Mazda Rotary Club

Cars by Model Type => Cosmo's and Other Rotary Powered Vehicles => Topic started by: Steve-A on April 10, 2010, 10:47:32 PM

Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on April 10, 2010, 10:47:32 PM
Hi guys.

I\'ve been lurking here for a while, slowing learning about these roundy-roundy engines, but I thought it was time to say hi.

I\'m Steve. A couple a years ago I bought an mx5. She looked like this:

(http://i199.photobucket.com/albums/aa196/steve-nc30/photo-7.jpg)

88k on the clock, a whole 88hp at the wheels... Either way I loved the drive and roof down experience and realistically it was 100 times better than any of the \'classic\' british roadsters I\'d been to test drive.

Very soon I joined an mx5 forum and started to get tempted into performance modifications.....

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3816.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3823.jpg)

Thats how she stands now. 200+ hp from the standard engine, turboed with different cams and megasquirt.

Anyway, meandering back towards rotaryness..... I\'ve always lied the idea of a 7. I love the lines of an FD and to me one of the most appealing things is the concept of rotary power. It seems to hold many similarities with two strokes, and I adore my two stroke motorbike. I had a Ducait 748 for a while, which was a work of art, but was blown away by the riding experience of a 20 year old knackered mismatched rgv250. I\'ve now done a complete rebuild on her mechanically. Crank, top end, gearbox, all suspension bearings, all brakes, the list goes on. Still havent started on body work.....

(http://i199.photobucket.com/albums/aa196/steve-nc30/IMG_0132.jpg)

So yeh rotary.... So I started reading more and more about rotary engines and I really like the idea. I was soooooo close to going out and buying an FD a few months ago, but there are just too many draw backs for me and the way I use my car. The biggest draw back is the lack of soft top. You cant beat a nice summers evening with a lady in the passenger seat and the roof down.... I know I could get an FC vert, but they just don\'t do it for me.

Having decided I couldn\'t quite go for an FD, I\'ve decided I\'d like to do a rotary swap into my mx5. I\'ve been doing lots of reading on the internet and I\'ve found masses of information. Its not an easy swap, infact is easier to drop an ls1 v8 from a corvette in than the 13b, but I like a challenge.

One thing to my advantage is that I\'d like to try n/a for a while, I\'ve enjoyed  having turbo power delivery for the last year but I\'d like to experience the pure revvy feeling of high tuned n/a. I very much like the idea of throttle bodies and quite an aggressive port and hopefully to end up near the same power as my current set-up. That said I\'m not very power focused, more experience and feel focused.

If I start with an n/a 13b from a FC there is one big advantage over any other rotary. The FC n/a gearbox is basically the same as an mx5 gearbox. By using parts from both I can use the FC bell housing and bolt upto the block easy yet retain all the mx5 mounting points, the mx5 prop and rear end.

I will need heavy modifications to the front subframe, or possibly to buy a posh tubular one from the states, to clear the 13b sump. I\'m gonna need custom engine mounts. I\'m gonna need a fully custom exhaust. I\'m gonna need to organise some engine management, I plan to use megasquirt.

I\'ve picked up a dead 13b, with good gearbox from a friend to use as template for subframes and stuff, and this week I\'ve started to sell of my turbo bits to raise some funds, so its project go! I\'ll try to keep this updated.
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on April 10, 2010, 11:39:21 PM
Welcome Steve! And I wish you the best of luck with this build
Title: Mx7? rx5? Newbies build thread begins
Post by: Nik da Greek on April 10, 2010, 11:50:20 PM
Wotcher, Steve, welcome to the club and all that. Liking your Gamma there, a rotary\'s the same except it goes round rather than up and down, nothin\' to it :Giggle You don\'t need such cobra-like clutch hand reactions with a rotary though :D The swap you\'re looking at has been done before, I think a fair few Yank cars have had it done. Martin at Speedline Imports on here is a good way through doing a similar conversion, and he\'s also a great source of bits! Be interesting to see how you get on
Title: Mx7? rx5? Newbies build thread begins
Post by: Paul-Tll on April 11, 2010, 06:45:20 PM
Great project, keep the pictures coming and good luck with progress of your RMX5. you should end up with a really good  and desirable car at the finish. Be sure to come along to some meets later this year, so we can have alook !:3gears-lh
P.
Title: Mx7? rx5? Newbies build thread begins
Post by: m1tch on April 11, 2010, 08:18:20 PM
Hi mate, ask Speedline imports, he has an MX7, I asked about it, all you need is custom engine mounts and a cut down propshaft and everything just fits :) regarding the egi/turbo route, get a turbo lump, with turbo ECU etc, and just plumb it in as an EGI, the ECU will just use the NA part of the mapping, then you can just bolt the turbo on when you get bored of beating everyone just a bit :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on April 11, 2010, 11:00:56 PM
Thanks for the useful info guys.

I\'ve got a list of 20 or so build thread from guys who\'ve done the same swap in the states to try and gleam some info from. It could be that I\'ve already read Martins thread on the mx5nutz website, if its not the same bloke then I only know of 2 rotary swapped mx5s in the UK and they are both owned by a bloke called Martin!

Having done lots of reading I\'m definitely going to start with the EGI engine, as it allows me to build the hybrid mx5/rx7 gearbox and use standard gearbox mounts, prop and diff. I\'d also really like to try the whole high revving n/a thing for a bit having only really had experience with turboed performance cars. I\'m sure the old snail with tempt me back at some point but the main thing now is to get over the mechanical aspects of fitting the rotary engine in.

ECU wise I think I\'m gonna build a custom loom to use with my megasquirt. Thats the simplest option wiring wise and I\'m very comfortable with the Megasquirt platform.

I\'ve got a buyer for my mx5 turbo kit confirmed, just need to drop my performance clutch out to sell as part of the kit, so thats useful.

I\'ve arranged to get the engine out of Lee Mills EGI now he\'s decided its too rusty to continue with, so will be going to collect that next weekend.

I\'ve been started to strip down the dead egi block I\'ve got to see what\'s usable. Gear box is fine, clutch looks fine, intake manifold and throttle body assembly is fine, so again useful stuff.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3836.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3837.jpg)

I\'ve got 8 injectors to get cleaned and pick the best 4 from, as I already had a set I\'d bought off ebay to use with my megasquirt and turbo mx5 block.

Finally I\'m gonna find out the shipping costs to get this: v8 roadsters subframe (http://www.v8roadsters.com/category-s/98.htm) imported from the states. Should eliminate the awkward cutting/welding needed of the standard subframe to clear the 13b sump, and be 5kg lighter and stiffer than standard.
Title: Mx7? rx5? Newbies build thread begins
Post by: Nik da Greek on April 11, 2010, 11:03:37 PM
Never mind all that old rotary nonsense, more pics of the 250 Gamma please :rollin

Martin has an advertisers section on here as Speedline Imports, dude if you wanna check it out.
Title: Mx7? rx5? Newbies build thread begins
Post by: BlitzBoy on April 12, 2010, 12:21:48 AM
Here is a link on how to use a Megasquirt with a Rotary engine
http://www.rx7club.com/forumdisplay.php?f=153

Martin\'s MRX5 achieved 270 at the wheels on low boost, which must be quite frighting on a small soft top car lol
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on April 12, 2010, 09:10:31 AM
Cheers Blitzboy, I have in fact already bookmarked that forum and there\'s also a very comprehensive guide over on http://www.diyautotune.com :)

From experience just over 200hp at the wheels feels pretty exciting in an mx5, so 270 must be rather wild! I\'m sure its the same Martin now as on the mx5nutz forum, and its a very nice build. My build will be a little more cheap and cheerful but hopefully just as functional.:)

p.s. Nik, this is the beautiful noise of a 250 twin on Lomas race pipes after a fresh rebuild.

type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="640" height="385">
Title: Mx7? rx5? Newbies build thread begins
Post by: Nik da Greek on April 12, 2010, 09:57:04 AM
Oooh, that\'s proper that is, that takes me back :yes. I want another stroker now :rollin No, not that sort of stroke, perverts :D
Title: Mx7? rx5? Newbies build thread begins
Post by: Marcrs on April 12, 2010, 10:10:23 AM
Hi Steve,

that\'s a pretty nice looking MX5 you have there...and a very interesting project, I\'ll be watching this closely :)

I remember riding my mates RGV250 when I had my Z900...not long after that I bought a GSXR750...and an RD400 to satisfy my 2 stroke urges ;)


good luck with the MX5, keep the pics coming :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Speedline Imports on April 12, 2010, 11:19:54 AM
Hey Steve, yes that would be my 13b turbo MX7 build on Nutz.  Any queries etc feel free to get in touch and I will try to help you out as much as possible.  Good Luck with it :)
 
Martin
Title: Mx7? rx5? Newbies build thread begins
Post by: od404 on April 12, 2010, 11:52:24 AM
Great to see you\'ve finally decided to rotary Steve!  I will be keeping a close eye on this thread for updates :3gears-rh
Title: Mx7? rx5? Newbies build thread begins
Post by: grinder on April 12, 2010, 05:24:27 PM
ohhh an RGV250 - not seen one of those in a while

i couldnt afford one at the time so i went with a KR1-250 instead
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on April 12, 2010, 05:28:30 PM
I wondered if you might have spotted this Steve, even if I get my own rotary powered car, I\'d still like that ride in your FD :P

Martin, it was your build that finally inspired me to take the plunge. I think I\'m fairly planned out for the moment but I\'m sure problems will surface along the way. The only thing I could do with a little info/help on is the subframe mods required. Nobodies very specific on the net so hard to know exactly what needs cutting, but as you\'re using the TII gearbox and a custom prop length I suspect non of your measurements will match up with my build.

My life would be made easier if I wasn\'t daily driving the mx5 while I plan this! Then I\'ve got a 1 week window to do the swap, so gotta do as much planning as possible!

KR1s are mean! Tankslapper is the word that comes to mind, haha. It almost seems like you guys need a 2 stokes sub forum :P
Title: Mx7? rx5? Newbies build thread begins
Post by: Nik da Greek on April 12, 2010, 11:27:24 PM
Hahaha, you could afford a KR1, Stu :eek:? The only reliable thing about them was the fact that sooner or later it would drop a ring peg and blow it\'s barrels into tiny pieces. Never saw monthly rebuilds as the cheap alternative hahaha  

Hmmmm, 2T sub forum :rolleyes:......I was always an Elsie type meself, can\'t beat a nice 350 LC on spannies where you know when it hits the power band it\'ll either spin up or wheelie or both, but its the anticipation guessing which it\'ll be :D........
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on April 19, 2010, 10:13:38 AM
A couple of small updates.

My garage now looks a little like a breakers yard. I\'ve got 2 13bs, one with a dead rotor, an FC gearbox, an mx5 gearbox and various ancillaries.

(http://i128.photobucket.com/albums/p186/flipkickbs/DSC01389.jpg)
(http://i128.photobucket.com/albums/p186/flipkickbs/DSC01390.jpg)

Went to Blackpool to pick up the gearbox saturday then down to Devon to pull the good 13b from Lee Mills FC that he\'s breaking.

Was a good if tiring weekend!

I\'m in conversation with the v8 roadsters guys about a subframe and over the next couple of weeks I hope to clean up the good 13 and build up the megasquirt loom. :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on April 20, 2010, 12:35:46 PM
Subframe is gonna come out at £700 + VAT, so leaning back towards modded stock one again.

I\'m also starting to think I might look for a cheap mk1 5 to run daily while I do the swap. I was considering general super cheap cars for £100 or something but thought with 5 I have plenty of spares + experience and know I can sell it when I\'ve got mine on the road again.

With another car to daily drive I should be able to get the 1.6 block outta my mx5 sooner rather than later and get a better idea of how the 13b will fit and what other problems I\'m going to come up against.
Title: Mx7? rx5? Newbies build thread begins
Post by: russellparkerx on April 20, 2010, 02:54:57 PM
Quote from: Nik da Greek;686888
Hahaha, you could afford a KR1, Stu :eek:? The only reliable thing about them was the fact that sooner or later it would drop a ring peg and blow it\'s barrels into tiny pieces. Never saw monthly rebuilds as the cheap alternative hahaha
 
Hmmmm, 2T sub forum :rolleyes:......I was always an Elsie type meself, can\'t beat a nice 350 LC on spannies where you know when it hits the power band it\'ll either spin up or wheelie or both, but its the anticipation guessing which it\'ll be :D........

 
 
Wonderful.  Sorry to threadjack, but we should all ditch these RXs and buy 350 lcs with day glo orange wheels, microns, boyesens and stan stephens borekits.  Then fill em up with 4 star and pre-mix Silky comp 2 and go out and have low speed crashes wearing insufficient protective clothing on sunny days.
 
Ah the memories.
 
Good luck with the MX7 Dude!
Title: Mx7? rx5? Newbies build thread begins
Post by: grinder on April 20, 2010, 04:53:04 PM
Quote from: Nik da Greek;686888
Hahaha, you could afford a KR1, Stu :eek:? The only reliable thing about them was the fact that sooner or later it would drop a ring peg and blow it\'s barrels into tiny pieces. Never saw monthly rebuilds as the cheap alternative hahaha  

Hmmmm, 2T sub forum :rolleyes:......I was always an Elsie type meself, can\'t beat a nice 350 LC on spannies where you know when it hits the power band it\'ll either spin up or wheelie or both, but its the anticipation guessing which it\'ll be :D........


ohh thread hijack again !!

yeah i ended up killing the KR1 - coming down the slip road at about 12K RPM in 3rd - it went bang in a big way

i think it did exactly as you mentioned - the upside was that it missed the recall and Kawasaki paid for £900 worth of parts and we just paid the rest - my dad rebuilt it in the garage for me !! :D

didnt help when we couldnt remove the power valves and my dad knocked them out with a hammer - then realised that they were £40 to replace

ahhhh them were the days eh !!

i have a 600 in the garage thats not been used for about 8 yrs - just got it running recently - but the better half wants me to sell the rex and get the bike back on the road .. cant see that happening to be honest - might just have to be gready and have the BMW , RX7 and the 600 as my toys :D

oh yeah - good look with the MX5 - RX7 conversion ;)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on April 25, 2010, 11:12:02 AM
Another week gone by and some fair progress made :)

I\'ve started to clean up the intake manifolds and sort out my stuck 5th and 6th port actuators, no pics of this but there\'s not much to see yet!

More importantly I\'ve built my gearbox, and its was much easier than I thought it was going to be!

Started with two gearboxes, fc n/a box on the left and mx5 5 speed on the right.
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3857.jpg)
Then took both the tail housings off, revealing the automotive smut that is the inner workings of a gearbox!
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3844.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3842.jpg)

Now the info I\'d read on the internet suggested that you needed to machine about an inch off the end of the input shaft when doing this swap, so we continued to strip the mx5 box down.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3850.jpg)

My friend Ian, was super psyched to have found a use for his new punch set, in removing roll pins from the gearbox linkages

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3847.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3848.jpg)

Then just as we started to strip the FC box we realised that you only need to machine the input shaft if you want to use the mx5 gear set. I\'m quite keen to try the FC gearset as apparently it has a longer 5th gear, which would be quite nice. The mx5 gearset means 3.5k rpm at 70 on the motorway.... So using the FC gears meant no machining, we fitted the mx5 tail section onto the fc bellhousing an gears, sealed it all up and its good to go!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3851.jpg)

My pile of bits to goto the tip is ever growing as I cannibalise the various engines and gearboxes that clutter my garage!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3852.jpg)

I\'m buying a cheap runabout car of a friend this week, so saturdays plan is the pull the engine from my MX5 and start working on proper plans for engine mounts/subframe mods.
Title: Mx7? rx5? Newbies build thread begins
Post by: TiddlesRX7 on April 25, 2010, 11:15:29 AM
Well done. I like threads like this.

Good luck with the rest of the project.
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on April 25, 2010, 07:38:58 PM
Great update. Lovely to see inside those gearboxes. :-)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 02, 2010, 10:05:09 AM
Another week goes by and some small progress. Unfortunately its taking a little longer than hoped to get a daily driver organised, so pulling the engine from my mx5 has been postponed till next week :(

I spent a fair amount of time yesterday cleaning up and modifying the inlet manifold. I\'ve removed all the extra features from the throttle body that I shant be using with megasquirt, the majority of which being the second throttle plate. I\'ve filled the holes with metal putty then began to smooth it over. Still needs some time with a finer grit sandpaper to really smooth things out.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3886.jpg)

Similarly I\'ve removed the 5th and 6th port butterflies, filled their holes and smoothed out the casting marks near by. I know this is a controversial thing to do and I\'ll loose midrange, but I fancied going for the simplest engine build I can. I\'ve also read that I shant gain any top end from doing this, only loose mid range, I can see how thats the case with the american style rotating tube that goes into the main housing but the UK style butterflies have got to cause quite a restriction on the 5th and 6th ports. I\'ve got a spare LIM with working actuators, so swapping back is easy enough. Heres a couple of before and after pics.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3856.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3883.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3884.jpg)

I\'ve also smoothed out the transition from plenum to intake runners. Again this is just rough at the moment and needs smoothing out more.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3887.jpg)

In the process of cleaning out the intake runners I broke one of the secondary injector baskets :( How important are these? I\'ve got spare ones of the short primary injector style baskets. Could I just use one of those?

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3888.jpg)

I\'m sending the injectors away to be cleaning next week, then I can rebuild the intake system :) Fingers crossed next weekend I\'ll be posting pictures of an mx5 with no engine!

p.s. I\'ve also been working on the body work for my motorbike! I\'ll post some pics for the two stroke crew at some point....

p.p.s running out of real work to do + being in garage with tools + spare parts = danger.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3876.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3874.jpg)

Again my friend Ian is the one who ends up looking silly on the internet as I stay safely behind the camera. It felt surprisingly natural to ride....
Title: Mx7? rx5? Newbies build thread begins
Post by: evans.I on May 06, 2010, 06:47:08 PM
I\'m definatly not looking like the most useful person to be lending a hand with this judging by all the pictures of me looking like a right nonce! :P

Looking forward to tearing down the 5 this weekend and hanging some rotary in the bay! You best get the coffee in stock!

Ian.
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on May 07, 2010, 08:20:26 AM
Tea boy at the ready!
Title: Mx7? rx5? Newbies build thread begins
Post by: clive on May 07, 2010, 08:58:17 AM
Hi Steve,

Sorry managed to miss this thread :Hammer

Whilst this has been carried out around the world as far as I know this is the first Rotary MX-5 here on MRC,

You know there was a myth/rumor that Mazda designed the MX-5 so the Rotary would not fit but just 2 weeks after it went on sale in Australia somebody had one fitted :Giggle

Much more up to date the currant MX-5 shares the same floorpan as an RX-8 and very nearly hit the streets Rotary powered, some of these cars are in Germany,

More recently there\'s a company also in Germany that fits RX-8 engines into brand new MX-5\'s and give them a 40K price tag :eek:

Good luck with the project and keep us informed
Title: Mx7? rx5? Newbies build thread begins
Post by: clive on May 07, 2010, 09:00:07 AM
Quote from: evans.I;692108
Looking forward to tearing down the 5 this weekend and hanging some rotary in the bay! You best get the coffee in stock!

Ian.


Welcome to MRC Ian
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 07, 2010, 09:55:17 AM
Quote from: clive;692248
Hi Steve,

Sorry managed to miss this thread :Hammer

Whilst this has been carried out around the world as far as I know this is the first Rotary MX-5 here on MRC,

You know there was a myth/rumor that Mazda designed the MX-5 so the Rotary would not fit but just 2 weeks after it went on sale in Australia somebody had one fitted :Giggle

Much more up to date the currant MX-5 shares the same floorpan as an RX-8 and very nearly hit the streets Rotary powered, some of these cars are in Germany,

More recently there\'s a company also in Germany that fits RX-8 engines into brand new MX-5\'s and give them a 40K price tag :eek:

Good luck with the project and keep us informed


Hi Clive, Unfortunately its not the first one on here, its the 2nd. Martin at Speedline has done a turbo II conversion. Though he did a much more intensive conversion with entire drive train swap. There\'s a guy on the mx5nutz forum who\'s having an renesis fitted by WGT right now, so I might not be the only one but one of three isn\'t bad :P

I didn\'t realise that about the new mx5 being very so similar to rx8! I knew the gearboxes were pretty much interchangeable but not floor plan!

Daily driver is all sorted now. As of 1am Saturday morning the mx5 is off the road and I\'ve gotta drive a Fiat, damn. :Hammer

Was gonna get going on the car tonight but I\'ve been offered the opportunity to go to Morgan to do some filming with an Areo, so rotary will have to wait till the morning!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 08, 2010, 07:00:56 PM
Today started with the collection of a very exciting car.... NOT

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3918.jpg)

Not exciting, but it can carry me to work and back while I do silly things to my mx5. So in between the rain showers I parked up the 5 for that last time for a month or two, and Ross and I set to work dismantling the engine.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3917.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3919.jpg)

Didn\'t get too far, we didn\'t start till 4:30 because of picking up Punto and engine crane. Most of the loom is clear, all the ignition and fuel components are clear. We then had to stop (so we could goto a party tonight!)

Weathers looking better for monday, and I\'ve the day off work, so gonna try to make real progress then.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 10, 2010, 08:04:58 PM
I had a day off work today, so Ian popped over and we made good progress on the 5.

This is how the day began, stripping more of the ancillaries from the 1.6

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3920.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3921.jpg)

Then lifted the 1.6 out.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3922.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3923.jpg)

Big space in there! Then out came the gearbox

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3924.jpg)

And in with the rx7/mx5 hybrid box. The clutch slave worked out just nicely, with the flexi line running right to the end of the mx5 hardline.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3927.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3930.jpg)

Then just to gauge how much work has to be done we dropped in the dead 13b I\'ve got, stripped right back.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3935.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3936.jpg)

It looks like its not far off, but its got not sump on there, and is sitting on the steering rack.

Next up is to revisit all the threads by people who\'ve done this before and do some serious thinking ready to get the fabrication work done. I may well have the transmission tunnel lightly modded to make room for the clutch slave so I can lift the front of the box up a little.

Hmmm, lots to think about!
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on May 10, 2010, 10:52:01 PM
How is it looking for exhaust clearence with the steering?
Cheers
Brian
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 10, 2010, 10:56:47 PM
errr not great! Where there\'s a will there\'s a way and all. The exhaust route is gonna be quite tough generally as the mx5 exhaust exits on the other side of the block, so there\'s more space to the otherside of the prop.

Having had a good read up this evening, I think the next step is to pull the interior, as its looking pretty likely that I\'ll need to take a chunk out of the transmission tunnel as it enters the engine bay, to allow me to lift the front of the box for steering rack clearance.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 12, 2010, 10:06:27 PM
Now you see it:

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3941.jpg)

Now you dont:

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3942.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3945.jpg)

Only a bit more to go, then I can start cutting :s
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 16, 2010, 11:48:09 AM
Another few days gone by and a little more progress.

Yesterday morning I dropped the box and, with some help from Ross, we started to cut the notch in the trans tunnel that was needed to lift the engine up off the steering rack.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3961.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3967.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3971.jpg)

So we\'d cut a hole to clear the clutch slave and top of the box as it enters the engine bay

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3987.jpg)

but as we lifted the box up pas the normal position it started to catch on the top of the tunnel further down :( So the grinder came out again, and we carried on cutting till it fit! As you can see we only need a few mm of extra clearance. Its a shame its resulted in so much more welding being needed.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3999.jpg)

And the end result....

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-3997.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4000.jpg)

Much better. :)

I was going to try and use the standard FC engine mounts and modify the sub-frame to take them, but having actually got the engine in the car I think its going to be much easier to follow the way most americans have done this swap and to source a 12a front cover and use the front style mount. This will also give a little more exhaust clearance, which will be very useful.

So cant really go much further till I\'ve had the trans tunnel welded up and sourced a 12a front cover. Then I can get on with the sump and oil pick-up.

In the mean time my turbo II CAS and coil packs have arrived so I\'ll start making the modifications to my megasquirt needed to run the rotaries ignition.
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on May 16, 2010, 03:01:11 PM
really enjoyed yesterday... even though Steve did all the work :)
Just hope you get hold of a 12a front cover soon and we can sort all the sump clearence stuff. Going to be a very cool next few weeks.
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on May 16, 2010, 09:54:56 PM
I have 12a front cover/s
sellabitnz  @   yahoo.co.nz  

remove the spaces
drop me a line
Cheers
Brian
Title: Mx7? rx5? Newbies build thread begins
Post by: jpc on May 24, 2010, 11:13:16 AM
Quote from: Steve-A;692260
Hi Clive, Unfortunately its not the first one on There\'s a guy on the mx5nutz forum who\'s having an renesis fitted by WGT right now, so I might not be the only one but one of three isn\'t bad


That\'s my \'94  being done by WGT, hopefully at the finishing stages now for delivery mid-June.

I also wanted N/A after driving a twin-turbo FD and supercharged MX5s for 15 years.

From my research, it was going to be hard getting more than 175bhp out of a 13B N/A without compromising driveability so I went for the 13B-MSP Renesis (~230bhp) which has larger ports than the 13B from the FD and also has the fancy intake system. The shallow sump of this engine should also help with clearance since the rotary has to sit so low.

Lessons from this build are:

1. Major mods required to subframe
2. RX8 box mates up to MX5 NC 6-speed tail housing to get PPF on the original side. Gear level is 12mm out from original position.
3. Engine interfered with power steering rack (mine is LHD) so now manual steering.
4. Custom PPF and prop-shaft
5. 2.5" custom exhaust used although still expecting to use an off-the-shelf back box. There isn\'t much room to fit the exhaust manifold so a custom one was made. No cat required on a pre-95 import.
6. No change to diff assembly
7. Rotaries generate a lot of heat, need a good rad and oil coolers
8. A/C removed


The car is stil being worked on at WGT if you want to take a look.

Jon.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 29, 2010, 07:18:19 PM
Well its been a fairly quiet couple of weeks. I was hoping to get the car away to have the transmission tunnel welded up and the engine mount started on last weekend but the welder guy I\'m gonna be using had hurt his back.

So in the mean time I\'ve fitted the 12a front cover (thanks Kiwimazda!) which will mean much easier fabrication of engine mounts.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4010.jpg)

I then refitted the front suspension, and this morning took the engine and gearbox out, ready to load her onto a trailer tomorrow and go for welding monday morning.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-23.jpg)

With a little luck all the trans tunnel welding and fab can be done on monday, then I can refit the interior and free up some space in my bedroom! If things go really well hopefully we can start on fabricating the engine mounts. Once the engines mounted securely then hopefully things will really get a move on and progress will speed up a bit :)

I\'m really missing driving this car, driving the Fiat is killing me :(

While I had some time with nothing to do on the car I took the old 1.6 lump to bits and I found a hell of a lot of coked up crap. Think I must have been getting some pre-ignition. Not too much signs of detonation though, which is good :)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4008.jpg)

I also made some progress with painting my bike, and got it MOTed, which means I can get some lean angle on the go again :) Just need to do the side panels now

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4018.jpg)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on May 31, 2010, 07:42:18 PM
Not really feeling awake yet, dad and I left at 6:30am tis morning with the 5 loaded up on a trailer.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-22.jpg)

By 7 the mx was safely tucked into a workshop and progress was being made!

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-17.jpg)

Very kindly Bill, who works with my Dad, had offered to help me out with the fabrication work on this build. I\'m confident I\'m in safe hands!

4 Hours later, this was the result. A fixed up transmission tunnel, with fresh bracket for heat matrix, and clearance for the rx gearbox.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-25.jpg)

We left him my spare subframe and some measurements to make up the engine mount, hopefully to be completed in some spare moment during the week. So back home Ian, Ross and Dan turned up to help me get the car back up the steep drive to its home. We then removed the front suspension and subframe once more, ready to receive the modified subframe and applied some paint to protect the fresh metal in the trans tunnel.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-26.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-28.jpg)

Next up is the interior back in over the next few days :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 04, 2010, 08:29:20 PM
Another friday off work ( freelance work has its advantages!) and a lovely day to make some good progress.

First thing, mx5 interior:

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-1.jpg)

... back in the car:

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-3.jpg)

Just the center consol bit, glove box and radio panel to go. There\'s no point putting them back till I\'ve finished off sorting out the megasquirt wiring under there. Gonna need to run a couple of extra cables through for the rx7 coils and crank angle sensor.

Then at lunch time I went to pick up this:

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-2.jpg)

Drilled some holes and the engine is in its final resting place! :D:D:D

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-4.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-5.jpg)

Plenty of room underneath for the sump and oil pick-up. Just held the oil pick-up in place to show how the sump is gonig to have to wiggle under the engine.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-6.jpg)

Will start cutting up my spare 13b sump, and get the cardboard and tape out either tomorrow or sunday and hopefully get it made in metal over the next week or so.

Hopefully gonna stop by a local place that does custom exhaust fabrication with some pictures and info tomorrow, see if they are game to help. Will also order a large capacity aluminum mx5 radiator in the next day or two then I can start working out what bits of hose I\'m going to need to build the cooling system :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 11, 2010, 07:50:05 PM
Another week gone by and some more progress.

Earlier in the week I drew up the plans for my sump. I was hoping to mod the 13b sump, but in order to minimise the cutting to the subframe this was looking like an impossible task. Luckily Bill, the guy who\'s doing my fabrication work, is rather good at creating complex shapes from flat plate so a fully custom sump seemed best. He tacked it up today, so will pick it up tomorrow morning and check it fits before final welding.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4074.jpg)

I also stuck some paint on my engine mount.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4078.jpg)

I got a nice parcel arrive this morning. It was the Racing Beat DIY manifold kit I had ordered from the nice people at Mazdarotaryparts.com. I kinda wish it was what it says on the box though....

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4081.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4080.jpg)

I had a chat to the exhaust shop in the week, and despite looking pretty scared when I showed them the pics and dimensions, they then said \'it\'ll be tricky, but its not the worst one we\'ve done, be about £900+VAT" so thats alright. Not too bad a price for a complete system including a very complex manifold.

So today I spent most of the day starting to prepare the good 13b to go in the car. Its a million times cleaner that it was this morning, not that its anywhere near perfect now! In he process of stripping the block down I found this anomaly...

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4083.jpg)

Looks like it must have been rebuilt at some point, and looks to have been built from 2 front rotor housings :s Oh well seemed to run alright in the car, so I\'ll take this as good news that its been rebuilt sometime in its life, so that means its probably got a few miles in it yet.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 18, 2010, 07:34:44 PM
Didn\'t get much more done last weekend as my \'reliable safe option\' daily driver died. Apparently Fiat saw fit to use a differential in the Punto thats only held together by friction fit on splines, no retaining C clips or anything nice like that. Mine had come to bits, so I spent all weekend ripping in out of the car and hitting it with a big hammer till it was back together....

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4089.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4087.jpg)

I\'ve been spending every spare hour I get working on the mx, since I last posted I have cleaned up the gearbox, especially the shifter turret which I took to bits and cleaned properly. It was amazingly dirty for something thats meant to be sealed! I\'ve also made a start on the loom. I\'m trying to do all the stuff that goes by the gearbox first, so done neutral and reverse sensors, starter motor and while I was on starter motor it made sense to do alternator.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4093.jpg)

Today I picked up my sump and extended oil pick-up from Bill. Its a work of art!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4090.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4094.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4092.jpg)

I\'ve spent most of the afternoon fitting the sump to the block, I needed to drill the mounting holes myself, and beginning to build up the engine. As you can see I\'ve got as far as the alternator! The inlet manifold/throttle body is all built up but will be left off to make it easier for exhaust guys to get in there.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4097.jpg)

Now all the gearboxy stuff is done the plan is to put the engine and gearbox in for good tomorrow and the continue with the loom and cooling system. Once I\'m happy the box wont have to come out again I\'ll get the front suspension back on :)
Title: Mx7? rx5? Newbies build thread begins
Post by: antnicuk on June 18, 2010, 10:57:18 PM
there is some really good work on this thread,  well done,   that sump is certainly a work of art,   you have a very good contact there.
you obviously have skills and are a bright chap,  would you not want to have a crack at the exhaust yourself?  you could save yourself a fortune.  buy several 2.5 inch bends from someone like burtons or the fella that gave you the price to make it and buy a cheap mig welder (gasless will be fine)  you can cut up the bends and make the exhaust as you want it and just tack it with the mig,  its really easy,  then use a couple of slip joints (which the exhaust bends will have swaged ends to enable this) and take it to your mate to weld up.

I have a kit car with a turbo II engine and its great fun but i fancy an mx5 as my next project.  

Plan ahead as i guarantee you will want a turbo soon!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 18, 2010, 11:20:30 PM
Yeh, I had considered trying to do the exhaust myself, but then its really really not gonna be an easy one! The underside of the mx5 is based on an exhaust leaving on the passengers side of the block, but the rotary exhaust leaves on the drivers side. The steering rack leaves very little room for the exhaust to exit then it has to bend round and under the gearbox whilst staying tucked right up under the car, because I\'d like to keep my current ride hight and ground clearance.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4071.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4067.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4073.jpg)

All in all I\'ve had a cheap build so far and its worth spending the money to get the exhaust done right I think. Learning to weld is high up on my agenda though!

Turbo maybe, I have to admit I\'m more tempted by the idea of drilling some big holes in the rotor housings.... ;) The main reason I\'m doing this build is I wanted throttle response and driving experience over pure power. I\'m sure I\'ll be tempted back to power......

Mx5s are fun, there\'s no doubting that! As fun as a kit car? not sure, more daily drivable though and very cheap to run :)
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on June 18, 2010, 11:35:59 PM
absolutely stunning, i cant believe the quality of some of the parts that are being made.

p.s.... turbo\'s always win :D
Title: Mx7? rx5? Newbies build thread begins
Post by: antnicuk on June 19, 2010, 09:23:22 AM
Oh well, if you have thought about it. Obviosly going turbo in the future will mean having to change the complicated front section.  I assume you are just using a second hand block at this stage with a view to building an engine in the future ?  Cos you will need to get rid of those nasty exhaust sleeves

Keep the updates coming
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 19, 2010, 09:35:49 AM
There should be updates later today of hopefully the engine in the bay for good!

Yes I\'ve 2 secondhand blocks, one thats basically a wreck i got for free thats been used for most of the fab work, then the block with 2 front rotor housings I bought off Lee Mills on here as a running block with reasonable compression :)

The plan is to build this up and see if I like it! Then if I do I\'ll start looking for parts for a proper build. Probably try to get the s5 n/a rotors as they have the highest compression. Then remove the exhaust sleeves and either use bridge ported 4 port irons or do it properly and go peripheral......

I would get rid of the exhaust sleeves now if I thought I could without pulling the block to bits.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 19, 2010, 07:25:40 PM
To be honest today hasn\'t been great.... ah well.

I started by fitting the gearbox, hooking up the sensors, filling it with oil. That all went well. :)

Next up was drop the engine in. I soon realised that the clutch release bearing I had was dead :( So phoned around every Mazda Parts supplier within 30 miles but no-one had one in stock :( Got one ordered a the local dealership to arrive tuesday morning.

So I knew I was just gonna be test fitting the engine once more but I wanted to fit the radiator and spec the cooling hoses I\'d need.

So I went to drop the engine in, and it wont go :( the sump is hitting the subframe. So subframe out and engine in and then subframe lifted up from below. I think thats only only way I\'ve ever going to be able to get it in and out.

Unfortunately the subframe doesn\'t quite clear the sump, I must have made a mis-calculation somewhere.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4099.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4100.jpg)

So out with the grinder to make some clearance.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4101.jpg)

Much better :) Will drop it with Bill monday morning to patch up the holes.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4102.jpg)

So now the engine fits, I dropped the rad in.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4103.jpg)

Looking good so working out which hoses I need, its slightly complicated as the race spec mx5 rad has got 32mm outlets and the 13b has 38mm so will need step up and down sections in the hoses.

Overall I\'ve still made progress though just hit more snaggs than I\'d hoped to. Still on track to have the suspension on ready to tow it to exhaust shop on the 28th.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 22, 2010, 07:10:03 PM
After Saturdays set backs today good progress was made :)

Bill had welded up my subframe where I\'d cut it for extra clearance, so it was engine in time!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4107.jpg)

As you can see the new areas are blue, as I ran out of black paint.... I kinda ran with this and as such ended up with various flourecent coloured brackets and blue and red tape all over the loom!  :paperbag:

Before the engine went in we fitted the sump properly

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4108.jpg)

An old school friend , Ben, has returned home with a piece of paper suggesting he\'s a master of engineering so he got roped in to help! Here he is making room for the giant Rx7 coils. We made up some brackets and got both coils all wired in.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4104.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4106.jpg)

We also made the timing marks more obvious, and fitted the CAS.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4109.jpg)

So engine in, after posting pictures of my friends working they insisted I post some of me, so heres me (in blue) inside the engine bay trying to get the engine to line up with the gearbox.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4112.jpg)

Engine in, subframe back on.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4114.jpg)

Ben and I made a considerable start on the loom, just coolant gauge for the dashboard, tach signal and oil pressure gauge to do. We also modded the main engine mount to give extra clearance for oil cooler pipe work and coolant hoses.

Its coming along rather nicely. Tomorrow night I hope to put the front suspension and wheels back on and then get the car back on the floor. I\'m hoping to have finished the loom before it goes to exhaust shop. I\'m waiting on MS mods to come in the post from the US and coolant hoses to turn up. Once thats all in its getting pretty close :D
Title: Mx7? rx5? Newbies build thread begins
Post by: cr33ch on June 23, 2010, 12:47:02 AM
bad ass project bud!!! only had a quick skim through, are you gonna be turbo\'ing the engine?

What are you doing diff wise? theres an MX5 on driftworks that running an 350bhp\'ish SR20 out of a 200sx and i know he had a world of trouble destroying plenty of diffs and diff mounts etc. but of course drifting is alot more harsher on the transmission, i dont know what you plan to do with yours once its done...
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 23, 2010, 09:16:54 AM
I\'m going to be running n/a, only likely to be around 170hp to begin with, but hopefully building up a proper n/a block at some point in the future to shoot for 250+hp. I did turbo on the 1.6 piston engine so fancied a change of approach.

Diff wise I\'m using the stock 1.8 open diff for the moment. I\'m hoping to get hold of a 1.8 torsen LSD at some point. The 1.6 spec diffs fall apart at anything over stock power levels but the 1.8 diffs are bigger and most people have few problems till they push past 280hp. Certainly lots of people drift with 230-250hp turbo set-ups on the 1.8 spec diff with no problems.

When its done I plan to drive it! Every day, up B road and A roads with the roof down and grinning like an idiot :p I might do a couple of track days but mostly this is to enjoy on the road.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 23, 2010, 09:42:39 PM
A small, but mentally significant, step was made tonight :)

First up a couple of bits I didn\'t get round to yesterday. Start motor fitted and connected upto the new loom extension.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4115.jpg)

Then red bolted down properly.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4116.jpg)

Next up I started to re-fit the front suspension. Her I\'ve got the wishbones and steering rack on, with brakes and anti roll bar to go.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4117.jpg)

Woooooo, on the floor, standing on her own 4 feet!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4118.jpg)

Got some old spare front wheels on, as I\'ve no idea where my alignments bolts should be as its not the original subframe. So the first few miles till i get to an alignment place could be tyre destroying.

Finally the most important step, I now figured it was far enough through the project that I could fit this....

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4119.jpg)
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on June 23, 2010, 09:48:43 PM
Yes Yes Yes!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on June 23, 2010, 10:20:56 PM
You  have to much time on your hands or no kids to keep you busy.lol
Good work
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 23, 2010, 10:27:06 PM
No kids, and not planning to for a while as it doesn\'t feel that long ago I was a kid:P

TBH every moment I\'m not with my lady friend or at work I\'m working on the car. I\'m a freelance video editor and at the moment I\'m only getting around 4 days a week work, so I\'ve got a fair amount of time to throw at it. That said I got back from work at 7 tonight, grabbed a snack and was out working on the car by 7:30, worked through till 5 mins before I posted those pics.
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on June 24, 2010, 10:25:53 PM
Steve\'s just a hard worker :)
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on June 24, 2010, 11:10:04 PM
Arnt we all
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 25, 2010, 06:25:47 PM
Well everyone, save for Ross*, is a hard worker :P

Got a few more bits and bobs done today.

Water hoses all cut to size and fitting

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4122.jpg)

Then I went to fit the intake manifold and found it didn\'t fit :( Something must have been out of line when I did my initial tests as it hit the body now :(

Ah well, because I\'m not using any of the emissions stuff, I was able to cut a fair amount of the side of the intake manifold. As you can see here compared ot my spare standard one.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4123.jpg)

I also took a small notch out of the body, its only spot welded and I didn\'t cut any welds out so I just sealed it up, no need to weld over.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4126.jpg)

Woo it fits.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4127.jpg)

Then just to see how it looked I dropped the upper inlet and throttle body on. Really starting to look like an engine now.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4128.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4129.jpg)

* Ross get that welding done!
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on June 25, 2010, 07:09:13 PM
god i love blue hosing :P



* Im trying damn it! lol
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 28, 2010, 02:49:42 PM
ARSE!

I dropped the car off at the exhaust shop this morning, and all was looking well. Was so nice to be behind the wheel again, even if I was being towed!

Just had a phone call to say they\'ve tired as much as they can but they cannot fit the exhaust to my specifications in without further subframe modification. My welders on holiday for the next fortnight, and it\'ll mean stripping the car right back again. Not cool :(


Gonna set me back 6+ weeks I think. :( :( :( :( :( :( :( :( :( :( :(

Ah well, I cant go on any longer in the Punto though, so will probably be spending my exhaust fund on a cheap mk1 mx5 or something.
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on June 28, 2010, 06:02:18 PM
Or you could but they FC I have for sale and then you have a good parts supply
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 28, 2010, 06:22:49 PM
I cant say the idea hadn\'t crossed my mind....
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on June 28, 2010, 08:01:55 PM
Though thinking about it, I need a daily drivable car, so cant start nicking bits off it for the project :P
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 02, 2010, 08:33:02 PM
So after a week of moping and grumbling, Ian came down and we got on with some wok on both 5s.

On the new 5 we:


(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4133.jpg)

Feels much more \'like a 5\' to drive now, much happier, though still cant wait to get back in the proper one!
Then we set about the project 5.

We put her back no the drive in her home, safely at the top by the house, and got the front up in the air. Ian\'s enjoying a nice cold Vimto there, many were needed across the day.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4130.jpg)

Front suspension out and subframe out.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4135.jpg)

This is the offending engine mount lump. Gonna ask bill to cut it back, possibly even kinda invert the lump to give the exhaust guys as much room as possible.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4138.jpg)

That done we sorted the oil cooler, one of the last things save for electrics and exhaust, to do. Take one old FC rx7 oil cooler...

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4139.jpg)

Measure up some brackets...

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4140.jpg)

Get a maniac with a hacksaw... (me)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4141.jpg)

Paint the brackets a silly colour

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4144.jpg)

Test mount it in the car

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4146.jpg)

Straighten out the fins as best as possible and give it a quick blast of silver

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4147.jpg)

Good as new :) I\'m hoping to get Bill to sort out the subframe for me week after next. In the mean time I\'ll finish the MS mods and loom, and so once the subframe and exhaust are done then it\'ll basically be turn the key time!


Finally Ian\'s thought for the day:

Engine crane, known as Big Red,  good

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4143.jpg)

TSW Alloys weighing 1 metric ton each, bad

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4145.jpg)
Title: Mx7? rx5? Newbies build thread begins
Post by: evans.I on July 11, 2010, 09:45:03 PM
Wahey, not long now till completion! If you want a hand this coming Saturday afternoon with any of it give me a shout.

Big red: GOOD!!!
1990\'s tsw lead anvils: BAD!!!

Ian.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 12, 2010, 10:29:57 PM
Bit of progress today, nothing much to see though.

Over the last week I\'ve been fixing the Punto (again, head gasket this time), much hammering and swearing was required. (In picture I\'m resorting to hammering an 11mm socket over a 12mm nut thats rusted itself into a round to remove the exhaust)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4153.jpg)

And I\'ve also been helping a friend with his MX5, turns out the big ends were ruined :(.

On the plus side, I dropped the subframe off with Bill today and he\'s gonna asses what he can do with it over the next few days then I\'ll have a time scale to re-book into the exhaust shop.

I\'ve also spent some time this evening working on the Megasquirt. Started like this...

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4154.jpg)

Ended like this.....

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4158.jpg)

Thats the Zeal daughter board that has the twin VR conditioners required to decode the Rx7 CAS. I\'ve also now wired it up to the main Megasquirt board, which was easier said than done! The thing that slowed me up the most was working across 4 sets of instructions (megamanual, the miataturbo note that i used originally, my original install notes and the rx7club MS install notes) to work out what things I had to change from the configuration needed for my 1.6 turbo.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 18, 2010, 05:55:40 PM
Made some reasonable progress yesterday.

Mid week I got the subframe back from Bill. As you can see from the pictures he\'s been able to add quite of lot of extra space for the exhaust to exit the block. Fingers crossed its enough!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4159.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4160.jpg)

So to start yesterday off I fitted a new wing mirror to my 2nd 5.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4161.jpg)

In an attempt to make it feel more eager earlier in the week I changed the air filter out for a fresh one and did the 14 degree mod. Still not feeling quite right, yesterday I swapped the AFM out for my spare one, and cleaned up the contacts.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4162.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4163.jpg)

Result is an engine that feels much more like it should :)

So onto the projects car... Ian and Ross came over and we put the subframe back in and the suspension back on.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4165.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4167.jpg)

Looks like there should now be enough clearance. Its booked back in at the exhaust shop for monday 26th July. I\'ve little work on next week so gonna push to finish a bunch of those little things that are easily forgotten as well as finalise the loom in an effort to get the a point where I can turn the key for the first time only a day or two after she comes back from the exhaust shop.
Title: Mx7? rx5? Newbies build thread begins
Post by: clive on July 18, 2010, 06:56:00 PM
Good to see this is still on course O/K Steve, sooooooo many projects get this far and die, but I can see this ones gonna get there :Thumbsup!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 18, 2010, 07:03:30 PM
Its gonna happen :)

Its gotta happen, cos I\'ve already got my rotorstock ticket and I cant go urning up in a piston engine car can I ! :P

The list of things left to do is basically:

1. Exhaust
2. Few bits on loom like swap the injector connectors over to the rx7 shape from mx5 shape and change connectors for the oil pressure sender.
3. Fuel lines, possibly need to modify the hardlines depending on the exhaust
4. Fit all new vacuum hoses / assemble intake manifold (which has all been test fitted)
5. Get some jubilee clips of cooling system and various other clips and things.
6. Turn key and start mapping the megasquirt!

So really considering how far its come this is the home straight.

The only stumbling block I\'ve got right now is getting hold of a couple of the plastic intake bits I\'m missing, mainly the injector baskets/mixing plate/ whatever they are called for the secondaries and the plastic section that goes from round section to the air filter to triangular section to bolt upto throttle body. I\'m keeping an eye on the for sale section though :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 19, 2010, 10:38:02 PM
Not much to show for it, but I spent most of my day tidying up the loom. I removed as much of the obsolete sections of the loom as i could without going nuts and puling it all out of the car. I then changed over all the connectors that needed changing and extended wires that needed it. Then wrapped and tidied it up. The engine bay electrics are now done! (did some more after the photo was taken). Basically just gotta wire up the wideband inside the car and plug the ECU in and thats the electrical side complete. :)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4173.jpg)
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on July 20, 2010, 04:54:32 PM
Theres nothing in there! ahha
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 23, 2010, 08:13:04 PM
Its been a busy couple of days.

Yesterday morning started like this:

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4176.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4177.jpg)

Bens mk2 started making horrid noises after its first oil change. A bit of investigation showed that the bottom end was buggered :( Looks like somewhere along the line someone tried to cover this up by filling it with extra thick oil, whether this was the dealer he bought it off, or the guy who part ex-ed it with the dealer we\'ll never know.  :wallbash: :wallbash:   Either way it was time for a new engine!

A few hours later and lots swearing and starter motor bolts later:

http://www.youtube.com/watch?v=X28TblIhqBY


Good stuff. Though I sound like a prat. Bens dad said off camera \'its much quieter than before\'.

So today we set about working on my car. First task of the day was to try and tuck some of the fuel and brake lines out of the way of the exhaust routing. Time will tell if its enough, I\'m not wanting to take any risk of fire! so if needs be I\'ll have to have new hard lines made. Unfortunately I forgot to take a before picture, but this is the after one.... You can see the fuel lines and the rear brake line tucked right over to the lefthand side of the picture, as far fro the exhaust run as possible.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-04.jpg)

Whilst doing the fuel lines I noticed a rust bubble under the car :( So out came the hammer and screwdriver...

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-07.jpg)

The dent is from 6 months ago when the jack jropped much faster than I expected onto a axle stand :( I really gave it a good battering/poking, and it was only that small section thats gone, but still better get it done soon!

Next up, fit the earth strap I knabbed from Ben\'s old block ( lost mine somewhere long the line!), made sure ot sand back the paint to get as good a connection as possible.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-08.jpg)

So then Ben and I started on the internal wiring.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-10-1.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-09.jpg)

A couple of hours later the wideband was all connected up, and the modifications to my MX5 loom were complete.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-11-2.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-13-2.jpg)

So that took us to 5pm or so. Now boredom had kinda set in, and thats normally bad news.......

My bootlid has had a hard life. Shortly after I bought the car I reversed into a collapsed fence, which I couldn\'t see in the dark, whilst parking at my girlfriends house. A fence post dug into the boot lid, folding the corner over and bending the whole thing up. So I hammered it flat and bent the corner back and drove around like that for a year. One day I was feeling frustrated by it looking crap so following my success with smoothing and filling motorbike bodywork I had a go at sorting it out.

I did my best buy the skin of the boot is very flexible and I struggled to get it fully flat. Then the paint I bought turned out to be a totally different red to my body colour :( And so its been a not quite smooth, off red boot lid for the last year or so.

Enter today... Now I could pick up a red boot lid from a breakers for £30-40, but thats no fun. I\'ve been tempted to do something silly with it for a while. So here we go.....

Take some bits from the scrap pile left over from this project....

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-15.jpg)

And some random cans of paint from the garage....

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-16.jpg)

And you end up with.....

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-17-1.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-18.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-21.jpg)

I cant quite work out whether its worked quite well and is a bit fun and different, or if it just looks ridiculous. I\'ll have a think over the next few days, and if I decide no I\'ll go get a red boot from that brakers....
Title: Mx7? rx5? Newbies build thread begins
Post by: od404 on July 23, 2010, 08:18:03 PM
Haha, loving the paint work Steve :mmmm

You still coming to Rotorstock?  Will be cool to catch up!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 23, 2010, 08:25:28 PM
Yeh, Ive got my ticket booked. Fingers crossed the car will be ready in time!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 27, 2010, 11:41:34 AM
No pictures today, but finger crossed some good news!

I dropped the car at the exhaust shop yesterday morning and, unlike last time, I\'ve heard nothing since. So I\'m presuming they have found they have enough room to build the exhaust I want :)I shall drop them a call at end of play today to see how they are getting on.

If all goes well I might even be ready for first start attempt on the weekend! :D:D:D:D:D
Title: Mx7? rx5? Newbies build thread begins
Post by: 1990_fc3s_t2 on July 27, 2010, 11:59:31 AM
Good luck with the exhaust! :Thumbs-up

Have you got all the intake bits you wanted? seen that triangular bit that goes on the throttle body in my shed i remember you wanted, and the injector basket things although one looks cracked.

Excellent work :Thumbsup!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 27, 2010, 02:02:57 PM
Thanks for the offer, but I think I\'m ok now :)

RamoNZ is sending me the triangular section from his FC that he\'s breaking, should be here in the next day or two. And having done some searching, I\'ve found that many people say the injector basket/mixing plates/air bleed inserts/whatever they are called are not really important in the secondaries if you have good clean injectors with a good spray pattern. Apparently they are quite important to the primaries though, and my primary ones are still intact :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 28, 2010, 01:50:48 PM
Just got the call, my exhaust is done!

Picking it up this evening, so expect pictures!

:D:D:D:D:D:D:D
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on July 28, 2010, 05:34:17 PM
wooooooooooooohooooooooooooooooo:god
Title: Mx7? rx5? Newbies build thread begins
Post by: tyson23 on July 28, 2010, 07:36:52 PM
all good work mate keep it up boot lid looks good lol
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 28, 2010, 09:18:24 PM
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4209.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4210.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4211.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4212.jpg)

There it be, safely back on the drive!

Exhaust looks pretty good :) The exit from front rotor is far too sharp, but without moving the steering rack this is never going to be any smoother, so its something I\'m willing to live with. I couldn\'t get in there with the camera but it winds beautifully under the gearbox and is tucked as high as it should be so I\'ll still catch chassis on speed bumps before the exhaust. Originally I\'d planned for one silencer, but I\'ve ended up with two. Both are 2.5" straight through though, so should offer little resistance to flow whilst helping to bring the exhaust note down to a more neighbor friendly volume :)

Today I realised I\'d forgotten to order an exhaust gasket, so I bought one. Fingers crossed it will come in time for friday when I have the day off work and Ross coming over to help do the final prep.

Having spoken to the guys at the exhaust shop we thought the fuel lines would be fine in their stock location, especially if I build them a heat shield and use heat reflective tape.

So Friday through to Saturdays plan is to build the heat shield, fit exhaust gasket, fit o2 sensor, fit inlet manifold, fill with fluids, and turn the key!
Title: Mx7? rx5? Newbies build thread begins
Post by: clive on July 28, 2010, 09:23:49 PM
Quote from: Steve-A;707392

So Friday through to Saturdays plan is to build the heat shield, fit exhaust gasket, fit o2 sensor, fit inlet manifold, fill with fluids, and turn the key!


Getting there now :chat
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on July 28, 2010, 09:35:06 PM
Exhaust looks great Steve, i hope your pleased with how it turned out. I look forward to Friday massively. I\'ve got a few weeks off now so im sure the time ahead will be worth spending on rotary projects :D

Nice one
Title: Mx7? rx5? Newbies build thread begins
Post by: RamoNZ on July 30, 2010, 04:21:31 PM
Intake hose make it OK?
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 30, 2010, 08:53:44 PM
Yes it did Ramon :) Thankyou very much.

Today has been a little frustrating. I made some good progress, but it wasn\'t exactly smooth going!

Dan and Ross came by to help out and first things first we got the car back to to flat area at the top of the drive. We jacked her up at the front and go to work. First up was the exhaust heat shield. Bill had kindly bent an S shape into some steel plate for me to make life easier, unfortunately it wasn\'t quite the right shape. I\'m to blame as I gave him the measurements! I took us most of the morning and into early afternoon to get this sorted out. In the end I managed to box in the areas of fuel lines nearest the exhaust. IU then covered the whole area in heat reflective tape.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4220.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4221.jpg)

Next up we fitted the cooling hoses. Here\'s me doing up a jubilee clip, Ross manages ot capture possibly the least exciting action shot of the day! haha.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4213.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4222.jpg)

Next the lower inlet manifold went on, and the next plan was the OMP.

This is where we hit the biggest problem of the day. I didn\'t realise my 13b OMP wouldn\'t fit my 12a front cover. :( So I decided for the sake of trying to stay the car this weekend, I\'d run premix to begin with. So a blanking plate was made...

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4223.jpg)

And the LIM, oil feed blanking plugs and primary injector rail fitted

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4224-1.jpg)

Time was getting on now, so I made one last push before giving up for the day. I managed the get the upper inlet manifold on, with the secondard injector rail and most of the vacuum hose connections.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4226.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4229.jpg)

So still good progress but not quite as far along as I\'d hoped. Tomorrow I need to extend one of the injector plugs as its just a fraction short, fill it up with oil/coolant, drain the fuel tank and put some premix in there, and turn the key!
Title: Mx7? rx5? Newbies build thread begins
Post by: antnicuk on July 30, 2010, 10:13:56 PM
good stuff,  i will check in tomorrow and im expecting to see a link to a you tube link of it starting :)
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on July 31, 2010, 06:15:42 AM
And doing big skids up the road
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on July 31, 2010, 08:51:47 PM
No video :(
No skids :(

I just typed a huge long post out then the compute crashed :(

Ross and I, with help from Ian in the afternoon, have spent all day trying to start the car. After many red herrings and other niggly problems it looks like its a problem with the fuel pump signal interfering with spark output A (leading trigger).

So megasquirt is out of the car and back on the bench, will look at it over the next couple of days and try to start the car again monday.

I could post a video of us cranking the car for hours whilst trying lots of different MS settings and tweaks to wiring etc but it\'s just depressing:P

I\'ve also found oil is seeming from the front cover gasket area on the exhaust side of the block.:( so that\'ll have to come off to be re-sealed.

Ah well..... Im off to get a cider!
Title: Mx7? rx5? Newbies build thread begins
Post by: shaunwil on August 01, 2010, 09:36:49 AM
Wow, awesome thread :D

Shaun
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 01, 2010, 06:35:25 PM
Right, a little less frustrated than yesterday, here\'s what happened....

Ross popped over around 11 and we set to work. First up we drilled a hole in the intake plastic to hold the intake air temp sensor and glued it in place. Then we extended the section of loom going to the 4th injector. Next we tried to drain the fuel tank, in order to fill it with premix. The anti syphon filler held us up for a bit, but then I thought to whip the carpet up from behind the seats and remove the access panel on top of the tank. I think we got almost all the fuel out of the tank.

1oz 2t oil to 1 gallon petrol seems the done thing if the OMP is completely removed, but seeing as this was first start and there was possibly a little fuel left in the tank we went closer to 2oz. It might be a bit smokey to begin with, but I cant go far without going to petrol station so will stick to 1oz per gallon then.

Next up we put some oil in her, she took 5L all in. In the FC rx7 this engine took 5.6L by the book, but my sump is a little smaller, will keep an eye on the oil level incase the oil cooler hasn\'t filled up properly yet. We did notice it was weeping a little oil from the front cover to main engine block gasket. :( For the short term I cleaned the area up with some carb cleaner to remove all traces of oil then smeared some RTV over the outside of the join pretty thickly. 6 hours later and its not showing any signs of weeping. Its only a short term fix but if it gets me on the road for a week or two I don\'t mind! Once I\'ve gone a few days without having the engine/car to bits I\'ll gather the enthusiasm to do fix it properly!

Then we filled the cooling system. It took a lot of water, that rad must have a huge capacity as we put 10L of water/coolant mix in! It again weeped from a couple of the silicone join, but a quick tighten up of the jubilee clips soon sorted that. The joins that leaked were either end of the alloy hardpipe section I used, the only part of my cooling system without a bead on the ends, so that may have to be changed, keeping a close eye on it.

So all set.

We turned the key, 1 click, then 2 ... Megasquirt came online. air temp -40 degrees. Damn! A bit of fiddling and I\'d read a diagram upside down, and so connected the AIT sensor up to the old airflow meter connections. That was soon sorted and time to turn it over. It span up to 300rpm on the starter nicely, all looked well but it didn\'t go. I pulled a plug it was damp, didn\'t look flooded but fuel was getting through. So checked for spark, no spark on leading plugs, spark on only one of the trailing plugs.

AFAIK MS1 only fires the leading plugs during cranking, so I went back and checked the wiring. Yep I\'d connected the leading and trailing triggers backwards. I only got spark on one trailing plug as the trailing toggle wasn\'t activated.

So turned her over again, she sounded keener to start but still a long way off. Now I knew this might happen as the CAS position was pure guess work. When I received and fitted my CAS I made what I thought was a good guess at its alignment at TDC, but knew it could be wrong. So we tried to use a timing light to see if we were ballpark accurate whilst cranking. This was tricky as it was a bright day and the timing light was struggling to trigger from the cranking speed. Either way it looked miles out, possibly 120 degrees or so.

So I started playing with trigger angles and we started manually moving the CAS to try and bring the timing into line. I now realise this is where the mistake came. Somewhere along the line the leading trigger output started acting oddly, it was staying low to often, and hanging low for a good 2 seconds after the engine had stopped spinning. This wasn\'t right. It was late, I was frustrated, we called it a day.

With a fresh mind this morning I had another look. First thing I re-flashed the firmware and then uploaded a fresh MSQ, same problem. Then I did some reading on the ms extra manual and the \'if in doubt RTFM\' theory came true. The trigger angle for my twin VR style CAs need to be either 0-5 degrees or 60-70 degrees apparently. I had set it to 0, but when I set it back to 65 all the odd issues with the leading trigger firing went away!

I also read on the ms extra manual about configuring one of the outputs to show when the ignition trigger is active, so you can turn the engine over by hand and see when it picks up each pick-up on the CAS, this should allow me to see the CAS position to within a couple of degrees without having to try and use the timing light while cranking it.

So thats tomorrows plan!
Title: Mx7? rx5? Newbies build thread begins
Post by: Mazdarotaryparts on August 01, 2010, 09:43:15 PM
Quote from: shaunwil;708092
Wow, awesome thread :D

Shaun


Yep :chat

Should be there with this soon :burnout
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 03, 2010, 10:29:20 AM
I started to post his yesterday, but then fell asleep before I finished it....

Quote

Today has been another frustrating day, if slightly more successful.

To star the day Ross rocked up around 10:30 and we set to work. Some internet searching had given us a better idea of where the CAS should be, so armed with this we set it and the car did sound more like it wanted to start. It was still a fair way off though.

So we had a coffee and a think, I\'m fairly sure I was horrid to be around all day as I\'ve a cold coming and I had a killer headache so was quite grumpy. We pulled the plugs and found front rotor plugs wet/damp and rears totally dry. Alarm bells rang an we started checking to be sure the rear rotor primary injector was working. We dis-assembled the upper intake manifold, to find the clip not on the rear primary injector, infact it wouldn\'t clip on correctly, a bit of stanley knife and file later all was well. The intake was re-assembled nd we tried again.

No better, again the plugs were pulled and rears were dry whilst the fronts had flooded. Intake to bits again, we checked through wiring loom and found the rear primary injector was wired backwards. That fixed we re-assembled the intake, removing liquid gasket got boring real quickly..... Still no fueling to the rear rotor. Luckily I have 3 spare injectors I had cleaned and flowed at the same time as the main set, so we dis-assembled it all AGAIN :( to fit a replacement injector.

Right all back together, turn key, nothing. Rad fan starts up, no lights on MS, everything dead. !!!! I quickly turned it off and then panicked. It was about 4pm, i was feeling really under the weather and it was looking like another day would go by without this car working. :( Eventually Ross talked me round and we started problem hunting, it took us a while but we realised that MS was getting no power, neither were the injectors. The fuel injection fuse had blown. So we stole one from the cooling fan, and soldered a normal blade type fuse across the contacts of the odd shaped fuses the main engine bay fuses seem to use in the mx5.

Finally the MS acted like it should, and both plugs were getting wet, but it still wouldn\'t catch. I realised it was closest to catching when I was foot to the floor, and that meant cranking injector pulse widths were too wide. So I halved them, took the plugs out and turned it over to clear any fuel puddle and we had another go.

LIFE! It lived! It was lumpy and missing like mad and really struggling but it was running. I quickly got the timing light out and found I was around 10 degrees to retarded. That set properly it was beginning to feel a little better. Unfortunately I think my LC-1 took exception to the amount of fuel in the exhaust pipe from it flooding repeatedly and just kept saying it was super rich.

The video is the 3rd/4th time the engine actually started, its running on a base map thats obviously not right for my engine really considering I had to halve the cranking fuel. We took her out for a gentle roll around the local area, hoping to clear the back-log of fuel in the exhaust and get the LC-1 working properly. Alas it wouldn\'t play the game, so no tuning could be done, this resulted in a very lumpy engine that has a long way to go yet before it runs right.

Aside from the wideband not working right the speedo isn\'t working, the coolant cap above the thermostat is playing up, my oil cooler is leaking a fraction and I\'m using a pair of my sisters tights as a temporary air filter. Oh and the noise! its a bit loud!

Tomorrows plan will be to try and resurrect my wideband and then get tuning.

Edit: Embed wont work for some reason, so heres a link:

http://www.youtube.com/watch?v=Yr4PojCNyFU (http://www.youtube.com/watch?v=Yr4PojCNyFU)
Title: Mx7? rx5? Newbies build thread begins
Post by: fil_auto on August 03, 2010, 01:37:22 PM
mate, hats off to you! Sounds n looks great in that engine bay ;o)
Am sure there\'ll be some tweaking to do but I thought it looked and sounded ace! :mmmm
Title: Mx7? rx5? Newbies build thread begins
Post by: TiddlesRX7 on August 03, 2010, 03:45:03 PM
Nice one fella. Looks and sounds good. See you at Rotorstock :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Carbon RX on August 03, 2010, 04:48:01 PM
epic thread!!!
 
Enjoyed reading every detail... Well Done !! :D
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 03, 2010, 08:12:53 PM
Glad it\'s meeting with approval :).

Spent most of today working on it. The coolant and oil leaks are now fixed :). I found the problem with the speedo, it seems the rx7 gearbox has a different size drive gear on it for the spedo and it\'s mashed all the teeth off my mx5 speedo drive. So i can either fit the spare mx5 speedo drive and drive gear to output shaft, which is mega hassle as it means re-building the box, or try to find an rx7 speedo drive. For the next couple of days I\'ll just use my phones gps!
 
Ross came over again and we spent most of the day trying to sort my wideband. It just doesn\'t wanna play. It acts normal when the ignition is on but the engine nt running but once the engine runs it doesn\'t do the normal light flash as the heater warms, it just reads a random arbitrary number and doesn\'t respond at all. Having had most of the interior to bits chasing the wiring around to check it\'s all plumbed in right I fear I\'ve killed the sensor when it was flooded for two days with not just petrol but premixed petrol and 2t oil. Ill get on the phone to the local motorfactors first thing in the morning.
Title: Mx7? rx5? Newbies build thread begins
Post by: antnicuk on August 03, 2010, 10:40:43 PM
well done,  it must be very satisfying.  What are your first thoughts of driving it?  it sounds like they did a great job on the exhaust,  it sounds great.
Title: Mx7? rx5? Newbies build thread begins
Post by: shaunwil on August 03, 2010, 10:41:09 PM
Does sound lovely though :D

Shaun
Title: Mx7? rx5? Newbies build thread begins
Post by: marcusd666 on August 03, 2010, 10:44:17 PM
Sounds great you have done a cracking job on it the 13B looks right at home in the MX5 as well.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 03, 2010, 11:31:11 PM
Quote from: antnicuk;708579
What are your first thoughts of driving it?at.


Well I\'ve not really had chance to drive it in anger, and its not been past 4k really. All because of this lambda sensor problem. First impressions are that it feels no flatter, possibly stronger, than my 1.6 did right low in the revs, and that as I took it closer to 4k it seemed \'happier\' like my 2t motorbike does as it gets towards the powerband. But with no idea what air fuel ratios are running right now I suspect there\'s far more power to come

I\'m sure its gonna be amazing when I can get out there and confidently wind it right up in the revs and scream along some lanes. :burnout

On more general car things, the gearbox felt great, much smoother than my old one, and nice for having been cleaned out. The wide spaced engine mounts meant the box was twisting very little with the engine torque, which is good. It felt soooooo nice to be back in MY mx5, bolted to the floor safely beneath my roll bar with hugging seats, firm suspension and a properly weighted manual steering rack feeding back loads of information to the wheel.

The exhaust does make a lovely noise. I\'m hoping it will quiet down a little as it soots up though, as its slightly anti-social loud right now! If anyone needs any custom exhaust work done the a44 exhaust garage in worcester seem like nice chaps and they\'ve done a good job with this one :) Just don\'t expect them to build you anything quiet :P

p.s. anyone got an FC EGI speedo drive?
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on August 04, 2010, 06:32:22 AM
Bloody brilliant. Dont worry about the anti social loud part. If you leave your house fast enough they wont see who it was.
Title: Mx7? rx5? Newbies build thread begins
Post by: antnicuk on August 04, 2010, 08:37:19 PM
your first drive was much more elegan than mine,  im almost too embarrassed to post it up due to the stupid commentary by my mates on the video...
Title: Mx7? rx5? Newbies build thread begins
Post by: RamoNZ on August 04, 2010, 08:49:19 PM
Looked like you are using tunerstudio? I\'m going to get VE Analyse for mine to assist with tuning. Apparently (obv not tried it) it is pretty good, but doesnt yet to WUE or EAE, but that really is minor stuff.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 04, 2010, 08:54:47 PM
Yeh I am using tuner studio, I much prefer it to megatune. The VE Analyse feature is a god send! Once you learn the best parameters to use with it, like how aggressively it can change the map and to set the limits so it doesn\'t get confused by things like over run fuel cut then its great. You just got for a drive and the car gets better and better!

Unfortunately my lambda sensor controller has died :( Gotta go buy a new one so cant really drive the car till thats sorted, which is gonna be friday at the earliest.

Antnicuk, I\'m not sure kangarooing up the road on a poor map with the car missing like mad counts as elegant :P
Title: Mx7? rx5? Newbies build thread begins
Post by: antnicuk on August 04, 2010, 09:05:59 PM
you wanna bet,   ignore the commentary!  it looks and drives very different now but i wont hijack yourth thread with my pictures.  I went with a microtech running a street ported 13b turbo engine and gearbox from a TII

http://www.youtube.com/watch?v=KhU3kVfoDag
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 04, 2010, 09:11:28 PM
haha ok, maybe mine was slightly more elegant......

Just ordered another wideband sensor and controller. Should be here friday, so I should be able to get some tuning done, and get out and drive it. Next step after that will be a proper alignment then I can stock my good wheels back on the front.
Title: Mx7? rx5? Newbies build thread begins
Post by: od404 on August 05, 2010, 09:04:30 AM
Awesome to hear it\'s up and running Steve! :driving
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 05, 2010, 03:17:53 PM
Few picture for you all.

This is how the interior stands right now. The new wideband controller should be here tomorrow morning so it can all go back together then.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-61.jpg)

This is how the engine bay was this morning:

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-62.jpg)

And this is how it looks now:

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-63.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-64.jpg)

I\'ve given it all a quick wipe over, and tucked the various wires I\'d pulled out over the last few days of problem solving back into the loom. More importantly I\'ve swapped out the coolant expansion tank for one I had in the garage from a Suzuki RG250 motorbike. This means there\'s now room for an air filter behind the passenger headlight where it should get a pretty good cold air flow. I\'ve just gotta order a filter now that will fit in that space. For the moment the tights will do!! :p
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 07, 2010, 08:11:02 PM
Lambda sensor came today :)

Plugged it in and it worked! Though had a bit of an idea about what might be up with my other one so will still try to fix that one too.

So I\'ve been out driving, 60 miles or so down, gonna go out and do another 50 to pick up the girlfriend later.

Map still needs lots of work, but its drivable! Still concerned bout the volume, might try putting the cat in next week, so how much quieter it is compared to how much performance lost.


eres a couple of quick pictures I took of the car in her natural habitat, the B road. Cant wait to get her aligned and get the proper front wheels back on!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4351.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4352.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4353.jpg)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 10, 2010, 07:48:21 PM
Well the cat went in, cant feel any loss of performance, it is a veyr free flowing cat designed for turbo use, but it is a bit quieter. I\'m hoping the noise might further reduce once I\'ve got an air filter rather than tights too :P
 
I\'m having a bit of a lean time for work, which sucks, but it does mean I\'ve got lots of time to spend on the car.
Today I finally got to the bottom of my CAS noise issues with megasquirt. I gave the CAS a good clean out, and then fitted a .1uF capacitor across the 2nd trigger input. The mods recommended for stock mx5 CAS always say to do this, but the rx7 guides dont mention it so I haddent bothered. Fitted it and bingo all is well :)
 
Yesterday I spent some timing making sure the exhuast was properly sealed up. I also phoned a guy who does classic car and race car fuel and oil systems about the best way to re-route my fuel lines. Despite boxing them in and doing my very best to shield them from the heat, and having driven 200+ miles without exploding, I\'d still sleep better at night knowing they were far far away from, the hot exhaust. Hes gonna look into it for me and call me back :)
 
My megasquirt map is coming along very nicely too, I\'ve got a pretty good fueling tune for power and I\'m working on effeciency. Done about 21-24mpg so far, which is promising for a mis tuned map and plenty of shortish drives with thrashing. Hoping to get nearer 30mpg on the commute (lots of motorway).
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 13, 2010, 11:45:53 AM
The final pieces of the puzzle ( for now!) are falling into place :)

Yesterday I went to get the car aligned, I knew the front was a mile out because i\'d had the subframe on and off a few times and had just put it back together with the alignment bolts centered.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Last12Months-1352.jpg)

Went with slightly lower front to rear camber ratio than before. I had gone for the 0.75 degree difference previously where as this time I\'ve gone for 0.4-0.5. I\'ve also  had some of the toe taken out of the rear as I never really felt I had the power to need its extra stability and liked the idea of a little more throttle controlled steering. I\'ve been for a bit of a drive this morning and its great. Its not overly aggressive or tail happy but when pushed I can feel all 4 wheels moving together, and when on the power exiting a bend the little extra rear steer from the lower toe is really pleasant. I suspect if I was tracking it a lot I may find I\'d want a little more toe again but for b road fun its a nice balance I think.

I\'ve also been working on my map and I\'ve added a few degrees timing up the top end. Its really starting to feel as I\'d hopped now, happily signing away at 5-8k and is such a nice fun engine to blast some b roads with. As I\'m using premix I decided against activating the overrun fuel cut, so there was still a little fuel and oil getting to the tips, which is making for awesome overrun pops and bangs  :Giggle

Yesterday my air filter finally arrived too.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Last12Months-1359.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Last12Months-1358.jpg)

Cant feel any extra restriction to airflow from it at high revs, MS is showing no extra vacuum at WOT. But it has brought the volume down once more. I\'d say its now basically the same volume as my 1.6 piston engine was, so not exactly subtle but not widow shaking loud! If anything it has added a little drag to the intake noticeable at high vacuum and idle, but this has actually helped stop the wild vacuum fluctuations and oscillations I was struggling to tune round at idle.

Because I\'d had the alignment done I was able to put my good wheels back on without worrying about destroying the tyres :)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Last12Months-1357.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Last12Months-1355.jpg)

Thing left to do are the speedo drive, which Ramon should be posting to me next week :), and I\'d still like to relocate the fuel lines to the other side of the engine bay for piece of mind. I\'ve got some nice braided fuel hose in the post and I\'ve bought a bead maker so I can shorter my hard lines and still make a proper safe connection. So in a week or thereabouts time it should be pretty done. Just in time for rotorstock  :burnout
Title: Mx7? rx5? Newbies build thread begins
Post by: od404 on August 13, 2010, 11:50:15 AM
Awesome work mate, glad to see it\'s all come together!

Will make sure I catch up with you at Rotorstock!
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on August 16, 2010, 09:21:41 PM
INSANE! so excited to be going to RS7 in this bad boy :)
Title: Mx7? rx5? Newbies build thread begins
Post by: RamoNZ on August 16, 2010, 09:58:47 PM
I got a bread maker - they are well good. I love the smell of fresh bread :mmmm
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 20, 2010, 06:36:01 PM
Right today was fairly average. I\'ve been waiting a little while for my fuel lines to arrive so I can replace the standard hard lines and run the new braided lines up the far side of the gearbox from the exhaust. Today they finally arrived!

Heres how my fuel lines used to run:

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4380.jpg)

I\'d boxed them in with sheet steel and covered that in heat reflective tape, but I was still uncomfy as they are mighty close to the exhaust.

So the day started with the now familiar sight of my car up in the air...

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4378.jpg)

Then I cut out the old lines

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4383.jpg)

And found the £40 beading tool I\'d bought was incorrect. Arse! In the picture below the lower line is the original hard line end. The beading tool I bought would have been able to replicate this exactly. With tomorrow being rotorstock I really needed to do something! So I wiggled a file about in the end of the line to try and create a basic flare. In the end I think its just as safe just really awkward to put the hose on! The line pictured was just a practice, for the final lines I made a slightly more aggressive flare.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4384.jpg)

Here the new line run:

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4386.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4387.jpg)

For most of the run there\'s either an engine gearbox or good 2ft of space between the exhaust and fuel lines. The closest point is as the lines come down to the floor level and curve towards the hard lines. They are around 1ft from the cat there, but thats still 1ft instead of 2" ! The braid should help dissipate any heat a little anyway.

Quick start up and test and all the joins are making a good seal, so all good to goto rotorstock!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 21, 2010, 10:43:08 PM
Today at rotorstock was great. I really enjoyed it, thank you to everyone who came up and talked to me about the car :)


The journey home wasn\'t so great. About 10 miles into my 100 mile journey the temp gauge suddenly jumped off the scale :( I pulled over asap and found this....

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4393.jpg)

Here she is abandoned at the road side some where in northants!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4394.jpg)

The one section of cooling alu piping that didn\'t have a bead on the end of it had popped out, dumping the coolant all over the a45. Ross and I were stuck in the middle of nowhere. We flagged down a passing runner to ask if he knew where we could get some water and he said from a village about 1/2 hours walk from where we were :( But then he offered to bring us some, he said it would take 15 mins to finish his run to the village then he;d be back. 20 mins later he came back in a car with loads of water for me. It was amazing, we were so lucky to have found such a generous member of the public :) I couldn\'t thank him enough.

After filling the system we drove home very carefully, I shan\'t drive it again till I\'ve had the pipe beaded and have filled it with proper antifreeze mix again. I just really hope I\'ve not killed the water seals with the heat :( We managed the 90 mils home with no drama, temps stayed good and it hadn\'t pushed any extra coolant into the overflow tank. I don\'t think it got hot for very long, but I know it doesn\'t take much.
Title: Mx7? rx5? Newbies build thread begins
Post by: captainbizzaro on August 21, 2010, 11:20:01 PM
Good to meet you today mate-hope no long term damage was caused,sounds like you caught it in time.
Title: Mx7? rx5? Newbies build thread begins
Post by: od404 on August 22, 2010, 10:16:35 AM
Sorry to hear about your luck Steve.  I think we actually passed you at one point on the A45 while it was bucketing down with rain (3 FD\'s) so I did wonder what had happened as you left well before we did.

Good luck getting everything sorted mate!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 22, 2010, 11:00:50 AM
Did the champagne test this morning.

http://www.youtube.com/watch?v=yazP38SAeKc (http://www.youtube.com/watch?v=yazP38SAeKc)

Watch in HD and you can see more.

Water stayed totally bubble free till it get upto temp, then it started to bubble as shown in the video. Rate of bubbling increased with revs.

I presume its f**ked? :eek: :(:(:(:(
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 22, 2010, 07:12:24 PM
Wooooo 3rd time of running the car, and no more bubbles. Think it must have just air locked a bit when we quickly filled her up to get home yesterday.

Yet again I\'ve a crap week for work (fingers crossed september is better!), so I\'ll get the cooling system sorted out properly over the next few days.

I also found the source of the slight petrol smell I was getting at times yesterday. One of my new braided lines had touched the starter motor and it has arced and melted the line :s:S:S:S:S:S:S:s Disconnected the battery as soon as I saw that, and I\'ll get that sorted before I run the car again. Doing the fueling system in a rush to get to rotorstock did worry me some, and justifiably so it would seem!

Oh well it didn\'t catch fire, which when there\'s sparks and petrol involved is pretty good going. Judging by how this afternoons going, I\'m off to buy a lottery ticket!
Title: Mx7? rx5? Newbies build thread begins
Post by: Will66 on August 22, 2010, 07:25:17 PM
This looks like one hell of a little car in the flesh, I love the sleeper appeal of it.  Stand fast the bootlid (which looks very striking).  It\'s a straightforward NA* MX5 from the outside but has a smooth rotary under the bonnet.  It will surprise people that way!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 23, 2010, 08:47:41 PM
I made the most of today, I should have more work on for september, which is good news for money and bad news for days spent on the car!

First up I improvised a bead maker to use on the alu tube that caused me to drop all the coolant on the way home from rotorstock.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4403.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4404.jpg)

Then I set about the fuel leak problem I\'d discovered. In this photo you can see the damaged line.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4399.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4411.jpg)

I\'ve replaced the section that goes by the starter with hard line, so that it has no chance of flapping about and causing the same sortta problems.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4407.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4409.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4410.jpg)
This is where the day ended, I\'ve just gotta assemble the intake and sort the small leak from the oil cooler tomorrow.

Coming in from working on the car to find I\'d got a couple of shots on speedhunters was awesome :) A nice end to the day.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 25, 2010, 09:45:05 AM
The good news is I\'ve done 100ish miles since my last post and the coolants still in the car where its meant to be, no signs of water seal damage. The fuels staying where its meant to say too, I repositioned the tank breather a bit and I\'m no longer getting any fumes in the cabin which is a bonus. :) On the whole its all looking good.

Yesterday I also did a bit of tweaking to the throttle linkage. Previously the slack in the linkage meant the secondary throttle plates opened a few degrees after the primary plate. This meant the secondary plates never quite locked fully open, they were only a couple of degrees off though, didn\'t look like it\'d make any difference. Now having taken the slack out of the system they all open exactly together, all the plates lock out together.  I\'ve had to add fuel at WOT, and I\'m sure I\'ve gained a few hp :)

Its going to the exhaust shop tomorrow morning to have a diffuser fitted to the tip to try and take a little drone out of the motorway driving. Which leaves the only current engine problems as the slight oil leak from my oil cooler and the speedo drive. Once thats done its time to save up for some new suspension and I\'ll need new brake pads soon so I\'ll go for the larger 1.8 disks, pads and caliper carriers.
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on August 26, 2010, 04:39:30 PM
power power power :) haha. How did the fin install go?
Title: Mx7? rx5? Newbies build thread begins
Post by: papercutout on August 26, 2010, 08:56:19 PM
Just read the whole thing - what a great thread! Good work mate, wish I had as much general knowledge as you (I\'m working on it though)...!

I saw the car at Rotorstock, but now wish I\'d read this before and said hi etc!
Title: Mx7? rx5? Newbies build thread begins
Post by: Zarterone on August 26, 2010, 10:33:09 PM
I just found this thread :o

were have I been

great work well done :god

Paul
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 27, 2010, 08:46:53 PM
Cheers guys :)

Unfortunatly this is the current state of the car....

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4421.jpg)

The small leak that I\'ve always had with the oil cooler has got worse over the last couple of days.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4418.jpg)

I thought it was the knackered crush washer causing the leak. But having investigated further the oil cooler itself is cracked :(

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4425.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4424.jpg)

The oil leaks now at a stage where I cant really drive the car till I\'ve got a new cooler. :( If anyones got an FC oil cooler about the place please let me know!

I\'ve also been back to the exhaust shop to have a diffuser fitted to the exhaust tip to try and cut some of the drone on motorway/cruising. Its worked very well but the design they\'ve built for me seems to also whistle a little.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4416.jpg)

This fits in the very tip of the exhaust. According to megasquirt I\'ve lost no volumetric efficiency by fitting it despite it looking like quite a restriction the tip is the coolest slowest flowing section of the exhaust so least critical.

I think I\'m gonna try and make my own diffuser along the lines of the ones used by a few guys on the american rx7club forum, as in this picture, to try and keep the reduction in volume but also not whistle!

(http://c4.ac-images.myspacecdn.com/images02/151/l_0feba07599cf4f4b9d01c256c0fd0cf3.jpg)

Its quite disheartening that I don\'t seem to be able to drive it for more than a couple of days at a time without running into a problem :( Ah well, onwards and upwards....
Title: Mx7? rx5? Newbies build thread begins
Post by: TiddlesRX7 on August 27, 2010, 09:26:49 PM
Your always gonna have problems like this when you first start driving a project like this. I wouldn\'t worry too much. You\'ve done so much so quickly and got it on the road and working that in itself is awesome. In a few weeks you\'ll have forgotten all about these little problems cause you\'ll be driving an awesome rotary MX5 :)
Title: Mx7? rx5? Newbies build thread begins
Post by: shaunwil on August 27, 2010, 10:43:24 PM
Can you not patch the oil issue up with chemical metal while you look for a replacement ? Give Tim at rx motors a ring to see if he has one, he has a huge array of second hand stuff !

These are all teething problems and once sorted you will get to use it plenty :D

Shaun
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 27, 2010, 11:15:01 PM
I did consider trying to bodge the cooler with chemical metal/rtv silicone or whatever, but I felt the rate at which its now leaking from the crack if my bodge failed I\'d soon loose all my oil and hurt the engine. I can borrow the girl friends car or ride my motorbike for a couple of days.

I\'ll drop Tim a call, thanks for the pointer Shaun.

I\'ve cheered up a bit now I\'ve sat down had some food and a nice glass of cider. Was just a bit stressed out and irritated to have to ride my motorbike in the rain this evening rather than drive the car :P
Title: Mx7? rx5? Newbies build thread begins
Post by: antnicuk on August 27, 2010, 11:30:03 PM
its not been motorbike weather.  I have stopped riding mine to work.   I have a stock turbo II oil cooler you can have for a small drink plus postage.  I have recently removed it from my kit car to fit a bigger mocal one.   Its a turbo 2 one, i assume its the same, it looks like yours.
Title: Mx7? rx5? Newbies build thread begins
Post by: papercutout on August 28, 2010, 08:33:01 AM
It\'s motorbike weather here atm, so use the excuse and have fun!

Ring round all the rotory places, they\'ll have something. Alternatively Pete might have one (pdtaylor) or Prof, because they just seem to accumulate stuff!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on August 28, 2010, 09:12:59 AM
Antnicuk, I believe they are the same, so I\'ll take you up on that offer! Please drop me an email at steve.atterbury@gmail.com and we can sort out money and delivery :) Thank you, I really couldn\'t have done this without the support and knowledge of the MRC community :)

When its dry its been alight bike weather, as its been warm but not super hot, but riding in the rain sucks. I did it for 2 years before I got a car but after my 2nd winter I\'d had enough! It wasn\'t the ice or rain but freezing fog that really got me. When you arrive at your destination and a layre of ice has frozen over your jacket and gloves its quite cold!
Title: Mx7? rx5? Newbies build thread begins
Post by: Nik da Greek on August 28, 2010, 09:29:26 AM
I got no choice but to ride about in the rain too atm. That\'s the beauty of having a rotary daily driver hahaha, it spends most of the time off the road forcing us to enjoy our beautiful British climate on two wheels
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 12, 2010, 09:22:47 PM
Well its been a few weeks. Working, a small holiday and difficult times with my girl friend  ( :() have got in the way of the car.

Yesterday morning I was finally able to goto the post office to pick up my oil cooler. Heres how she looked, a little rough around the edges but non leaky!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4167-1.jpg)

So I gave it a quick cleaning up, didn\'t have any high temp silver paint left so was just solvents and a bit of gentle wire brushing and then fitted my brackets.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4168.jpg)

And chucked it in the car. Ran it up and all seems well, I\'ve done 150miles since yesterday morning and so far not a hint of oil seepage :)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4169.jpg)

I also realised my slow coolant loss could well be down to having two pressure caps in the system, and that only one was connected to the expansion tank. My two caps were 1.1 bar and 0.9 bar and the 1.1 was on the expansion tank. For the short term I\'ve swapped the caps over and so the lowest pressure is now on the expansion tank. I\'m gonna get on and find a fixed cap for the filler asap :)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4170.jpg)

Its been lovely to drive the car again :) I had an awesome drive today, 10 miles of b roads never letting the revs drop below 4k. It may have used a stupid amount of petrol but its made me smile more than anything else has for the past fortnight. I\'m so glad I managed to go through with it and complete it.

It got washed this morning, I have friends who have VWs who are more into washing and polishing than I am, so it even got dried properly and the faded bumper got waxed. Its an odd feeling having a clean car! Will try and take some pictures tomorrow.
Title: Mx7? rx5? Newbies build thread begins
Post by: captainbizzaro on September 12, 2010, 09:28:58 PM
Good work!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 13, 2010, 12:55:23 PM
Cheers :) Right now being able to drive it is really cheering me up :)

The only downside is I\'ve spent £40 on petrol this weekend, and only done 150 miles or so. :o Heres the pics I mentioned yesterday, not the best weather but the car is unusually clean so seemed a good idea to document it!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4172.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4174.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4178.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4179.jpg)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 15, 2010, 04:48:27 PM
Few of the guys on the mx5 forum were after another vid of the car now its running properly. Heres a quick clip of the car driving up a local road. The proper video I\'d like to make of it will have to wait a few months so i just got my sister to hold a camera. She was struggling a little with the bumps!

Either way you can hear the exhaust well, if not the pops and bangs on over run so well. They are there but sound more like one of the many interior rattles!


http://www.youtube.com/watch?v=RDK7GF5rgP4 (http://www.youtube.com/watch?v=RDK7GF5rgP4)
Title: Mx7? rx5? Newbies build thread begins
Post by: marcusd666 on September 15, 2010, 11:45:53 PM
its looking really good steve was good to see it in the flesh at rotorstock and meet yourself and chat. If idi not have my FD3 i think i would go this route with the rotary you have done a really good job.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 20, 2010, 03:25:18 PM
New toy!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4235.jpg)


I\'ve been thinking about buying one and learning to weld for quite a long time. So I thought I\'d bite the bullet as my sills will need work in the no so distant future, and there\'s that small hole in my frame rail and I need to work on the diffuser design for my exhaust.

Heres how the diffuser stands right now:

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4233.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4234.jpg)

This definitely makes a difference to the drone, if not the overall volume. I think the key is using the restrictions to break up the gas flow into high and low pressure sections then it will tumble and will break down the harsh pulses the rotary engine creates.

I\'ve still a long way to go before my welding is good enough to weld anything that matters/need to be strong so I\'m trying to find things to do to practice. Thought I\'d play with some thin stuff so made my girlfriend a metal butterfly this morning.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4236.jpg)

On the whole the car is just working as it should beside the speedo not working yet. I\'ve done lots of miles and I\'m enjoying thrashing it and still concerned about the fuel economy!
Title: Mx7? rx5? Newbies build thread begins
Post by: Nik da Greek on September 20, 2010, 03:38:53 PM
http://www.youtube.com/watch?v=FD-0dfhAgAU

Cool butterfly, dude :Giggle Reminds me of when I was doing my chainsaw training and we used to have to carve little chairs and stuff out of logs to get the fine control sorted. Except mine never seemed to end up with legs the same length :o
Title: Mx7? rx5? Newbies build thread begins
Post by: rossonza on September 20, 2010, 06:23:34 PM
haha thats ace Steve!! i happen to know a fellow who requires some welding work doing........ ;)
Title: Mx7? rx5? Newbies build thread begins
Post by: shaunwil on September 20, 2010, 06:45:09 PM
Very cool butterfly. I have welded my exhaust up more times I can mention on the fb !

Shaun
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 20, 2010, 10:33:29 PM
Gonna need a hell of a lot of practice before I\'m ready to face your rot box Ross :P
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 23, 2010, 10:54:35 AM
Been doing some research into why my car is chewing up speedo drives. I\'ve found this highly useful website: http://www.solomiata.com/Drivetrain.html (http://www.solomiata.com/Drivetrain.html)

Judging by the gear ratio chart, and how the revs match the speed of the rx7 box vs my mx5 box I\'d say I\'ve not got the s4 box I thought I had but likely a s3 box. Which would explain why 5th isn\'t as long as I had hoped it might be.

It would also explain why I\'m chewing up speedo drives. All mx5s and s4/s5 n/a rx7s should have interchangeable speedo drives just with different gears on them to account for different ratio diffs. The s3 box has a different tooth pitch on the speeod drive to all the others. So I\'ve posted a wanted thread and I\'ll keep my eyes open. If anyone has a 17 tooth speedo drive from a s1, s2 or s3 fb gearbox I\'d like to buy it off you!

If I cant get the right speedo drive I will have to rebuild the box with the mx5 gear on the tail shaft so I can use an mx5 speedo drive. The actually gearbox rebuild section would take 20 mins, but I fear due to the way I\'ve shoe horned the gearbox into the car I\'d need to remove the entire exhaust system, to remove the exhaust I need to disassemble the entire intake assembly, the whole front suspension assembly will have to be removed so the front subframe can be dropped so the engine can be swung forward, which means removing the rad and oil cooler to make room to swing, so I can get to the gearbox off the back of the engine, clearing the clutch.

Not cool!!!

I\'ve been thinking about my exhaust diffuser too, whilst cutting the drone is has resulted in quite a \'blowy\' kinda sound to the exhaust, especially at low revs. The diffuser seems to be working by breaking up the exhaust path so the harsh pulses of sound don\'t hit the end of the exhaust so cleanly. Which got me thinking. Tonight I\'m going to try and weld up an extension to the exhaust tip with a 30 degree or so angle to it, downward pointing, which firstly should add more tumble and disturbance to the exhaust flow breaking up the pulses and secondly point the sound at the floor to dissipate rather than up into the air behind the car. I will then slash cut the end of the 30 degree section so once again the exhaust pulses don\'t hit such a definite end to the pipe. Hopefully that will further help take the edge of my exhaust.

If the car was a hard top then i\'d say its currently acceptably loud but with the roof down cruising its just still a bit harsh.
Title: Mx7? rx5? Newbies build thread begins
Post by: kiwimazda on September 23, 2010, 08:01:59 PM
Back to the oil cooler issue.
I ditched my mazda ones years ago and went for Mocal. Never ever have I had a problem and they were to  find some one for testing them for vibration then I am the man with the amount of "off road" excursions i have had
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 23, 2010, 10:48:04 PM
Thanks, worth knowing for the future.

For the moment my temps seem well under control and there\'s no sign of any leaking from the new cooler. :)

Why didn\'t I buy a welder sooner, its soo much fun/so useful.

Tonight I further modified my exhaust tip to have a downward slashed tip. The result is no real reduction in volume (I wasn\'t expecting any) but it has taken some of the hashness of the sound, making it smoother and easier on the ears. The proof will be in tomorrows commute!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4301.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4302.jpg)

Also having posted in the mapping thread I\'m gonna play with my trailing split tomorrow and see how that goes. :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 27, 2010, 08:56:40 PM
Speedo drive is in the post :)

I\'ve had a play with the trailing spark advance and its really transformed the drivability of the engine. Its much smoother on cruise and now runs out of puff at 8,100 rpm rather than 7,700 rpm  :popcorn:

Unfortunately there\'s a black cloud kinda hanging over the car right now :( I\'ve been doing some maths and as my daily driver, doing the amount of millage I\'m now regularly doing petrol is gonna kill me :(. Most of my friends live 25 miles away, as does my girl friend, and my main client is 50 miles away. This all comes down at 500-600 miles per week, and quite possibly £4-500 per month in petrol which is a bit ridiculous.

I knew the fuel economy would suffer when I started this but sometimes my heart just runs away with me! It lied to me and told me I could afford it  :paperbag:

I cant carry on like that, so somethings gotta change. There\'s various options I guess.

I could buy a daily driver and keep the rotary 5 as a weekend toy. This would be good as I\'m so pleased with how the 5 has turned out and I\'ve put so much of my heart and soul into it. The main downside is that I\'ll be doing many many hours in the daily so really would like something economical, with a nice driving position, fun to drive at low/standard power and really Id miss my soft top on the commute if I went for tin top. I think its fair to say I\'m pretty much describing a 5 there! but I don\'t want two cars practically the same.

I could sell up the rotary 5 :( and buy another turbo 5, back to 40mpg on the cruise and 200+hp at the right foot when wanted. Good in terms of money. I\'ve become really attached to these roundy-roundy engines though, they feel some awesome when thrashed! The other main downside is that my project car would once again be my daily. Doing the rotary swap I\'ve noticed how in a way I enjoy playing with spanners as much as I do driving, and when taking on fairly big modifications its a real pain to have to always have the car back together in time for work.

I could sell the rotary 5 and buy a standard mk1 to daily drive then have a different project car. This way I could have all the fun of the 5, and the soft top, for normal use and the project can be really impractical and wont matter if its a tin top. I\'d be very tempted by a 1st gen Rx7 so I could retain the rotary awesomeness. And if I bought a ratty one it would be a good project to get stuck into. On the other hand I\'ve wanted an Alfa 105 chassis coupe for a very long time, and that HAS to be a 2nd car which is why I\'ve always discounted it. On the downside I\'d have to insure/tax/maintain two cars.

I really don\'t wanna let go of my rotary 5 but at the same time I don\'t wanna be driving a crappy euro box most of the time and I cant afford £500 a month on petrol! :(:(


Either way I\'ve still got finishing touches to do on this 5 and I don\'t think this decision will be made lightly so not gonna rush it.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 29, 2010, 12:11:46 PM
Well I\'ve got round to posting my v5 off to the DVLA with the new engine number, and I\'ve got new copper washers for the oil cooler to stop it weeping in the post and I\'m working towards finishing the car. Whether I keep it or sell it I could do with a final push to finish the last few niggles.

Yesterday afternoon I attempted to fit the speedo drive that was very kindly dug out for me. Unfortunately when I took the old one out I was greeted with this sight:

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4361.jpg)

Thats the speedo gear inside the box being split in two. :( Bad times. Gonna need to get the box apart to fix that. will think long and hard about the best way to do that. Part of me thinks I might be able to unbolt the prop from the diff, then drop the back of the box down and remove the tail section while the front section is still bolted to the engine and in the car. If there is enough room to do that it would be by far and away the easiest.

I don\'t know why the speedo gear is split, nor if that has been part of the problem all along, nor if its me putting the wrong speedo drives in there that has cause the gear to break. Either way the best thing, and only thing, to do now is to put an mx5 gear inside the box from my spare gear set and then use a standard mx5 drive too.

I also had a go at my frame rail repair.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4363.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4364.jpg)

Here I\'ve cut out the rusty bit where the two section of rail join. I made a small patch and welded it in. I spent quite a long time practicing with the same thickness of metal and my welder making sure I had it set just right to get good penetration yet not blow holes. I wanted this to be neat.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4365.jpg)

Thats the end result. Not neat :( As soon as I\'d tacked it in it started blowing holes. I don\'t know if the chassis is made of steel blend that melts easier than my repair metal or whether it was just my shoddy torch control from lying under the car. Its done though, its plenty strong, just not very pretty. I then chucked some under seal on it and went out for the night!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on September 30, 2010, 11:38:45 AM
Hmm still really mixed on what to do with this car.

Had an awesome drive in to work today. I went via Stratford on the a46, roof down sun out, engine singing. Since I played with the trailing spark it really does come alive and want to be revved.

But on this tank I once again did 21 mpg, which whilst not THAT bad for a rotary meant I put £40 tuesday afternoon and need to fill up again before I head home or I\'ll run out on the way :(

I\'ve agreed with my parents I can have a project car in the garden, where my mums vegetable patch used to be, if I sort out some pots for the remaining veg and flowers. So I\'m kinda leaning towards finishing this off (speedo + rust on drivers door) then selling to to buy an rx7 to play with an a standard mx5 to daily.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on October 01, 2010, 06:18:25 PM
Today is good news!

Despite my other money worries, I\'ve had a little money put aside for quite a long time for something special. Today they arrived!

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4367.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4369.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4368.jpg)

:D:D:D:D

14x6.5 Wats, not sure of the et but it would be 24 or 30 or something. There are no et marks stamped into the wheels themselves and a previous owner has painted over the original Watanabe stickers. I tried scratching he paint off the sticker but it took the lettering with it :(.

Either way its not big deal they sit lovely with my 25mm spacers. I will be taking a drive with them tonight, just to test them out, then they will be going for shot blasting painting in either a gun metal or kinda classic bronze and then having some new t1rs fitted :)
Title: Mx7? rx5? Newbies build thread begins
Post by: shaunwil on October 01, 2010, 06:24:06 PM
Very nice. Compliments it very well.

Have you thought about a dyno session to tune a better mpg into the map ?

Shaun
Title: Mx7? rx5? Newbies build thread begins
Post by: captainbizzaro on October 03, 2010, 10:01:22 AM
That transforms her mate, looking good. Trouble is you\'ve got to change your avatar now:D
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on October 03, 2010, 03:57:46 PM
Cheers guys. :)

I had thought about it Shaun, but I don\'t think it will work miracles. Most of you guys seem to be running mpg in the 20s and really for the amount of mies I\'m doing I now realise low 40s, or better, is kinda necessary.

Either way I agreed to buy RossOnza\'s s2 first gen that needs some work as a project and over the next couple of weeks I\'ll be doing that speedo fix and replacing the drivers door on the mx5 then she\'ll go up for sale. It\'ll be sad to see her go but I\'m excited about the 1st gen project too and it\'ll be nice to have a comparatively quiet and comfortable drive for commuting in the form of a fairly standard mx5.

I\'ll keep the new wheels for either the daily 5 or to have adapters made for the 1st gen. :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Ian65 on October 03, 2010, 09:15:18 PM
Quote from: Steve-A;719320
Cheers guys. :)

I had thought about it Shaun, but I don\'t think it will work miracles. Most of you guys seem to be running mpg in the 20s and really for the amount of mies I\'m doing I now realise low 40s, or better, is kinda necessary.

Either way I agreed to buy RossOnza\'s s2 first gen that needs some work as a project and over the next couple of weeks I\'ll be doing that speedo fix and replacing the drivers door on the mx5 then she\'ll go up for sale. It\'ll be sad to see her go but I\'m excited about the 1st gen project too and it\'ll be nice to have a comparatively quiet and comfortable drive for commuting in the form of a fairly standard mx5.

I\'ll keep the new wheels for either the daily 5 or to have adapters made for the 1st gen. :)


look forward to seeing you in the 1st gen section then Steve!!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on October 03, 2010, 11:32:54 PM
I\'ll be there Ian.

Will start a fresh build on the FB, got some fairly big plans for it!, after next weekend when I\'ll have been to see it and started to prep it to be transported to my house.
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on October 24, 2010, 10:34:25 AM
Well its been a little while since an update.

I\'ve been working to finish up the little things on the car so its in a condition I\'m happy to sell it in.

I\'ve spent quite a lot of time working on my choke settings and starting pulse widths to make the starting ad cold running as OEM as possible, rather than the slightly lumpy rough tune I\'d used to use as little fuel as possible.

Last weekend Ian and I set about sorting out this speedo drive problem. As I posted a few weeks ago I needed to change the speedo gear from inside the box.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4109-1.jpg)

To change the drive we had to get the gearbox tail section apart. To take the tail section apart we had to remove the gearbox, because of the way this engine is shoe horned in the car to remove the box we had to remove the engine, to remove the engine we had to remove the front subframe, i don\'t know why she swallowed a fly, perhaps she\'ll die.

So we spent most of a day having a relaxed attack at the car, and basically only managed to unplug some ancillaries and get the exhaust off (right git that was). Here\'s Ian going mano a mano with the exhaust slip joint.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4104-1.jpg)

And the engine coming out.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4106-1.jpg)

And the old gear on the right and new one of the left.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4107-1.jpg)

Now here\'s the real issue behind all my speedo problems, despite what the internet says, on the left in an rx7 speedo drive and on the right an mx5 speedo drive. They are NOT interchangable! And because the teeth on the gears are at different angles, the gear inside the box has to match too.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Library-4108-1.jpg)

So now I\'ve got the mx5 drive inside the box and just need to pick up an mx5 speedo drive.

I\'ve got a drivers door from a breakers in the post to replace my rusty one and then once the DVLA post me my V5 back with new engine number and capacity its ready to sell.
Title: Mx7? rx5? Newbies build thread begins
Post by: captainbizzaro on October 24, 2010, 01:39:24 PM
Thats a lotta work for a flippin cog!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on October 24, 2010, 05:49:26 PM
Its a lotta work for an assumption that the internet is correct! :P
Title: Mx7? rx5? Newbies build thread begins
Post by: captainbizzaro on October 24, 2010, 06:17:18 PM
Oh right, best of luck then lol. If you read it on the net, it must be true!
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on December 07, 2010, 06:21:35 PM
Been a little while, I\'ve been busy with my rx7 so the mx7s taken a slight back seat, but she\'s not been neglected.

Over the past few weeks I\'ve:


Today the frost was very pretty so I took a couple of pictures :)

(http://i199.photobucket.com/albums/aa196/steve-nc30/rexanne/Library-4145.jpg)
(http://i199.photobucket.com/albums/aa196/steve-nc30/rexanne/Library-4132.jpg)

I\'m still really really enjoying driving her, its such a shame the mx5 never came with this engine from the factory. But the fuel bills are still crippling me, so it will have to go once I\'ve got this DVLA thing sorted (and the weathers warmed a bit so mx5 sales speed up!)
Title: Mx7? rx5? Newbies build thread begins
Post by: shaunwil on December 08, 2010, 06:17:24 PM
Truly Cold, but Monday the Frost was stunning !

Shaun
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on January 28, 2011, 10:14:12 PM
I got my v5 with correct engine number and capacity back a couple of days ago, so I\'ve been making preparations to sell the mx5 :(

I\'ve spent the last couple of days giving her lots of TLC, tidying up little bits here and there, she had done another 3k miles so oil change, oil filter, new plugs and going in in the next couple of days a new set of brake pads :)

I\'ve also given her a good clean and taken some nice pictures. She was looking lovely in the wintery hints of sunshine today.

(http://i199.photobucket.com/albums/aa196/steve-nc30/Last12Months-1496.jpg)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Last12Months-1507.jpg)

Then it just so happened that the garage where my friend Ian works was quiet, so we slotted in for a quick power run on the dyno.

(http://i199.photobucket.com/albums/aa196/steve-nc30/LastRoll-12-1.jpg)

(http://i199.photobucket.com/albums/aa196/steve-nc30/Last12Months-1526.jpg)

Considering thats basically a stock EGI engine with Megasquirt and a less than optimal exhaust set-up (compromised header for steering rack clearance & I\'m running a cat), ~160hp at the wheels and ~175hp at the fly is good with me :)
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on January 28, 2011, 10:35:02 PM
http://www.youtube.com/watch?v=XBfai1Oi-Nc (http://www.youtube.com/watch?v=XBfai1Oi-Nc)

Video from my phone there.

MOT time on thursday, then write up an advert :(
Title: Mx7? rx5? Newbies build thread begins
Post by: papercutout on January 28, 2011, 10:41:20 PM
Good work! I\'d be happy if my TII had more than 160bhp at the wheels :p


Bet this is total fun, I\'m really gutted for you.
Title: Mx7? rx5? Newbies build thread begins
Post by: Brett on January 29, 2011, 07:18:07 AM
Those are great figures for that setup :)

How much will u want for it then?
Title: Mx7? rx5? Newbies build thread begins
Post by: Steve-A on January 29, 2011, 09:28:13 AM
:) Cheers Brett.

She\'s a really hard one to value.... I don\'t wanna under value it and loose out on all the hard work I\'ve put in and not have much cash to put into my 1st gen, but I also don\'t wanna ask too much and just push away buyers.

On one hand I believe there are only 3 of these in the uk, and as far as I know, mines the only one with tax and test on the road right now. Mx5 guys are always talking about how cool a rotary conversion would be but very few go through with it because of the chassis mods etc. So she could be worth lots....

On the other hand its a poverty spec UK model mx5, thats been used all year round for the last 16 years, has done 130,000 miles and has got a few parking scrapes etc.

If it was stock I\'d be asking £1400, with the same spec as it is but on the standard engine making 160 rwhp I think it would be worth £2700 or so and people will pay between £4-6k for a good condition turbo 5, making 200 rwhp or so.

I was gonna say £4,300 and see what happens. I\'m after something to drive day to day while I work on my 1st gen, so offers and p/xs and stuff will be on the cards.