Mazda Rotary Club

Cars by Model Type => 1st generation RX-7's => Topic started by: Casey on April 02, 2011, 08:47:05 PM

Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 02, 2011, 08:47:05 PM
Some of you will know that I purchased a 1983 (with 1985 bodyshell) Silver 1st Gen which had been owned from new by John Odd, a former MRC member. Sadly, John recently passed away and his car was put up for sale by his widow. The car was transported down from Yorkshire on 29th March 2011 and now sits (for the time being) in my double garage, alongside my RX-8 :). The car did have an MOT until 23rd March 2011, but has been on SORN for a year or so, due to John Odd\'s illness.

The car\'s bodywork is generally in very good condition, with just surface rust in a few places. There does not appear to be any need for welding work as the main structure appears solid. As far as we can tell, John bought a "C" Reg S3 in 1995 and arranged for the S2 running gear to be transplanted into the bodyshell of the "donor" S3, reasons inknown.

The engine runs well but, due to the SORN and no MOT, we\'ve only been able to move the car a short distance in 1st and reverse, but all seems well. The brakes are binding a bit, probably due to lack of use, but there are NEW pads in place all round. The wheelrims are in a very poor state, but we also have a spare set of rims with the car which look far better. We\'ve got a different brand of tyre on each corner too :eek:

The plan is for the car to be shared with 3 other MRC members; Seanp, Will66 and Hypothermia. Our initial strategy is to clean the car up from a year\'s worth of grime, do a full mechanical check and service, get a fresh MOT and then maybe get her onto a ramp to deal with the underside surface rust before it takes hold.

The project started today when 3 of us; I, Will66 and Seanp spent 4-5 hours cleaning her inside and out, plus a quick cleanup in the engine bay. We\'ve also taken out the back seats to give them a thorough clean and inspect around the inside of the wheel arches. Thankfully, there is only a small trace of rust on the nearside arch, the offside looks like it just left the factory!

The car is now back in my garage and up on 4 axle stands with all 4 wheels removed, ready for some serious under arch cleaning and brake work.

So far, the car is beginning to look better than I\'d hoped for. We\'ve found lots of little things that need doing, but all fairly basic stuff, nothing major spotted today. A few pictures after the first wash, no claying or waxing yet......

(https://farm6.staticflickr.com/5312/6899456874_6e83e2c41d_c.jpg)[/url]

(https://farm6.staticflickr.com/5194/7045553565_687578f42f_c.jpg)[/url]
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: captainbizzaro on April 02, 2011, 08:52:04 PM
Welcome to the slippery slope that is 1st gen ownership-tell your partners/wives to get used to smelling of fuel. You will never have so much fun with your clothes on that is a fact.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: kev-yorks on April 02, 2011, 08:53:59 PM
Where you all in white suits Malc? If so i bet the locals thought CSI had desended on them:Giggle. Being serious she\'s looking good, i think most of my early gen parts supply have gone now but anything your short of give me a shout you never know.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: syebba on April 02, 2011, 08:54:17 PM
Looks to be very smart.
Maybe rear valence iffy?change the aerial,& back box is\'nt standard[should have 2 exit pipes].
Always fun cleaning up a new acquisition.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: syebba on April 02, 2011, 08:55:04 PM
Quote from: captainbizzaro;753380
Welcome to the slippery slope that is 1st gen ownership-tell your partners/wives to get used to smelling of fuel. You will never have so much fun with your clothes on that is a fact.

Hehe:evillaugh
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 02, 2011, 08:59:19 PM
Glad you got it home safely...
He must have loved that car to go to the trouble of re-shelling it... what a strange thing to do.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: captainbizzaro on April 02, 2011, 09:05:42 PM
Quote from: Ian65;753385
Glad you got it home safely...
He must have loved that car to go to the trouble of re-shelling it... what a strange thing to do.


Us S2 fella\'s are a strange breed....:Giggle
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 02, 2011, 09:09:32 PM
Posted 12 minutes ago and 5 responses already!

Thanks guys, we wouldn\'t have entered into this adventure without knowing there is a very knowledgeable and helpful bunch of you on here. I\'ve witnessed how you\'ve helped other 1st Gen projects and I hope we can rely on your support as we go along. Hopefully we can reciprocate in turn as we gain experience.

Our target is to get her looking good for Rotorstock, where maybe we can meet some of you guys in person.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 02, 2011, 09:15:15 PM
Quote from: syebba;753382
Looks to be very smart.
Maybe rear valence iffy?change the aerial,& back box is\'nt standard[should have 2 exit pipes].


Yep, we need to drop off the rear bumper to have a look. Both bumper side attachments are broken and there are signs of stress cracks in the plastic bumper paintwork, suggesting a minor rear end shunt. The valance underneath looks a little out of shape, but not too bad.

I kinda like the aerial, so it can stay for now at least. Not original, but it works.

It seems there is a "Janspeed" mild steel exhaust system on the car at the moment, hence the single exit pipe. Looks resasonable quality to my (untrained) eye. Make a nice sound too!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: syebba on April 02, 2011, 09:16:59 PM
(http://www.mazdarotaryclub.com/forums/attachment.php?attachmentid=51258&stc=1&thumb=1&d=1301772931) (http://www.mazdarotaryclub.com/forums/attachment.php?attachmentid=51258&d=1301772931)
 
Just to be really a$al,i see the upper door frames have been sprayed silver to match the car,looks pretty good like that[stock colour is black].
I\'ll go & find something more productive to do with me time now.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: syebba on April 02, 2011, 09:19:18 PM
Quote from: Casey;753390
Yep, we need to drop off the rear bumper to have a look. Both bumper side attachments are broken and there are signs of stress cracks in the plastic bumper paintwork, suggesting a minor rear end shunt. The valance underneath looks a little out of shape, but not too bad.
 
I kinda like the aerial, so it can stay for now at least. Not original, but it works.
 
It seems there is a "Janspeed" mild steel exhaust system on the car at the moment, hence the single exit pipe. Looks resasonable quality to my (untrained) eye. Make a nice sound too!

Not end of the world if u do need a new rear valence,only £38 from mazda.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Clarky on April 02, 2011, 09:42:18 PM
Congrats! on your first purchase, i just love the one i have just bought as well.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on April 02, 2011, 10:08:06 PM
I was the only one in a White suit and I am not CSI, it\'s from work. As Malcolm has already said she\'s in remarkably good shape. The engine sounds really sweet and after a good clean it was clear she\'d be looked after. There\'s work to be done getting her to Rotorstock but she\'s such a lovely old car it\'s going to be a pleasure getting her used again.

One thing that we noticed today was that there is a fair bit of play in the steering. The track rod ends and the box look and feel good and it feels like there is something with too much play in it in the column/steering box. Is it possible to adjust the steering box to remove any slack or do we need to look at a replacement?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: syebba on April 03, 2011, 09:50:32 AM
There\'s a bush on the column,it\'s a common fault,simple 15 min job to replace & cheap.
Don\'t know if it can be adjusted,help will be on it\'s way soon!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on April 03, 2011, 12:18:18 PM
Hmmm, we\'ll have to look at this further.  It would be nice if it was a bush rather than the steering box.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 03, 2011, 12:35:18 PM
It\'s come up lovely Guys.

It was a bit grubby true but you did say you each wanted something to get you out of your houses.......

A 1st Gen Breaking List for March Attached.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on April 03, 2011, 12:38:39 PM
Its on the opposite side of the engine bay to the steering box. Mine had been filled with silicon when I first bought the car ! Amazing the difference a bush makes !

It looks like it is in very good condition, glad you guys have it in safe hands :D

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 03, 2011, 12:43:55 PM
It\'s top of the column that the play seems to exist, rather than the box or idler. It\'s the idler that\'s the easy fix; sorry but that seemed OK to me, so far as could be seen. But I suppose you guys have now had a far better look than I did.

I would strip down at top of the column for a looksee.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on April 03, 2011, 12:46:45 PM
You get used to it quite quickly :Giggle

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 03, 2011, 01:13:12 PM
It\'s a strange sort of play Shaun, rather more of an \'up and down\' at the wheel and a clonky noise that says \'Column Top\'. It\'s not the oil tanker steering that we all know and love.
You know our sort of steering play....\'the driver of a 1st Gen gets a vote for steering direction, but the car gets another\'. It\'s not that.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on April 03, 2011, 01:26:03 PM
It almost feels like the steering wheel mount has a bit of slack in it.  It requires further investigation, once the brakes are not binding will have another look, it came with two workshop manuals as well so we\'ve got plenty to read up on!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on April 03, 2011, 01:33:31 PM
Ah right, I\'ve not experienced that one on my FB !

The Tank slapper steering can take a bit to get used to. Just don\'t overtake too agressivly at first !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 01:44:05 PM
Quote from: David Nock;753484
I would strip down at top of the column for a looksee.


Cripes, I\'ve just remembered the last time I stripped down a steering column was back in 1974, to cure a squeaky nylon bush on a Mini 850 (1966 vintage).

So, I suppose I\'m overdue to do another one :)  - we can give it a good clean up too whilst at it. It\'ll have to wait as I have to take my ever forgiving wife, Gwyn, on a cruise this Friday to make up for all this "old banger" trauma (as she\'s dubbed it)  :) Only away for a week though.....:2Rolleyes

Gwyn didn\'t quite appreciate the fact that, by sheer accident of dates with the trailer delivery guy, the car was dropped at our home on the very day of our 31st wedding anniversary, oops, tactical error :eek

Will add this task to the list I\'ve started, following our quick inspection yesterday. If it\'s not in the column, then we\'ll have a look at the bush in the engine bay, as Shaun has suggested.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on April 03, 2011, 01:47:28 PM
We\'ll worry about that when we\'ve got it back on the road.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 01:48:18 PM
Quote from: shaunwil;753511
The Tank slapper steering can take a bit to get used to. Just don\'t overtake too agressivly at first !


Thx Shaun - I think we\'ll work up slowly to overtaking manoeuvres then. We\'ll have to remember we are driving Mazdas, but not RX-8\'s :Laugh
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 01:58:11 PM
Quote from: Will66;753515
We\'ll worry about that when we\'ve got it back on the road.


Oi, what are you doing on here - I thought you were supposed to be working today - not too much action "shoreside" I guess ;):D

Thanks for your help yesterday - pity you had to leave early. The inside is looking a lot better after Sean and I stripped out the back seats to clean and gave the inside a full vacuum. I started to have a go at the plastic trim - much better now. Sean got carried away in the engine bay and most of the excess grime and clutch dust - thrown out through the missing inspection plate (yes, that\'s on the list!) has been removed too.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on April 03, 2011, 02:32:43 PM
I am engaged in what is known as millitary waiting time.
 
I am looking forward to us getting it running again.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 02:50:16 PM
Quote from: Will66;753523
I am engaged in what is known as millitary waiting time.


I guessed something like that - hope not too boring!

I hope Sean won\'t mind me posting up a link to the photos he took yesterday. Can anyone identify the spare set of 13" rims that came with the car? - pics of all 4 at the end of the photos.

LINK TO SEAN\'S FB PICS (https://picasaweb.google.com/thepearces/RPMFirstFB?authkey=Gv1sRgCLeQwJvYj_7VkQE&feat=email#)

They look in better condition than the rims on the car itself. Not sure what they\'ll look like on the car though?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: syebba on April 03, 2011, 03:23:20 PM
Those last 4 rims are off a S1.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: syebba on April 03, 2011, 03:25:21 PM
(https://lh6.googleusercontent.com/_5frEH6JfnBg/TZe6tQb1dNI/AAAAAAAAnTs/SHc34XF04Ps/s640/IMG_8736.JPG)
 
Not many of these left nowadays with less than 10 roadgoing S1\'s.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 03, 2011, 04:36:15 PM
Yep S1, should be same fit for S2? Same tyre size?.....Don\'t know my S1 facts properly, sorry.

I would guess they\'ll look brilliant on the car.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on April 03, 2011, 04:44:08 PM
Quote from: Casey;753516
Thx Shaun - I think we\'ll work up slowly to overtaking manoeuvres then. We\'ll have to remember we are driving Mazdas, but not RX-8\'s :Laugh


It doesn\'t weigh as much as the rx8 so you will be surprised at just how well it goes :D

They can be a handful :D

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 04:57:16 PM
^^ Ah, thankyou, syebba & Dave.

So, if we put those on the car we\'ll have a S1/S2/S3 hybrid :Giggle

Either that, or we sell them to pay towards a refurb of the S2 rims! Having said that, I think a couple of the S2 rims might have gone too far to save....

We have also acquired a set of 4+1 (the fifth one a different pattern) 15", 5 hole (S3?) rims with tyres, most of which have loads of tread. If there might be any interest in these I\'ll put up some pics.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 04:59:39 PM
Quote from: shaunwil;753539
It doesn\'t weigh as much as the rx8 so you will be surprised at just how well it goes :D

They can be a handful :D


Oooooh, sounds good, can\'t wait for first road outing :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on April 03, 2011, 05:09:35 PM
It weighs about 350kg less than the RX8.  But the RX8 has 228 bhp whereas the FB has 100 bhp, although I reckon this one will be quite lively with the tubular manifold, I think the emissions gear has been taken off the carb as there are a few vacuum ports that have been capped.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 03, 2011, 05:10:17 PM
interesting pictures... series 2 interior with series 3 front seats!
Are you going to return it to series 2 spec or leave it mix and match?
I think Cliff is selling a black series 2 interior, the correct colour for this car.
Those wheels are definitely series 1 alloys. Mazda factory fitted 2 types of wheel to the S1... a 5j x 13" steel and a 5.5j x 13" alloy  ... the alloy being the most common type.
The S2 was this wheel...

(http://i589.photobucket.com/albums/ss333/gsxrmovistar1/wheel1-1.jpg)

Both series 1 and series 2 wheels had a PCD of 110.0 and so are interchangable

The series 3 wheel, as seen in my avatar, was 14" and had a PCD 114.3 so won\'t swap with s1 and s2

All 3 series used 4 studs/nuts per wheel

I see your car has a Janspeed exhaust as well... I haven\'t seen one of those for years... a good mod for more HP they were back in the day!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 05:12:53 PM
Quote from: David Nock;753538
...... Same tyre size?.....


What is the standard tyre size on the S2 rims? We seem to have 185/70 R13\'s at the moment. Does anyone run with other sizes? I\'m sure I\'ve read of 200/60\'s being used (2.2% speedo over-read), and 195/65\'s (0.91% speedo over-read).

As we may have to source new tyres, it\'ll come down more to price and availability (but none of us would dare opt for "budget" brands!)..

Any recommendations on tyres?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 03, 2011, 05:25:03 PM
availability will the deciding factor... wide 13" tyres like 205\'s are hard to get these days.
From the factory, the s2 was fitted with 185/70 HR13 tyres on 5.5J x13 wheels.
Aftermarket wheels are limited for s2\'ss due to the pcd and diameter of the wheels
There is a guy selling a set of Elford turbo sonic alloys, as fitted to the S2.... they are 6J x13 and will take 205/60 x 13\'s
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 05:40:09 PM
Quote from: Ian65;753544
interesting pictures... series 2 interior with series 3 front seats!
Are you going to return it to series 2 spec or leave it mix and match?

I suspect we\'ll just tidy it up as much as we can. Given it\'s an S3 bodyshell it\'ll be a tough job to go "pure S2" anyway.

Quote from: Ian65;753544
Those wheels are definitely series 1 alloys..... 5.5j x 13" alloy  ... the alloy being the most common type!


Yep, seems you are all in agreement. They are marked "5.5J" so that clinches it. Reckon we\'ll clean those up and see what they look like on the car.

Quote from: Ian65;753544
The series 3 wheel, as seen in my avatar, was 14" and had a PCD 114.3 so won\'t swap with s1 and s2

All 3 series used 4 studs/nuts per wheel


Ah, that\'s strange then, I\'ve just been and checked, we have a set of 4 matching wheels, with 205/60 R15 tyres, (plus one matching rim with no tyre) but they all have 5 stud fixing. The centre caps clearly say "Mazda", so where did they come from? We also have one different pattern wheel, identical size rim and tyre. There was also a bag of 16 wheelbolts, same bolt type as on the S2, but about 20mm (by eye) more thread.

Any idea where these wheels came from?

We have 5 rims like these;
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 03, 2011, 05:44:34 PM
Quote from: Casey;753554
I suspect we\'ll just tidy it up as much as we can. Given it\'s an S3 bodyshell it\'ll be a tough job to go "pure S2" anyway.



Yep, seems you are all in agreement. They are marked "5.5J" so that clinches it. Reckon we\'ll clean those up and see what they look like on the car.



Ah, that\'s strange then, I\'ve just been and checked, we have a set of 4 matching wheels, with 205/60 R15 tyres, (plus one matching rim with no tyre) but they all have 5 stud fixing. The centre caps clearly say "Mazda", so where did they come from? We also have one different pattern wheel, identical size rim and tyre. There was also a bag of 16 wheelbolts, same bolt type as on the S2, but about 20mm (by eye) more thread.

Any idea where these wheels came from?

We have 5 rims like these;


they are 2nd generation (s4) alloys
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: captainbizzaro on April 03, 2011, 06:00:15 PM
I had a Janspeed on my first FB, it did make a big improvement on performance but I personally didn\'t like how it sounded.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 06:11:49 PM
Quote from: Ian65;753556
they are 2nd generation (s4) alloys


:god Thankyou. Mystery as to what they are is now solved, but the mystery remains as to why John Odd, who only had an S2, was doing with them in his garage....I\'ll guess we\'ll never know that now, shame.

Maybe he had an idea to add bits of a S4 to the car; what with S1 rims, S2 running gear, S3 shell.......there\'s a pattern in here somewhere.....definately an "Odd" car..........:D
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 03, 2011, 06:12:42 PM
Quote from: captainbizzaro;753563
I had a Janspeed on my first FB, it did make a big improvement on performance but I personally didn\'t like how it sounded.


my mate put one on his s3 back in the 80\'s when his factory system burnt out and the noise was terrible! It didn\'t half tranform the power of the car though.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 03, 2011, 06:16:26 PM
Quote from: Casey;753564
:god Thankyou. Mystery as to what they are is now solved, but the mystery remains as to why John Odd, who only had an S2, was doing with them in his garage....I\'ll guess we\'ll never know that now, shame.

Maybe he had an idea to add bits of a S4 to the car; what with S1 rims, S2 running gear, S3 shell.......there\'s a pattern in here somewhere.....definately an "Odd" car..........:D


it\'s certainly a puzzler... I would have thought he\'d have used the s3 running gear... the s3 has stronger suspension, bigger brakes, ventilated discs as standard... then again, he may as well have just bought a s3 if he was going to do that.. does the shell still have the s3 stamped in vin or did he change that over too?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 06:18:01 PM
Does anyone know where we can source the cover (inspection?) blanking plate (and the two fixing bolts) that attaches to the the rear of the engine housing (passenger side) and allows one to view the flywheel spinning? From memory, the plate would be roughly about 4"x1".

Dave Nock noted it was missing and it kinda worries my that something might drop down in there accidentally. Plus, I\'m pretty sure it is the source of a lot of blavck dust spread on the passenger side engine bay bodywork. Sean vacuumed a load of the stuff out yesterday....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: captainbizzaro on April 03, 2011, 06:34:51 PM
Seriously, unless there is one breaking near you, you won\'t go wrong with rxmotors he has such a huge amount of 1st gen spares it\'s unbelievable and he\'ll post parts nice and prompt.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 06:55:14 PM
Quote from: Ian65;753566
it\'s certainly a puzzler... I would have thought he\'d have used the s3 running gear... the s3 has stronger suspension, bigger brakes, ventilated discs as standard... then again, he may as well have just bought a s3 if he was going to do that.. does the shell still have the s3 stamped in vin or did he change that over too?


The puzzle, and the fact we can\'t ask the previous owner, is half the fun at the moment. Trying to determine which bits were original and which bits have been added will take some time I reckon. BTW, is it standard to have the oil cooler sitting just in front of the main rad on the S2? There\'s some VERY new (I\'d say brand new) hoses connecting the cooler to the engine.

VIN, now there\'s a question! Dave Nock spotted the V5 VIN, and the one on the latest MOT, didn\'t match the number stamped on the chassis!! After pondering this, and considering Dave\'s views, I decided to send the V5 back with the "correct" (later) VIN number, as a "change". We\'ll see what that throws up at DVLA! Thought we\'d better do this now, rather than it get spotted when a fresh MOT is done.

All adds to the "Odd" history of this car.......
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 06:56:11 PM
Quote from: captainbizzaro;753570
Seriously, unless there is one breaking near you, you won\'t go wrong with rxmotors he has such a huge amount of 1st gen spares it\'s unbelievable and he\'ll post parts nice and prompt.


Thanks, that\'s very handy to know.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 03, 2011, 07:29:52 PM
Quote from: Casey;753575
The puzzle, and the fact we can\'t ask the previous owner, is half the fun at the moment. Trying to determine which bits were original and which bits have been added will take some time I reckon. BTW, is it standard to have the oil cooler sitting just in front of the main rad on the S2? There\'s some VERY new (I\'d say brand new) hoses connecting the cooler to the engine.

VIN, now there\'s a question! Dave Nock spotted the V5 VIN, and the one on the latest MOT, didn\'t match the number stamped on the chassis!! After pondering this, and considering Dave\'s views, I decided to send the V5 back with the "correct" (later) VIN number, as a "change". We\'ll see what that throws up at DVLA! Thought we\'d better do this now, rather than it get spotted when a fresh MOT is done.

All adds to the "Odd" history of this car.......


That could open a nest of spiders... I hope it doesn\'t.
With monocoque bodyshells the id is non transferable and the car might end up getting vosa inspected to determine it\'s provenance
It may end up with the s3 identity on it or a Q plate if they can\'t be sure which of the 2 cars it actually is.
I\'m surprised it\'s cleared a previous mot if the stamped in vin doesn\'t match dvla\'s database in relation to the index number.
I hope all goes well and no one picks it up but it could possibly be a little bit dicey.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on April 03, 2011, 08:15:04 PM
Quote from: Casey;753513
Cripes, I\'ve just remembered the last time I stripped down a steering column was back in 1974, to cure a squeaky nylon bush on a Mini 850 (1966 vintage).
 
So, I suppose I\'m overdue to do another one :) - we can give it a good clean up too whilst at it. It\'ll have to wait as I have to take my ever forgiving wife, Gwyn, on a cruise this Friday to make up for all this "old banger" trauma (as she\'s dubbed it) :) Only away for a week though.....:2Rolleyes
 
Gwyn didn\'t quite appreciate the fact that, by sheer accident of dates with the trailer delivery guy, the car was dropped at our home on the very day of our 31st wedding anniversary, oops, tactical error :eek
 
Will add this task to the list I\'ve started, following our quick inspection yesterday. If it\'s not in the column, then we\'ll have a look at the bush in the engine bay, as Shaun has suggested.

 
Now that was a very crafty move - what a way to remember your wedding anniversary, have an RX7 FB delivered to the house, brilliant idea - wish I\'d thought of that one!

Back to earth now Cliff - glad to see the car has polished up so well and getting some very good information of the cars\' condition.
The guys here will help out the best way we can - as a team, well actually, more like a family so just ask away.
Good luck guys with the project.
Cliff
:yes
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on April 03, 2011, 08:19:27 PM
Quote from: Casey;753528
I guessed something like that - hope not too boring!
 
I hope Sean won\'t mind me posting up a link to the photos he took yesterday. Can anyone identify the spare set of 13" rims that came with the car? - pics of all 4 at the end of the photos.
 
LINK TO SEAN\'S FB PICS (https://picasaweb.google.com/thepearces/RPMFirstFB?authkey=Gv1sRgCLeQwJvYj_7VkQE&feat=email#)
 
They look in better condition than the rims on the car itself. Not sure what they\'ll look like on the car though?

1stly I\'ve not read any of the later posts but the 13" rims are the original SA S1 alloys - I had these with my 1st RX7.
Cliff
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on April 03, 2011, 08:22:09 PM
Hi Casey, I have a set of 4 series 2 wheels in my garage that I got for £10 each from a breakers when I picked up some bit and pieces, you can have them for what I paid if your interested.
 
   Dibs
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 08:30:10 PM
Dibs - many thx, we might take you up on that offer. Condition is everything; the ones we have are very corroded and manky! Could you post up a pic of the worst one in the set you have?

We\'ll also see how well the S1 alloys clean up and how they\'ll look on the car. I might also have a word with a local wheel refurbisher that I\'ve used before and see if they think the S2 wheels can be salvaged, but I think I already know that\'s going to be too expensive!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on April 03, 2011, 08:42:12 PM
Casey The Wheels are stored in a place not easy to get at and I\'m out of the country for a couple of weeks, so when I get back I\'ll get in touch.
   Dibs
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 03, 2011, 08:50:38 PM
Dibs, no rush, I\'m out of the country for 10 days at the end of this week too. It\'ll also be a while before we sort out the brakes, etc, before we worry too mauch about the wheels. Whenever you\'re ready; many thanks.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on April 03, 2011, 09:53:07 PM
Looks like a really good project guys, nice to see its gone to a good home and sounds like you\'re not gonna be scared to get stuck in.

I have to say compared to any other car I\'ve worked on the 1st gen is just like mechano, so easy to work on :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on April 03, 2011, 10:05:17 PM
Hi Folks,

Just thought I\'d pop my head above the parapet here (is is it out of the engine bay!).

No problems Malcolm, posting the pictures - I was going to post them myself but have had a bit of a malfunction on my main PC :-(

Well, I must say I thoroughly enjoyed Saturday and getting down and dirty with the FB... I even did some "mechanical" work - undoing some bolts (yes, really a first for me!), and manging to snap one on the rear seat hinge... Will remember to WD40 liberally next time before attacking rusty bolts! (hopefully easy to drill-out and replace!)

With respect to the Steering box, I noticed that there\'s some kind of adjusting screw on top - would that have anything to do with the play, or some other purpose?

The wheels stories here are very interesting, and the pictures above of "good" S2 alloys look amazing, but as Malcolm has said the ones fitted are truly shocking.

I think we have no choice to name her "Odd" - or in true Japanese Style "Kimyona" (which is japanese for Strange, but also seems to mean "Odd" in the sense we mean here! http://translate.google.com/#en|ja|Strange%0A%0A :-)) Maybe Kim or Kimi for short?

Kimi and Kimiyo also mean "Withou Equal" as a Japanese girls name: http://www.issendai.com/rpgs/japanese-girls-names-3.shtml
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 03, 2011, 10:24:33 PM
Sean,
have a look here on my website and you can download the factory workshop manuals for free for your car...


http://www.tech-leisure.com/index_files/Page344.htm

I\'d download both 1981 -1983  and the 1984-1985 manuals as you\'ve got a bit of each on that car... the steering box was slightly different between the series 3 cars and the series 3.
The s2 box usually has less play in it and is easier to adjust but gives slightly heavier steering, the s3 is a touch harder to adjust and is a bit lighter on the arms.
There is also a cheap haynes workshop manual on ebay at the moment that
will give you loads of good info for maintaining the car...


http://cgi.ebay.co.uk/MAZDA-RX-7-OWNERS-WORKSHOP-MANUAL-1979-1985-/290552259134?pt=UK_CarParts_Vehicles_Manuals_Litterature_ET&hash=item43a643a23e

download these books and get a haynes and you\'ll be sorted... all the info you need!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on April 03, 2011, 11:16:56 PM
Hi Ian,

Thanks for that -- actually I have downloaded them, we were also supplied with 2x copies with the car! Time to start reading I guess :-)

Will keep any eye on that Haynes manual on eBay (and probably bid on behalf of the \'RPM\'), hopefully not bidding against anybody else here??
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 04, 2011, 12:34:08 AM
Quote from: seanp;753648
I think we have no choice to name her "Odd" - or in true Japanese Style "Kimyona" (which is japanese for Strange, but also seems to mean "Odd" in the sense we mean here! http://translate.google.com/#en|ja|Strange%0A%0A :-)) Maybe Kim or Kimi for short?

Kimi and Kimiyo also mean "Withou Equal" as a Japanese girls name: http://www.issendai.com/rpgs/japanese-girls-names-3.shtml


Very clever Sean - the idea of "Kim" or "Kimi" is growing on me, given those Japanese connections :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 04, 2011, 12:42:30 PM
Quote from: Casey;753575
BTW, is it standard to have the oil cooler sitting just in front of the main rad on the S2? There\'s some VERY new (I\'d say brand new) hoses connecting the cooler to the engine.

.

What\'s happened is that the S3 radiator has been retained in the S3 chassis. The S2 rad is shorter (by the height of the oil cooler, which normally bolts into place under the radiator). The S3 didn\'t use a front oil cooler, instead an engine mounted \'beehive\' cooler.

So, given the taller S3 rad the fitter has chosen to loop the oil cooler pipes round to the front of the rad and mount the cooler there, low down. Unusual to say the least. I would guess cooling will still be satisfactory but if there\'s any untoward temperature rises it might be be necessary to re examine what\'s to-do here.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on April 04, 2011, 01:04:39 PM
I had no cooling issues running an oil cooler in front of the lower potion of my radiator on my 13b mx5.

If the oil cooler is still at stock height, then basically you should have an s2 sized amount of air flow to the radiator and any flow you get from behind the oil cooler will be a bonus over the standard s2 cooling!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 04, 2011, 01:13:17 PM
Quote from: Steve-A;753805
I had no cooling issues running an oil cooler in front of the lower potion of my radiator on my 13b mx5.

If the oil cooler is still at stock height, then basically you should have an s2 sized amount of air flow to the radiator and any flow you get from behind the oil cooler will be a bonus over the standard s2 cooling!

Yep, makes sense.

There is a difference in the cooling method though.....air cooled (S2) versus water cooled (S3).....I doubt that it will cause the slightest problem though.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on April 04, 2011, 05:10:52 PM
At the risk of going off topic.... Is the s3 water oil cooler meant to be more or less efficient than the s2 air oil cooler?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 04, 2011, 05:25:21 PM
common consensus is that the air cooled oil cooler is more efficient.... although I\'ve never seen any evidence to convince me one way or another.
What is apparent though, is that most performance rotaries, whether factory designed or enthusiast builds, use an air cooled cooler.
I\'d say  that if you\'re were just going to use a 12a in a pretty standard road car and drive it normally, a beehive would be fine.
If you\'re going forced induction, porting the engine, going racing, doing track days etc etc... air cooled is the way to go.
Although it was probably cheaper to produce, Mazda dropped the beehive for the 2nd gens and turbo 2\'s ....which maybe tells us something ( or maybe not!)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on April 04, 2011, 05:28:40 PM
Quote from: Steve-A;753857
At the risk of going off topic.... Is the s3 water oil cooler meant to be more or less efficient than the s2 air oil cooler?

I\'ve no proven answer to this but would put my thoughts into the ring for debate:-

The S2, being air cooled, will rely upon forward motion (along with a minimal assistance from air drawn towards the radiator by the viscous coupling fan) to reduce the ambient air temperature along with the oil heated by the engine - yes?
The S3 water cooled engine will maintain the oil at a constant temperature which is governed by the hot water of the radiator - yes?
Therefore my powers of deduction would lead me to believe that the S2 cooler in theory should be slightly more efficient based upon the air temperature being far less than the engine/water temperature - but then again, I\'m not an Engineer.

Cliff
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 05, 2011, 12:06:39 PM
I figure you\'re all correct guys; I think that\'s the consensus.

Having said that, in a few full-on traffic jams the S3\'s we\'ve owned have behaved perfectly. So I figure that with the S3, if the rad cooling and water pumping is OK then the beehive oil cooling is bound to function.

And it\'s so simples.......
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on April 14, 2011, 11:52:00 PM
(removed, incorrect content)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on April 14, 2011, 11:54:18 PM
I know we got two copies of the Mazda Service manuals, but I couldn\'t resist a bid on eBay and won this:

(https://lh6.googleusercontent.com/_5frEH6JfnBg/Tac1wXSRWlI/AAAAAAAAnew/OMOQ_0ngpG8/s512/IMAG0290.jpg)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on April 15, 2011, 08:47:05 AM
Quote from: seanp;756102
I know we got two copies of the Mazda Service manuals, but I couldn\'t resist a bid on eBay and won this:
 
(https://lh6.googleusercontent.com/_5frEH6JfnBg/Tac1wXSRWlI/AAAAAAAAnew/OMOQ_0ngpG8/s512/IMAG0290.jpg)

Well done - and what sort of price did you pay for it?

I also have two copies:-
a softback which I use
a hardback which is still in its\' original wrapping unopened - sad or what?
Cliff
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on April 15, 2011, 09:34:23 AM
Quote from: CHC;756125
Well done - and what sort of price did you pay for it?
 
I also have two copies:-
a softback which I use
a hardback which is still in its\' original wrapping unopened - sad or what?
Cliff


essential reading!
2 copies are a must as well.... one for in the garage when your hands are covered in oil and a nice clean copy for in the house...
my \'garage\' copy is one I\'ve had for 25 years!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on April 15, 2011, 11:43:08 PM
Quote from: Ian65;756131
essential reading!
2 copies are a must as well.... one for in the garage when your hands are covered in oil and a nice clean copy for in the house...
my \'garage\' copy is one I\'ve had for 25 years!

 
and isn\'t there an electronic/pdf copy floating around too!  Only the best for us proud owners.
:cool
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on April 16, 2011, 12:40:13 AM
It\'s a "used" copy (a few oily finger prints - probably sold by somebody hereabouts!), but got it for under a £10 including postage. A veritable bargain - others and new ones going for ~£25??

Now I know what the "beehive" looks like too -- and ours definitely doesn\'t have one of those :-)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on April 17, 2011, 11:56:12 PM
Used or not Sean - still a bargain for under a tenner mate, well done.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 28, 2011, 08:33:08 PM
Things have been quiet as I\'ve been on holiday and then away again for last Bank Holiday (which took in a visit to the Spring Rotor Show at Brooklands). However, myself, Will66 and Hypothermia have set aside a few hours this coming Sunday to tackle the brakes and start a long list of other items that need attention.

I bought an angle grinder today to blitz some rust. I also ordered; Marine Clean, Metal Ready and 6 mini-cans of Grey POR15, ready protection after the rust blitz!

I\'ve also been reading up about the electrolytic rust removal for parts I can remove from the car. I\'ll be buying some soda crystals at Tesco tomorrow to give this a go with an old battery charger I was about to throw away. Looks like people get very good results using this method.

I\'ll try and get some pictures up after the weekend to show the work in progress!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: california styl on April 30, 2011, 12:45:52 PM
haha! lo tech and hi tech combined......!
Good luck over the weekend!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 30, 2011, 03:10:52 PM
^^ Thank Robbie!

OK, help please in somewhere to source an oil seal for the rear axle.

Whilst checking over the brakes and calipers (which seem fine), we\'ve discovered a fair amount of oil leaked onto the stone guard and back of the brake disc, nearside. So, tomorrow we plan to remove the axle and take a look, but the only place the oil can be coming from is via a failed axle oil seal?

I\'ve phoned my local Mazda dealer who found the part (1011-26-154; thanks for the parts lists you Gen 1 guys have made available!), who said is was available, but not in the UK. Price £4.60, but couldn\'t tell me how long it would take to get the part imported! Anyone know anywhere to source more quickly?

Thanks!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 30, 2011, 05:48:15 PM
Rotechniks in Berkshire are my usual port of call for this kind of thing. There\'s also Rx Motors in Dorset, WGT in Cheshire and Jimmys in Norfolk. Other people might have alternative sources for getting hold of this part? Dealers are often very quick though; a few days usually.

The half shafts often come out fairly easily, you shouldn\'t need a slide hammer.
Then (from memory) the oil seal just taps gently into the end of the axle tube.

Be aware though, as a point of information, that S2 half shafts have a different number of splines to S3 half shafts. I would guess that the oil seal is the same but I\'m not certain.

Worth checking for axle tube cracks I suppose, though I\'ve never encountered this. Seal failure is much more likely.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 30, 2011, 06:07:32 PM
^^ Many thanks Dave, I\'ll ring around those places on Tuesday, assuming when we get the shaft out tomorrow that my diagnosis is correct. I\'ve got an axle puller available, should it be needed! And thanks for the heads up about possible different seal in the S2/S3 half shafts. I\'ll double check before ordering :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on April 30, 2011, 06:13:14 PM
So we\'re getting the Axle off tomorrow, I\'ll bring my three foot breaker bar!  We can attack the rust on the axle and diff casing as well!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 30, 2011, 06:25:53 PM
Oooh \'eck. Sounds like Malcolm\'s set for precision engineering work but Will\'s decided to give it \'what for\' in the nuts!.......:D
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 30, 2011, 06:56:41 PM
Quote from: David Nock;759169
Oooh \'eck. Sounds like Malcolm\'s set for precision engineering work but Will\'s decided to give it \'what for\' in the nuts!.......:D


Dave, you\'re getting to know our characters quite well now.... :Laugh
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on April 30, 2011, 11:52:22 PM
At least I\'m not bringing my big hammer!  Things may have been precise when they left the factory, however after 25 years of British roads, sometimes things need a little robust persuasion.  Normally I tickle the stubborn nuts first with some penetrating fluid or something, see if they\'re going to play nice, but sometimes you\'ve got to show the pesky threaded fasteners who is boss!  :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 01, 2011, 05:31:11 PM
Big team of us looking at KIMI today. Got a fair look around and found several issues as follows;

Pics, left to right; after removing half shaft and seal on the rear axle we spotted this damage when the seal was removed. Someone before us was a bit heavy handed removing a previous seal? Damage to seal inner also spotted (small nick going through the rubber) in the last picture below. This probably explains the oil leakage. What do people think about the damage to the axle (under the seal). If we simply replace with a new seal, are we likely to get leakage due to surface damage under it?

Picture 2 shows TWO mystery boxes under the passenger side footwell carpet. What do these do? One (marked 8553C) was electrically connected. Another box 8553D, was not connected. Assume this is an S2/S3 issue of some sort?

Pictures 3 & 4 (pic 4 dead centre) show an opening into the clutch bell housing (rusty flywheel can be seen in both pics). Should there be a cover plate here? Pics 3 & 4 taken from driver\'s side, looking down into engine bay (in case there was any doubt!).
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on May 01, 2011, 06:05:58 PM
Put a smidge of locktight on the damaged part of the axle tube as you refit. That should form a gasket with the metal backing of the new seal.

The boxes are a first primitive version of a management system for emissions etc. I presume that the connected box will be the correct one, (S2), swopped over when the shell was changed. In any event they seem to be remarkable bits of kit as I\'ve never known a reported fault with one - ever. The \'ECU\' is shown in Haynes. My thoughts would be to try and squeeze the connected one into it\'s proper position without disturbing the wiring, and remove the other unit - keeping it safe if needed in the future.

I\'m sure there should be engine cover plates. I had noticed the top one was missing but hadn\'t noticed the other space. I think there is a flanged piece of metal to be fitted here. Anyone else on this?
Why would a mechanic leave these off??
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on May 01, 2011, 06:42:35 PM
Quote from: David Nock;759325


I\'m sure there should be engine cover plates. I had noticed the top one was missing but hadn\'t noticed the other space. I think there is a flanged piece of metal to be fitted here. Anyone else on this


There should be 2 cover plates, this one at the top...


(http://i589.photobucket.com/albums/ss333/gsxrmovistar1/DSCF1499.jpg)


(http://i589.photobucket.com/albums/ss333/gsxrmovistar1/DSCF1493.jpg)


(http://i589.photobucket.com/albums/ss333/gsxrmovistar1/DSCF1494.jpg)


and the side one...


(http://i589.photobucket.com/albums/ss333/gsxrmovistar1/DSCF1497.jpg)


(http://i589.photobucket.com/albums/ss333/gsxrmovistar1/DSCF1496.jpg)


(http://i589.photobucket.com/albums/ss333/gsxrmovistar1/DSCF1498.jpg)


you will probably be able to get these from a scrapper or somewhere like RX motors... they definitely want replacing though.... you don\'t want anything finding it\'s way into the bellhousing.



Quote from: David Nock;759325
Why would a mechanic leave these off??


a mechanics probably wouldn\'t.... but a bit of a bodger probably would!

I agree with Dave re the ecu... sounds about right!

.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on May 01, 2011, 07:26:09 PM
With the seal make sure you get rid of any high spots too to reduce the amount of work the sealant will do.  Looks like they screwdrivered it out on the wrong side making it a harder job !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 01, 2011, 08:03:05 PM
:god Grateful thanks for the advice.

Shaun & Dave, exactly what we thought, try and smooth off the high spots and smear some sealant in the damaged area. Hopefully it will provide an oil tight seal!

Ian, superb, now I know what I need I\'ll ring around onTuesday to see if I can pick up the two blanking plates.

Boxes under the carpet - we thought it was some sort of simple ECU! We\'ll take the "D" version out and fix the "C" one in as best we can. The cables seem too short at the moment to fit in the "proper" position, so we\'ll have to take a closer look.

And massive thanks to Will, Ian and Aston for coming over today and working on KIMI with me. Thanks too to Crissy  for coming over with a set of "square drives" that we needed to try and remove the diff drain plug. Unfortunately, it seems the diff plug needs a 10mm square drive, but we only had a 9mm and 11mm. We tried a 3/8" as well; no joy, the drain plug is in their tight - we tried panetrating oil, but she wouldn\'t budge!

Can anyone confirm the right tool is a 10mm square drive?

Can anyone
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on May 01, 2011, 08:51:09 PM
Thinking about sealant in the bath...as yer do.....I used \'Ozotite\' to seal the diff on my car, (it\'s a gasketless joint), applied with a toothbrush. A little of that dabbed onto the damaged tube might be as good as locktight if not better.

The drain plug is best \'attacked\' with one of them universal drain plug spaners, you know the things, 8 tapered drives in a cast steel cruciform shape, double ended - 4 each end. Get Will on it, he\'ll not pussyfoot around with it.

Maybe a lump hammer needed as well, plus a block of wood to drift against the spanner.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on May 01, 2011, 09:03:37 PM
I think I used a 3/8in Sq breaker bar on with my S3 diff. Its about 15in long !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 01, 2011, 09:29:58 PM
The problem we\'ve got is that the plug isn\'t in the best shape and I\'m concerned that if I start swinging on it like a loon that I\'ll round out the plug and we\'ll be stuck.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: captainbizzaro on May 01, 2011, 10:02:47 PM
Give it some heat first.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 02, 2011, 07:50:09 AM
I\'ll bring my blowlamp!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Arnie_O on May 02, 2011, 09:18:14 AM
May be a job for the hammer again Will, It worked on the gearbox filler plug, but i would say your going to need to get a proper fitting sump plug adapter first
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 02, 2011, 09:42:55 AM
We\'ll try the hammer and if that doesn\'t cut the mustard we\'ll go for some heat.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 02, 2011, 09:42:56 AM
Quote from: David Nock;759360
Thinking about sealant in the bath...as yer do.....I used \'Ozotite\' to seal the diff on my car, (it\'s a gasketless joint), applied with a toothbrush. A little of that dabbed onto the damaged tube might be as good as locktight if not better.


Thanks Dave, I\'ll check that stuff out.

Quote from: David Nock;759360
The drain plug is best \'attacked\' with one of them universal drain plug spaners, you know the things, 8 tapered drives in a cast steel cruciform shape, double ended - 4 each end. Get Will on it, he\'ll not pussyfoot around with it.

Maybe a lump hammer needed as well, plus a block of wood to drift against the spanner.


OK, I hadn\'t seen these tools before, but see my local Halfords has them in stock for about £6, so looks like another useful tool to add to the collection. I actually phoned Halfords yesterday, whilst we were doing the job, and asked if they had a suitable "socket". The guy went away to check and said no, but didn\'t offer the universal tool, despite describing what we were trying to do!! I\'ll get hold of one of these and try the "lump hammer and piece of wood". If that doesn\'t work, it\'ll have to be the blowlamp :eek: (must invest in a new fire extinguisher first :o )
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on May 03, 2011, 03:00:22 PM
Sounds like a good time was had? How did the rust treatment etc. otherwise go? Any more pictures?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on May 03, 2011, 04:39:41 PM
Quote from: Will66;759373
The problem we\'ve got is that the plug isn\'t in the best shape and I\'m concerned that if I start swinging on it like a loon that I\'ll round out the plug and we\'ll be stuck.


If that were to happen and there was just a bit of external thread showing, you might just be able to get a 2\' or 2\'6" Record Pipe wrench to bite into the threads? Need to stop it spinning off downward as you apply pressure though.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 03, 2011, 05:10:51 PM
Quote from: seanp;759749
Sounds like a good time was had? How did the rust treatment etc. otherwise go? Any more pictures?


Hi Sean, I hope the trip Portugal was good!

Yes, we made some good progress with the mechanical side. The electrolytic "rust removal" bath process was a bit messy, and a little slow as my ancient 12v supply was only able to deliver about 100mA through the bath. However, there is no doubt the process works, as much of the rust has been removed on the small piece I tried. Hydrogen gas was clearly being produced and the bath is a lot dirtier than when it started - see pic!

Will and I attacked a small area of surface rust on the rear valance with my new angle grinder and a flap wheel. Rust was removed with little effort and very quickly. We sprayed on some Hammerite "anti-rust" primer to protect the fresh metal. I don\'t plan to do any more rust removal until the POR15, plus the prepping chemicals arrive - ordered online from "Frost".

Another few pics are attached that Ian took of "work in progress" - note good use of the Haynes manual in one shot!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 03, 2011, 05:32:12 PM
V5 update - letter from DVLA arrived today. As David Nock suspected, the DVLA have picked up on the chassis discrepancy and have said my application "is being delat with". I immediately phoned to get more information, but the person dealing with the case was not in the office :Hammer. However, another helpful lady said the V5 for this vehicle had been reissued twice, and she suspects the one I returned was not the latest one. The V5 I signed appears to have a datecode of Dec 2004, well after the chassis change, and still has the wrong number (as does the most recent, 2010 MOT). The GOOD news is that she found the CURRENT chassis number did exist on their system, so it looks as though, maybe, Mr Odd did declare it after all, and I have an old V5. If that is the case there shouldn\'t be a problem. Worst case, I\'ve got to get the car up to Ipswich (20 minutes away) to get the local office to inspect the car. I\'m told there is no charge for this. However, it might delay things as I\'ll have to get the MoT and insurance sorted, plus get DVLA authority to drive to the local office without road tax on the car - could get complicated......

Oil seal - rang Rotechniks and spoke to Gary Marks. He has offered to get a seal, but will have to import it - 3 days, to maybe a couple of weeks. Price is ~£4+VAT . His mechanics thought there might be a difference between the seals used S2/S3. I\'ve ordered the part number that looks correct from the parts catalogue for a non-vented disk back axle (and I can\'t see another part number anywhere), but Gary has said if they are the wrong ones he\'ll happily take them back. - on that basis I\'ve said go ahead and get two. Murphy\'s law suggests if one seal has gone the other one might be on it\'s way or, the first attempt to replace the failed seal might not stop the leak due to the collar damage and a 2nd attempt might be needed....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on May 03, 2011, 10:56:38 PM
I got the wrong seals the first time round too, took a couple of weeks to get as well for mine. Not good on a daily. The FD got some good use.

The car body looks in extremely good condition. You still have the bottom of the doors too which is exceptional. Definately looks like alot of fun !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 06, 2011, 01:43:15 PM
^^^ Yep, bodywork looks remarkably good for her age (the car I mean :chat)

Small update;

1. Pack of POR15 and the two prep chemicals arrived yesterday, so I can spend the odd hour touching up whilst she is still on the axle stands.

2. Tim at RX Motors said he has the correct oil seal in stock :wiggle - just paid via Paypal for him to ship us one! I\'ll leave the other orders in place (Mazda dealer and Rotechniks are importing seals for us) until we are sure it\'s the right seal. They are cheap anyway, so we\'ll probably start our spares collection going when they arrive!

Speaking to Hypothermia last night about the axle seal seating damage - he has a Dremel tool which we will use to try and reduce the high spots on the damaged area before putting the new seal in place, plus a smear of some sealing compound (I\'ve had a quick look through the Loctite range - mind boggling!)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 09, 2011, 03:36:54 PM
:D Great news on the V5. I\'ve just spoken to the very nice lady at the DVLA and she has confirmed everything is in order and she will be sending out the new V5 this afternoon. Apparently, Mr Odd did register the chassis change to the DVL; it just appears he kept the old V5 as well as the new one and his wife must\'ve located the old one to sign over to me.

Relief, no VOSA inspection required :D

OK, just awaiting the oil seal now, as the car can be made roadworthy again fairly quickly once that job is done.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on May 09, 2011, 04:30:22 PM
Now that\'s what I call a result - back of the net, good to hear :Party
Now you can continue without worry guys.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on May 09, 2011, 06:02:43 PM
Super news...

Those of us who\'re getting on a bit and \'control\' the domestic paperwork maybe need to take a lesson from this? Leave a tidy paper trail for the Missus to follow?

Or is it just me who needs to do this?......Gulp.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on May 09, 2011, 06:07:36 PM
Now what shoebox did I put that in ................:rollin
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 13, 2011, 01:35:49 AM
:Party V5C arrrived today! One potential hurdle "jumped" :)

Still awaiting oil seal from RX-Motors :( Have left seal orders with other two suppliers and they haven\'t got back to me yet (but they both have to import the part).

Ah well, been busy with work anyway, so not had much time to do much....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 22, 2011, 07:48:11 PM
Some small progress today:
1. Oil seal arrived from RX-Motors :yes, but haven\'t fitted it yet..:o
2. Managed to remove the stubborn diff drain plug with breaker bar - yippee. However, both the fill and drain plugs have seen better days so I\'ll try and source some replacements. Noted also some slight thread damage in the diff housing fill hole though, but think we\'ll get away with it.
3. Removed the viscous fan to check the bi-metal strip and pin operation. I\'ll post up a query on the RX-7-fb forum about what I found.
5. Spent a good few hours cleaning and prepping the rear nearside wheel arch and hub and put on two coats of grey POR15. Not up to "Rexanne" standards, but might slow down the dreaded rust! See before and after pics (click on images for better view).
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 22, 2011, 08:17:58 PM
Nice Work Malcom!  The wheel arch was wearing well but showing its years before, now it looks factory fresh!  Good news on the diff as well! Can\'t wait to work on her some more!  Rotorstock is getting ever closer!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on May 22, 2011, 08:18:07 PM
Super job Malcolm!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on May 22, 2011, 10:36:58 PM
nice job.... that shell does look very clean.:Thumbs-up
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on May 23, 2011, 02:39:14 PM
nice work Malcolm - always good to see the undersides being cleaned and painted, a dirty and messy job at the end of the day but at least you know the condition of the bodywork.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on May 23, 2011, 05:18:53 PM
I\'m off this week trying to do the same but the weather isn\'t helping !

Looking very nice :D

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on May 23, 2011, 10:45:29 PM
She\'ll be back on the road in no time, looking good! That grey POR15 works well with the silver body, looks like just the right shade of grey in the photos.

I\'ll be interested to hear your driving impressions. Like myself you guys have bought an FB which you will have put lots of time and love into before you get to take her out on the road and se whats its really like to drive!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on May 23, 2011, 11:10:32 PM
You will enjoy it, Amazing to think how far modern cars have come. Brand new stuff doesn\'t give you as much pleasure. Keeps you on your toes !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on May 23, 2011, 11:13:58 PM
I truly hope so! My Alfa annoys me because it\'s too quiet and comfy :P
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 23, 2011, 11:48:41 PM
No doubt there will be several back-to-back comparisons of the FB and our respective RX8s.  Having not driven another RX but having an MX5 at home (the girlfriend\'s car) which does feel like the people at Mazda like their cars to feel a certain way I reckon there will be a common feel to the way the RX7 performs, an honest, straightforward feel to the chassis that encourages spirited driving.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on May 23, 2011, 11:56:13 PM
Quote from: Will66;764488
an honest, straightforward feel to the chassis that encourages spirited driving.


This sounds like the feeling I loved about the mx5 and I miss from the Alfa so much, and that I am hoping for from the FB.

It makes me wonder if other Mazdas, for example the mx3, have that same feeling or if its reserved for their sports car chassis.

The FB does have a very similar driving position to the mx5, with the same steering wheel switch gear and same gear box and clutch, it will have many similarities. It will be very interesting to compare the suspension and steering differences.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 24, 2011, 12:11:43 AM
jumping between threads here. i think there will be a noticeable difference between the fwd of the mx3 and the rwd of an mx5/rx7 in steering response, early models without all this traction control etc.

on my az3 (mx3) the rear wheel suspension allows the rear wheels to turn slightly as you corner so that you get that driving on rails feeling. the mx3 was based on the mazda 323f pop up light model, same interior, so more of a sports coupe/hatchback.

the rx8 uses the mx5 geabox, so similar short shifter changing. a 1st series mx5 is on my list too lol, easier to get than an fb. but no power steering on early fb\'s so just have to drive them all and see ;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 24, 2011, 12:16:57 AM
I reckon the big differences will be the ride, the FB is a live axle so when one wheel moves the other one does too so the ride will be less composed on rough surfaces than an MX5 or an RX8 but live axles mean the tyres won\'t end up on edge so you\'ll get progressive breakaway and it ought to be controllable over the limit.  I\'m not sure about the steering but I learned to drive in an Old Land Rover so it\'s got to be better than the slightly "democratic" method of choosing the direction of travel that had.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 24, 2011, 12:20:57 AM
Quote from: spoddy;764492
the rx8 uses the mx5 geabox, so similar short shifter changing. a 1st series mx5 is on my list too lol, easier to get than an fb. but no power steering on early fb\'s so just have to drive them all and see ;)


The gearbox in the RX8 depends on the model.  The 5 speeder and the Series 2 6 speed are from the MX5 but the series 1 6 speed is an Aisin Box that I believe is also fitted to the Honda S2000.  The box in the Series 2 (R3) has had a lot of problems both in the RX8 R3 and the MX5.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on May 24, 2011, 12:22:33 AM
The rx8 gearbox is the same as the mk3 mx5 isn\'t it?

The mk1-mk2.5 5 speed mx5 box, the rx7 s1-3, the rx7 s4-5 n/a and rwd 626 all use essentially the same box.

Yes the live axel will be interesting! And manual steering is great!

The mx5 has lovely sharp steering and despite the annoying power steering the Alfas isn\'t bad either so time will tell how the steering box performs. Personally I\'m hoping that with fresh bushes throughout and good general service it really won\'t be as bad as some make out!

I drove a Defender 130 for a day once, it was kinda more like riding a horse or something where you asked it to go in a direction for you rather than feeling connected!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 24, 2011, 12:32:38 AM
Quote from: Steve-A;764496
The rx8 gearbox is the same as the mk3 mx5 isn\'t it?



The six speeder in the R3 is the same as the mk3 MX5 box but the older 231 ps models have a different box.  Seems to have less problems than the mk3 MX5 box as well.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 24, 2011, 12:59:55 AM
yeah its a bolt action rifle of a change in my rx8 231ps. i got a new clutch in a few thousand miles back and previous to that changed the oil and diff oil just after the 70k mark. it all helps but going into first can slot in so easy one day and stiff the next. really need to be at a halt though as no selector for 1st if i\'m right?

1st to 2nd you really feel and hear the clunk lol, gotta love going up to 9000rpm in second though :)

that sounds bad in the R3, with the change in the ratio, has that caused the problem.
it was a tweak for more torque i think. i had been wondering what an R3 6 speed would be like in a series 1 rx8, but maybe best avoiding that plan?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 24, 2011, 08:21:37 AM
Errr, nice discussion guys, and interesting, but you are rather wandering off the 1st Gen topic just a tad...:p;):)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 24, 2011, 11:24:58 AM
Just a bit!  Did the
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 24, 2011, 09:05:19 PM
yeah sorry lol. but atleast it was mazda related ;)

so whats been happening with little kimi? the undersealing with the POR stuff looked really good. very tidy car to begin with, real credit to that man who was the previous owner, most i see you couldn\'t even put an axel stand where you have the rear stands as they seem to really suffer there.

are you going to keep kimi original setup, or more plans with the engine, steering and suspension?

whats the best way to find fb\'s for sale?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on May 24, 2011, 09:44:22 PM
Quote from: spoddy;764652

whats the best way to find fb\'s for sale?


Hi,
welcome to the forum...
the best way to find 1st gens for sale is to check this thread regularly...

http://mazdarotaryclub.com/forums/showthread.php?t=54589&page=123

there are very very few 1st gens for sale in the uk that don\'t get flagged up on here within a few hours of being offered for sale.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 24, 2011, 10:19:54 PM
thanks mate, you are all truely gents and thanks for the welcome.
as alot of fb\'s are in england etc its handy having you guys around as eyes and ears. one thing i hate is having to travel a long distance to see something like mushy pea that you had on the link you showed me. i have been sent pics for fb\'s that i was told was more solid underneath than it looked lol, but wasn\'t far off that wee green car.

i had seen that wee car on ebay and its a real shame it was so bad underneath, i loved the green savana model, the mirrors on the wings, and a leather interior too. ah well atleast it can be used again in a project for someone.

appreciate all your help guys.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 25, 2011, 12:01:03 AM
Quote from: spoddy;764652
yeah sorry lol. but atleast it was mazda related ;)

so whats been happening with little kimi? the undersealing with the POR stuff looked really good. very tidy car to begin with, real credit to that man who was the previous owner, most i see you couldn\'t even put an axel stand where you have the rear stands as they seem to really suffer there.

are you going to keep kimi original setup, or more plans with the engine, steering and suspension?



We\'ve got David Nock to thank for doing an "onsite inspection" of the car before we agreed to purchase. The bodywork is in very good condition for it\'s age. I can only think the original owner had a major problem with rust in the original car,  "re-shelled" it with a "good-un" (hence the result - S2 running gear in S3 shell) and then decided he\'d need to look after it to prevent the same problem from happening again. I have to say some of the original owner\'s handywork is a little "eyebrow raising", e.g car mats cut up and cable tied under areas of the rear wheel arch to protect vunerable parts. Very effective though!

Plans? Initially, minimal mechanical work to ensure she is healthy, reliable and safe to drive. Protect as much of the underbody as possible to prevent any rust from taking hold. I hope we can get her MOT\'d next month. Ultimate plan for this year is to get her fit enough to drive to Rotorstock (and back!) in August and be in a "showable" enough state not to embarrass us if we park up next to Rexanne and the like :o
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 25, 2011, 12:39:05 AM
that carpet tied up to protect the arches etc reminds me of the stuff they have on the rear arches on the rx8. it is great protection, so i hope my rx8
will last and last.

if it helps protect the underneath then who cares, once you have her all done, need to keep her garaged and take out when its dry (good luck on that one) lol.

must be great fun fixing her up though, seeing you all with your fb\'s is making me jealous lol.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 26, 2011, 04:19:39 PM
OK, to save someone else the pain of getting the incorrect parts - Shaunwil said this might happen :(....

I used the Mazda parts diagrams and, due to the variation in back axles it was not 100% clear on which oil seal we needed. As it turns out, Tim at RX-Motors sent the CORRECT part, based on my description, whereas I got two INCORRECT ones by giving the wrong part number to another supplier. So, for the rear axle with solid brake discs the correct oil seal part number is 1312-33-065 - outside diameter of 55mm. The incorrect part is 1011-26-154, unless your oil seal has an O/D of 62mm!!

EDIT: Watch this space, it turns out BOTH seals are incorrect. I will edit agian when we\'ve got the correct one! I think the one in the centre is a FRONT axle oil seal...

Anyone in need of the "wrong" part? Cost me £12.60 for the pair of 62mm parts (delivered) - happy to accept any offers .... If not, I\'ll stick them up on eBay!

Pics, original (worn) part on the left......(click on image to enlarge)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on May 26, 2011, 06:35:37 PM
Yep, my problem was I had already removed them from the axle when I realised !

Not good on a daily !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 26, 2011, 09:17:22 PM
well get stuck in man, only thing on this weekend is champions league final, unless you\'re gonna be stuck in front of the telly or down the pub watching the game lol.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 26, 2011, 09:30:48 PM
^^^ :Laugh planning a "blitz day" on the car on Sunday.

Put 2nd coat of Hammerite on rear n/s caliper and bracket tonight, so that\'s now ready to go back on. I have a nice new set of rear brakepads ready. Just need to sort out painting the stoneguard on Sat morning, so we\'ll be ready to reassemble the rear half shaft and brakes on Sunday.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 26, 2011, 09:45:07 PM
lucky man, i\'d love to get my hands on an fb to tinker about with and put back on the road. my father got his 300d w124 merc back, great job done on the rusted chassis and rear arch near the mudflap. all rust cut out and new metal welded in and mechanic put this black waxy stuff on, made a great job of her. now just to rebook mot and get her on the road again, but for £80 welding costs, not bad. sorry not fb related but was impressed with the work so now know someone who could repair an fb etc if i got one.

but if you ever hear of anything let me know.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on May 27, 2011, 11:09:46 AM
I\'m still watching Spod.

I used a Triumph Body Specialist to repair the back reinforcing plates on my FB. Glad to say that any proficient body repairer can deal with \'em they\'re so straightforward.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on May 27, 2011, 12:18:09 PM
I plated mine up last year on the drivers side on both sides. Seems to have stood up quite well.

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 29, 2011, 09:54:54 AM
Arrgh...

Went to Halfords yesterday to pick up a list of stuff we needed, including some antifreeze. Confronted with about ten different products, all eth-glyc based. Can someone advise on the "correct" one(s) to use and the ones to avoid? I recall reading "don\'t use the red/pink ones, only blue?"

What\'s the difference, anti-corrossion additives?

Anyway, here is the Halfords product range, advice would be much appreciated!

Halfords Anti-Freeze (http://www.halfords.com/webapp/wcs/stores/servlet/SearchCmd?srch=anti-freeze&action=search&storeId=10001&catalogId=10151&langId=-1&x=19&y=11)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on May 29, 2011, 07:35:30 PM
My advice is to forget Halfords for this Malc. The best in my opinion is \'Bluecol\'.

Find some at motor factors in 5litre size. May be difficult to find but it\'s worth it. That size will last then for 2 or 3 changes.

Change every 2/3 years or so...then next time the old coolant is drained out of the car it will still be clean and blue.

Used this stuff since 1964. Used it in the FB\'s for the last 25 years.

Dave
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on May 29, 2011, 11:04:52 PM
Is this the stuff David? http://www.bluecol.co.uk/index.cfm?product=61

We had another look at the car today and unfortunately once the rad had been drained and been disconnected it it became clear that there wasn\'t  anything other than water in there :confused: Very heavily silted up to be sure, but still water. Looks like we\'ll be doing a very thorough flush of the engine! We did flush out the rad with a garden hose, but that\'s only part of the system. Its still disconnected as we don\'t have a cooling fan connected back on yet.

Thanks for all your help so far as well... very much appreciated. We\'re all enjoying working on the car and learning as we go...

Malcolm has an update on the oil seal for the back axle - I\'ll let him spill the news...

Ian.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on May 30, 2011, 12:43:44 AM
Bluecol everytime :InLove
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on May 30, 2011, 11:19:29 AM
Quote from: HypoThermia;765623
Is this the stuff David? http://www.bluecol.co.uk/index.cfm?product=61

Ian.


That\'s the stuff Ian.....Link repeated; another plug for my favourite.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 30, 2011, 02:17:04 PM
^^Thanks David and Cliff for the Bluecol advice. Crikey, I\'d forgotten that brand, which I remember using on my very first car back in the 1970\'s, but I didn\'t know it still existed! I will order some; no stockist near me so have found some online, about £23 for 5L delivered.

- Report of work that Ian (Hypothermia) & I did yesterday....

1. Ian carefully dremeled out the high spots in the rear axle bore ready for the new oil seal. I had some Loctite gasket sealant ready to go on, but we removed the new oil seal from the wrapper to test fit it and, ARRRRRGGGGHHHH, it was found to be loose in the bore! It’s diameter is about 1mm less than the original one!! So it seems I have two different oil seals and they are BOTH the wrong ones! Gutted, to say the least, that this prevented us from reassembling the rear axle. I’ll get onto Tim at RX-8 Motors tomorrow and see if he can now identify which is the correct seal. I wish I’d test fitted it earlier.....
2. The radiator is out. Top hose came off easily, the bottom two hose were a real pain, especially as some of the clips had rusted up solid! The radiator was then thoroughly flushed with a hosepipe to clear the totally BLACK liquid & silt that came out for ages (see pic). We then attacked some rust spots on the rad mounts with angle grinder and dremel. I just need to clean the rad up of some dirt and it’ll be ready for a coat of black Hammerite on the tanks and mounts. We’ll then leave it out until the electric fans that Will66 has ordered are available to fit.
3. We filled the gearbox with Race Synth 5 oil (~1.5 litres), so that job is now complete.
5. We used my brand new “Clarke” bolt extractor set to try and remove one of the (non-critical) rear seat bracket mounts. Hmmm, that didn’t go well. We tried making the extractor starter hole with the supplied HSS 2mm drill bit but it hardly touched the bolt – we maybe got 1-2mm hole at best. That drill then snapped! I had a titanium 2mm drill which then did the job much better. We then used the extractor tool and it too SNAPPED before the bolt moved, leaving part of the extractor in the bolt we were trying to remove.Hey-ho, we\'ll have to give up on this one for now! An interesting experience using a tool we’d never used before!
6. We had a look at cleaning up the “new” set of wheels (with the set of Michelin tyres); “Wonder Wheels” didn’t do anything much, and the dremel tools didn’t really work either (and would have been really slow). The wheels will need some aggressive polishing with an electrical tool and "compound" of some type. I’ll experiment a bit on this one.....
7. A small drop of oil has again collected on the engine sump. As we had degreased this area previously, Ian and I have identified the oil is either coming from the drain plug or the OMP situated just above the drain plug. I’ll clean up and degrease the area again  so we can investigate further. This is much easier now with as, with the rad and fan removed I can almost step into the gap between the front of the car and the engine!
8. We started to angle grind the rust from the rear bumper, probably about a third done I guess, before we decided to call it a day....

Satisfying progress on the things that did go well, but everything is taking a lot longer than originally anticipated - no surprise there then :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 30, 2011, 04:31:57 PM
the common hold up being rust lol.
bolts rusting up, having to drill out, but sure it will be worth it in the end.

don\'t give up and take your time and it\'ll be done right first time.
are you going to pre-mix the fuel when you get the car going?
been reading how important it is, even with the modern rotary engines.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 31, 2011, 05:19:43 PM
Quote from: shaunwil;759896
I got the wrong seals the first time round too


We seem to have "bettered" you Shaun! As you can see from the last report, we now have the wrong seals twice :o

Have now emailed Tim at RX-Motors with photos of the failed and incorrect parts in the hope of identifying the correct one.

Having gone through the 1984-85 parts microfiche it may be we have the 1985 rear axle, not the original 1983 one, as this is a different part number again..... The line diagram of the rear axles are identical, as are MOST of the part numbers, except the oil seal, so maybe this is it ;)

How many oil seals could Mazda have used for the same application over a 2 year period :confused:

As a "hedge" I also popped into my local Mazda dealer (walking distance from my home) and spoke to the guy at the parts counter. We chatted for ages as he is a bit of a rotary enthusiast. He put me on to Paul at Mazda Braintree (not far from me either), who has "been around a while" and it was thought might be able to help better. I\'ve since spoken to Paul and he\'s been very helpful on the phone and has gone off to try and find out what the correct part number might be.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on May 31, 2011, 05:34:45 PM
Thought there was only 2 types of seals ! At least it isn\'t your daily driver :Giggle

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on May 31, 2011, 05:44:47 PM
^^Thank goodness it isn\'t a daily driver! I just hope the new part number I\'ve found is the one. Surely there can\'t be any more types out there!

Quote from: spoddy;765757
are you going to pre-mix the fuel when you get the car going?


Hmm, spoddy, interesting question - one I was saving for later, but as you\'ve raised it....

There is huge debate about this in the RX-8 forum. Some (minority) now use premix in their RX-8\'s.

What is the view of the RX-7 Gen 1 owners on this? I\'d be tempted to say we should pre-mix. If that is the concensus, what oil and what concentration? Has anyone removed the OMP and relied solely on premix?

Is there any danger of clogging up the carb through pre-mix?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on May 31, 2011, 06:15:46 PM
The axle should be S2 as you\'ve got S2 wheels, 13" with bolts. I remember they\'re bolts on Kimi.
The S3 uses 14" wheels with nuts onto studs in the half shaft, so the only chance of an S3 axle housing is if the diff and half shafts were changed over at the time of reshelling, rather than the fitter pulling all the suspension apart to change the complete axle assemblies....quite possible I suppose, as an easy fix, always assuming S3 oil seals will fit the diameter of S2 shafts.

I use Pre Mix now with a working OMP, because of the engine\'s age. I use Millers KB2T at a premix into the tank of 250:1. That\'s 80ml per 20 litres of fuel. He smokes a bit on start up but that quickly clears. No clogging up occurs.
I figure that it\'s a belt and braces to prolong engine life at this time.

Plenty folks use Pre Mix with no OMP. I think the mix goes up to 100:1 in that case....anyone confirm that mix?

Dave
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on May 31, 2011, 09:50:38 PM
I have been pre-mixing my RX8 since I got the new motor, seems to like it.  Either Protek-R or Motul 710.  I figure it can\'t hurt particularly given my penchant for "rigorously exercising" the engine once it\'s warmed up nicely.

Whilst I will not be driving Kimi with such abandon, I reckon it would be a good idea to preserve the motor.  We\'ve got no compression figures for her but we got her up to running temperature and shut her down, left her for five minutes or so and then restarted her, she fired up almost instantly without any choke so the signs are reasonably positive.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on May 31, 2011, 10:38:30 PM
yeah i read that pre-mixing debate on the rx-8 forum.
but it would make you think all rotaries should be pre-mixing.

after reading the views and mazda introducing a third oil hole for the middle of the apex seal on the rx-8 r3, it sounds to me the more oil in and around the apex seals the better for them and a longer living engine.

my rx8 has 86200 odd miles, i tried adding some pre mix the odd time over the years, but don\'t really do it. she drives great though, i red line to keep the carbon monster at bay, but reckon i\'ll start using the stuff you mentioned to keep her lasting even longer.

oh, on the quiet, i might be getting an fb, series 3. but will have to wait and see if it works out ok. sssshhhh keep stumm lol ;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: myatt1972 on May 31, 2011, 10:45:43 PM
Quote from: Will66;766082

Whilst I will not be driving Kimi with such abandon,

Haha, thats what they all say :3gears-rh
 
Keith...
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on May 31, 2011, 10:47:01 PM
The bluecol is now ordered and I\'m also picking up a bolt removal kit as well as some tappers. Malcolm if you could soak up the bolt with some penetrating oil, we\'ll have one more go...

Ian.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on June 01, 2011, 11:31:37 AM
Quote from: spoddy;766112
.

oh, on the quiet, i might be getting an fb, series 3. but will have to wait and see if it works out ok. sssshhhh keep stumm lol ;)

Suspense is killing me already.....Do the numbers in it\'s Reg add up to 18?
Just say yeh or nay, then I\'ll know I\'m right (or start chewing my finger nails again).......:Thumbs-up

Sorry guys, another small off post.....Excitement!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on June 01, 2011, 01:11:34 PM
oh, on the quiet, i might be getting an fb, series 3. but will have to wait and see if it works out ok. sssshhhh keep stumm lol ;)[/quote]
 
 
Yeh we\'ve all said this too - shhhhh keep it quiet - WHAT WITH A ROTARY! NO WAY BABY :3gears-rh
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 01, 2011, 01:17:36 PM
Quote from: David Nock;766201
Sorry guys, another small off post.....Excitement!


No problem David, given the help you\'ve given us!

Paul at Mazda Braintree phoned back this morning "having blown the dust off his microfiche". He confirmed he\'d found another part number (which I\'d also found, so promising). He said there were none in the UK, but would check if stock was in Belgium (if so, delivery next week) or if it would have to be sourced from Japan (unknown delivery time!). He is due to phone me back later.

I\'ve also phoned Tim at RX-Motors and he\'s also looking at the photos I sent. I think he actually sent us a FRONT oil seal......Have asked him about sourcing the 2 missing "flywheel inspection plates" too.

Typical, work is picking up too, so not much time to spend on Kimi at the moment. But I did order a few minor bits and pieces we needed :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on June 01, 2011, 01:19:19 PM
Quote from: HypoThermia;766115
The bluecol is now ordered and I\'m also picking up a bolt removal kit as well as some tappers. Malcolm if you could soak up the bolt with some penetrating oil, we\'ll have one more go...

Ian.


In my experience of the rusted bolts on my mx5 and rx7, after fiddling with bolt removing tools for a while I usually end up giving up and drilling the bolt out and re-tapping. So now I tend to go straight for the drill if the bolts sheared due to rust/seizing.

The bolt removers work well when the heads rounded off an otherwise perfectly good bolt. :)

Sounds like its coming along well guys. The black gunk in the rad is pretty grim! If the rad turns out to be not great, I\'ve got a perfectly good s2 one here you can have. The side bracket needs re-soldering, but thats a 5 min job but the core and fins are good.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on June 01, 2011, 01:24:18 PM
You guys are obviously in it for the duration so don\'t panic about getting it all done this month - "KIMI" will still be there waiting for his regular medicine. Better to get it right 1st time. :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on June 01, 2011, 09:08:17 PM
Quote
Yeh we\'ve all said this too - shhhhh keep it quiet - WHAT WITH A ROTARY! NO WAY BABY :3gears-rh

last time i tell you anything... :Laugh

not much to say yet really as have to sort stuff out a place for it to live lol and not sure if owner is selling yet and have to go see her.

so no point saying anything more just yet and don\'t want to offend the owner if he visits here, but i am very excited inside. like i say some things to sort out and then will be able to say more... so everyone breathe and relax and stop being 10 again and its christmas eve night and santa is coming lol.

 i dunno if reg adds up to 18, haven\'t seen it and its not the blue in rugby, although it looked good for the money. this one is black but thats all i can say and not attention seeking lol.:Laugh
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on June 01, 2011, 09:22:16 PM
The fans have arrived at home, however because I\'ve not been home for two weeks and my missus was at work when they arrived the postie left it at a neighbour.  Said neighbours have just got a new dog, a rescued border collie that had previously been abused.  When my missus went over to pick the parcel up the dog bit her and she needed 6 stitches!  So people have bled to get this car back on the road!  

As for the dog thing, the missus doesn\'t want anything done, the dog has a poor past and the neighbours who keep it are experienced dog owners who are looking after a neglected and abused animal.  They have promised to muzzle it whenever it\'s out of the house and to contain it away from visitors and all sorts.  They were apparently more distressed than my missus by the whole affair.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on June 01, 2011, 09:41:00 PM
no surprise as a dog could be destroyed over such things, better muzzling the dog before some child gets it. its understandable if the poor dog had a terrible life.
sounds terrible for your missus, is she ok? i am sure her hand is sore, very good of her to leave it, but sure she didn\'t want the animal any more problems etc.

i would feel awful too if i was the owners, i am sure she will make friends with the dog some time in the future and can look forward to a proper meeting.

so your missus is fb first blood, part one, a few curses with rusty bolts etc and you\'ll be first blood part two... ;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on June 01, 2011, 09:49:31 PM
She\'s okay.  Her parents live barely a mile away from us so she\'s on home turf while I am away.

I\'ve managed to avoid bleeding with the RX7 so far although I\'ve skinned more knuckles than I care to remember on various other cars in the past.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on June 01, 2011, 10:09:29 PM
i\'ve had my hand chewed by our dog a few times, but always made up lol. he\'s a yorkie, big one, 1 foot tall, but stands his ground in a fight lol.

yeah you always notice scraps after working on a car. an fb is easier to work round than say an rx8 or fd. i had a fight changing the oil filter on my 8 was too tight the old one and no room to work. managed to loosen it with the chain and then by hand.

i recommend those K&N oil filters and a magnetic sump nut :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on June 01, 2011, 11:12:49 PM
The 7 is very easy to work on, we just need to get the right parts and we can get it going again!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on June 01, 2011, 11:39:46 PM
Quote from: spoddy;766343
last time i tell you anything... :Laugh
 
not much to say yet really as have to sort stuff out a place for it to live lol and not sure if owner is selling yet and have to go see her.
 
so no point saying anything more just yet and don\'t want to offend the owner if he visits here, but i am very excited inside. like i say some things to sort out and then will be able to say more... so everyone breathe and relax and stop being 10 again and its christmas eve night and santa is coming lol.
 
i dunno if reg adds up to 18, haven\'t seen it and its not the blue in rugby, although it looked good for the money. this one is black but thats all i can say and not attention seeking lol.:Laugh

Hope it all works out nicely for you Spoddy (fingers crossed)
Cliff
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 01, 2011, 11:40:20 PM
I am really sorry to hear about your "betters half" ;) being bitten on an errand for Kimi! I do hope it\'s not too painful and heals quickly.

Not good news on the oil seal front today. I got back from a customer visit about 6.30pm to find a message from Paul at Braintree Mazda which said there are no seals in Europe, so he\'ll have to order from Japan - delivery time uncertain, but anything from 2-5 weeks :2eek

Not a good day, but we\'ve got plenty of other stuff to be getting on with I guess. I just hope that seal, when it eventually gets here, is the correct one! In the meantime, maybe Tim might come up trumps.....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on June 01, 2011, 11:43:18 PM
Quote from: Will66;766349
The fans have arrived at home, however because I\'ve not been home for two weeks and my missus was at work when they arrived the postie left it at a neighbour. Said neighbours have just got a new dog, a rescued border collie that had previously been abused. When my missus went over to pick the parcel up the dog bit her and she needed 6 stitches! So people have bled to get this car back on the road!
 
As for the dog thing, the missus doesn\'t want anything done, the dog has a poor past and the neighbours who keep it are experienced dog owners who are looking after a neglected and abused animal. They have promised to muzzle it whenever it\'s out of the house and to contain it away from visitors and all sorts. They were apparently more distressed than my missus by the whole affair.

Good to hear that fans have arrived Will and I hope your better half isn\'t too shaken with her ordeal and soon recovers.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on June 02, 2011, 12:03:16 AM
When we get Kimi running I\'m going to have to take her somewhere nice in her.  Probably involving shops and my credit card! :(
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on June 02, 2011, 12:05:13 AM
well if all goes well, i\'ll find out for myself lol, it\'ll be the end of the summer though. :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on June 02, 2011, 11:30:04 AM
Quote from: Casey;766411


Not good news on the oil seal front today. I got back from a customer visit about 6.30pm to find a message from Paul at Braintree Mazda which said there are no seals in Europe, so he\'ll have to order from Japan - delivery time uncertain, but anything from 2-5 weeks :2eek

Not a good day, but we\'ve got plenty of other stuff to be getting on with I guess. I just hope that seal, when it eventually gets here, is the correct one! In the meantime, maybe Tim might come up trumps.....


Hmmm....BlackDragonAuto.com in the States only list 1 oil seal for the 79-83 cars. They ought to be the same item?

Part No. 61-121.....it\'s a few dollars.

Might be worth checking out? a Jiffy Bag TransAtlantic might be quick?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on June 02, 2011, 11:47:17 AM
Page 118 in the Black Dragon on-line catalogue.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on June 02, 2011, 12:27:33 PM
At this rate we\'ll have a monopoly on all of the rear axle oil seals in the world :rollin The plan for world domination starts here :evillaugh

Ian.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on June 02, 2011, 01:04:46 PM
...and as long as you remember who your friends are when you are fixing your prices ......:rollin
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 03, 2011, 03:09:11 PM
Quote from: David Nock;766478
Page 118 in the Black Dragon on-line catalogue.

Thx again Dave. I couldn\'t find an email address for Black Dragon on their website :Hammer so I phoned "Elivira" on the "worldwide sales line". Rather than explain the problem I got their email address and have now sent an email to see if the part in their catalogue is one we haven\'t collected yet - my plan of world oil seal domination is coming together nicely :evillaugh:evillaugh
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: rote8 on June 04, 2011, 09:15:57 PM
Guys, have been avidly reading this thread and getting the updates and it\'s looking as though things are moving along at the sort of pace one would expect of such a project. :Thumbs-up

I am even more gutted now that I found it impossible to enter into the RPM collective. :(
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 05, 2011, 12:12:28 AM
^^^ Yeah Ray, we were hoping for quicker progress, but were always aware with an older car that things often don\'t run to plan, and that\'s how it\'s turning out.

We still really want to get her to RS8. She may not be the prettiest by then, but hopefully running and reliable enough for the journey!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on June 05, 2011, 12:52:24 AM
sounds like alot of work? is it a combination of rusty old parts and hard to get bits like the seals which is slowing you down.

at least there are no fancy electronics like in an rx8 to deal with. all your experiences will be of benefit to people like me who will know what they are letting themselves in for.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 05, 2011, 01:17:12 PM
^^It\'s the seal mainly, and then deciding the fan would need replacing. Minor things, but taking time. Until we can get those sorted and the car rolling again, we can\'t be sure there are other issues that might need attention once we drive her, and attempt an MOT.

Rust level is pretty low overall; it will attention to stop it getting worse, but not a "critical item" at this stage.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 08, 2011, 09:52:09 PM
Quote from: Casey;766728
Thx again Dave. I couldn\'t find an email address for Black Dragon on their website :Hammer so I phoned "Elivira" on the "worldwide sales line". Rather than explain the problem I got their email address and have now sent an email to see if the part in their catalogue is one we haven\'t collected yet - my plan of world oil seal domination is coming together nicely :evillaugh:evillaugh


:):) Black Dragon have confirmed they have parts in stock of a different Mazda FB rear axle seal - the only other one I can find that we DON\'T have, so very hopeful. Just $9.90 for TWO plus shipping, so I\'ve placed an order. They are due to contact me to confirm shipping arrangements and costs. Maybe, just maybe......
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on June 09, 2011, 06:02:14 PM
Hopefully we\'ll have the seal we need!  If we can get it on the car next weekend we should be close to getting the car MOT ready.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 14, 2011, 05:21:26 PM
I\'ve been chasing Black Dragon on the telephone as my order confirmation email said they would contact me with shipping options. It\'s taken a week and I\'ve just received this :eek:

*****These quotes are shipping costs ONLY. Total for the part/s is NOTincluded*****

UPS Worldwide Expedited for $144.62, taking 3-5 business days for delivery.
Priority Mail for $34.85, taking 10-15 business days for delivery.

None of the above shipping methods include any taxes, duties, brokerage fees or customs.  All additional fees will be your responsibility.  Time quotas do not reflect time spent in customs.

Ouch! I don\'t think I\'ll be taking the $144 option! I don\'t normally order stuff form the USA, so is this shipping cost normal, and does anyone know what extra "taxes, duties, brokerage or customs" fees I might incur on $9.90 worth of parts - can\'t be much, surely?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on June 14, 2011, 05:45:02 PM
The second sounds about right, but for such a small item its still steep. The biggest problem is parcel farce this end if they get hold of the package. For such a cheap item they most likely will just be put through your door.

Its probably a minimum weight thing. Wouldn\'t mind to know if they included some door seals if the postage would change any !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 14, 2011, 05:53:16 PM
Quote from: shaunwil;769018
Its probably a minimum weight thing. Wouldn\'t mind to know if they included some door seals if the postage would change any !


I suspect you are right - the shipping cost will be for a minimum weight and size that the seals are no-where near. I can always ask about adding the door seals, do you have the B-D part number and price?

I\'m also tempted to look through their catalogue and add some stuff we might need to make the shipping look more palatable!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on June 14, 2011, 06:21:45 PM
They are

59-342 DOOR WEATHERSTRIP-LH 1 REQ
59-343 DOOR WEATHERSTRIP-RH 1 REQ

Both are $49.95 each ! Blimey that isn\'t all that cheap !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on June 14, 2011, 10:07:46 PM
I would also have made the same suggestion to bulk up the order and make it more cost effective.
PM Steve (alias Rexanne) re additional costs - he recently imported Poly bushes for himself & Ian so will have some idea of anticipated extras.
Cliff
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 14, 2011, 10:37:00 PM
Shaun - I\'ve emailed B-D to check on whether the shipping will remain the same if I added the bits you wanted. I\'ll let you know what they come back with. If the same shipping and we go halves it won\'t seem so bad! If that is the case I can bring the bits up to Oulton Park next month...:)

My wife did a bit of research and thinks there may be an import charge of 0%-2.5%, plus VAT to add.

Yep, I\'ll have to ensure we do a decent sized order next time when ordering from abroad, and flag it here in case others want to split the shipping costs!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on June 14, 2011, 11:39:57 PM
Sounds like a plan :D Need to get them sorted before the weather turns nasty agin. They are just flapping off the door at the minute :Giggle

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on June 15, 2011, 09:49:58 AM
Yeah those postage costs seem about usual.

If you do get \'got\' by import tax and parcel force, then the tax itself will be tiny, but you get get stung with a \'parcel force handling fee\'.

I\'ve paid £.60 import duty and £18 parcel force handing fee, for sending me a letter to say i owed them 60p, before. :(
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on June 15, 2011, 10:48:02 AM
I ordered a set of poly bushes from the US on 24th April cost $234 of which $75 was for shipping, but I\'m still waiting for them to arrive.
 
   Dibs
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 15, 2011, 02:37:40 PM
Quote from: Steve-A;769140
Yeah those postage costs seem about usual.

I\'ve paid £.60 import duty and £18 parcel force handing fee, for sending me a letter to say i owed them 60p, before. :(


I don\'t feel the charges sound so bad, having heard that tale Steve!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on June 16, 2011, 06:25:52 PM
Quote from: A7RXY;769155
I ordered a set of poly bushes from the US on 24th April cost $234 of which $75 was for shipping, but I\'m still waiting for them to arrive.
 
   Dibs

Turned up today after coughing up another £25.74 tax and handling charge. You do seem to get a lot for your money with this kit.

   Dibs
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on June 16, 2011, 06:56:10 PM
Quote from: A7RXY;769557
Turned up today after coughing up another £25.74 tax and handling charge. You do seem to get a lot for your money with this kit.

   Dibs


did you go for the ReSpeed kit Dibs?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on June 16, 2011, 06:59:01 PM
Yes Ian, I hope you will be taking lots of pics when you fit yours, as I hope to do mine over the winter.

   Dibs
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 16, 2011, 08:35:50 PM
Question for you guys out there, any advice appreciated to help with this Saturday\'s main task, getting the rad and electric fans installed.

We have all the bits; electric fan, thermostatic controller (THIS ONE) (https://www.electricalcarservices.com/rad-fan-temp-controller-capillary-type-any-fitting-ecs-lfc01-p-839.html), relay, wiring and fuseblock. I\'m happy with how to wire it all up, it\'s just a matter of routing the cables and mounting bits in convenient positions. I have a separate 4 way std blade fuseblock to use for the control circuitry and relay to feed power to the fans.

HOWEVER, where is the easiest/best place to pick up a ignition switched +ve battery feed; is it best drop off the fusebox and "tap" in there, or is there somewhere else - I guessing not, because everything else should be a fused feed off the main fusebox? Haynes shows a Black/White wire with ignition feed to the fusebox....

And yes, I will remember to disconnect the battery before doing any wiring :)

Any advice before Saturday would be most welcome.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on June 16, 2011, 09:00:37 PM
Wire direct to the battery through a fuse for the fan relay, will also kick in when you switch the car off and help get rid the hot air.

All the thermostat is a jumped up version of a switch. Turning on at a given temp.

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on June 16, 2011, 09:04:54 PM
or drop the fusebox off by undoing the 2 no posi screws and connect onto the large black/white wire which is the switched lived...

(http://i589.photobucket.com/albums/ss333/gsxrmovistar1/DSCF1332.jpg)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 16, 2011, 09:31:38 PM
Shaun - I was thinking about that, but preferred the circuit to be isolated via the ignition switch. If the engine is too hot we\'ll just sit with the ignition on for a short while I guess. Hopefully, with the thermo control, that situation shouldn\'t arise!

Ian - that\'s exactly what I was looking for, and ties in exactly with the Haynes manual on the cable colouring. That\'s perfect, many thx :Thumbs-up
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 18, 2011, 09:28:20 PM
Well, Kimi now has a working, thermostatically controlled radiator fan! However, fitting it was full of challenges! Many thanks to Will, Sean (+young son Joseph) and Ian (Mothersole) for their help and support today.

Will arrived this morning with the two MR2 fans and we immediately spotted there was no way that we could fit two of them to the S2 rad! So we found a way of mounting one and then discovered the fan motor fouled on the water pump boss when we tried to fit everything in :Hammer

A bit of lateral thinking and we managed to offset the fan, and shift it forward sufficiently to clear the water pump. We had no issues with wiring up the controller and then came the moment to test it all. We switched on the ignition and twiddled the thermostat control knob and the fan kicked in fine. So, onto the real test, the engine fired up after about 5 seconds of cranking and eventually the engine got warm enough and we got the fan to kick in. It seems to work fine, but whether a single fan will be good enough only time will tell. We left her ticking over for quite a while and she seemed fine.

For this test we just used tap water, which I\'ve now drained out. It\'s pretty clean so I\'m happy we can now to top up with the supply of Bluecol that Ian (Hypothermia) had purchased and Sean delivered today.

Joseph (with Sean\'s supervision) also did some Hammerite black satin painting onto the rad top shroud, so his fine handiwork will be on display under the bonnet!

One question, the temp gauge on the dash is hardly moving at all off the stop. Is this normal? Is there a way to test operation of the gauge and the sender? I see the sender is shown as a variable resistor type and I didn\'t spot it\'s physical location today, but Haynes shows it connected with a Yellow-White wire, located somewhere near the oil filter area? I I have some variable resistors from my hobby days, so I might give one a try to test the gauge.

A few pictures of the install. Not terribly elegant, but if it does the job for now we can tidy and paint it up later!

First pic shows our carefully crafted fan brackets, pic 2 shows the "tap" into the main ignition power (thx Ian65), third shows the thermostat installation and fourth show the close clearance between the water pump boss and the fan motor. We\'ve taken lateral movement of the engine on the mounts into consideration and it looks fine...

Click on an image to enlarge.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on June 18, 2011, 10:03:00 PM
to test your temp gauge, look on the side of the engine just below the oil filter and you\'ll see the oil pressure switch.... a big round thing with a wire going to it! Behind this, scewed into the block, is water temp sender no.1 Pull the wire off it ( the yellow and white one)and earth it onto the engine block or body... the gauge should go to max.... the other water sender ( no.2) is by the thermostat housing onthe to of the water pump housing.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 18, 2011, 10:12:53 PM
^^ Thx again Ian. Superb, that\'ll test the gauge fine. Any way to test the sensors? Presumably they should (both), go to a lower resitance with temperature? So If I stuck an ohmmeter on them as the engine warms up I should be able to measure a change. Any idea on the resistance v temp I should see? If they are slightly "dodgy" with age, but still change a bit I might be able to strap on a parallel resistor to compensate maybe!

I won\'t have a chance to do anything for 10 days or so as Gwyn and I are off to the IOW next week. Typical, the April showers are late and we are going to get them next week by the looks of it :(
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on June 18, 2011, 10:14:20 PM
It can take forever to rise when you aren\'t driving the car down the road. Can take a good 30mins to warm up enough to kick the fan on when ticking over on the drive !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: captainbizzaro on June 18, 2011, 10:15:12 PM
Hopefully you put an inline fuse in place not far from that joint.......
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 18, 2011, 10:36:17 PM
Quote from: shaunwil;770142
It can take forever to rise when you aren\'t driving the car down the road. Can take a good 30mins to warm up enough to kick the fan on when ticking over on the drive !

Shaun


Ah, maybe that is it. I\'m used to the RX-8 gauge which moves up within 5 minutes! We probably ran the engine for about 20 minutes and simply checked the controller would kick the fan on and off, but cannot determine  the correct setting for the controller yet. Maybe we can really only do this once she is on the road and after she has done a "spirited run" and than comes to a halt for a while and heat soak kicks in.

Quote from: captainbizzaro;770143
Hopefully you put an inline fuse in place not far from that joint.......


:Thumbs-up Good point, yep, we did a cable run to the passenger footwell (cable way out of harms way thorough the centre console*) and installed a four way blade fuse box high up the footwell, under the carpet. That way we can add some further electrical circuits more easily in the future.

*I intend putting some further cable ties in place to ensure this cable won\'t move, as I realise it\'s carrying an unfused battery supply via the ignition to the "slave" fusebox. If that cable is compromised with the ignition on......:o
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 01, 2011, 03:52:17 PM
Oil seal saga - chapter 379.....;)

Black Dragon emailed me 2 days ago to say they wouldn\'t ship to the UK using a cheap carrier, insisting $35 or so was the best they could offer on a $5 part, so I was just pondering what to do when John Pease (Mazda dealer) left a message whilst I was away to say they had recieved the two seals I had requested from Japan and they were awaiting collection :Party

As the seals I ordered are the ONLY part number not yet in my "FB oil seal world domination master plan" :evillaugh I sincerely hope we\'ve secured the correct ones at last :o

The dealer about 30 minutes drive away and I need to visit a customer near them next week, so will have them soon......if they are the wrong ones......:Hammer:Hammer
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on July 01, 2011, 04:26:32 PM
fingers crossed :D

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on July 01, 2011, 07:38:25 PM
C\'mon Mazda Dealer be the right seal!  I shall leave offerings of high octane fuel on a shrine to the rotary gods to ensure the correct part arrives and we can get Kimi on the road and running!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on July 01, 2011, 10:25:45 PM
Then you will know what proper steering is like :Giggle Always a handful of fun to drive, not like the namby pamby power steering with a rack and pinion, good old pulman arm !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on July 02, 2011, 10:28:11 AM
I am looking forward to seeing what it is like on the road.  Should be an interesting drive, given it\'s a pulman arm system that\'s pretty similar to my old Land Rover\'s steering which worked in a largely advisory capacity.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on July 03, 2011, 02:30:02 AM
use your handbrake to help you go round corners lol.

i\'m looking forward to getting an fb and seeing how they drive even compared to my mx3 which is not too far off the rx8. just finished cleaning and re-oiling my mx3 K&N oil filter, gonna do the K&N filter for the rx8 tomorrow, should be a good day to get it done. its amazing the amount of flys and hair get stuck to these oiled filters inside the oem air box.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 05, 2011, 07:05:18 PM
Drum roll......picking up the seals tomorrow around 1.40pm....

In the meantime, to keep me occupied, I was concerned that when we ran the engine for about 10 mins on idle, the temp gauge was hardly reading at all. Worried we might have a duff gauge and/or sensor (and have no temp monitor!!) I decided to do some simple electrical tests, as the Mazda manual had some useful information on testing the gauge.

See scan of gauge spec below. I made up a simple test lead and used a selection of resistors I had lying around from my electronics hobby days. Using a 15 ohm resistor from the gauge to ground resulted in a needle movement of about 90% of scale - so not bad cf spec. A 56 ohm resistor put the needle about half way up the scale, 100 ohm near the bottom, so gauge looks good.

I then removed the temp sensor from the engine block. Veyr easy, just 14mm deep socket or ring spanner needed. It\'s located just below the oil filter (thx Ian65 for tellign me that earlier).

I then measured the resistance of the sensor at room temp; 557 ohms, which, as expected, wouldn\'t cause any needle movement. Exposing the sensor to near boiling water gave a reading of 55 ohms, which, based on the gauge test, would put the needle just about dead centre, so all looks good.

See photos of sensor tests.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 06, 2011, 09:48:17 PM
:Party:Party:Party:Party:Party:Party

The two seals are the correct ones! £8.50 for the two, inc VAT, delivered from Mazda in Japan to local dealer - result :Thumbs-up

The bad news is, I can\'t see me/us having any time to fit the seal before the w/end 16/17, my diary is just too busy :o

Regardless, it puts us back on track to get her ready for Rotorstock, providing we don\'t find anything unexpected during an MOT and test driving locally :Thumbs-up
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on July 06, 2011, 10:08:11 PM
Yay! The end of a saga. Want to be there for the fitting...

Wonder what the next one will be :Giggle

Ian.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: rote8 on July 06, 2011, 10:08:55 PM
Well done Malcolm. :Thumbsup!

Now you have the seal I shall quite miss the saga of world parts domination. :Giggle
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on July 07, 2011, 05:44:24 AM
YES! Fingers crossed there is nothing more sinister for the MOT!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Brett on July 07, 2011, 06:07:55 AM
Good work :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on July 07, 2011, 08:20:24 AM
Wonderful :D

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on July 07, 2011, 11:09:06 AM
Quote from: Casey;774224
:Party:Party:Party:Party:Party:Party

The bad news is, I can\'t see me/us having any time to fit the seal before the w/end 16/17, my diary is just too busy :o



Diaries don\'t tend to cover the hours between midnight and 6.00 am.....yawn, yawn.......:Snoring

Seriously pleased you\'ve got the seal Malc.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: myatt1972 on July 07, 2011, 08:58:30 PM
Congratulations !
Please post part numbers to save us the saga, also does the seal show any sizes on it that we could match with a non gen part.
Cheers,
Keith...
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 07, 2011, 09:29:40 PM
^^^ Unforutunately, no sizes on the seal packaging, just P/N\'s!

The correct number for our S2/S3 hyrid is
0187-26-154 ; O/D of ~55mm

Incorrect P/N\'s are;
1312-33-065 ; O/D of ~54mm (I now think this is a FRONT axle seal)
1011-26-154 ; O/D of 62mm
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: myatt1972 on July 07, 2011, 09:55:49 PM
Thanks for that very useful info :Thumbsup!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on July 16, 2011, 09:18:05 PM
A couple of pics from the work done on the car today - I think the first pic speaks for itself :D

We did have a slight problem with a sticking nearside rear brake caliper, which we put down to a slightly rusted brake disk and the LSD intervening. We\'ve not had a chance to put any load onto the car or see if the handling has been affected. I\'ve got a video of all of this - currently uploading to YouTube.

We also filled the rad, replaced the engine oil and filled the brake lines with brake fluid. The pic of the dashboard shows the oil at 0 psi, which was traced back to a connector cable slipping off the sensor so no harm done.

The last two pics are of course a pleasure to behold - we drove the car out of the garage and parked it on the driveway to adjust the parking brake. I\'ve never driven a car without power assisted steering, so it felt very "heavy". All in all a very satisfying days work...

Ian.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on July 16, 2011, 09:42:18 PM
Here's the video of the sticking disk...

http://www.youtube.com/watch?v=vDzOCm_Q4Uk
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: captainbizzaro on July 16, 2011, 10:41:35 PM
Have you got an American rear end on her then?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on July 16, 2011, 10:51:32 PM
Quote from: HypoThermia;776442
I\'ve never driven a car without power assisted steering, so it felt very "heavy". All in all a very satisfying days work...

Ian.


Gives you a good workout for sure. Makes you corner a bit quicker to keep the momentum up !

Looking like extremely good progress :D

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on July 16, 2011, 10:54:08 PM
Quote from: HypoThermia;776462
Here\'s the video of the sticking disk...


Sure its not a sticky piston ? Does the handbrake work ok (could be adjustment possibly ???)

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on July 17, 2011, 08:44:45 AM
I guess I was describing the symptoms rather than the cause - the disk stops rotating without any brakes being applied :confused: It did get better as we worked the brakes, but I don\'t think it ever went away.

We did adjust the handbrake and Kimi held on the incline. It holds at around 8-10 notches on Malcolm\'s drive.

Cheers,

Ian.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 17, 2011, 10:11:58 AM
I\'m not quite sure what the issue is with the rear n/s brakes - it could be a sticky pistion I guess. Until we can get the car up to road speed and test the brakes properly it is difficult to tell.

I\'m very pleased with the progress we made yesterday; definately a case of 3 heads (and pairs of hands) was better! It felt so good to get Kimi moving again, if only for a few yards - shame that Will had to leave just before we got to that stage.

The brakes, clutch and engine all felt fine - the engine seemed very strong and willing to pull! The electric radiator fan seems to be cutting in and out and doing it\'s job very well too in this small test.

I think we are close to me getting some day insurance sorted so we can book her for an MOT.............
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on July 17, 2011, 12:12:10 PM
Quote from: HypoThermia;776516
I guess I was describing the symptoms rather than the cause - the disk stops rotating without any brakes being applied :confused: It did get better as we worked the brakes, but I don\'t think it ever went away.

We did adjust the handbrake and Kimi held on the incline. It holds at around 8-10 notches on Malcolm\'s drive.

Cheers,

Ian.

4 to 5 notches is the \'rule of thumb\' MOT testers requirement  - what a great pun in there....:rollin...... Did you find the adjuster in the handbrake lever?

For brakes dragging, wouldn\'t you just spin the wheel and tyre by hand? It should turn freely but with a little rubbing/rasping noise as the pad just touches the disc. Particularly noticeable if he\'s been stood awhile. There will always be a little rubbing/friction.
Then when you touch the brakes or handbrake it should lock solid against you trying to turn the wheel.

Do you think it\'s LSD? Why? That stop/starting of the hub on the vid? That\'s just the axle diff allowing the shaft to stand still on one side at low revs isn\'t it? Am I talking bunkum here? Please alert me if I am!!!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 17, 2011, 01:45:22 PM
^^^The problem was, when we used the handbrake adjuster to set it to ~ 5 notches travel, then released the handbrake, we couldn\'t rotate the n/s rotor, but could rotate the o/s rotor. I looked under the car and could see the "T" bar pulling the two cables and it seemed to be pulling evenly. I think we have a sticking caliper or piston maybe? I think I will remove the lower caliper slider pin-bolt and give it a good clean and lube (copper grease OK, or something else?). That bolt did feel very tight; Ian and I had some difficulty getting the pin started. My feeling is it should have gone in very freely. Some brake cleaner in the bore to clean out as well maybe?

How does the rubber boot attach to the lower caliper slider pin bore? We tried to ease it out and didn\'t suceed - we thought it might tear it if we applied any more force.

Any help with the above would be great, before I disassemble/reassemble.

Another question re brake pads. In the end we had to re-use the old pads, after a good emery paper clean to remove oil contamination. We had a new set of pads but they turned out to be the wrong shape. I\'ve just gone on several websites to search for pads, using the car and model and 9/10 would have sent me the WRONG ones. It\'s only when I enter the part number (FA18-49-280, or FA67-49-280HA, which both appear to be the same) that I get the correct part. However, most suppliers don\'t let you search by the OEM part number! Pictures of the incorrect and correct parts (slightly smaller, different shape lugs) are attached. Can anyone shed any light on this issue? Even Clive managed to send me an incorrect set, having described the car and model (non-vented rotors).....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: mpk490p on July 17, 2011, 03:32:08 PM
i know the S3 rubbers just slide over the top on the calliper, i got new replacements for mine from http://www.rockauto.com/
http://www.rockauto.com/catalog/moreinfo.php?pk=541641
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on July 17, 2011, 07:19:37 PM
FA 67-49-280 is the part No. for Series 3 Rear Pads.

So the mystery deepens. The hubs (with bolts not nuts/studs) seem to be Series 2, but the pads are S3.

Back to a thought from a few posts back.....Has Kimi got an S3 axle tube with the original S2 diff/half shafts/hub assembly? Is that possible?

Or does it have S3 calipers on an S2 axle?  Is that possible?......Oh dear not straightforward at all.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on July 17, 2011, 07:25:34 PM
Quote from: David Nock;776545

Do you think it\'s LSD? Why? That stop/starting of the hub on the vid? That\'s just the axle diff allowing the shaft to stand still on one side at low revs isn\'t it? Am I talking bunkum here? Please alert me if I am!!!

no UK spec 1st gens came with lsd as standard.
To check, jack the back end up and spin a wheel by hand. If both wheels turn in the same direction, it\'s a limited slip diff, if they turn in opposite directions, it\'s a standard  diff.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on July 17, 2011, 07:32:17 PM
And from memory the S3 rear pads are slightly bigger than S2.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on July 17, 2011, 08:07:32 PM
Been to garage to measure my old pads. Those above with \'729\' on are deffo Series 3 pads (vented rotors)..... part no FB 712 628 ZA appears on the old packaging for the replacement pads (now on the car) direct from Mazda.

But a dealer gave me FA67-49-280 as another part No. for the same S3 pads. And he knew his stuff at that time.

Slider pins should be fine with a touch of copper grease or moly grease, something like that.

Hope that helps sort out the confusion???
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 18, 2011, 12:34:11 AM
^^^Thanks Dave, that input has helped me get this sorted.

If you look at THIS LINK (http://cn.oemol.com/oem/en_oem_detail/49111/D0235-7148/*.html) for FA18-49-280H, then it shows the pads we need (with "notches", rather than lugs on one pad). However THIS LINK (http://cn.oemol.com/oem/oem_detail_show.asp?id=49111&oem=FA6749280HA&lan=en) shows FA67-49-280HA to be the same shape!!!! These two websites would indicate that FA67-49-280A and FA18-49-280 are identical, but that is incorrect!!

A further search revealed THIS LINK (http://www.infodozer.com/catalogs/rspec/application.php?part=RSA-3051K) showing FA67-49-280 pads to be a different shape, more in line with what you have stated, Dave - they wouldn\'t fit our calipers, so I must assume for S3 with vented disks..

So, it seems safe to use the part number FA18-49-280, but none of the suppliers on the internet seem to use this part number (virtually no UK hits for this item...). I can see it\'s going to be a problem ordering spare pads by part numbers, as we need to check the shape! Wherever I tried to "dummy order" pads using 1983 (or 1985) RX-7, every supplier seemed to want to supply the S3 shape! For example, I tried the EBC website (search by car reg, which = S2) I got THIS RESULT (http://www.ebcbrakesdirect.com/search/byregistration.asp?regno=A778+YCU&x=13&y=15#) - clearly incorrect....

Ah! to confirm the above, I\'ve just found THIS LINK (http://www.mazdatrix.com/j-2brake.htm) which appears to show the S2 ("49-280A-FA18" - correct shape for what we need) and the "other shape" for later years (therefore assume S3).

Arrrgghh, got there, but my brain hurts:Hammer;);)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on July 18, 2011, 09:35:58 AM
Well you guys are certainly putting in the hours of research for the rest of us to benefit from :P

Just to confirm, my s2 takes the rear brake pads with the \'notch\', and I recently bought some EBC ultimax pads that fit fine. I got them here on eBay.. http://cgi.ebay.co.uk/MAZDA-RX7-2-3-EBC-ULTIMAX-REAR-BRAKE-PADS-79-83-/200484637183?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item2eadd0c9ff#ht_2857wt_948 (http://cgi.ebay.co.uk/MAZDA-RX7-2-3-EBC-ULTIMAX-REAR-BRAKE-PADS-79-83-/200484637183?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item2eadd0c9ff#ht_2857wt_948)

Interestingly the picture is of a s3 pad, but they do have a separate listing for s3 rear pads and the pads they sent me were correct!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on July 18, 2011, 10:28:22 AM
Excellent work folks! Sorry I could not make it. Looking forward to seeing her on the road, and I hope the rear brake trouble turns out to be something simple to resolve. :-)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 18, 2011, 10:48:17 AM
^^^Steve, many thanks for that.

It shows you have to be very careful when ordering the pads "unseen". The link you gave shows the wrong shape diagram, but the correct dimensions, suggesting the diagram is incorrect and the pads would be fine, as you have confirmed by ordering some.

.....and as for the photo of the pad in the ebay listing :rolleyes:

However, if they had sent you some with the shape shown, but the dimensions were wrong, they\'ve have had to go back...

Sean, you\'ve just popped up a message as I was typing this - good morning! Yep, really happy with where we are and hope to get a chance to pop the wheel and caliper off soon to check for sticking cailper or piston before booking for MOT, hopefully before the end of this month, or very early August!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on July 18, 2011, 12:42:23 PM
My pads only cost £15 last week for the rears buying them locally !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 18, 2011, 01:09:42 PM
^^Shaun, that\'s a good price for local pickup. Who stocked them locally for you - is it a national chain? We did drop down to Halfords on the off chance they might stock them, but they don\'t and they could only get Ferodos to order - I didn\'t bother to ask the price!!

Not an immediate problem as, after sanding the old ones, they look good and have plenty of meat left - almost like new.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on July 18, 2011, 06:02:40 PM
Just a local motor factor I use a lot ! Always a good service too.

The top of the pad isn\'t exactly the same but should have knocked off by now on the lip of the disk !

Done 50 miles on them already !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 10, 2011, 07:29:19 PM
Update.....

1. Rear steel bumper plus one of two mounts given the full POR15 treatment (see photo). Plan to refit bumper tomorrow.
2. Rear n/s caliper disassembled; copper grease on slide pin, missing pad clip put back on, and noted the piston was 90 degrees out and wasn\'t locating on pad properly. Reassembled and now the handbrake seems to work fine on 4 clicks - so should be OK for MOT :)
3. Disassembled front n/s indicator as the connector is dodgy - lots of rust in bayonet connector. Reflectors rusted too. In process of cleaning up to go back on tomorrow.
4. Positioned new 4 way fusebox (for electric fan) under glovebox and tidied up wiring.
5. Noted we still have a slight oil leak form sump/OMP, but can probably live with it for now.

Also, sorted out insurance for me to drive from midnight this Sunday - £141.34 for a year with Peter Best (3,000 miles)! Fully comp, £50 excess, windscreen covered (no excess), breakdown cover also included - bargain I thought.

I have spoken to local independent garage about getting MOT done next week and they are happy for me to observe whilst it\'s being done. I haven\'t booked it, but they only need a day or two\'s notice. If all goes well I will make a booking on Friday for next week.

So, RS8 is still a possibility if no unforeseen issues are discovered :):)

Pics of rear bumper with 2 coats POR15, rear valance (damaged before we got the car) with coat of Hammerite anti-rust paint (for now) and one bumper mount treated with POR15.

Click on pics for larger image....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 11, 2011, 08:13:25 PM
HELP!...........


Rear bumper back on, front n/s light cluster "refurbed" and lights in the cluster working fine now.

I was just doing a final check before phoning to book the MOT and discovered two problems;

1. Reversing lights don\'t work (not an MOT fail luckily) - bulbs are OK so I\'m guessing reversing switch or associated wiring on gearbox?

2. MORE IMPORTANTLY, the rear fog light doesn\'t work (MOT fail!)! I\'m assuming this operates from the switch on the steering column behind the hazard light switch? Nothing happens when this switch in "on", no light at the back and I can\'t see a tell-tale on the dash either (where is this located?). the bulb and wiring into connector on rear loom (Blue with Green stripe) are OK. If I check for volts on the connector I get nothing with the rear fog switch in "on" position (and ignition "on" of course :)).

Any ideas?

I can\'t see the rear foglight in any of the wiring diagrams in Haynes! Any idea which fuse it uses? Is it likely to be the switch on the column?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on August 11, 2011, 08:26:54 PM
Reverse lights, I had an issue with dirty connectors at the gearbox side under the car with mine.

Rear fog light, you have normal lights on as well as the ignition on and the earth is good? Fingers crossed you get it sorted.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 11, 2011, 11:27:28 PM
:o:o:o Doh!,Well done Steve, how did I miss that? Absolutely correct, when I put on the lights on first, the rear fog worked fine and the tell-tale lit on the dash too :Thumbs-up

Reversing lights - yep, that would be my call too. The switch is in a position to where corroded contacts would be very likely, so I\'ll have a look at that soon, but luckily not an MOT issue!!

I\'ve just gone through a 75 point MOT checklist I found on this interweb thingy and the only item I haven\'t checked is the windscreen wipers & washers, so I\'ll check them tomorrow and if OK, will book the MOT :)

It\'s going to be very tight for RS8!!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on August 11, 2011, 11:40:15 PM
Good news. :) On the foglight, I almost made the same mistake myself when checking before the MOT!

Good luck for friday :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on August 11, 2011, 11:46:09 PM
The wipers and washers worked fine when I was fiddling with it the last time I was down helping out!  Fingers firmly crossed for the MOT though!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 12, 2011, 10:15:39 AM
:eek: I\'ve booked the MOT for Monday at 2pm, fingers well and truely crossed :Giggle
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: mpk490p on August 12, 2011, 10:38:13 AM
good luck! sure it will be fine ;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on August 12, 2011, 02:42:17 PM
Good luck :D

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: CHC on August 13, 2011, 09:57:14 AM
Very best of luck guys - fingers & everything else crossed for you.
Sorry been away again and have missed all the \'fun\' stuff here.
Don\'t forget if they try to fail you on emissions - this is not relevant to this year of manufacture!
:Thumbs-up
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: mpk490p on August 13, 2011, 10:01:34 AM
unless you fall into 86 like me :(
luckily i have a friendly MOT station
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 14, 2011, 08:43:02 PM
Thx guys, I\'m hoping for the best tomorrow! I spent much of today giving Kimi a thorough clean, although could have spent a lot longer to get her cleaner still!

Hoping that, if she has a marginal MOT issue, the tester might look kindly on her if she looks as though she\'s being cared for :D

Some pics of  her, after claybar and waxing....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 14, 2011, 09:12:04 PM
that\'s looking great Malc.... good luck for tomorrow and don\'t forget, 1st gens first used before 1st August 1987 don\'t need to be tested for emissions, it\'s a visual check for smoke only...

Check this out...

http://www.rx7fb.com/viewtopic.php?f=12&t=211
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on August 14, 2011, 11:38:20 PM
good luck mate. she looks really well and if you have covered the points in the test, then you\'ll be ok. once you get her through, then its down to the car tax office and get a disc then out onto the road :)

i was at our car show and quite a few fb\'s were at it. been speaking to a few contacts and got to see the \'dark grey\' or black interior which i actually liked. to me it looks more black and goes ok with the grey seats etc so was great to actually see it in person rather than from pics were light can affect the colour.

so something might be on the cards for me as got a few people looking out for an fb for me. but want one more than ever now :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: mpk490p on August 15, 2011, 08:34:27 AM
Quote from: Ian65;782235
that\'s looking great Malc.... good luck for tomorrow and don\'t forget, 1st gens first used before 1st August 1987 don\'t need to be tested for emissions, it\'s a visual check for smoke only...

Check this out...

http://www.rx7fb.com/viewtopic.php?f=12&t=211


Thanks for that mine always struggles to get through always take it to the same garage who are helpful but i guess that won\'t matter now!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 15, 2011, 08:38:55 AM
Quote from: Ian65;782235
that\'s looking great Malc.... good luck for tomorrow and don\'t forget, 1st gens first used before 1st August 1987 don\'t need to be tested for emissions, it\'s a visual check for smoke only...

Check this out...

http://www.rx7fb.com/viewtopic.php?f=12&t=211


:Thumbs-up Many thanks for that piece of information, Ian.

I\'d heard that emissions was "visual check only", but couldn\'t find any reference to it anywhere. I\'ve printed out the item above will take it with me, in case there is an issue.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 15, 2011, 11:33:15 AM
Best of luck Malc, Kimi\'s looking oh so good.....:Thumbs-up

My trick is to always use the same tester like Mark, but also I\'ve memorised the VIN.

So when the tester is leaning over the bulkhead making a note, just stand behind him and recite it......it usually floors him!

Then he thinks....wow this guy does care.

You\'ve got a couple of hours.....common....repeat after me.....\'JMZFB13120070XXXX\'.

Any trouble with emissions Malc, tell the tester that we have contact numbers for DVLA (they have helped me in the past - my car is AFTER the first use exemptions for emissions but STILL qualifies due to it\'s earlier build date).

Dave
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 15, 2011, 03:46:07 PM
:Party:Party:Party:Party:Party:Party::):):):):):)

Passed with no advisories; tester really impressed with condition of the car and underside. I stayed with him throughout the test and he was really chatty, and into older cars. We talked about old Ford Anglias and such!

His only verbal comment was that the bushes looked a little cracked, but there was no play to be felt, so he was happy, as are we! I was concerned about the brakes (mainly because they hadn\'t been used for so long), but he said they were fine.

Glad I took along Ian\'s "get me out of emissions free" card, as they had only vaguely heard of the "let off" clause. He was happy once he\'s double-checked with a colleague.

Best part, went to settle up and was presented with a bill for £18.95! They had a special offer on MOT\'s that I wasn\'t aware of - I hope my luck is changing:)

The bad news is I have\'t got my insurance docs yet (I was "on cover" from 1pm today) so I need to chase that to get the car tax and maybe "RS8 is GO!"
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on August 15, 2011, 03:54:44 PM
:burnoutWell Done ........... Wellcome to the RX7 drivers Club .........:burnout
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: mpk490p on August 15, 2011, 04:32:53 PM
nice, always good when a old lady passes first time ;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 15, 2011, 06:34:12 PM
Gre.....at Stuff.....Very Pleased.

My tester says he doesn\'t worry overmuch about Jap bushes. He says they do crack but dont give play in the joints.

Once again....great.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on August 15, 2011, 06:42:22 PM
Wonderful news :D

Then you can enjoy oldskool motoring !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 15, 2011, 06:53:53 PM
that\'s great news guys... a just reward for all your hard work.
It\'s great to see another old car saved and returned to the road... you should be very pleased with yourselves... the aims of the RPM fulfilled!
Looking forward to seeing it in the flesh sometime...
well done!! top work!!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on August 15, 2011, 08:18:30 PM
Wooo awesome news!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: spoddy on August 15, 2011, 10:29:12 PM
knew you\'d pass. your MOT in england seems handier than ours, being able to go to a garage etc. better being safe and everything in good order so you\'re safe. plenty of rx7\'s only one of you ;)

but great news, insurance will be sorted easily then get out and enjoy her :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: re japi on August 16, 2011, 04:14:50 AM
Nice! Good job :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: C J R on August 16, 2011, 12:26:24 PM
Well done guys, nice to hear another Rotary has passed its test.
 
Look forward to seeing it at RS8.
 
Chris
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian.Mothersole on August 16, 2011, 02:27:09 PM
:Party:Party:Party:Party
Very good news indeed
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: rote8 on August 16, 2011, 09:25:17 PM
Well done the RPM.  :Thumbs-up:god
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 16, 2011, 10:28:14 PM
:) Thanks guys, I\'m still really chuffed we seem to have got her ready for a trip to RS8, which was the first objective we set the RPM. She may look a little "tatty" up close, but she\'s pretty solid overall (and excellent for her age!). With more time and effort she will gradually get better. My thanks to the rest of the RPM team for their support in getting this done in time :Thumbs-up

I\'m annoyed that my insurance covernote, supposedly posted from the brokers yesterday (their office is only about 20 miles from me) didn\'t arrive today, so I still can\'t get the tax sorted :mad: I\'m out all tomorrow, so the earliest I can get the tax sorted now is Thursday.......
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on August 17, 2011, 06:14:41 AM
Casey, can you not do the tax on line if the car was on a SORN ?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 17, 2011, 07:58:05 AM
I thought about that, but the DVLA website says to allow several days for delivery of tax disc, so it may not arrive in time. I suspect also that my new insurance wouldn\'t yet be registered on the DVLA database, as it takes a while for this to happen - it certainly was the case the last time I tried it :(

If the covernote doesn\'t arrive in the post today (whilst I\'m out) then I\'ll be driving to the broker to collect it tomorrow and then take it straight to the PO for the disc - I will not be defeated :Laugh
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on August 17, 2011, 09:09:59 AM
Tax is a bit of a pain isn\'t it.

How did it feel too drive her to the MOT station? Did she live up to expectations?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 17, 2011, 09:29:20 AM
^^I\'ll get the tax sorted one way or the other :D

The route to the MOT station was only about a mile, but I took a longer route, and picked up some fuel on the way. The roads were all 30mph and built up, so no chance to get my foot down. Kept under 4,500rpm as I didn\'t want to risk anything enroute to the test!

However, she felt willing, and pulled well, just had a bit of trouble finding the gate to 3rd gear :o - I\'m so used to the short-shifter on my RX-8 :)

Brakes were surprising good, although the bite is way UP the travel - only have to touch the pedal to get some retardation. Maybe I adjusted the handbrake too close for the MOT!?

Really looking forward to a longer test run as soon as the tax is sorted.

Got some curious glances at the Tesco petrol pumps! The Janspeed exhaust is quite "raspy" too, so that drew some attention....

BTW, is is worth using V-Power or Momentum, at least every now and again (for the additives), or just stick to regular 95RON?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 17, 2011, 10:46:28 AM
Hi Malc.
Don\'t think the handbrake adjust will have an effect on the footbrake? (unless you\'re binding badly....and you\'d sense that.....plus one or both back hubs would get mad hot in that case). More likely that pads are newish??

V Power, divided opinion on this. I say it\'s great to give the car an edge....more response and smoother running. The wife swears by it and to prove it she knew when I\'d put V Power in. Ladies don\'t seem to do fill ups do they?

A thorough scientific test I saw said if your engine is a high worker and stressed, V Power is of real benefit. If it\'s a lazy old donkey you\'re wasting your money as the higher octane won\'t help it. So you have to be objective, put a few tankfuls in and see what you think yourself.

It\'s great at junctions, petrol stations and the like isn\'t it? The 1st Gen really turns heads.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 17, 2011, 07:57:39 PM
Quote from: David Nock;782794
Hi Malc.
Don\'t think the handbrake adjust will have an effect on the footbrake? (unless you\'re binding badly....and you\'d sense that.....plus one or both back hubs would get mad hot in that case). More likely that pads are newish??


Yep, the pads have plenty of meat and look almost new, so could be that.

Quote from: David Nock;782794
V Power, divided opinion on this. I say it\'s great to give the car an edge....more response and smoother running. The wife swears by it and to prove it she knew when I\'d put V Power in. Ladies don\'t seem to do fill ups do they?

A thorough scientific test I saw said if your engine is a high worker and stressed, V Power is of real benefit. If it\'s a lazy old donkey you\'re wasting your money as the higher octane won\'t help it. So you have to be objective, put a few tankfuls in and see what you think yourself.


OK, I\'ll fill up the tank with V-Power to start with, then try a tankful of Tesco 95 to see if I can tell the difference :)

Quote from: David Nock;782794
It\'s great at junctions, petrol stations and the like isn\'t it? The 1st Gen really turns heads.


My RX-8 doesn\'t get any special looks around here as there are so many of them in Essex. I got more looks in 10 minutes at the FB than in a year in the RX-8!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 17, 2011, 08:02:05 PM
Hooray, insurance docs arrived today. I skived off a customer project to go home, collect the documents I needed, then headed to the main PO and we now have a TAXED, MOT\'s FB:Party

Was planning to take her for a test run this evening - it\'s been a beautiful day here but......

Got home from work about 6.30pm, stepped out of my daily (Honda Jazz) and it started to pour with rain :(. It\'s still raining now and gettign dark, so the extended test run will have to wait until tomorrow!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: rossonza on August 17, 2011, 09:25:59 PM
fb in the rain? what more could you ask for!??! haha
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 17, 2011, 10:31:15 PM
^^^ :Giggle As we\'ve not treated the surface rust underneath yet, I don\'t want to expose her to wet roads if I can avoid it :p
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 18, 2011, 10:43:40 AM
HELP!! I did a short run of about 10 miles, up to 50mph and stopped half way to do some checks;

Good news;
1. Engine, g/box, clutch OK
2. Electric fan working well and is more than adequate to cool the rad.
3. Steering is much better than I\'d been led to believe :Laugh

Bad news;
1. Now I\'m more "tuned in" I did sense the brakes were binding a little; no noise, just a sense of a little drag. After 5 miles, with no more than a little light braking, all four discs were very hot. Backed off the handbrake adjuster a little and drove 5 miles home with hardly any brake application and discs still very hot. I hardly have to touch the brake pedal before the brakes are applied, almost like they are half on already? Any ideas? I\'ve had a quick look in the Haynes manual, could it need there is an adjustment for "free play" on the pedal - is this something to try? The odd thing is, with the car jacked up, the wheels spin with only a small amount of drag and the MOT guy didn\'t make any comment either when he tested this. Not keen to do 100 miles to RS8 with risk of brakes overheating :2eek

2. Minor issue maybe. Noticed a slight dripping of oil from the bottom rear of the diff housing. It\'s not coming from the drain or fill plugs, but appears to be running down from the very top of the rear diff housing. There is some sort of plug (pressure release?) on the top of the housing, but I don\'t think it is coming from there. Is it possible that corrosion has eaten a hole at the very top of the housing? I\'ve cleaned the area now to see what happens when the car is standing, but I suspect this leak will only occur when the oil is being thrown about by the diff gears. No time today to jack the car up and take a better look.

I\'m off to work now, but I do have all tomorrow free, so any advice on what I can try tomorrow would be gratefully received! Hopefully can get it fixed in time for RS8.....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on August 18, 2011, 10:52:50 AM
If the wheels spin freely when up in the air then I can\'t see it being the brakes binding? Compared to the other cars I\'ve driven recently the FB brakes do seem to bite early in the pedals travel, and are in pretty damn powerful. Not really sure what to suggest other than double check for dragging by jacking the car up and do one run in your rx8 then in the fb and compare the heat of the disks. Disk brakes DO get hot and if the disk was cold enough to touch comfortable after a run that means the brakes not working. If its dragging you\'ll find it get so hot you may see dis-coulouration of the rotor and should feel the heat in the wheel or just radiating off the rotor before you\'ve touched it.

The diff housing is a 2 piece thing, and there is a seal line than runs vertically that joins the front half of the diff with the pinion gear and stuff to the main axel. Mine was a bit weepy. Just as a temporary fix you could always smear some RTV silicone round its join if that looks likely.

The plug on top is simply a tube into the diff covered with a plastic cap, it is a vent valve. I suppose if you\'ve overfilled it slightly it could be splashing out a bit.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 18, 2011, 11:01:01 AM
if the wheels are hot from normal road use, then the brakes are binding... maybe all the time or maybe just being slow to release after being applied

The only proper solution is to rebuild the calipers and clean out all the rust and crud to ensure a smooth operation.
this is the repair kit for the front calipers.... series 3 and series 2 kits are the same ones, the pistons are identical...

http://www.rx7fb.com/viewtopic.php?f=14&t=134

I rebuilt mine a couple of months back...

http://www.rx7fb.com/viewtopic.php?f=4&t=93&start=30

Easy repair.

my car now brakes in a straight line, wheels stay cool and performance and economy is up

.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on August 18, 2011, 11:10:39 AM
Looking Forward to Rotorstock and seeing Kimi running :-)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 18, 2011, 11:31:32 AM
With all four discs hot I think I would pedal adjust as a first step. Is the push rod into the master cylinder adjustable? Should there be some free play and there isn\'t any? Otherwise slow to release....? Master cylinder again.

A full brake bleed is very easy on the FB. Pre ABS and all that complication. Ian mentions dirt and crud.... it might help shift it although it won\'t do the job of a rebuild.

Start at the rear O/S wheel (farthest) and slacken the nipple with a good titchcy little socket, immediately retightening. (The socket frees the nipple without rounding it off, but then you want the feel of a good openend spanner for the actual job).

One RPM sits in the car, another has a bleed tube on the nipple. Put brake pressure on and then the wheelman shouts \'Down Fast\' as he loosens the nipple. Woosh..fluid into the air as the tube flies off....no not really.
He retightens before shouting \'Up\', at which point the pedal can be released. Repeat this 3 or 4 times then move to shouting \'Down Slow\'. The trick here is for the wheelman to close off the nipple during the downstoke. Repeat this \'Slow\' business 3 or 4 times.

Then move on to the N/S back. Then Front N/S,  finally front O/S next to the master cylinder. All the time you have to watch the resevoir and keep it topped up with fresh fluid.

Mrs Nock and I are the world champs for this job on the FB. I keep trying to give her the wheelman\'s job but no luck so far.

Rear axle....always a weep/drip on mine and most others I know of. As a problem I think it can be ignored.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 18, 2011, 11:41:21 AM
Quote from: Casey;782912


OK, I\'ll fill up the tank with V-Power to start with, then try a tankful of Tesco 95 to see if I can tell the difference :)



I think you have to have several successive tankfuls.....though they would say that wouldn\'t they.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 18, 2011, 11:54:21 AM
Quote from: David Nock;783041


Start at the rear O/S wheel (farthest) and slacken the nipple with a good titchcy little socket, immediately retightening. (The socket frees the nipple without rounding it off, but then you want the feel of a good openend spanner for the actual job).

One RPM sits in the car, another has a bleed tube on the nipple. Put brake pressure on and then the wheelman shouts \'Down Fast\' as he loosens the nipple. Woosh..fluid into the air as the tube flies off....no not really.
He retightens before shouting \'Up\', at which point the pedal can be released. Repeat this 3 or 4 times then move to shouting \'Down Slow\'. The trick here is for the wheelman to close off the nipple during the downstoke. Repeat this \'Slow\' business 3 or 4 times.

Then move on to the N/S back. Then Front N/S,  finally front O/S next to the master cylinder. All the time you have to watch the resevoir and keep it topped up with fresh fluid.

Mrs Nock and I are the world champs for this job on the FB. I keep trying to give her the wheelman\'s job but no luck so far.


Blimey Dave,
it\'s been a good few years since I went through that palaver!
Bought a one man bleed kit a decade ago and never looked back....

http://www.ebay.co.uk/itm/ONE-MAN-BRAKE-AND-CLUTCH-BLEEDING-KIT-NV16-UNIVERSAL-/370533599044?pt=UK_Hand_Tools_Equipment&hash=item5645860744

the best fiver I ever spent!.... probably.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on August 18, 2011, 11:59:11 AM
I must have had a crap one man bleeder because it was crap! I went back to the technique Dave described.

Be glad to be the wheelman Dave, it\'s the skilled side to the job. You\'ll find most friends/partners/relatives/pets can perform the pedal work, but it\'s takes experience to get a good bleed from the wheel end. :Giggle:rollin
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 18, 2011, 12:49:45 PM
Quote from: Steve-A;783049
I must have had a crap one man bleeder because it was crap! I went back to the technique Dave described.


it must have been because I\'ve had the same one for the last 10 years and it\'s fantastic.... never again will I fanny about with 2 people to bleed the brakes or clutch.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: johnnyboy on August 18, 2011, 01:55:19 PM
Quote from: David Nock;782794
Hi Malc.
V Power, divided opinion on this. I say it\'s great to give the car an edge....more response and smoother running. The wife swears by it and to prove it she knew when I\'d put V Power in. Ladies don\'t seem to do fill ups do they?
 
A thorough scientific test I saw said if your engine is a high worker and stressed, V Power is of real benefit. If it\'s a lazy old donkey you\'re wasting your money as the higher octane won\'t help it. So you have to be objective, put a few tankfuls in and see what you think yourself.

Back in the day (RX3 day that is...) it was "common knowledge" that Rotaries needed only the lowest grade fuel on sale - it was particularly noticable in foriegn parts (eg. Saudi Arabia, Kuwait, India) in the mid 70\'s that Japanese cars in general and RX\'s in particular had less trouble with the poor quality petrol on sale than Land Rovers did.
 
I can also vouch from my rallying days that you needed to tune to a particular fuel grade to get any benefit.
 
Finally and most important, I asked this question of Tim at RX motors in regard of Miss January (and he knows a bit about rotaries...) and he was quite definate that we should use RON 95.
 
So I do...
 
John
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: A7RXY on August 18, 2011, 02:07:34 PM
When I got my frist RX in 81 I was told to use lead free petrol, in the UK then the closest you could get to that was 2 star, as the lead clogged up the tip seals.
Now its all lead free but I have always run mine on the lowest grade I can get and never had any problems.
 
 Dibs
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 18, 2011, 02:17:56 PM
Quote from: A7RXY;783082

Now its all lead free but I have always run mine on the lowest grade I can get and never had any problems.
 
 Dibs


me too....
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Steve-A on August 18, 2011, 03:49:50 PM
I\'m also a fan of 95 :) I\'ve run it in both my rotaries.

As John says you need to tune the engine to take advantage of the higher RON fuels, the FB was, like most cars of the era, tuned to run on the \'standard\' petrol of the day, which was more likely 89-91 RON so even 95 is overkill :P

All the marketing companies like shell put out, about increased fuel economy and more power, is based upon modern cars with ECUs that have evolving tunes that will detect the extra knock prevention of the higher grade fuel and then tune the engine automatically to make use of it .
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 18, 2011, 05:01:04 PM
I always use premium unleaded 95 ron in my cars.... in my modern it is the  fuel specified by the manufacturer..... petrol\'s a big enough rip off as it is without paying an additional 6 or 7 pence a litre.
No benefit in super unleaded or performance fuels for me.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 18, 2011, 05:49:50 PM
Quote from: Ian65;783048
Blimey Dave,
it\'s been a good few years since I went through that palaver!
Bought a one man bleed kit a decade ago and never looked back....

http://www.ebay.co.uk/itm/ONE-MAN-BRAKE-AND-CLUTCH-BLEEDING-KIT-NV16-UNIVERSAL-/370533599044?pt=UK_Hand_Tools_Equipment&hash=item5645860744

the best fiver I ever spent!.... probably.


Naah.....A bit of old rubber gas pipe, you know, the stuff you used to connect your gas poker to...(:Nono!), an old jam jar, some fluid and \'orf you go.
The Nock duo can do the bleed in 30 mins or so, plus another 10 mins for the faffy clutch. (Can\'t get the jam jar to stay put)!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 18, 2011, 05:56:54 PM
Quote from: David Nock;783122
Naah.....A bit of old rubber gas pipe, you know, the stuff you used to connect your gas poker to...(:Nono!)

gas poker!! I haven\'t seen one of those for 40 years!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 18, 2011, 05:58:48 PM
Quote from: David Nock;783041
With all four discs hot I think I would pedal adjust as a first step. Is the push rod into the master cylinder adjustable? Should there be some free play and there isn\'t any? Otherwise slow to release....? Master cylinder again.


Looking at Haynes there is a pedal adjust Malc. It seems you need 1/4 inch at the fork where the pedal connects to the master cylinder. So there is some pedal travel before the brakes are applied.

Worth checking.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 18, 2011, 06:01:03 PM
Quote from: Ian65;783124
gas poker!! I haven\'t seen one of those for 40 years!


You\'ll be telling me next you don\'t drain the water out of the engine every winters night! I bet you use this new fangled antifreeze mixture?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 18, 2011, 06:11:38 PM
guys, since John reshelled this car, has it ever been on the road or didn\'t he finish the reshell?
I ask as if it\'s been on the road but now has the occasional gremlin through lack of use, the solutions to any problems may be different to issues caused by stuff being assembled / installed incorrectly...
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 18, 2011, 07:52:20 PM
Many, many thanks for all the ideas on the two issues I spotted this morning.

Quote from: Ian65;783134
guys, since John reshelled this car, has it ever been on the road or didn\'t he finish the reshell?
I ask as if it\'s been on the road but now has the occasional gremlin through lack of use, the solutions to any problems may be different to issues caused by stuff being assembled / installed incorrectly...


The car was reshelled in 1995, so John must have sorted out any teething issues long ago (I hope!).

As all four discs seem equally hot, I\'m hoping it might just be the pedal free play adjustment. If it is, I can easily do that tomorrow. I had already thought of Ian\'s suggestion that may be all the calipers need a refurb, but I\'m hoping this won\'t be needed. In fact the rear o/s caliper is clearly new, or a complete refurb unit already. The car brakes evenly and the heat in the discs is even, so I\'m still backing the theory the pedal needs adjusting as it\'s casuing some drag. The Haynes manual shows the adjustment method and that there should be 7-9mm gap between the pedal and the piston on the brake servo. I\'m hopign to find this gap is too small, causing slight application of the brakes with the pedal fully up.

The RPM team have already flushed the system with new brake fluid using the two-man method Dave so eloquently described :) , so I\'m guessing it\'s not that. There is no "mushiness" in the pedal, just ~zero travel to the bite point.

I\'m pleased the weeping diff is not unheard of. I\'ll try and track the source tomorrow and smear some sealant around as a temporary measure for now.

OK, I\'ll be up early tomorrow to have another look, then do another test run. Fingers crossed I can sort it tomorrow, so I can take her on a pilgrimage to RS8, where the other RPM\'ers can have a chance to drive her too.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on August 18, 2011, 09:14:08 PM
Hopefully it\'s just the pedal adjustment.  Fingers crossed!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 19, 2011, 11:42:27 AM
Good and bad news again;

The GOOD :mmmm

Brakes are sorted! There was ZERO free play in the pedal, which meant the brakes were slightly "on" all the time. Not enough to fail the MOT obviously, but enough to cause some drag. Just been for another run and the car feels so much better. It was a real joy to drive :yes I did about 20 miles on mixed roads and couldn\'t detect any problem from the driving seat. Temp about 1/4 to 1/3 on gauge, oil pressure ~50psi and no ominous noises or vibration. Got her up to 70mph ;) and she was just fine. Handling is surprisingly good (my expectations wuite low, so well exceeded). Found the buzzer works too :Giggle

The BAD, but hopefully simple to fix......

The leak from the diff seems, on a quick look, to be FUEL, dripping down onto the diff from above, so not the diff at all. There wasn\'t enough before to make out it was fuel - by the time it had run down from the top of the diff housing, dissolving years of grime, it didn\'t seem like fuel.

I\'m just about to go out and jack the car up for a better look. I\'m assuming it\'s a leak in the fuel lines which I think runs over that area? If I\'ve got a hole in the top of the fuel tank it might be another matter.....


Ignore that! I\'d just refueled the car and got a splashback which has left a lingering petrol smell around. Car jacked up and we have 4 small corrosion holes on the top/rear (of car) of the diff housing. They can\'t be seen until the car is jacked. I\'ll try, as a temporary measure, to seal these with RTV silcone and try another test run when it\'s set. However, I guess it means we need a new diff longer term (or at least housing)?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on August 19, 2011, 12:12:02 PM
So -- is that a green light for Rotorstock 8, then ? :-)

Do RPMers need to organise Day insurance so we can have a quick spin?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 19, 2011, 12:40:14 PM
Quote from: Casey;783320


Ignore that! I\'d just refueled the car and got a splashback which has left a lingering petrol smell around. Car jacked up and we have 4 small corrosion holes on the top/rear (of car) of the diff housing. They can\'t be seen until the car is jacked. I\'ll try, as a temporary measure, to seal these with RTV silcone and try another test run when it\'s set. However, I guess it means we need a new diff longer term (or at least housing)?


That\'s a very unusual problem....never, ever come across this before.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 19, 2011, 01:34:46 PM
OK, pics of the corrosion holes and silcone repair.....

Dave, should I be pleased we are the first to find this problem? - not sure on that, but at least others might like to check for this problem if they have a "weep" around the diff :D

I\'m going to get some lunch now, and do another test run when the sealant has set.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 19, 2011, 01:39:04 PM
Quote from: seanp;783327
So -- is that a green light for Rotorstock 8, then ? :-)

Do RPMers need to organise Day insurance so we can have a quick spin?


Well, it\'s looking good so far, subject to the test run later. I think if you get day insurance it might put the mockers on me getting there ;)

Also, when I looked into day insurance it was ~£25 per day, whereas I\'m paying £143 for a year (6 days at day rates...).

I was thinking there are lots of private roads at Santa Pod to take her for a little drive on private land - but don\'t be tempted to take her on the strip :p

If the journey up is uneventful, we might do an RPM "vote" on whether a "show run" on the sprint track is in order..............
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 19, 2011, 04:33:05 PM
OK, I\'m happy enough to attempt the drive to RS8 after the latest test run. Brakes are definately now OK, but still minor weeping from the repaired diff area. I\'ve dolloped on a load more silicone and will keep a check on it on the journey up.

Hoping to get to RS8 at about 8.30am if all goes smoothly......:D
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on August 19, 2011, 05:30:18 PM
When you get back Malc, check out something called Belsona. (belsona.com) It\'s a fabulous plastic metal. I used it once to repair a cylinder block that was blowing between cylinders. Once set you can actually machine it, saw it, anything that you can do to metal.

You would need to remove the silicone sealer, grind back to bright metal and use the Belsona. Might never need a new axle housing. There\'s no pressure there at all.

The problem will be bits falling in through the hole while you\'re grinding. Hard to see a way to stop this without pulling the diff. Maybe accept it and immediately do a couple of changes using cheap oil? Need to spin the diff in the oil by hand as well to get the bits out of the teeth?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on August 19, 2011, 06:23:18 PM
May just be a bit of a mig weld job to weld over the hole. Be surprised if its corroded out because the diff is just covered in oil !

I got 46.61 last year in my FB, good target !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 19, 2011, 06:48:57 PM
Well, we\'ve got to tackle the underbody surface corrosion before it takes hold, so, at some point, it looks like we should drop the whole back end, inc fuel tank, and have a good go at everything under there, POR15, etc, changing bushes too...

Fingers crossed no unforeseen issues occur on the way to Santa Pod. It\'s almost exactly 100 miles each way, so a good long test run :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian.Mothersole on August 19, 2011, 07:08:31 PM
Im sure it will be fine! :)

See you in the morning :Thumbs-up
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on August 19, 2011, 08:21:38 PM
does anyone know if the rear axle/diff housing is the same for s2 & s3 cars..... I know the driveshafts, diff, splines, etc are different but what about the actual casing?
I ask because I\'m going to fit my refurbed axle onto my car in the winter when I fit the polybushes so will have a spare s3 axle which you could have for free if it would fit....
does anyone know?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on August 19, 2011, 10:17:57 PM
Different lengths between the S2 and S3 because of the swap from drums to discs.

I can tape measure up next week after RS8 !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 19, 2011, 10:52:37 PM
Quote from: Ian65;783410
does anyone know if the rear axle/diff housing is the same for s2 & s3 cars..... I know the driveshafts, diff, splines, etc are different but what about the actual casing?
I ask because I\'m going to fit my refurbed axle onto my car in the winter when I fit the polybushes so will have a spare s3 axle which you could have for free if it would fit....
does anyone know?


Ian, that would be fantastic, if it fits! Given our history with finding the correct oil seal for the rear axle, our run of luck has got to change, surely.......;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on August 19, 2011, 11:14:23 PM
If it fits it would be great!  However I think if there are a couple of other FBs, ideally a series 2 and a series 3 at Rotorstock it would be worth a bit of a poke about on both to see what parts of Kimi are series 2 and what are series 3.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 22, 2011, 01:47:37 PM
Fantastic, about 200miles clocked up to Rotorstock 8 and back, plus Wii66 took her on the sprint track for a shakedown. Hypo tha Seanp also got a chance to give her quick test drives around the private roads.

Throughout, not a single problem. The sealant on the diff housing has sealed the leak; she used a little oil, but nothing unexpected for the mileage and use. No loss of coolant. Temps and oil pressure remained fine throughout.

I wasn\'t sure about her going on the sprint circuit until I completed the journey up and found she drove so well - a real, real pleasure to drive. Handling is far better than I expected and the when that 2nd carb opens she is a real delight, and just wants to go:3gears-lh.

Will66 managed the sprint circuit in 63 seconds, in a car he\'d driven only 4 miles, and knowing I had to drive it home when he\'d finished. Bearing in mind standard RX-8\'s were doing 56-60 seconds, I\'m well chuffed Kimi managed 63 with some "restraint". I\'m uploading some pics to Flickr as I type this - I will place a link here later. In the meantime, this is one of my favourite pics of Will66 and Kimi in action on the sprint circuit.....click on image for larger version.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on August 22, 2011, 02:46:57 PM
I like that shot, she\'s a pleasure to drive.  Steering is a bit vague about the straight ahead and has a lot more turns lock to lock than the RX8 but there\'s plenty of feel through the rim, brakes are good and strong and it\'s quite grippy despite the old tyres we had on.  I did lock the fronts when I was trying to suss out the brake pedal feel but only briefly.  
 
It requires a different driving style to the RX8, provided you can get the front turned in on an RX8 you can simply drive around the corner on the throttle with the limited slip rear diff keeping the power on between the wheels and the multi-link rear keeping both wheels on the ground even with the DSC off.  I think because the FB has a live rear axle and an open diff, the same technique results in the inside rear wheel spinning power away.  It seemed to like a silky smooth style far more.
 
Very impressed with the motor though.  I\'ve not been in any other FBs but Kimi was getting to an indicated 60 mph from a standing start before braking for the first corner, my RX8 was getting to an indicated 75 mph before braking.  I\'ve got no basis for comparison but I reckon ours is a good motor. It pulls well from low (for a rotary) revs too.  In the RX8 I was swapping between 1st and 2nd gear on the sprint track and I simply left Kimi in second, initially in deferency to her 28 year old transmission and a desire not to leave Malcom stranded on his drive home, but also because it felt unnecessary to drop into 1st.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on August 22, 2011, 05:09:44 PM
I\'m still amazed at how well she drives (engine, gears and handling), and was very impressed with how she looked on the sprint circuit.

OK, here\'s a link to a set of photos of Will66 driving her how she was designed to be driven............

We won\'t be doing this every day, but it seemed a good idea to give her a good workout and see how she performed :mmmm

BTW, a very rough calculation suggests we are getting about 20mpg.

Flickr Pic Link (http://www.flickr.com/photos/16924880@N03/sets/72157627493136104/)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: mpk490p on August 22, 2011, 07:14:43 PM
nice photo, good to meet you too ;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: lennycarloff on August 22, 2011, 10:56:38 PM
Kimi sure looked good out on the Sprint track ,it just goes to show what lots of time and a strained relationship can get you , hope to see her out more
Jim
:cheers
Title: S3 axle into an S2?
Post by: johnnyboy on August 25, 2011, 09:45:19 AM
Hi Guys.
 
With the expierence you have gained on S2/S3 back axles, is there any way I coiuld put S2 hubs on an S3 axle?
 
I have an S2 and I want an LSD, but also want to retain 13" wheels. I have come across a couple of S2 LSD\'s on american Ebay but they are expensive, unknown condition and shipping would be horrifying.
 
Best option appears to be an MX5 Torsen, but that fits an S3 axle...
 
Any suggestions?
 
John
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on August 25, 2011, 11:58:34 AM
Johnnyboy.  Unfortunately our experience doesn\'t stretch that far.  I\'m pretty certain we\'ve got an S2 Axle of some sort.  We\'re possibly looking into a new one since our axle casing is very rusty and there\'s a possibility of finding an S3 axle easier than an S2, at which point we\'ll possibly be into a similar set of circumstances as you.  An LSD would be good too but that\'s another discussion!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on October 16, 2011, 06:33:05 PM
Help! Georgous weather today so planned to take Kimi for a drive before the winter weather set in. She started fine, pushed the clutch pedal down and thought "that\'s a bit light!" Sure enough, tried (gently) to engage reverse to get out of the garage to be met by a noise that clearly showed the clutch hadn\'t disengaged :(. Checked clutch hydraulic fluid level - fine, and no leaks obviosuly apparent.

Shame, as I was really looking forward to a drive in the sunshine.

Any ideas on the likely cause?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on October 16, 2011, 06:53:07 PM
Most likely clutch slave cylinder seals or master cylinder seals Malc.

Test first by trying to see if the slave is extending and pushing the clutch fork, I suspect not.

Second I would put a bleed line on the clutch slave and see if you can get any fluid out of the nipple when the pedal is going down?

If you can get fluid out try and block the pipe into the slave somehow, (clamp flex pipe) to see if you can get pressure as well.

Those tests should show the way. Unlikely to be anything inside the clutch if it parked up OK?

Hope that helps.....Dave
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on October 16, 2011, 07:26:06 PM
Thanks Dave; yes, she was parked up 3 weeks ago after a ~250 mile excursion with no problems at all. My first thought was a dodgy hydraulic seal somewhere too. I doubt I\'ll get a chance to jack her up to take a look until next weekend now. Thanks for the advice on the diagnostics to perform.

Oh well, I was just getting to the point when I was thinking we should start on some "winter" project work on her. Looks like the list of work has just been extended (it\'s a long list already) :Giggle
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on October 16, 2011, 07:38:35 PM
Damn, smells like something in the Hydraulics though so shouldn\'t be an impossible fix.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on October 16, 2011, 07:39:12 PM
Quote from: David Nock;783378
When you get back Malc, check out something called Belsona. (belsona.com) It\'s a fabulous plastic metal. I used it once to repair a cylinder block that was blowing between cylinders. Once set you can actually machine it, saw it, anything that you can do to metal.

Just had a quick peek at that link to belsona.com (http://belsona.com) and got a.... Japanese flute orchestra! I know these cars need some special attention, though that does sound like an interesting way to repair a car :rollin

I think this is the stuff that you\'re after... www.belzona.com/ (http://www.belzona.com/) ;)

Fingers crossed for Kimi...

Ian.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on October 16, 2011, 10:29:42 PM
You can buy rebuild kits for both ends.

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on October 23, 2011, 05:07:24 PM
Quote from: David Nock;794743
Most likely clutch slave cylinder seals or master cylinder seals Malc.

Test first by trying to see if the slave is extending and pushing the clutch fork, I suspect not.

Second I would put a bleed line on the clutch slave and see if you can get any fluid out of the nipple when the pedal is going down?

If you can get fluid out try and block the pipe into the slave somehow, (clamp flex pipe) to see if you can get pressure as well.

Those tests should show the way. Unlikely to be anything inside the clutch if it parked up OK?

Hope that helps.....Dave


Thanks Dave; clamped flexible hose and pressure on the master side is fine, so concentrated on the slave side. When the clutch pedal was operated (still VERY light) the fork moved back about 1/2". I\'m guessing that is not enough and merely the free play before the springs on the pressure plate start to operate. Tried to bleed the slave, only to find I couldn\'t. There was so much air getting in from somewhere that I got more air coming out than fluid!. There was evidence of some fluid in the rubber boot, but not a lot. Decided to remove the slave and inspect. The bore, even well inside the cylinder, looks corroded and is rough to the touch, so I\'m guessing new or refurbed slave cylinder needed?

Any advice from anyone on the best place to source a replacement cylinder?

Also noted, when checking pedal adjustment for any problems that the height adjustment bolt is completely missing! Hopefully I\'ll find a suitable bolt and locknut lying around the garage somewhere
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on October 23, 2011, 06:01:28 PM
Casey,
I bought 2x master cylinders and 2x slaves last week for £87.00 shipped inc all duties.... so £43.50 for a complete set.....
here\'s the link...

http://www.rx7fb.com/viewtopic.php?f=14&t=286

don\'t bother trying to rebuild it.... it\'s probably the roughness of the bore that\'s done the seal so a new seal won\'t last long.... bin the slave and stick a new one on.
UK dealers will absolutely sting you for a new master or slave.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on October 23, 2011, 08:05:45 PM
Quote from: Ian65;795824
Casey,
I bought 2x master cylinders and 2x slaves last week for £87.00 shipped inc all duties.... so £43.50 for a complete set.....
here\'s the link...

http://www.rx7fb.com/viewtopic.php?f=14&t=286

don\'t bother trying to rebuild it.... it\'s probably the roughness of the bore that\'s done the seal so a new seal won\'t last long.... bin the slave and stick a new one on.
UK dealers will absolutely sting you for a new master or slave.


Perfect! Thanks again Ian - I see you only posted that info a few days ago! I agree the roughness of the bore means it\'s not worth just putting new seals in.

At those incredibly low prices, and with shipping a relatively high element, I\'ve ordered two different brands of slave, plus a master. Might be tempted to change the master at the same time as it\'s looking very tired!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian65 on October 23, 2011, 08:15:40 PM
Quote from: Casey;795842
Perfect! Thanks again Ian - I see you only posted that info a few days ago! I agree the roughness of the bore means it\'s not worth just putting new seals in.

At those incredibly low prices, and with shipping a relatively high element, I\'ve ordered two different brands of slave, plus a master. Might be tempted to change the master at the same time as it\'s looking very tired!


the way Rockauto work is they list stock from various suppliers... so if you order stuff from 2 or more different locations, you pay shipping from each ....
but once an item is in your shopping cart, they put a \'van\' icon against other items from the same supplier so that you can have them shipped together and save on the postage.
Even with the shipping and duty, they are still ££££££\'s cheaper than you will get them in the UK. I paid £8.00 for the slave and £12.00 for the master cylinder and brake caliper rebuild kits for £2.00 per wheel....  so even with the shipping and vat they are a real bargain.
Just goes to show the markup on stuff like that for the parts sellers in the UK.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on October 29, 2011, 12:51:12 PM
Hmmm, the "wrong parts" saga continues with the RPM "Odd" car...

I\'ve posted over here;

LINK to clutch slave puzzle (http://www.rx7fb.com/viewtopic.php?f=14&t=286&p=2364#p2364)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on October 30, 2011, 06:41:19 PM
New master and slave clutch cylinders now fitted, with fresh fluid flushed through the system. My conclusion is the failed slave cylinder I took off was the WRONG one. The new one seems perfectly positioned when the clutch is engaged, with the piston way back in the cylinder bore, as expected. The "wrong" one must have been working well "forward" in the bore and it\'s a surprise it worked at all! As you can see from the pictures, the actuating rod, with the clutch engaged, looks to be just right, with the dust boot near fully compressed, but not quite.

A  test drive revealed some slight adjustment needed at the pedal end to take up some slack, but the clutch operation is fine.

I need to get a bleed nipple cover from somewhere as the original was missing and none was supplied with the new one!

First pic shows faileded slave on left and new one on right, with mountings 20mm back....

2nd & 3rd pics show new slave sits perfectly on mounting point, correct distance from clutch arm, how did the old one ever work :3Confused

"Odd" one....reflecting this car\'s history ;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on October 30, 2011, 10:07:30 PM
Good to hear its fixed :D

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: HypoThermia on October 31, 2011, 08:23:14 PM
And I have some bleed nipple covers running spare - would have given them to you on Friday but couldn\'t make it to the meet.

Ian.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on January 16, 2012, 11:27:21 PM
Right, Kimi is now "laid up" for some winter work. First off is to dismantle everything underneath the back end, clean up, refurb, replace bushes, paint, etc. Not a task I\'m especially looking forward too, but planning to do it slowly and steadily as I get a spare hour or so, and with the help of other RPM members, when they can make it.

Started last week by getting her up on some stansds and dropping the fuel tank and pump. Only reasonably pleasant surprises so far. All the bolts came off OK. It looks like the petrol pump has been refurbed or replaced recently, plus the fuel tank is in remarkable condition. It has been coated with a thick "waxoil" type product and, on top, there is no signs of any bubbling of rust. Underneath, there are a few places where stones have chipped off the coating, by no significant rust there yet, so just patching needed.

Some pics; as I say, nothing too horrifying (yet!) but I\'m thinking it could be a good plan to change the back axle. It already has several holes in the casing that I\'ve patched with RTV Silicone, and the drain plug thread is badly damaged and would need repairing as the plug won\'t screw in far and there is a constant oil weep. Has anyone got a spare rear axle lying around? - else I\'ll start looking at who\'s currently breaking.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on January 16, 2012, 11:54:26 PM
Wow! She\'s not looking too shoddy at all under there... Will have to find another weekend to come around and spend some time getting down & dirty, and learning how not to shear bolts off!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on January 17, 2012, 12:11:08 AM
Likewise!  She\'s very clean!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Arnie_O on January 17, 2012, 12:15:22 AM
Nice Work There Malcolm
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: re japi on January 17, 2012, 05:37:56 AM
She´s got clean ass. ;) Hmm, interesting. My brother has -84 FB, and that fuel tank seems very different looking. Or is my memory just playing tricks on me... ;)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Will66 on January 17, 2012, 07:27:21 AM
This one is a bit unique, all the running gear is 1983 but the shell is 1985.  Makes finding bits for her interesting!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on January 17, 2012, 12:18:13 PM
Quote from: re japi;807669
She´s got clean ass. ;) Hmm, interesting. My brother has -84 FB, and that fuel tank seems very different looking. Or is my memory just playing tricks on me... ;)

No, you\'re right.

That is a Series 2 fuel tank. The Series 3 has the pipes in/out via a circular gasketted plate, not seperate through the tank top.

We\'re sure Kimi is a Series 3 shell from the VIN, but the late owner John had piled all his Series 2 parts onto it, (including his series 2 Registration).
The tank is presumably a newish S2 one that John had found somewhere.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on February 19, 2012, 06:14:31 PM
No progress on the planned "backend underbody refurb" since the report above.

However, the sun made a very welcome appearance today so I decided on the spur of the moment to don my overalls and get to work removing the rear axle. As most people have said, what a PITA job :D. However, it was satisfying to get to the stage where everything is now unbolted/disconnected, with the axle/diff resting on stands, ready to pull out. I\'ll going to need at least another RPM member over here to help with that one!

The nuts on Watts linkage central pivot bar were rusted solid. One end bolt sheared (despite a soak in penetrating oil last week), so I took a nut splitter to the other one. Other than that, the nuts and bolts elsewhere came apart - some easier than others, thank goodness for my 3ft breaker bar!

I had also suspected a petrol leak from the tank as I ahve noticed a smell of petrol when filling the tank more than half full and then leaving the car in my garage. Today, in pouring the remaining 10L or so of petrol from the tank into a can (which came out very clean with no debris :Thumbs-up) I noted petrol was spilling out from the seal around the sender unit. Hopefully that will be an easy fix! Now I look back at the first photo of the tank above I can see petrol must have been seeping out and dissolving away the black "underseal" on the tank around that area, exposing the metallic blue paint underneath. Glad I spotted that one!

Also spotted were a couple of small holes on the exhaust pipe, just upstream of the backbox - maybe the Janspeed isn\'t quite as loud after all :Laugh

I\'m going to feel it in my muscles tomorrow - I need a soak in the bath tonight I think :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on February 19, 2012, 06:38:01 PM
Those little screws that hold the sender in are a bit of a pain Malc. I think I had to drill  mine out when I swopped tanks.
The seal is a fairly chunky cork thing (again from memory).
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on February 19, 2012, 10:16:08 PM
Sounds like you have had an enjoyable day !

Its the Diff swap that is an absolute pain. The axle in itself isn\'t too bad, just heavy !

You should be able to make your own gasket up out of the correct material sheet and a pair of scissors.

Have you got a welder to fix the exhaust ??

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 04, 2012, 07:51:04 PM
Quote from: shaunwil;812966
Sounds like you have had an enjoyable day !
I did indeed!
Quote from: shaunwil;812966
Its the Diff swap that is an absolute pain. The axle in itself isn\'t too bad, just heavy !!
It certainly took both my my son and I to move it safely from under the car, with the help of two trolley jacks

Quote from: shaunwil;812966
Have you got a welder to fix the exhaust ??!
We\'ll probably just Gum-Gum or bandage it for now. May decide on a different strategy once we remove it for closer inpection.

OK, now after some help on what to do with the axle. I think is is salvagable, but would it be better to source a better one from a breaker, if I can find one? There are three main issues;

1. Rust on the diff housing (see pic) - I think the best plan is to remove the diff and take a look on the inside to see the extent of the rust there. If not too bad it might be repairable by some metal epoxy? Any other ideas?
(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Axle/DSC_0006.jpg) (http://s1152.photobucket.com/user/casey_kimi/media/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Axle/DSC_0006.jpg.html)

2. The fill plug thread is badly damaged. Maybe best to tap to a slightly larger size and fit a short metric bolt with crush washer?
(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Axle/DSC_0008.jpg) (http://s1152.photobucket.com/user/casey_kimi/media/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Axle/DSC_0008.jpg.html)

3. Watts link is pretty badly rusted, but probably OK once it\'s been cleaned up? I\'ve already sheared one bolt :o
(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Axle/DSC_0007.jpg) (http://s1152.photobucket.com/user/casey_kimi/media/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Axle/DSC_0007.jpg.html)

Any advice form those more experienced would be most welcome!
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: mpk490p on April 05, 2012, 09:04:50 AM
i might have a good diff case
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 05, 2012, 09:24:35 AM
Quote from: mpk490p;818782
i might have a good diff case


Oooo! Is it for a Series 2? Please let us know more..........:)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: David Nock on April 05, 2012, 12:25:01 PM
Just my thoughts.....

I\'d out the axle case, keeping the internals (of course). There\'s at least 3 problems with that one (=scrap)

An S2 complete axle should be possible from a breakers if Mark doesn\'t have a spare banjo housing.
And perhaps the Watts linkage on the breakers axle might be more amenable?
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on April 05, 2012, 12:56:21 PM
Quote from: David Nock;818803
Just my thoughts.....

I\'d out the axle case, keeping the internals (of course). There\'s at least 3 problems with that one (=scrap)


Yes, I that\'s pretty much the conclusion I\'ve been pondering. It all depends on how easy it will be to secure a better casing somewhere not too distant. If Mark has an S2 axle casing in better nick than KIMI\'s, then I think that will be brilliant.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 19, 2012, 11:58:57 AM
Update - I was down in Poole last month and had arranged with Tim at RX-Motors to inspect an FB S2 rear axle he has on a car he is breaking. Come the time, there was an almighty downpour all through the night and the day of the planned visit. I called Tim and he said not to bother as we\'d have to inspect in a muddy field! Neither of us fancied crawling under a car in a field in a downpour.

However, I\'ll be down in Dorset again this Friday, so fingers crossed for better weather and I\'ve arranged with Tim to drop by to look at the axle.

In the meantime, progress has been slow on Kimi, but I\'ve spent a few hours recently on the lovely job of removing rust from under the o/s wheel arch. It\'s not too bad though and nothing that needs welding.

I also managed to dismantle a couple of stubborn suspension bolts with WD-40, two breaker bars and a lot of brute force! Still got two left which are proving to be really difficult......

Still hoping to get her ready to get to Rotorstock this year, as we did last year :)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on July 09, 2012, 05:07:02 PM
Update - went to see Tim at RX-Motors to inspect the rear axle. Looks a lot better than the one we have, so agreed to purchase. He\'s now got to remove it from the "breaker car" then I\'ll go down to collect.

Progress is slow on Kimi. Once I started on the rust removal I decided it had to be done thoroughly, as I didn\'t want us to be doing it again in a hurry, so WIP shots here, after attacking with wire wheels, brushes, angle grinder and dremel :) No yet happy it\'s ready for chemical prep and POR15 treatment, but getting there.....

(https://farm9.staticflickr.com/8149/7501211514_33c78f5f72_c.jpg) (https://flic.kr/p/cqRER1)

(https://farm9.staticflickr.com/8019/7501213178_befc961542_c.jpg) (https://flic.kr/p/cqRFkG)


A while back the driver\'s side window had jammed shut and the motor wasn\'t moving it. It had always been painfully slow anyway, so decided to remove the motor, windows and regulator mechanism so I could clean and refurb those components and also get a chance to inspect inside the door. Glad to say the inside of the door is very clean and rust free, so need to treat that with some rust-proofing sealant before putting everything back together.

Here\'s the motor after taking it out;
(https://farm9.staticflickr.com/8283/7536183520_fb380d5d18_c.jpg) (https://flic.kr/p/ctWUNC)

It tested OK, but a bit slow - ignore the 24v on the meter on my homebrew bench power supply ;);
(https://farm8.staticflickr.com/7277/7536185182_2fa360052f_c.jpg) (https://flic.kr/p/ctWVih)

Decided it was best to dismantle it to inspect and clean up;
(https://farm9.staticflickr.com/8141/7536185770_31150256d2_c.jpg) (https://flic.kr/p/ctWVtq)

Re-greased the worm drive ready to re-assemble;
(https://farm9.staticflickr.com/8430/7536186264_58620a5de6_c.jpg) (https://flic.kr/p/ctWVBW)

After cleanup and test, runs much sweeter now!
(https://farm9.staticflickr.com/8007/7536186686_a5a628b4d5_c.jpg) (https://flic.kr/p/ctWVKd)


Unless a miracle occurs, I can\'t see us getting her to Rotorstock this year, there\'s so much to do and not that much time to get it done.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: C J R on July 09, 2012, 05:20:01 PM
WoW Malcolm, Thats a lot of effort and time your investing (and patience).
 
Keep up the excellent work ethic.
 
Chris
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: shaunwil on July 09, 2012, 06:06:26 PM
Some very nice work, wish mine looked as clean as that on the rust front !

Shaun
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Ian.Mothersole on July 10, 2012, 10:34:59 AM
I wish my RX-8 looked as good as that on the rust front!

Great work there Malcolm
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on October 24, 2012, 07:25:59 PM
It\'s been a while since I\'ve been able to get some significant time to progress the work on Kimi, but spent a good few hours on her last weekend. I also took today off to collect a used "DoubleS" brand complete Stainless Steel exhaust from an ex-FB owner, Paul Osborne, down in North Kent.

Gwyn came down with me and we took a few hours out whilst in North Kent to visit Whitstable and had a lovely lunch there :)

The SS exhaust;
(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Exhaust/DoubleSStainlessExhaust_zpsec68c360.jpg)
Rear Offside Wheelarch; "Marine Cleaned" and "Metal Prepped";

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Offside%20Wheelarch/Finalacidetch3_zps467a09c5.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Offside%20Wheelarch/Finalacidetch2_zps1cae290f.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Offside%20Wheelarch/Finalacidetch7_zps6bf3a145.jpg)

Two coats of POR15;
(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Offside%20Wheelarch/Offsidewheelarch031_zps480a4d6a.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Offside%20Wheelarch/Offsidewheelarch023_zps2cbe4a9c.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Offside%20Wheelarch/Offsidewheelarch029_zps19660934.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Offside%20Wheelarch/Offsidewheelarch028_zpsf20378dd.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Rear%20Offside%20Wheelarch/Offsidewheelarch016_zps60d318a6.jpg)

Also did the full derust, Marine Clean, Metal Prep and 2x POR15 coats on fuel pump bracket;
(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Fuel%20related/Fuelpumpbracket2_zpsf8b27d08.jpg)
The wiring on the fuel pump and it\'s connector was a bodge, so soldered on new connector;
(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Fuel%20related/Fuelpumpandwiringbefore_zpsfaa66e3b.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Fuel%20related/Fuelpumpconnectorbefore_zps8af9c8bd.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Fuel%20related/Fuelpumpandwiringafter_zps1ef99e0c.jpg)

(http://i1152.photobucket.com/albums/p481/casey_kimi/Mazda%20RX-7%201st%20Gen%20-%20KIMI/Fuel%20related/Fuelpumpwiringsolderedandheatshrinked1_zps52c8afd4.jpg)
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: rote8 on October 24, 2012, 08:44:17 PM
Excellent work Malcolm, coming on a treat and you have the whole of the winter months to progress it further. :evillaugh

Seriously looking great.
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: C J R on October 24, 2012, 09:32:35 PM
Malcolm, you have too much time (http://www.mazdarotaryclub.com/forums/images/icons/icon7.gif)
 
The project is coming on really well. Looking forward to seeing the finished article next year.
Keep up the good work.
Chris
Title: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: seanp on October 25, 2012, 04:32:49 AM
Wow! Super work Malcolm :)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: re japi on January 09, 2015, 08:17:49 AM
Any updates??? :)

Just went thru this thread, again. Stunning work even thought you had some problems. :)
But I think I missed something. Was your engine in running condition or did you rebuild it?
And is that diff s2 or s3, how many splines in axles?

Anyways, very good job :)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on January 09, 2015, 11:17:00 AM
Hi Jarno  8) - progress has been slower than I would have liked, but I deliberately haven't set myself any deadlines as I really enjoy working on the car when I do get some spare time. Diff and rear axle are S2 and I ran the car on the road for a year after an initial "quick fix" period, just to shakedown any possible issues. That revealed a rear axle seal leak, brake binding, diff housing corrosion, failed clutch slave cylinder, but the engine pulled really well (160k miles on the clock with undocumented rebuild around 90k). Having enjoyed some driving on the road I decided she was good enough to do a much more thorough restoration, primarily to sort out the rust underside (which isn't too bad for a 31 year old car!), and that's still the current focus of work.

A few pics of work since the last update:-

I decided the diff and axle were salvageable, so got a local machine shop to weld up the holes and cut a new thread for the fill plug to fit a proper bolt with crush washer. Once I got that back I thoroughly cleaned the whole axle and diff housing and gave them both the full POR-15 treatment.

After clean up:
(https://farm8.staticflickr.com/7574/16051262247_7ccc2e63b4_c.jpg) (https://flic.kr/p/qsoV3P)

Axle housing after POR-15
(https://farm9.staticflickr.com/8650/15614689634_c13990988e_c.jpg) (https://flic.kr/p/pMPndN)

(https://farm9.staticflickr.com/8580/15617249463_6b28872bd8_c.jpg) (https://flic.kr/p/pN3uaM)

Diff, before and after;
(https://farm4.staticflickr.com/3887/14411495641_077f823630_c.jpg) (https://flic.kr/p/nXuFyM)

(https://farm4.staticflickr.com/3869/14414846515_cc0cd4e7aa_c.jpg) (https://flic.kr/p/nXMREt)

Suspension arms going through the POR-15 treatment, ready for Energy Suspension re-bushing;
(https://farm4.staticflickr.com/3849/14228236238_3f545bc1db_c.jpg) (https://flic.kr/p/nFiqVU)

(https://farm6.staticflickr.com/5509/14228253510_34b698d280_c.jpg) (https://flic.kr/p/nFiw4G)

Fuel straps getting the POR-15...
(https://farm4.staticflickr.com/3878/14228229348_91a3bb50f9_c.jpg) (https://flic.kr/p/nFioT7)

(https://farm3.staticflickr.com/2925/14228194919_89fd67f2e5_c.jpg) (https://flic.kr/p/nFidDv)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: boosted on January 09, 2015, 11:24:11 AM
Had not seen this thread before!  :13: :00123102: had a good read exceeeeelent thread. hoping to see this 1 day .....and have a go! :3some:
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: re japi on January 09, 2015, 11:38:09 AM
Awesome  :13:
How much that Energy Suspension bushing cost, and where did you buy it?
Ya, shakedown was a good idea. Quite interesting is that your car seems to be in very good condition. I have seen few UK FB project pictures ;)
I wasnt sure what you did to diff. So thats why I was curious ;) Do you want to buy s3 diff with 5.125 and lsd ;)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: C J R on January 09, 2015, 12:35:50 PM
Well done Malcolm, Good to see your still making progress.

No deadlines but which shows will you bring it to in 2015 !!!!  >:D
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on January 09, 2015, 03:26:18 PM
Thanks for the comments guys!

@C J R - it would be a miracle if I made to to any shows this year, so much to do. Contemplating doing a full POR-15 fuel tank refurb, especially after watching the legendary Aaron Cake refurb his RX-5 Cosmo tank. It took him DAYS with all the cleaning and prep work, but the result was stunning. I've just got a mini usb camera which I'm going to use to inspect the interior of the tank to see what it looks like - expecting to see a lot of corrosion on the top inside....

@re_japi, FULL set of Energy Suspension bushes cost £145, inc shipping from USA. I don't think the S3 diff is compatible with the S2 axle and half shafts? If it was, I would be interested!

@boosted, it was great to be able to get to Rotorstock a couple of years back, giving a few other guys the chance to drive it without worrying about road insurance. I was very surprised how well it handled on the sprint circuit in comparison to the RX-8, not bad at all for a 30yr old  (the car that is!)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on January 09, 2015, 03:43:23 PM
With this project I'm very keen to try and lean some new skills and gain better mechanical experience. I've done simple jobs on most of my cars in the past but nothing on this scale. As an example I thought it would be a nice idea to learn about electro-plating (not done any since Chemistry back in school days). So, i bought a "Gateros" plating kit and decided to have a go at cleaning up the suspension bolts. Here's the results; right hand one has been mechanically cleaned but not plated, the rest have been plated. Quite pleased with the outcome - even though they will be pretty well invisible when back on the car!

(https://farm8.staticflickr.com/7511/16237734952_2d8d3d197c_c.jpg) (https://flic.kr/p/qJSCTs)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: re japi on January 09, 2015, 03:50:40 PM
Yes, propshaft flange is different. And driveshafts are different. S2 has 24 splines and are smaller shafts with smaller outer bearing and S3 has 26 splines with bigger shafts with bigger outer bearing.

But you can fit S3 diff to S2 housing with 24 spline side gears made in Oz (unknown quality) are about £165 plus post. One UK gentlemen helped me alot to figure out this :D

And thanks for info about those bushes :)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: rote8 on January 09, 2015, 05:00:03 PM
Liking the attention to detail Malcolm. And all respect for the time and effort you are making, on what was originally a joint project.
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on January 26, 2015, 06:56:49 PM
Slow progress still, but I bought some bits from re_japi in Finland, as they were in better condition than the parts on Kimi. Amongst the parts were a pair of rear light clusters, with some before and after clean-up pics.

Not much I know, but every step is getting me towards my goal  :)

Top cluster as recieved, bottom one after some cleaning
(https://farm9.staticflickr.com/8577/15752318343_f7d7a699f4_c.jpg) (https://flic.kr/p/pZYKrz) 
(https://farm9.staticflickr.com/8598/16186432127_a06abfecaa_c.jpg) (https://flic.kr/p/qEkGkZ) (https://farm9.staticflickr.com/8602/15749870224_890df1a0a6_c.jpg) (https://flic.kr/p/pZLcGC)
(https://farm9.staticflickr.com/8607/16184924850_a4ac6ae075_c.jpg) (https://flic.kr/p/qEcYhs)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on January 27, 2015, 12:05:49 AM
This also arrived from Finland - much better condition than the current one in Kimi  :)

(https://farm8.staticflickr.com/7311/16190409419_38bb671139_c.jpg) (https://flic.kr/p/qEG5DZ)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: re japi on January 27, 2015, 05:23:46 AM
We are glad that you liked those parts mate :)
Title: Re: "KIMI" - The RPM 1st Gen S2 (with bits of S3...)
Post by: Casey on June 16, 2015, 11:44:55 AM
Just letting people know that slow progress is still taking place on KIMI  :)

More derusting and POR15 treatment over the last full weeks. Fuel tank ready to go back on with repaired sender and refurbed straps. Fuel pump checked for fuel delivery volume and passed with flying colours. Pic below of test rig  :)

(https://c4.staticflickr.com/4/3718/18852064922_cbbda371a5_c.jpg" width="800" height="450" alt="FB Fuel Pump testing"></a>)