View Full Version : Geoff's 1997 Mazda Protege ES Worklog

01-25-2009, 11:47 PM
Well here it goes, my clutch crapped out me awhile back and the current engine was leaking oil from the valve cover gasket and various other places and I didn't feel like fixing a high mileage engine, so I picked up a 30k donor from Russ McHugh whom some of you might remember auto crossing his 1997 Protege ES in the showroom stock class for awhile. My plans are modest and I only want to have the head ported and polished, with a three angle valve job and 1mm over-sized valves. In addition to that, I plan on using the the 1999-2001 Miata cams for a mild performance gain. For the block, I plan on using the 10:1 1999-2001 pistons and installing a MBSP from a 90-94 Protege. I don't think I will be turboing the car in the near future, I just want something reliable with a little more power; maybe a g-series tranny with an LSD? Who knows?

Please keep comments focused and relevant about my build and help is ALWAYS appreciated.

NOTE: All pictures are thumbnails and will link to the larger versions when clicked

01-25-2009, 11:49 PM
Originally Posted on 07-18-2007

Here are the first pics from the initial tear down of my car prior to pulling the old engine (still need to get a hoist):

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01298.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01298.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01299.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01299.jpg)
Man I look goofy here.

It took me about 1-2 hours to remove the lights, grill, radiator shroud, bumper, and ac condenser. Once I get a hoist I'll start to move faster.

01-25-2009, 11:50 PM
Originally Posted on 07-18-2007

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01300.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01300.jpg)
Removing the valve cover.

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01301.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01301.jpg)
Valve cover off; looks pretty clean inside.

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01302.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01302.jpg)
Got that pesky intake manifold off and removed all the head bolts (which were a bitch to get out, but thankfully I had a 12pt socket to get the job done ;))

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01306.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01306.jpg)
Head is off, time to wrap it up and drop it off at the machinist's (I'll remove the cams and lifters later on).

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01307.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01307.jpg)
A look inside the block: looks like it should.

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01308.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01308.jpg)
A close up of one the cylinders.

http://i188.photobucket.com/albums/z145/gwhench/th_DSC01304.jpg (http://i188.photobucket.com/albums/z145/gwhench/DSC01304.jpg)
My guard cat.

01-25-2009, 11:52 PM
Originally Posted on 10-27-2007

Couple Updates:

Went to the machine shop and inspected some progress:

Going to have the head ported and polished next, but the only work they've done is surfacing and a valve job. Here are some updated pics:

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0172.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0172.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0171.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0171.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0170.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0170.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0169.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0169.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0168.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0168.jpg)

01-25-2009, 11:53 PM
Originally Posted on 11-14-2007


Pulled the engine and tranny out today, pictures will follow tomorrow.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0257.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0257.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0256.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0256.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0255.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0255.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0254.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0254.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0253.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0253.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0252.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0252.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0251.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0251.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0249.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0249.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0250.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0250.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0248.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0248.jpg)

01-25-2009, 11:55 PM
Originally posted on 02-27-2008


Alright, finally got some time to strip down the block a bit more and have a look over it before it gets dropped off at the machinist's to be checked, cleaned and whatever else needs to be done to it (hot tanked, honed, etc.). Engine had about 164k on the odometer when it was pulled and outside of leaky seals, everything looks great to me. Also going to drop off I/E gaskets to have the head ported and polished (just port matching) and get that finished up.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0361.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0361.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0362.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0362.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0363.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0363.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0364.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0364.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0365.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0365.jpg)
A look inside each of the cylinders, still looks good to me, how about everyone else?

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0366.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0366.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0367.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0367.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0368.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0368.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0369.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0369.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0370.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0370.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0371.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0371.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0372.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0372.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0373.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0373.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0374.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0374.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0378.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0378.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0379.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0379.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0380.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0380.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0381.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0381.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0382.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0382.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0383.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0383.jpg).http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0384.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0384.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0385.jpg (http://i188.photobucket.com/albums/z145/gwhench/IMG_0385.jpg)
Test fitting my MBSP.

01-25-2009, 11:57 PM
Originally Posted 07-01-2008

Ordered my bottom end parts:

Main Bearings
Rod Bearings
Main Bearing Cap Bolts
MBSP Bolts
Miata 10.1:1 Pistons

All Bought from MMS, so hopefully I can get my bottom end balanced and back soon enough.

I have some 30k mile rods that are going to be shot peened as well since I can't justify buying forgies while staying N/A for awhile.

01-25-2009, 11:58 PM
Originally Posted on 08-14-2008

Dropped all the parts off at the machinist's, going to have the engine balanced as well. I also want to have the flywheel shaved down a bit, but I can't decided on the weight. I'm thinking 15lbs so it won't be too light, but not as heavy as the stock one (~22lbs). If anyone wants to throw their two cents in about that, go ahead.

01-25-2009, 11:59 PM
Originally Posted on 12-13-2008

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0022.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0022.jpg)
Got these in the mail today.

I have so more updates being that all the machine work is done, I've just been ubber lazy as always

01-26-2009, 12:00 AM
So, I went outside and decided to put some of my pieces parts together into an engine:

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0040.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0040.jpg)

Already assembled and torqued the bottom end, but didn't take pictures of that; oh well!

I did the following:

Installed rear main seal
Installed oil pump with new front seal
Installed MBSP with sealant
Installed old style metal oil pickup tube with screen
Installed oil pan with sealant
Installed water pump and gasket
Torque all the bolts towards the higher end of Mazda specifications

Yep, today was a good day today.

01-26-2009, 07:29 AM
This is one of the cleanest n/a builds around. The small things are what matters the most and you're not skimping out on them. Good luck the rest of the way. I'll be watching closely

01-26-2009, 03:03 PM
bump for flywheel pics ;)

01-28-2009, 03:46 PM
Here are the lightened flywheel pictures:

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0041.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0041.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0043.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0043.jpg)

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0047.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0047.jpg)

Weighed in at 15lbs on my home scale (definitely not precise though lol).

On another note, you know that o ring that fits on the towards the top of the oil pump on the back? Yeah, I didn't install that so that means opening and sealing everything again...great, just great!

02-14-2009, 11:25 AM
bump for updates

02-19-2009, 02:20 AM
http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0064.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0064.jpg)
Close up of the intake port and some of the port work.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0065.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0065.jpg)
Pic showing the surfacing.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0066.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0066.jpg)
Another pic showcasing the surfacing (no oversized valves or chamber work, maybe with my spare head in the future).

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0067.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0067.jpg)
Close-up of the exhaust port and port work.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0068.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0068.jpg)
Full on pic of all the exhaust ports.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0069.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0069.jpg)
Showing the gasket over an exhaust port.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0070.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0070.jpg)
Pic of ARP head studs and head gasket.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0071.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0071.jpg)
Another ARP head stud and head gasket shot.

http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0072.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0072.jpg)
Pic of the head bolted on the engine (ignore the minor surface rust on the cam caps, it's gone now).

02-19-2009, 02:44 AM
Looking good man! Did you do the port & polish yourself? Also, will your engine stay non-interference with those miata pistons? Are you going to be running the stock ECU? Sorry lots of questions lol :)

02-19-2009, 03:01 AM
I did not do the porting myself, did not want to try it myself with the head I knew was going to put on; maybe with a spare.

Yes, the engine will remain non-interference since I did not have the head or blocked decked and the pistons have recesses like the stock pistons.

02-19-2009, 01:21 PM
very nice, the port work doesn't look too extreme which is good. are there any plans for boost in the future??

03-08-2009, 05:19 PM
I cant believe ive missed this thread.
THAT is one clean motor.
Nice headwork too.

03-08-2009, 10:48 PM
very nice head very clean also any plans to boost the engine down the road

03-08-2009, 11:39 PM
Maybe boost, but I was happy with the engine in stock form with just suspension stuff driving around the mountains, so maybe not. Money and time with be the deciding factors in the end.

08-15-2009, 10:52 AM
Thanks for the bump spammer, lets get an update on this thread! lol

08-15-2009, 12:59 PM
Bump for motivation

08-15-2009, 02:48 PM
Haha, I haven't been able to do much since school started for me again. Hopefully on the next full, free weekend I have, I can work on it.

08-15-2009, 04:30 PM
Haha, I haven't been able to do much since school started for me again. Hopefully on the next full, free weekend I have, I can work on it.

when is your fall break?

08-15-2009, 07:03 PM
I don't get one...I get like 3 days off for Thanksgiving and then Winter Break starts around Dec 22.

08-19-2009, 04:21 PM
BUMP for updates

08-19-2009, 04:40 PM
Bump for motivation

10-13-2009, 11:23 AM

10-22-2009, 11:31 PM
I opened up the trans, I'll post some pics of the internals and diff swap after finals though.

Just had time to open it up a bit and snap a pic.
http://i188.photobucket.com/albums/z145/gwhench/th_IMG_0297.jpg (http://s188.photobucket.com/albums/z145/gwhench/IMG_0297.jpg)

02-18-2010, 12:44 AM
Ok, I said F-it and had a shop assemble the trans properly, should be back sometime next week with some pics.

Also got a 28 spline intermediate shaft en route courtesy of FTjandra.

02-18-2010, 02:13 AM
kia halfshaft=thicker ;) which is a good thing considering i've somehow managed to shear a OEM BP one

02-24-2010, 10:29 AM
nice project

02-25-2010, 10:56 AM
hows that transmission coming?

03-05-2010, 05:27 AM
how much have you invested in the motor alone, not the tranny?

04-15-2010, 01:34 AM
hows that transmission coming?

It's done now, I don't know how I missed this comment

how much have you invested in the motor alone, not the tranny?

The motor? Not sure, nor do I feel like adding it all up at the momment lol.

I need to:
pick out a clutch kit
pick up some axles
get my full set of mounts from AWR
replace the front wheel bearings
replace all the front end bushings

After that, I should be good to go.

09-22-2010, 11:28 PM
Bump on an update status.....

1st Gen
09-23-2010, 12:08 AM
Thanks for the bump. I'm all subbed up now.

09-23-2010, 12:33 AM
It's slow going, lol, I have an assembled engine and trans, but no mounts yets.

09-23-2010, 03:05 PM
dead thread is dead

10-06-2010, 01:27 PM
any updates?

10-06-2010, 07:21 PM

10-06-2010, 07:46 PM

OH jeez, gtfo my threads lol. I'll let you know when I get some work done.

10-07-2010, 12:51 PM
sry just wanted to make sure you were still alive, plus i am bored at work.

10-07-2010, 12:54 PM
im going to post in , poorlie speeled sentances and crappi puncuations till you update this :P

09-03-2012, 04:02 AM
It's been 2 years and I was wondering if there was an update

09-03-2012, 04:06 AM
yeah seriously, if im updating the 323 log you cant be slacking here :p

09-04-2012, 03:03 AM
I still have this..sadly it's just been sitting, me being in my last quarter of law school and all.