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enginebuilds.html
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<!DOCTYPE html>
<html>
<head>
<title>R. Oliver Zanone</title>
<link rel="stylesheet" type="text/css" href="style.css">
</head>
<body>
<div id="header">
<div id="imageHeader">
<a href="https://oliverzanone.github.io"><img src='images/profile.jpg'/></a>
</div>
<div id="textHeader">
<h2>R. Oliver Zanone</h2>
rzanone@clemson.edu
</div>
</div>
<!-- Create a navbar that has collapsable items -->
<div class="navbar" id="navbar">
<a href="index.html#aboutme">About Me</a>
<a href="index.html#research">Research</a>
<a href="index.html#education">Education</a>
<a href="index.html#fun">Other Projects</a>
</div>
<div id="main">
<p>
<a href="images/CarJetski.jpg"><img src="images/CarJetski.jpg", class="left"></a>
This page outlines some of the various car/jetski projects I have done.
<br><br>
My primary project car is a 1997 Miata. I am fortunate to be the third owner of this M edition.
Upon purchasing, I performed general maintenance tasks such as new filters (air/fuel), fluid changes (oil/coolant/trans/diff), hose replacements (coolant/vacuum/fuel),
radiator/thermostat, spark plugs, timing belt, water pump, front main seal, cranksaft seals, and valve cover gasket to name a few.
<br><br>
I then proceeded to perform modifications, starting with a stronger clutch kit and lighter flywheel.
This was done as the throwout bearing was beginning to make some noise, and I wanted to future proof it for a turbo setup.
Unfortunately, by the time I got to installing a turbo system a few years had past and I already needed another clutch.
<br><br>
The turbo system was pieced together slowly over time. The first purchase was the turbo, a Garrett SR20DET.
After spending hours hammering and torching it apart, a rebuild kit was installed to get it back to original condition.
The next purchase was the ECU, a kit from DIY Autotune. This required soldering an auxillary board to interface with the Miata sensors which connected to
the main microcontroller for real-time processing.
A custom harness was also fabricated to plug into the Miata harness.
<br><br>
From this point, it was mostly running oil/water lines, routing intercooler piping, higher flow rate injectors, adding gauges (boost/AFR), temp sensors, MAP sensors,
boost controller, and finally, I taught myself welding and fabricated a custom downpipe and exhaust. Although the welds looked terrible, they didn't leak and did the job.
<br><br>
This setup has been running reliably on a street tune and 12 pounds of boost for the past three years now.
I have a 2002 engine with variable valve timing that I am in the process of rebuilding for higher compression and boost.
</p>
<div id="center">
<div class="image-container">
<div class="image-wrapper">
<img src="images/CarEngineBay.jpg">
<p class="caption">The completed turbo assembly, although additional wire tucking/tubing reroutes were done later.</p>
</div>
<div class="image-wrapper">
<img src="images/DIYTransmissionLift.jpg">
<p class="caption">When removing the transmission, this is one method to keep it suspended while removing bell housing bolts.</p>
</div>
</div>
</div>
<div id="center">
<div class="image-container">
<div class="image-wrapper">
<img src="images/RearMainOutput.jpg">
<p class="caption">The Flying Miata stage two clutch and lightweight flywheel.</p>
</div>
<div class="image-wrapper">
<img src="images/TurboInstallation.jpg">
<p class="caption">Trying to decide the initial clocking (orientation) of the turbo.</p>
</div>
</div>
</div>
<div id="center">
<div class="image-container">
<div class="image-wrapper">
<img src="images/ECUAuxBoard.jpg">
<p class="caption">The DIY Autotune aux board with some components soldered. </p>
</div>
<div class="image-wrapper">
<img src="images/ECUMainBoard.jpg">
<p class="caption">The ECU Mainboard.</p>
</div>
<div class="image-wrapper">
<img src="images/ECUHarness.jpg">
<p class="caption">This is the custom harness I made to interface with the factory Miata harness.</p>
</div>
</div>
</div>
<div id="center">
<div class="image-container">
<div class="image-wrapper">
<img src="images/TurboStand.jpg">
<p class="caption">Here I bolted the turbo to some wood to be able to torch and hammer it apart for rebuilding.</p>
</div>
<div class="image-wrapper">
<img src="images/WeldedDownpipeMidsection.jpg">
<p class="caption">My terrible looking welds (that worked) for my downpipe and midpipe.</p>
</div>
</div>
</div>
<div id="center"><iframe width="373" height="663" src="https://www.youtube.com/embed/uAt91IqdQTc" title="Miata First Turbo Run" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" allowfullscreen></iframe></div>
My other project car is a 1989 Nissan hardbody 4x4 V6, but have focused my priorities elsewhere for now.
<br><br>
<h3 style="text-align: center;">Jetskis</h3>
After moving closer to a lake, I decided to purchase some jetski's and now own four 90s model Seadoo's, three of which have the 787 Rotax engine.
The one I use most frequently is a 97 SPX, and is the one I have worked on the most.
There is a lot of additional information I will share about these projects, but for now, the below images highlight some of the work I have done, essentially rebuilding everything.
<div id="center">
<div class="image-container">
<div class="image-wrapper">
<img src="images/JetskiFuelLines.jpg">
<p class="caption">First step is to replace old fuel lines and filters.</p>
</div>
<div class="image-wrapper">
<img src="images/JetskiMikuniRebuild.jpg">
<p class="caption">Rebuilding the Mikuni carbs, including pop-off pressure and leak-down tests.</p>
</div>
</div>
</div>
<div id="center">
<div class="image-container">
<div class="image-wrapper">
<img src="images/JetskiCylinderHead.jpg">
<p class="caption">The top end can be rebuilt with the engine still in the ski. This one clearly has damage.</p>
</div>
<div class="image-wrapper">
<img src="images/JetskiPistonDamaged.jpg">
<p class="caption">The whole jetski will need to be torn down to check the lower end for damage.</p>
</div>
</div>
</div>
<div id="center">
<div class="image-container">
<div class="image-wrapper">
<img src="images/JetskiTeardown.jpg">
<p class="caption">The teardown, all in a days work.</p>
</div>
<div class="image-wrapper">
<img src="images/JetskiRotaryDamaged.jpg">
<p class="caption">Looks like something fell in the intake, busting the rotary valve.</p>
</div>
<div class="image-wrapper">
<img src="images/JetskiRotaryShaftDamage.jpg">
<p class="caption">The rotary shaft gear is toast.</p>
</div>
</div>
</div>
<div id="center">
<div class="image-container">
<div class="image-wrapper">
<img src="images/JetskiRebuiltFinal2.jpg">
<p class="caption">All major seals/gaskets replaced, loctite set, and torqued down to spec.</p>
</div>
<div class="image-wrapper">
<img src="images/JetskiRebuiltCompressionTest.jpg">
<p class="caption">Initial compression looks good! Time for engine burn-in procedures.</p>
</div>
</div>
</div>
<div id="center"><iframe width="560" height="315" src="https://www.youtube.com/embed/h-WaCv7oD4o?si=rBoZjBEZT_ZDPxD8" title="YouTube video player" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" allowfullscreen></iframe></div>
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