Project.L update: 4-2-1 header, cooling system, Mazdaspeed strut brace

Last weekend, I managed to get the Lantis back on the road while Fulk was visiting to get his timing belt fixed.

First of, an adapter pipe was welded to the Hitech headers to accomodate the mounting of a flex pipe.

Then I had to drill the hole for the O2 sensor because for some reason that wasnt done before and re-cut the threads in the sensor bung.

I then coated the headers with matte black high temperature lacquer.

Since the paint is very delicate after application I let it out in the sun for a day before applying the heat gun for 1.5h.

After that, the paint had hardened enough to install the headers. The flex pipe had been welded to the Magnaflow cat. Luckily, the measurements I had taken were spot on so everything bolted right up.

Before thad, I had already installed a new OEM B6EW alternator that I had found on ebay that just needed a bit of modification with a different connector terminal and a bit of drilling:

This cured the bad disturbances the old alternator caused in my audio system as well as a loud operating noise.

For the cooling system, I had bought a new OEM water pipe connecting the water pump with the heater core. I got some silicone plugs to block off the heater for the throttle body and connected the BG GT oil/water heat exchanger with some silicone hoses and 90 degree brass connectors. 

The heat exchanger now is spliced into the cooling system before the heater core.

On a side note, I used two threaded rivets in the front frame rail left over by the webasto heater I removed for a more stealthy installation of the alarm siren bracket:

After reassembling everything with a new radiator and getting the car back to the ground, I flushed the cooling system with water before adding fresh coolant. 

Apart from a more challenging bleeding procedure due to a massive air bubble apparently forming in the oil/water heat exchanger everything was spot on and worked perfectly.

The paint on the headers was then burning in and happily smoking like a camp fire:

To celebrate the occasion, I swapped my old strut brace for a genuine Mazdaspeed part I acquired in spring:

As seen in the last picture, I also managed to buy a new set of my broken Italian signal horns that I really like. 

To celebrate the occasion I washed the car and took it for a drive :)

The engine still needs a lot of attention. but at least I can drive the car again.

Also still on the list: suspension bushes, brakes, cam shafts, seats... 

Project L: Status update cooling and engine

Progress is slow but steady on the Lantis.
In the last few weeks, i cleaned the engine bay, treated some minor surface rust, removed the heater and test fitted the new radiator and hoses.
Luckily i managed to fine a solution for the lower radiator hose:
The lower hose off a 2.0 Protege5 that i had laying around fits nicley and clears the A/C compressor without any issues:

The keen observer might also have noticed the cleaner bay and different exhaust header. I took the opportunity to finally test fit my Hitech Headers 4-2-1 header that I imported from down under some years ago.
So I went from this...

...to this:

It lines up rather nicely with the catalytic converter. I chose to add a flex pipe to limit the stress to the material as far as possible since the header seems to be rather cheaply put together (which is a shame considering the purchase price). So I ordered this (amongst other goodies):

I will get this welded up as soon as I can.

I also fitted the water/oil cooler off a 323 BG GT to get the oil temperature up quicker and limit oil temps on the autobahn as well.

Not an easy job with the engine in the car since space is limited, especially with aircon. 

I ended up removing the alternator and some of the VICS components (to be able to remove tha alternator) to get the short threaded oil pipe out of the block.

This is the part I'm talking about next to its replacement:

I installed a new seal to the cooler and connected it to the small cooling route in line with the heater core. 

I still need to figure out the final installation of the hoses but it fits so far. I also ordered a new water pipe that connects the water pump with the heater core (the one that goes around the engine block) but that hasn't arrived yet.

Speaking of stuff that hasn't arrived yet, I dropped off the new wheels at the paint shop a few weeks ago and hope i can pick them up maybe next week...