1st Teardown While I Build Up

[Awines2326]

Been an MS3 fan since 2013 when I got a Stock Gen2. Drove it for a couple years but had to let it go... Fast forward to 2023 when I decided to get myself a speed3 as a project. I happened to stumble on a great find.

2008 Speed3
Dankai 1 Blueprinted Engine
CS Intake
CS EBC
Full Damond motor mounts
CS HPFP Internals
3 inch catless exhaust
Freektune 21PSI K04

Since purchasing I have added:
CS intake Manifold
CX Racing Dual Core FMIC
CST6
JBR True 3.5 Silicone Intake
Tubular Exhaust Manifold
3 inch catless downpipe - straight dump exhaust
44mm Tial EWG
Freektune 20PSI


I am currently waiting on a CS full Aux Fueling kit to get rowdy with port injection!

It's getting more fun now, and I understand I'm approaching the limits of the Dankai 1 motor. So I tracked down another built motor that was having head gasket / coolant in cylinder issues. I am mid teardown with the intention of building the next motor, with some beefier internals. This will be the first time I've gone inside of the 2.3 MZR so the resources on this forum are gold!

So far I have found the intake cam is trashed, caps were very loose and there are deep groves on every intake cam cap. Crank is scored, the OEM main bolts were also loose and the clutch side main bearings was dug deep while the rod bearings looked perfect. Pulling out Manley rods & Manley 88mm Platinum Pistons that don't look to have very many miles at all. Pictures attached of what I've found so far, and incredibly open to hearing advice and suggestions from those more experienced than myself on this journey!

 

[Awines2326]

The head on this new motor already has a DIY port job done on the intake and exhaust ports so I figured I might as well dive in. And it has begun...

 

[Awines2326]

Finally got the 12pt socket to pull the ARP head bolts and remove the head. Dang thing looks like it just got machined. Brand new Cometic head gasket, and I can clearly see the shiny stamp of 008 from the machine shop I assume signifying .008 was removed.

Bore appears to be 87.75 so there is room to bore out to 88m thankfully! Because there is a bit of scratching on #4 cylinder. The top of the piston also made contact with the exhaust valves on #4. I looked closer and the exhaust valves on 4 where actually stuck open about a quarter inch. The piston touched it a total of 4x it looks like, and the nic marks are barely noticable to your finger nail so I'd imagine they're still perfectly fine but would love to hear from someone if that piston is any good now?

Pics attached

 

[Awines2326]

After much discussion with my neighbor the machinist, it has been decided I cannot repair the cylinders on this block due to a couple having somewhat deep scratching. Any attempt to hone them out would be too detrimental to the piston - cylinder clearance and would completely ruin my plans of a balls 2 the walls block.

So I have decided this block with get some new Darton Dry Sleeves, so I can keep proper clearance and not consume oil from the start. Looking like I'm going to have to sell some of my current toys to fund this rabbit hole...

 

[Awines2326]

Crank is at the machinists getting a fancy keyway for peace of mind. Getting my build mapped out now. The plan is to do the following:

Darton Dry Sleeves
12mm Head Studs
Freektune FTW Pistons
I Beam Rods
Kelford C Cams
Supertech STD sized Valves
"Fancy" P&P
Supertech 70lb Valve Springs (Open To Suggestions Here)

Anyone please feel free to poke holes in this build and save me a potential headache!

 

[Awines2326]

Getting some work done on this head while I patiently await this AUX fueling setup from Corksport. Have injectors being cleaned by SP63 as well ready to throw in with fresh CS injector seals, and intending to clean and walnut blast intake valves all while installing this CS Aux setup...

 

[Awines2326]

Made a bit of progress on the intake ports today, managed to get all of the smaller ports roughed up. As well as I knocked down the lump in the middle of all the larger ports. Should just be some sanding and polishing and the intake side will be complete! Exhaust should be simple but I'm waiting for my CS exhaust manifold to get here so I can match it up for the outlets. Will just do a small amount of cutting from the dome and polish everything up before that. I've seen some aggressive work done to the bowl on these before but I don't think I'll do much more than a light sand and polish there either. Not interested in screwing with my CR

 

[Awines2326]

Was able to get a bit of bowl sanding done yesterday but not nearly enough time to play in the garage. Should be getting some more done tonight.!

 

[Awines2326]

Corksport delivery! 8 port Aux setup, now I'm just waiting on my cleaned injectors to come back from SP63 & Freektune's H11 Head studs!

 

[Awines2326]

Bit of progress but my kit included the wrong AN fitting from the bottom of the fuel cell direct to the 1st fuel filter. Waiting on an adapter to come from Amazon to increase from 12AN to 16AN but managed to get the tank in, wire the low fuel light, and put everything together to be installed. Just need to wire in the SSC and run fuel lines. Oh, and remove my intake manifold and drill it for the injectors! Also still waiting on SP63 to send back cleaned injectors to be installed with fresh CS seals.

 

[Awines2326]

Update, been having a ton of fun lmfao. PI is almost complete. Cleaned my valves out, and they were bad! Currently stuck with 1 injector pulled, 2 stuck, and another that the torx retainer bolt is rounded, so also stuck. Fun fun fun! I also managed to extend my wiring harness to tuck it once my rotation plate arrives.

 

[Awines2326]

Ran into a couple snags getting my Port Injection setup. The CS Fuel Cell sprung a leak! Spoke to Corksport and apparently it's happened a few times where the fittings molded into the tank aren't sealed properly causing them to leak, so I'm waiting on a new Fuel Cell to put it back together. I also installed stoptech braided lines all around and found all the fittings from hard line to rubber line were toast. One of them actually broke when I was trying to move the line a bit spraying brake fluid everywhere. So thanking God these lines didn't blow on a WOT pull!! Replaced a few inches of hard line on each wheel to connect to the stoptech lines. Installed a clutchmaster braided clutch line as well. BUT, one of the front calipers is also toast because the rubber line fitting snapped off inside, and I cannot get it out... Found a part out and got all 4 calipers from a nice rust free donor!

Got my Freektune H11 head studs, so I'll be putting those in this weekend. Also pulled the trigger on the Dry Sleeves and Freektune FTW pistons so I can send my spare block off to the machinist. Picked up a Cx7 with blown motor I plan to throw my current motor in once I assemble the new "Full Send" block

 

[Awines2326]

Managed to install the CS exhaust manifold, looks solid but that sucker is waaaaaay heavier than my Tubular manifold!

Got my new brake calipers and threw some super hard high head caliper epoxy on them so they don't end up as corroded as the originals...

Also got my TB Performance front and rear torsion bars installed! Anyone attempting the rear bar, don't expect it to go on without modification. I slotted mine and had to install the passenger side first, then pull the drivers side almost all the way out and you can rotate it in. The fuel tank being right at the passenger side makes it pretty tricky...

Also got my Kelford C-2 cams ordered with a great deal from RealStreet and watching for the Kelford 84lb springs to go on sale!

 

[Awines2326]

Kelford C-2 cams showed up! The pieces are all starting to come together!

 

[Awines2326]

Freektune FTW pistons are in and look glorious! Now I just need some 12mm head studs so I can send all this stuff off to the machinist!

 

[Awines2326]

Still not done with porting this head, but all the major material removal is complete. Pictures attached next to an oem head. Need to finish the center of the runners by hand and put a polish on everything so it's slippery smooth! Kelford 84lb springs and titanium retainers showed up today.

Ordered +1mm Supertech Iconel exhaust valves along with Standard Supertech Black Nitride Intake valves. Need to get my hands on some 12mm head studs and send this stuff off to the machine shop!

 

[Awines2326]

Supertech valves arrived today! Went +1mm Exhaust in Iconel and std size intake black nitride. Didn't feel like the iconel was necessary on the intake side hopefully I'm right!

Also pulled my clutch and got a Gen2 transmission with 100k miles. Should eliminate my 2nd gear pop-out and give me that extra stretch in the gearing! Unfortunately my ACT HD Pressure Plate is shot along with my street disk. After doing WOT logs for the new port injection tune I slipped hard in 4th gear and apparently that was enough to put a proper burn on things... ACT 6 Puck with the Xtreme PP on the way!

Also, rear main still has the signature of Corksports Vincent Melon, and date from back in 2018 when corksport assembled this Dankai 1 block!

 

[Awines2326]

Got my new 6 puck ACT disk, and have been waiting on the Xtreme pressure plate to show up for a while now. Finally came in, and turns out I have the old style prolite flywheel, so it won't fit. Now I've gotta order a new flywheel to get the clutch back together...

Good news is I've had some more time to work on the head for the new motor, I'm thinking the increase to intake ports is approx 15% so I feel like it's going to be noticeable. With the final finish being mirror polished and slick like butter I think it will help keep temps down and dramatically increase flow! I still need to polish all intake sides, and 3 of the 4 exhaust sides but all cutting and sanding should be done. Icing on the cake will be taking the texture out of the dome.

 

[Awines2326]

Still have quite a bit to do on this head, but I've made some major progress!

 

[Awines2326]

Starting to feel a lot better about the exhaust side now. I think I'm actually done removing material now. Think this should allow more total volume while keeping up velocity. Hopefully keeping ideal backpressure when I try running big boost!