155: Building The Worlds Best Sounding 5 Rotor

David Mazzei may well have the best-sounding turbocharged rotary on the planet, but how he chased down that elusive F1 V10 sound with this masterpiece of an engine is somewhat unexpected.

Rotary engines are often labelled as temperamental and unreliable, but David Mazzei of Formula Mazzei believes the opposite. In his view, rotaries can be among the most reliable engines when properly understood.

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In this episode of Tuned In, David shares his journey from a childhood fascination with technology and cars to becoming a rotary engine expert. He discusses the challenges and rewards of owning and daily-driving his first RX-7.

We dive deep into rotary tuning, starting with the fundamentals—air-fuel ratios, exhaust gas temperatures, and the critical relationship between ignition timing and engine reliability. David also shares his views on engine building, apex seals, and porting, and explains why rotaries deserve a far better reputation than they’ve been given.

We explore the evolution of his five-rotor engine, what it took to bring such an ambitious project to life, and the challenges of building something this complex. David breaks down the science behind its unforgettable sound and reveals how his background in music helped him dial in and replicate the pitch of an F1 V10.

David’s passion for the rotary engine is undeniable. He’s a wealth of knowledge, and what he’s achieved with his MF5 Superlite is nothing short of extraordinary. If you have even a passing interest in rotary engines, this is an episode you don’t want to miss.

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Follow David here:

Instagram: mazzei_formula
Youtube: mazzeiformula
Facebook: David Zachary Mazzei

Timestamps:

0:00 Building The Worlds Best Sounding 5 rotor
4:11 How did you become interested in cars?
17:20 How did daily driving your first RX7 at 17 go?
21:55 Rotary reliability
29:16 How did you learn to tune?  
37:24 Can you explain the different rotary engine ports?
40:15 Can we get good driveability with modern ECU’s on a bridge port or peripheral port?
46:15 EGT’s on rotary engines
55:15 Air fuel ratios and timing on rotary engines
1:06:05 Can you explain rotary split?
1:12:33 How did the 5 rotor project develop?
1:23:17 Is the turbo charger irrelevant to the sound of the engine?
1:30:30 How do we go about building a 5 rotor?
1:38:23 Billet vs factory cast blocks
1:42:46 What’s your opinion on apex seals?
1:46:25 Should we be running premix in our rotary’s?
1:53:37 How important is injector timing?
1:57:25 Final 3 Questions