AWD Speed 3 Project - Halfmilespeed3

Hello Guys & Gals,
As winter rolls in here in the PNW, I am preparing my car for an AWD swap. I see that @Roger Mesler has been doing fantastic work with his and I have gleamed some info from it; thank you. While I haven't been great about documenting the many phases my car has gone through, I want to document this phase for the sake of the community. I think have more than one step-by-step available to people would be great.

The car in question is my 2009 Mazdaspeed 3 that I have been modifying and building for half mile drag racing for the past couple years. The power plant is an Overspeed built block with all the CS goodies and some custom one-off items I've built myself and with local friends. With the Xona 9569s turbo, I am touching 900whp to the front. IG: @halfmilespeed3

The parts I've collected so far:
- Speed 6 Trans
- Speed 6 T-Case
- CX-7 T-Case (edit not needed)
- CX-7 rear suspension (complete from rotor to rotor) (Edit only need teh center subframe and diff)
- CX-7 mid-driveshaft (might be able to use some of it)
- Speed 6 OEM AWD control module

Parts I'm still looking for and /or will need:
- Speed 6 Front LSD (edit sourced from Damond Motorsports)
- Speed 6 rear diff to pull the LSD from
- Modify Passenger Front DSS 5.9 CV Axle
- Custom length rear axles TBD
- Custom mid-driveshaft setup TBD

My first priority is to get the system 100% installed and functioning to a confident useable state.
Next would be removing excess weight that is not needed.
Lastly, my end goal is to made a tubular rear subframe to really reduce weight, but I need all the kinks worked out of the system.

Hold me accountable to posting and keeping this update. This may be an early post to make, but best to get started now I say.
I respect this, this is a major undertaking.
 
A couple updates over the weekend:
Finished up some assembly of the Radium FCST (Fuel Cell Surge Tank) system. Added the second fuel pick up in the surge tank for another external pump (running a MagnaFuel 525 for PI and a Quantum 380 for DI). Setup the "hellcat" 525 in the lift pump location to feed the surgetank and installed the level sensor. Need to order a filter sock for the lift pump still.
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I then working on the filler neck/plumbing setup. While I could just use a cap on the tank itself, I wanted to keep a more OEM like setup and I didn't want to be required to remove the parachute, to open the hatch to then move the firewall cover to then fuel the cell...so I'm using the OEM location instead.
Now here is the best part. I was trying to use Radium's remote filler inlet/cap but was struggling...my buddy had the bright (and obvious) idea to use the OEM filler cap since it already fit...duh.
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But how do we connect the dots?
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So we cut nearly all of the OEM plumbing off and removed the flapper inside the filler so its jsut an open funnel now.
Using a 1.50" OD SS pipe with 6inch legs and 45deg bend and my plumbing and a bit of CAD (cardboard assisted design) I was able to get a good route that clears the tire and has a shallow slope to it.
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I cut a hole through the wheelwell and presto! Perfect routing.
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Now the Radium filler hose (1.50" ID) will fit over the SS pipe and run down tot he remote filler spout elbow on the tank (also Radium)

So how to cut the OEM filler plumbing?
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Cut the OEM plumbing right below where it reduces in diameter. Measure to be sure but it should be right at or under 1.40" OD. You want a little bit of material left over to insert into the 1.50" OD Pipe for welding.
What size is the radium fuel cell?
 
Safety First! Following the NHRA requirements, I have been building a firewall enclosure for the Radium FCST System in the back of the car. Per NHRA you can use 0.024" steel or 0.032" AL sheeting for the firewall. Per my local NHRA tech inspector, the level of "sealing" needs to be "pretty good" with no major openings that would render the firewall compromised.
With that in mind and with the tools I have, I opted to construct mine from AL sheet and structure for weight and workability.

Sealed up the wheel tub cutout ahead of the fuel cell
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Using the suspension crossmember as the main division wall and anchor point for mounting tabs. All the tabs are for M5 rivet nuts.
this was the most difficult section to produce as it had to fit between the shock towers and had two formed bends. The shock towers are also not perfectly square and straight so it was alot of check and minor adjustments.
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Since the sides are fairly complex in profile and and the overal width is larger than the hatch itself, I wanted the sides to be separate panels that stay in the car. The center area above the fuel cell will be its own panel that can be removed and provide 99% access to the fuel cell.
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1/16x3/4 angle aluminum was used for supports.
CAD (cardboard assisted design) templates made and checked over and over again before cutting the aluminum panels.

Then transfer the template to AL sheeting
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Again these are all mounted via welded tabs with M5 rivet nuts.

The nearly final product with the fuel cell mounted. Looks pretty damn good...not perfect but will get the job done.
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I'll be finishing the access panel this week along with some other goodies that arrived.
 

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Hello Guys & Gals,


Parts I'm still looking for and /or will need:
- Speed 6 Front LSD (edit sourced from Damond Motorsports)

I helped Phate a bit on his suspension, especially rear spring rates and ustom rear bar. He found someone who provided the Torsen LSD that worked perfectly. If needed, I can provide more info on the purchase.

Kevin
 
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