Contrive AWD MS3 Build

[ClintH]

Hi Guys,

I've been posting a few updates on FB, but figured I'd start a thread here to document the build process for anyone who might want to go down this road in the future.

Quick background, about a year ago, I bought @Mtnbker3531 2013 MS3. His build thread is here, for anyone interested: https://mazdaspeeds.org/index.php?threads/well-its-out.13831/

When I bought it, he doomed me to this path by mentioning a guy named Barett (@Barett@ContriveDesignInnovations) and an AWD conversion kit he was making. That planted the idea of AWD and I couldn't get it out of my head.

I put down the deposit and started gathering the required spare bits from junkyards, namely:

CX-7 Subframe
CX-7 Rear Diff
MS6 T-case
MS6 Rear Diff
MS6 Transmission
Volvo S40 Gas tank

As I got further into it, I realized how in over my head I was. Even though I've owned a MS3 for almost 10yrs, I've never gotten this deep into one. My fab skills are limited, and I just live in a small townhouse, so garage space is pretty non-existent for this level of project.

By sheer happenstance, I discovered we have a great Mazdaspeed shop here in Denver, Speedcraft Autoworks. Nick there has been invaluable in helping me learn more about the technical stuff, tear down and rebuilding t-cases and transmissions, and overall planning the build out.

Also, we have an awesome collection of people in the Contrive build group who are bouncing ideas off each other, sourcing parts, organizing group buys, etc.

That's one of the things I love about this platform is the support from the owner community.

I'm trying to say if a schmuck like me can make this project happen, you can, too.

 

[ClintH]

Alright, all that out of the way, here's some catch-up from the last year or so:

First was sourcing a CX-7 rear subframe from an AWD drive model. Extra points earned for picking it up with a MS3:




There was a good bit of surface rust, so sanded, brushed, and coated the subframe with phosphoric acid and a rust-converting undercoat paint.






Up next, and probably the hardest part to source was the MS6 T-case. I found one, and Nick had another laying around. We recently tore both down and combined the best of both. It also got Graveyard billet caps and fresh seals while it was apart this far:







The Volvo S40 gas tank also gave me a headache to source, and I'm not fully convinced it will work with the CX-7 rear diff mount. Looking at other AWD builds, I suspect there might be clearance issues (will need to confirm once the subframe is in place). If you end up going with this tank though, you'll want it from an '04-'12 S40 AWD or V50 AWD. Make sure it's AWD with the saddle for the driveshaft. A fortuitous discovery is the sending units will work with a gen2 MS3 fuel gauge perfectly if wired together in series. The gen1 fuel gauges, however, use exactly half the resistance, so you'll need to figure out a way to divide the reading if using in a gen1 car.

 

[ClintH]

Next, rear diff: You have a couple options. You can either use a straight CX-7 rear diff, or you can combine a MS6 rear diff housing with the nose section from a CX-7. The benefit of the second option is it retains the limited slip diff in the MS6 (The CX-7 does not have an LSD) while allowing you to use the dual mounting points of the CX-7 nose housing (highlighted by the red circles below). I opted for the second option, but haven't yet combined the two. Bigger fish to fry at the moment.





Next, rear axles and driveshaft. Barett organized a group buy through DSS. I believe these are now or soon will be available through his website.





For the transmission, the plan is to use a MS6 housing and transfer my gen2 gear set into it. The idea being to retain the taller gear ratio from the gen2 gear set. I also wanted to add a Damond LSD to the front while we were in this deep, and Damond was kind enough to do another production run for us.

Final little bits and pieces are CX-7 rear wheel bearings, which can be found on Rock Auto for ~$100. A turbo oil drain tube that will clear the t-case (I went with a Mazdaspeed Wire Tuck.) Rear dampers for a Focus RS.

And then of course, exhaust. Sadly, this will need to be custom because of the t-case and tight fit.

Finally, shamelessly stolen stock photo of the components of the Contrive kit. I haven't fully laid mine out yet, but happy to snap a closer photo if anyone wants to see something specific

 

[ClintH]

Alright, on to the work...
Engine and transmission came out of the car back around the beginning of Aug. The engine has been getting Corksport manifolds, a PI kit, Reflex setup with wiring kit from Greg Senge, a new Xona 5557S turbo, powdercoated bits, and some new braided AN cooling lines.














We just dove into the transmissions yesterday to complete the gear swap into the MS6 case and add the LSD. Tribodyn was in the MS3 transmission and it's interesting stuff. It left a persistent blue film on EVERYTHING inside the case. Initial inspection shows the shift pads, syncros, and gears all in really good condition, so there might be something to it. @Mtnbker3531 did say he mostly used Redline up until the last 11k miles, though, so not sure how much of the minimal wear signs to attribute to the Tribodyn.








Damond LSD next to the stock diff. Looks like it should be a direct fit right now.

 

[ClintH]

That about catches things up for now. I'll update as the real work on the AWD parts of the build start.

The biggest hurdle I see at the moment is figuring out the fuel tank fitment. That's going to require mock-up and some trial and error.

Goal now is to get the engine, transmission, and t-case back into the front of the car so we can then focus on the rear.

 

[Rokusek]

HAHA OHH BOI!!!

Excited for you, me and everyone else to do this! I'm about to throw mine on stands here soon to get started.

You are for sure sticking with gen2 trailing arms right? Baret filled me in on that. I'm currently searching for a set to send him for you!

 

[DISIFTW]

Looking good!!!

 

[ClintH]

HAHA OHH BOI!!!

Excited for you, me and everyone else to do this! I'm about to throw mine on stands here soon to get started.

You are for sure sticking with gen2 trailing arms right? Baret filled me in on that. I'm currently searching for a set to send him for you!

Hey PJ,

Yeah, I just pulled my gen 2 set yesterday and shipped them off to Barett. He thinks his machinist can turn them in about a week, so hopefully the timing will work out for when we have the engine/trans ready to go and need to move the car into the lift bay again.

I really appreciate the offer and you looking for arms for me, though. This just seemed simplest, and pulling them really wasn't too big of job after talking with Barett.

Mine also have a ton of surface rust, so not sure anyone would've even wanted them for a core, anyway. I'm going to see about getting them bead blasted and either powdercoated or painted with some undercoating paint once they're back.

Also ended up pulling the lower control arms for the same reason.

 

[Barett@ContriveDesignInnovations]

Looking great Clint! Great pictures aswell...keep them coming!

 

[Rokusek]

Hey PJ,

Yeah, I just pulled my gen 2 set yesterday and shipped them off to Barett. He thinks his machinist can turn them in about a week, so hopefully the timing will work out for when we have the engine/trans ready to go and need to move the car into the lift bay again.

I really appreciate the offer and you looking for arms for me, though. This just seemed simplest, and pulling them really wasn't too big of job after talking with Barett.

Mine also have a ton of surface rust, so not sure anyone would've even wanted them for a core, anyway. I'm going to see about getting them bead blasted and either powdercoated or painted with some undercoating paint once they're back.

Also ended up pulling the lower control arms for the same reason.


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Glad you got them moving! I did find a set for Barett to use as cores too.

Before you put anything back together, get with @Matt@DM and put some new bushings in everything. I have some info on that in my build thread as well.

Looking good right now!