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Even with the scuffs, it's still a great car and a wicked car for the money.
Interesting about the two cats, but I suppose that's one way to do it. They weren't the cleanest cars out there :) and they typically run richer AFRs than many other cars for safety. I'd be tempted to run 0-1 cats most of the time. In that setup with your 3" exhaust and turbo inlet duct (3" initially?) you might hit 15psi+. The wastegate on the S4 turbo is pathetically small. It's a common modification to port the wastegate to keep the boost to sane levels and then use the boost controller (if necessary) to bump it up a bit. These cars came from the factory with 182hp, but a good 3" exhaust can bump it up 50-60hp and potentially more with your TID and tune. People don't like turbo lag, but it can actually add to the entertainment factor when the boost hits this hard.
Regarding the oil cooler, the factory location is front bottom. I'd just make sure the new location seems like it will get a lot of air flow. It's also important that the under tray is intact so air doesn't simply bypass the oil cooler and radiator. The under trays seem to be more fragile than in some other cars.
Based on your outline, your car seems to be properly modified. The only thing I'm not necessarily in agreement with is the pulsation damper removal, but that's controversial and I don't know if it's reasonable to expect to have a reliable one in a 32 year old car.
The one thing that is kind of neat about these cars is they were pretty much the fastest thing on the road in their day (balance of performance attributes). C4 Corvettes were faster, but other than that, it was only exceeded by rare/fragile exotics. In many ways they're a seriously beefy car. There's a picture Mazda took during the development where they launched it off a ramp into the air to ensure durability. There are people putting 600hp through essentially stock drivetrain and engine.
wvumtnbkr said:
Careful with anything much above 10 psi. The stock turbo can do 12 psi without too much inefficiency. However, the air temps start to rise faster than teh boost at that level.
Opening up the exhaust can cause CRAZY boost creep. This CAN hurt the engine.
If you open up the exhaust (even replacing a cat), keep an eye on your boost the first couple of times you drive it.
With a 3" downpipe and a 3" exhaust, I could get to 14 psi with a fully ported and welded wastegate (cut hole bigger than flapper and weld a big washer on it). I actually had to put in a fairly restrictive resonator to get boost back down to around 10 psi.
Rev the piss out of it on a regular basis.
Also, the S4 temp gauges work fairly well. The water temp gauge should sit about 1/3 of the way up. If it gets to half way, shut it down and let it cool off.
If you didn't know, those are s5 tail lights.
That car is in VERY good shape.
Dont remove anything plastic from the interior. It WILL break. Be Super careful doing any interior work. All the clips like to break off.
So, took the car to get emissions today. It fast-passed, which is great!
Some things I noticed:
1) It's boosting to ~8psi according to the aftermarket boost gauge that's in there. This seems low based on what I'm reading in this thread, but maybe it was tuned down a bit with the RTek7?
2) Idle Air/fuel fluxuates between 16.5-17.2. This seems really, really lean to me. I assume that additional tuning is needed? The car runs ~14.7 (stoich) under light load while cruising and ~12.5 under heavy load/boost.
So far, I really REALLY enjoy this car. It's night and day different from my V6 MR2 which has gobs of torque down low but falls on it's face up top.
Engine bay photo: