and polished. I then dried and removed the foam and wiped the area clean. Lastly, I flushed the blower from the inside with WD40, just in case.

[Tom @ Fast Forward]

Just don't show them how to port the blower and LOSE 8WHP. :)

[99mx5]

Heres the intake of the blower with the TB adapter mounted. Smooth flow from the throttle body to the rotors. :)

http://upload3.postimage.org/250935/PortmatchedTBadapter.jpg (http://upload3.postimage.org/250935/photo_hosting.html)

[99mx5]

Heres a pic of the IM with the ports opened up to match the gasket and polished.

[99mx5]

Heres the solid Intake Manifold brace.

Cut from a piece of steel 1/2" square tube and painted black.

[99mx5]

Heres a pic of the IAC bracket with the small brass elbows.

[99mx5]

I added a fillet to round the corner for airflow on the inner edge of the IM top plate.

http://upload3.postimage.org/250947/top_plate_fillet.jpg (http://upload3.postimage.org/250947/photo_hosting.html)

[99mx5]

Heres the prototype throttle cable bracket.

[99mx5]

Heres another pic of the TB adapter and the EGR bracket with countersunk bolts for more space by the fuel rail.

[99mx5]

Ever wondered what the blower looks like without the nose assembly?
Nows your chance :)

http://upload3.postimage.org/250958/blower_rotor_gears.jpg (http://upload3.postimage.org/250958/photo_hosting.html)

[Wayne-n-Fla]

I added a fillet to round the corner for airflow on the inner edge of the IM top plate.

http://brpforum.infopop.cc/groupee/forums/a/ga/ul/5341061412/inlineimg/Y/99mx5_top_plate_fillet.jpg
Did you actually add something or just round over the edge ?

[99mx5]

Im sorry, I meant to say rounded the edge of the blower port on the IM top plate. The two sides that I didnt do are flush with the IM wall.

[JTod]

[quote=99mx5]Heres the solid Intake Manifold brace.

Cut from a piece of steel 1/2" square tube and painted black.



Nice pics, thanks for sharing. Why did you go to a solid manifold brace?

[99mx5]

The eyebolts on the brace developed play. I installed it with a bit of upward tension and transferred the measurements to the solid brace. No more play and I dont need to adjust it after its installed.

[99mx5]

I didnt want to drill holes in the car to mount stuff, so I made a panel for the firewall area to mount things on. It uses factory mounting holes to mount the panel.

Heres a top view of the firewall panel, IAC relocation and vacuum distribution block with hose routing redesign

http://upload4.postimage.org/360323/DCP_3269.jpg (http://upload4.postimage.org/360323/photo_hosting.html)

[99mx5]

Another view. Notice that the PCV hose goes directly into the throttle body adapter manifold and the angled IAC bracket. Also notice VDB fittings facing down.

...yes folks, thats a brand new blower, thanks to Tom. :)

http://upload4.postimage.org/360342/DCP_3276.jpg (http://upload4.postimage.org/360342/photo_hosting.html)

[Tom @ Fast Forward]

Nice job. Looks like there is even a spot left on the right of the VDB for the VTCS solenoid on the 01-05.

[99mx5]

I didnt want to drill holes in my pillar panel. At first, I used double sided foam tape to stick it on, but the heat make the tape slide and the pod eventually came off. I then make some small hooks to hook the pod on the top edge of the pillar panel and use the foam tape to keep it in place.

The hooks are small strips of stainless steel that are epoxied to the inside of the pod. I placed tape on all the contact surfaces in the pod. The result is a pod firmly mounted to the pillar that has no pins or screws. The pod is removable and leaves no marks on the pillar panel.
http://upload4.postimage.org/566268/DCP_3220.jpg (http://upload4.postimage.org/566268/photo_hosting.html)

[99mx5]

Another view of the pod hooks.
http://upload4.postimage.org/566273/DCP_3221.jpg (http://upload4.postimage.org/566273/photo_hosting.html)

[99mx5]

Top view of inside of pod.

http://upload4.postimage.org/566282/DCP_3222.jpg (http://upload4.postimage.org/566282/photo_hosting.html)

[99mx5]

Mounted to pillar. You can see the tube under the pod. I wrapped the wires in black tape but forgot to do the tube.

http://upload4.postimage.org/566316/DCP_3082.jpg (http://upload4.postimage.org/566316/photo_hosting.html)

[99mx5]

I made a new washer bottle bracket and mounted the VDB and IAC valve on it.

http://upload4.postimage.org/1240883/DCP_3336.jpg (http://upload4.postimage.org/1240883/photo_hosting.html)

[99mx5]

Close up of the hoses.

http://upload4.postimage.org/1240902/DCP_3338.jpg (http://upload4.postimage.org/1240902/photo_hosting.html)

[99mx5]

Top view.

http://upload4.postimage.org/1240921/DCP_3343.jpg (http://upload4.postimage.org/1240921/photo_hosting.html)

[socal pat]

Very purdy! I deleted my wiper bottle and have lots of room over there. One thing though. I was looking at the closeups and see you have a different hose configuration to your VDB than I do? For one thing I don't have a hose going directly from my IAC to the VDB. My IAC runs to the TBA and the TB. Also I see a line with a TEE. where does that go to? Mine runs fine, but if you are seeing a benifit from running Vacuum lines differently I'm all ears.

[Kyp J]

That does look cool. But it brings up something that has been bothering me about the valve cover vent hose. How is the (air, blowby or whatever)going thru that hose getting the MAF to recognize it's existance in the system. Does the MAF not have a function at low volume air as in "idle". Also, do all engines have enough volume of air available from that source to add enough to properly enhance the idle. Mine seems to be providing a nice breeze, but I'm not sure if my rebuild is as tight as it could be. My compression isn't all that.

[Tom @ Fast Forward]

The hose gets it's air from the front side of the BTB. That air comes through the MAF. All incoming air has to come through the MAF.

[99mx5]

That tee in the hose connects the valve cover breather and IAC to the throttle body. That air comes post-MAF but is ambient (not vacuum).

This layout is uses the vacuum hose routing diagram of the latest install instructions.

[Kyp J]

That tee in the hose connects the valve cover breather and IAC to the throttle body. That air comes post-MAF but is ambient (not vacuum).

This layout is uses the vacuum hose routing diagram of the latest install instructions.

That is what I mean, your picture shows air from the valve cover going to the IAC. Even if not directly connected it goes into the common vacuum in other vacuum line arrangements like mine, which in turn provides some air and is un metered.

[99mx5]

All the air that is used in the system passes through the MAF and is metered. The old layout had a black block unter the TB where the IAC connected at one side and the valve cover connected to the other side. The TB block was removed and replaced with a elbow fitting and now the same hoses tee together away from the TB instead of at the block under the TB.

The vacuum side of the IAC used to go to the TBA block. That TBA port is now connected to the PCV. The other side of the TBA connects to the VDB and the IAC now connects to the VDB. It the same configuration but now the VDB is connected between the IAC and the TBA.

This layout is identical to the original except that the IAC has been relocated off the engine. I had the case where I was breaking IAC bolts when it was mounted to the engine and this moves the IAC away from the engine and eliminates vibration that brakes the IAC mounting bolts.

The only air that is entering the vacuum system is the air that comes in from the TB which is post-MAF and metered.

Edit: I think I know what you are asking about.
The air that comes in from the TB is metered at the valve breather side of the tee with the PCV valve. The PCV valve has a constant rate of flow and this flow is compensated for. The PCV valve is connected to vacuum at the TBA, so it constantly is having air pulled from it and it enters the engine via the hose connected to the tee that connects to the TB. That "loop" is one channel for metered air. The other "loop" is the hose that connects the tee to the IAC and is metered by the IAC valve itself. That "loop" is the TB to the tee to the IAC then to the VDB and to the vacuum of the TBA. The third source for air to reach the vacuum of the TBA is the air that goes through the throttle.

So, the air that goes through the TB is metered by the TB idle adjuster screw and the gas pedal for the air that goes around the butterfly and the air that loops through the VDB metered by the IAC valve and the other loop that goes through the engine and is metered by the PCV valve. Of these three sources of air, only two are constantly changing flow. The IAC changes flow according to load at idle and the driver changes flow by pressing the gas pedal.

[Kyp J]

I don't want to be argumentative, but when you say "metered" by the IAC, I consider it controlled by the IAC via the ECM which is going by, I assume, the RPMs. The MAF "meters" or "measures" air going into the system to control the injectors (I think, not sure because the O2 also controls that) otherwise, why would it care how much air there was?

Mainly I am questioning the word "Meters" and how is the air from the valve cover measured when it comes from (?) (not the air filter).

I wasn't disputing the hose hook up you have since I don't think it really matters how the air is chaneled that goes into the vacuum arena.

[99mx5]

No probs Kyp. I dont have that impression and hope I didnt give the wrong impression. Im just trying to be informative. :)

You are right "metered" is vague. IAC controls flow and MAF measures flow.
The PCV also controls flow. The flow through the PCV is constant.

The valve cover breather lets air enter the engine that has been displaced by the flow of the PCV valve. The PCV is like a controlled leak that lets the air circulate through the engine and into vacuum. The air going in the valve breather is regulated as it exits the PCV valve.

[Kyp J]

OK, now I think it has leaked into my thick head. I was looking at the vent hose as an output of the valve cover. It was, in my engine, after my pistons and cylinders went crispy. It provided a bunch of oil to the throttle body and into the intake manifold. If the PCV is sucking through the valve cover from the ambient in the pre throttle plate area via the vent hose, I now see it is seen by the MAF.

What gives me a little uneasiness is the flow of uninvited air out of the valve cover when the PCV is pulled out while it is running. It also doesn't affect the idle speed when I do that. The vent hose shouldn't be able to pressurize the valve cover. Blowby?

[99mx5]

Thats the main functinality of the PCV, to provide a steady flow of air to vent the crankcase. No matter how much suction is applied to the PCV valve it will only allow a fixed amount of air. So you can pull the PCV from the engine while its running and the PCV will flow the same amount of air except it wont flow through the engine breather. This is why the PCV is mounted with a seemingly loose rubber grommet in only has to pull air from the valve cover at a slow rate. There shouldnt be any pressure in the engine, in fact it should be at a slight vacuum. This keeps oil from being blown out of the seals and vents the engine.

The rubber grommet should keep the PCV valve from popping out.