Tired 2000 Protege lx getting Speed3 swap

How easy does the protege body flex?

I know one of the big deals with the mazda3 was how rigid the unibody was compared to previous chassis' that mazda was producing before. Dont want any popping windshields, or doors bending fenders after such an in depth swap.
 
Bracing/supporting is on top of list. I have speed body to see where everything is stronger, and will support/brace accordingly best I can. I am also going to transfer the behind dash A pillar support bar to the protege. Strut towers will be fully braced, and tied into firewall like speed. Corner bracing at lower c pillars like speed, and just generally making it similar to speed bracing and locations. Rear subframe mounts and frame need supporting too. It still may twist, creak, and groan when done, but I will try to get it stiffened up so it doesn't.
 
IMG_20191113_170200.jpg IMG_20191113_165855.jpg IMG_20191113_170045.jpg IMG_20191113_165958.jpg IMG_20191113_172903.jpg I got the dash removed today. These cars are so close in so many ways I just can't believe it! Even the floor to bottom of windshield is the same. The dash has a crazy thick support bar that connects the A pillars together, as well as providing dash support, and lower mounting points. Replacing the complete firewall, and floor pan in one piece is looking very promising.

When I cut out speed firewall, as I get to lower bar mount, I plan on cutting outward into A pillars and cut out the lower dash mounts still attached to firewall. That will allow me to bolt up dash to speed firewall once welded into place on the protege, without aligning anything. It will provide all the pedal mounts, center console mounts, seat mounts, trailing arm mounts etc...

Tomorrow I plan to, remove Master, abs unit, pedals, and remaining wiring harness. Then finally start cutting it up into manageable, and useable pieces. Once cut up, the Protege will be disassembled for final measurements, and decide if it is a go, or not... I am 99% sure at this point I can make it all work. I will need to remove engine/trans, front subframe, center console, seats, and carpet out of the Protege. Once I am at that point, and plan on moving forward, I will make the "official" build thread.

Stay tuned! Please, if you see something maybe I am overlooking, or think you have a better way of doing something, I am open to all suggestions and comments.
 
Protege dictionary meaning:
Dependant Pupil

Opposite of Protege is Mentor.

Mentor dictionary meaning:
Counseler/Teacher

It definitely won't be a "Dependant Pupil" anymore.

I will call it "Mentor", because it will be schooling other cars!
 
The Mazda3 spoiler fits the protege body shape perfectly! The speed spoiler mounts the same, just using this for checking fitment. I can make the speed spoiler look factory installed it fits so well. That's how close these bodies are to each other.IMG_20191118_131104.jpg IMG_20191118_130933.jpg IMG_20191118_130924.jpg IMG_20191118_131014.jpg IMG_20191118_131026.jpg
 
Firewall, floorpan, and rear frame rails should be cut out tomorrow.
After that, clean up, organize.
Next I will remove engine/trans, front subframe, and rear subframe from the Protege. That will give me much more room to set stuff in place, and come up with a plan.

I am super happy with everything so far...IMG_20191118_152346.jpg IMG_20191118_152244.jpg IMG_20191118_170430.jpg IMG_20191118_170354.jpg IMG_20191118_170335.jpg IMG_20191118_152433.jpg
 
StreetSpeed6 said:
Looks like a crazy endeavor but a protege is 1000lbs less than a speed so will be crazy fast
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The 09 Speed3 Sport weighed 3160 lbs with 1/2 tank fuel. 00 Protege weighed 2450 lbs with 1/2 tank. 710 lbs lighter, but once I install the Speed engine/trans, sub frames, bigger wheels/tires, etc, It will be much heavier than 2450 lbs. My guess is it will end up at 2950 lbs once completed.
 
Easter Bunny said:
isnt the block in the protege iron? the aluminum DISI block will offset some of the weight gain from the turbo parts
Click to expand...
Yes, Protege has iron block. But engine is not the only weight being added. The Speed transmission, front & rear subframes, anti sway bars, exhaust, seats, all weigh more than Protege. Plus all the added bracing, and overlapping metal. I'm hoping it will be super light, but I'm still guessing around 2900 lbs when all done, 1/2 tank fuel, Speed spare tire installed, etc...
 
Tools/materials/services/general things used for this project... not listing common sockets/wrenches for general disassemble/reassemble.

Harbor Freight 7.5 amp sawzall
Angle grinder w/6" cut off wheel
Wire Feed Welder using .030" shielded wire
Tape measure/Laser
Seam Sealer
Brake Fluid
Recharge A/C
$ for trip to dealer to bleed brake system and verify ecu for B.A.R. certification
B.A.R. certification

Almost ready to start stripping Protege down...

Here are some of the measurement differences from Speed to Protege:

Protege/Speed

Weight: 2450/3160
Wheelbase: 102.8"/103.9"
Firewall to radiator: 32"/31.5"
Front frame rail inside width: 36"/35.5"
Top of front frame rail to ground: 19"/21" (protege lowered 2")
Track width: 66-1/4"/68-1/4"
Overall length: 174"/175"
Hood width @ strut towers: 56-3/4"/61-1/4"
Center front axle to center of valve cover: 10-1/2"/7-1/2"
Overall width: 66-1/4"/69-1/4"

The biggest difference being the engine, trans, subframe, and struts are mounted about 3" more rearward on the Speed.

I can't wait to start the "official" build thread. I still can't find anything major preventing it from working.
 
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