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165: Pioneering the Mazda FD3S RX-7

165: Pioneering the Mazda FD3S RX-7

Tuned In Jul 01, 2026 124 min
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About this episode

Peter Ferrell of Peter Ferrell Supercars joins the show to share his journey from Royal New Zealand Air Force engineer to factory IMSA racer and legendary Mazda RX-7 tuner. The discussion dives deep into the complexities of the FD3S RX-7 platform, detailing how PFS pioneered the first aftermarket tuning solutions for its notoriously difficult sequential twin-turbo system. Ferrell also demystifies the 13B rotary engine, explaining why these powerplants get a bad reputation and sharing the tuning secrets required to keep them reliable on and off the track.

Technical Too Afraid to Ask
Car

Mazda RX-7 FD

"He set me up in a conference room at a big table with all the heads of departments for the FDR-X7. So on my left was Kojima, who designed the suspension."

A famous Japanese sports car from the 1990s that uses a unique rotary engine instead of a normal piston engine. It is highly prized by car enthusiasts for its beautiful, curvy styling and incredibly sharp handling on twisty roads.

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Person

Peter Ferrell

"Welcome to the HPA Tune In podcast, I'm Andrey your host, and in this episode we're joined by Peter Ferrell from Peter Ferrell Supercars."

A professional race car driver and car tuner from New Zealand who moved to America and became famous for building and racing fast Mazda RX-7 sports cars.

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Concept

rotary engine

"Now Peter's got a very interesting background with a love of rotaries and a love of competition racing both on gravel and on tarmac."

An engine that doesn't have normal pistons going up and down. Instead, it has a triangular part that spins in a circle to create power, making it very smooth and compact but prone to wearing out faster.

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Part

sequential twin turbo system

"This is a platform that's quite difficult to provide an aftermarket standalone ECU for due to the complexities around the sequential twin turbo system."

A system with two turbochargers where one works at low speeds to help the car accelerate quickly, and the second one turns on at high speeds to give maximum power.

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Part

Apexi Power FC

"And PFS was actually the first company to bring a tuning solution to market even before the popular ApexE Power FC."

An aftermarket computer used to control a car's engine. It was very popular because it let tuners plug it in and easily adjust how much fuel and spark the engine got using a small handheld screen.

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Term

piggyback ECU

"This was a piggyback tuning system, and it did have its limitations of course as you could imagine, but this unlocked the performance of the RX7."

A small add-on computer that plugs into a car's existing factory computer to trick it into making more power, rather than replacing the whole computer entirely.

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Part

Mazda 13B

"We also get into some of the intricacies of the 13B engine, or rotary engines in general, why they sometimes get a bad reputation and what needs to be done with the tuning in order to keep them reliable."

A famous, compact 1.3-liter engine made by Mazda that uses spinning rotors instead of pistons. It is loved for its high-revving power but requires careful maintenance.

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Car

Ford Escort RS2000 (Mk1)

"So that put the brakes on it for a little bit until 1979, 1979 I bought a Mark I Ford Escort RS2000 Rally car."

A classic, lightweight British Ford from the 1970s that became famous for winning off-road rally races.

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Part

Cosworth BDA

"Truthfully watching the Walmart, Mike Marshall and Hanoomickler in the Mark I Escort RS 1600 BDAs back in the early rallies in New Zealand..."

A famous high-performance race engine from the 1970s that was known for making an incredibly loud, high-pitched screaming sound at high speeds.

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Car

Ford Orion

"So I quit aerospace and joined the Air Force in 1976 and I went on to survey years in New Zealand Air Force, worked on the C-130s and the P3 Orion's Iroquois helicopters and I really found my home with the P3s and the engines, the big T56 turboprops and you know I was qualified to do high power test runs on those engines and stuff and that sort of really excited me."

The Ford Orion is a simple, vintage four-door family sedan that was sold in Europe. It was basically a hatchback car with a traditional trunk added to the back.

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Car

Ford Expedition

"... hitching a ride on a C 130 and it was a shopping expedition. Yeah, it was called indulgence travel if anybody..."

The Ford Expedition is a very large, three-row family vehicle made by Ford. It is built like a truck, which makes it good for carrying lots of people and towing heavy trailers.

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Person

Possum Bourne

"I actually won my first event, which was the Woodhill rally where I had the privilege of actually beating possum born."

A beloved and highly successful rally racer from New Zealand who won many championships driving Subaru rally cars.

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Car

Subaru Wrx

"...onal folks might relate to us. He was driving the Subaru WRX at the same time as Colin McCray, etc. and compet..."

The Subaru WRX is a sporty, four-door sedan made by the Japanese company Subaru. It is famous for having a powerful engine and an all-wheel-drive system that helps it grip the road well in all kinds of weather.

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Term

detonation

"And next thing I was into building fresh engine, which I did. And we had to just tune it by thrashing up and down the road basically."

When the fuel inside an engine explodes too early and violently instead of burning smoothly. This creates a metallic pinging sound and can easily break engine parts.

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Concept

water-methanol injection

"A draw through side draft Weber 45 Weber and it used water injection to prevent detonation. Yes, the problem with a draw through setup of course is that you can't run an intercooler..."

A system that sprays a fine mist of water and alcohol into the engine's air intake. This cools down the engine internally, allowing it to run more boost safely without exploding.

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Term

compression ratio

"And also we cut the compression ratio back to like 7 to 1. Yeah. So we used to machine the top off the TRW forged pistons and drop the compression way down..."

A measurement of how tightly the engine squeezes the air and fuel mixture inside its cylinders before igniting it. Squeezing it less (lower compression) helps prevent engine damage when using a turbocharger.

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Car

Mitsubishi Lancer

"...y cars in New Zealand was mine, Morrie Chandler's Lancer Turbo. He just got that."

The Mitsubishi Lancer Turbo is an older, sporty four-door sedan from the 1980s. It used a turbocharged engine to go much faster than a standard family car.

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Term

turbo lag

"Talk about turbo lag down in hindsight, had a lot of turbo lag. Yeah, I was a couple of things I want to dig into there. First of all, detonation."

The hesitation or delay you feel when you step on the gas pedal in a turbocharged car before the turbo spins up and the extra power suddenly kicks in.

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Car

Peugeot 205 T16

"...r, a guy that a good friend of mine had a Peugeot 205 T16. And then, unfortunately, John was killed in a sm..."

The Peugeot 205 T16 is a rare, high-performance racing car built in the 1980s. Although it looks like a small hatchback, the engine is actually in the back seat, and it has four-wheel drive to go extremely fast on dirt roads.

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Car

Peugeot 205

"...n Woodner, a guy that a good friend of mine had a Peugeot 205 T16. And then, unfortunately, John was killed in ..."

The Peugeot 205 CTI is a small, sporty convertible hatchback made by a French company. It was designed to be fun to drive with the roof down.

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Car

Born Bournes

"And he also co-drove for Possum in the Australian series. I remember seeing that name on Possum Bourne's car, yes. Yeah, yeah. In fact, his car, his name's on the 323 GTX that's down"

The Cupra Born is a modern, sporty electric hatchback. It runs entirely on battery power and is designed to be fun to drive while producing zero emissions.

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Car

Plymouth GTX

"...ah, yeah. In fact, his car, his name's on the 323 GTX that's down at the museum in Southland. I saw it ..."

The Plymouth GTX is a classic, powerful American muscle car from the late 1960s and early 1970s. It was designed to be both fast and comfortable, featuring a very large V8 engine.

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Car

Audi Quattro

"...-wheel drive car. John Buffum was running an Audi Quattro and they were brand new hot machines at the time...."

The Audi Quattro is a famous German sports car from the 1980s. It was the first major racing car to use all-wheel drive, which helped it win many races on slippery dirt roads.

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Car

Datsun 510

"...e went. So what made it work is I bought a Datsun 510 coupe off John Woodner. And this is a car that wa..."

The Datsun 510 is a small, classic Japanese car from the late 1960s and early 1970s. It is loved by enthusiasts because it is lightweight, simple to work on, and fun to drive.

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Car

Datsun 510

"...erica we went. So what made it work is I bought a Datsun 510 coupe off John Woodner. And this is a car that wa..."

The Datsun Bluebird is a classic, small family sedan from Japan. It became very popular because it was affordable, reliable, and surprisingly fun to drive.

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Car

Mitsubishi Starion

"So I went and being a turbo guy, I went and managed to sell a rally car to a guy, collected the money, and I went out and bought a brand new Mitsubishi Starion ESI in 1985."

A sporty, wedge-shaped Japanese car from the 1980s with pop-up headlights and a turbo engine that sent power to the rear wheels.

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Car

Dodge Charger

"...lown off down the back straight by a Dodge Shelby Charger that's meant to be 145 horsepower and that's gone..."

This is a sporty hatchback version of a Dodge car from the 1980s that was upgraded by a famous car designer named Carroll Shelby. It was designed to be affordable, lightweight, and fun to drive.

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Car

Dodge Ram

"...o play. Well, Steve went out and promoted up some Dodge Ram race trucks. There was a brand new series called ..."

The Dodge Ram is a large, powerful American pickup truck designed for hauling heavy loads and working on tough jobs.

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Term

bump drafting

"And that was probably a super competitive series. All the trucks were fairly equal and that's where I learned to do bump drafting."

A racing trick where a car behind gently hits the bumper of the car in front to push both of them faster down the straightaway.

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Car

Honda CRX Si

"We were competing against the Honda factory teams back then with the Honda CRX SIs that had been dominating in the smaller categories and that I found myself with a competitive car."

A tiny, two-seat sporty hatchback made by Honda that is famous for being incredibly light, fun to drive, and great on gas.

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Car

Chevrolet Camaro

"...is we're going down the back straight besides Z28 Camaro. Yeah, just don't get caught."

The Chevrolet Camaro is a classic American two-door sports car built by Chevrolet. The 'Z28' version is a special model designed to go faster and handle corners better than the standard version.

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Car

Mazda MX-5 / Miata

"...as time for the launch of well, I helped with the Miata, the MX five launch that was massive, but I didn'..."

The Mazda Miata is a small, two-door convertible sports car made by Mazda. It is famous for being very fun to drive, easy to park, and highly reliable.

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Car

Chevrolet Corvette

"...hose, the Porsche Turbos and, you know, Chevrolet Corvette Lotus, factory Lotus team with the Lotus Esprit X..."

The Chevrolet Corvette is a famous American two-seat sports car. It is known for its sleek, low-to-the-ground design and powerful engine.

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Car

Lotus Esprit

"...Corvette Lotus, factory Lotus team with the Lotus Esprit X180R, which was a specialty Lotus Esprit that wa..."

The Lotus Esprit is a low, wedge-shaped British sports car. The 'X180R' is a special, rare version built specifically for racing on tracks.

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Car

Porsche 911

"...e all had the same tire, of course, but the turbo 911 turbos were better because they had the weight ov..."

The Porsche 911 is a high-end German sports car with its engine located in the very back of the vehicle. The 'Turbo' version uses a special system to force more air into the engine, making it much faster.

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Part

Penske double adjustable dampers

"I had good suspension. I had Pinsky double adjustable suspension. That was when Pinsky were just getting into the shock absorber business."

Very expensive, high-tech racing shock absorbers that let mechanics adjust how the car reacts when hitting bumps and when settling back down, helping the tires grip the track better.

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Car

Bmw 5

"...r, the BMW guys at the time did, there was a, the BMW 5 series had the European transaxles in them becaus..."

The BMW 5 Series is a comfortable, mid-sized four-door luxury car made by the German company BMW. It is designed to be both a comfortable family car and fun to drive on the highway.

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Part

power plant frame

"It was a power plant frame rigidly connected to the gearbox, rigidly connected to the front of the diff. All that torque is going through the nose of the diff casing."

A metal brace that connects the transmission directly to the rear axle gears. It keeps the drivetrain stiff and prevents it from twisting under hard acceleration.

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Car

Datsun 240Z

"...oh, I made my own engine management system for my 240Z. And I said, hang on, come back here."

The Datsun 240Z is a classic, two-door Japanese sports car from the early 1970s. It has a long hood, a short rear end, and is highly prized by collectors for its beautiful design.

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Car

Nissan Gtrs

"There was a few guys floating around that were running in the 11s. One guy had a GT-AR in the San Pauxa, there's a couple of GT-Rs, R32 GT-Rs, and a couple of Evo's."

The Nissan GT-R is a highly famous Japanese sports car. The 'R32' version from the early 1990s is loved for its incredible speed, high-tech grip, and racing success.

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Car

Nissan R32

"...T-AR in the San Pauxa, there's a couple of GT-Rs, R32 GT-Rs, and a couple of Evo's."

The Nissan Skyline is a family of Japanese cars that includes everything from regular sedans to incredibly fast, high-tech sports cars.

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Car

Eagle Talon

"...And I'd been following what was going on with the Talon Eclipses in the US and I ended up with a Mitsubis..."

The Eagle Talon is a sporty two-door car from the 1990s. It was built through a partnership between Chrysler and Mitsubishi, sharing almost all of its parts with the Mitsubishi Eclipse.

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Car

Mitsubishi Eclipse

"...d been following what was going on with the Talon Eclipses in the US and I ended up with a Mitsubishi Evo 3 ..."

The Mitsubishi Eclipse is a sporty two-door car that was very popular in the 1990s. Some versions had all-wheel drive and a turbocharger, making them very fast and popular for customizing.

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Car

Mitsubishi Evo

"...he Talon Eclipses in the US and I ended up with a Mitsubishi Evo 3 and built that up. And I don't really know how ..."

The Mitsubishi Lancer Evolution is a high-performance version of a standard four-door family car. It has a powerful turbocharged engine and all-wheel drive, designed to go very fast on both paved roads and dirt tracks.

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Car

Nissan 300 ZX

"...e was friends with Doug and Doug was running that 300 ZX Twin Turbo in the Supercar series I mentioned ear..."

The Nissan 300ZX is a sporty, low-slung Japanese car from the 1990s. The 'Twin Turbo' version has a highly powerful engine that makes it very fast.

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Car

Jensen Interceptor

"...t that time. And he had a device called the crane interceptor and that which he, which was a piggyback computer..."

The Jensen Interceptor is a vintage luxury sports car from the 1970s. It was built in Britain but used a large, powerful American engine to make it fast and smooth to drive.

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Car

Ford Mustang

"...and was being sold through crane cams for the 5.0 Mustangs. I think I even remember that product."

The Ford Mustang is a famous American sports car. The '5.0' version refers to a model with a large, powerful V8 engine that makes a loud, classic rumble.

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Car

Lucid Air

"my intake, the PFS intake was getting the air out of that intercooler duct. So it was cold air ..."

The Lucid Air is a high-end, fully electric luxury sedan. It is designed to travel very long distances on a single battery charge and has a very modern, spacious interior.

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Car

Mazda Rx8

"So I'm currently running a RX8 and the Mazda RX8 series. And we get, you know, 28, 30 cars on the grid at all the, you know, top tracks in New Zealand..."

A sporty four-door car from the 2000s that used a unique rotary engine and had small rear doors that opened backwards to make getting into the back seat easier.

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