Mazda Rotary Club

Cars by Model Type => 3rd generation RX-7's => Topic started by: Bobfish on February 08, 2006, 09:41:29 PM

Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 08, 2006, 09:41:29 PM
day one...

Well,

Booked a week off work, Started to work today on the car. First priority is the headlights. Have budgeted three days for these babys, then the final 2 days i will be pulling the engine out.  Over the next two weeks, its teardown, cleaning and painting time, rebuilding and then i have another week off to finish off and drop it back in, fit my wheels and new exhaust and off we go!

Pics:

The workspace:
(http://www.face2faces.co.uk/RX7/lights/DSC00042.JPG)

(http://www.face2faces.co.uk/RX7/lights/DSC00043.JPG)

New engine parts:

(http://www.face2faces.co.uk/RX7/lights/DSC00044.JPG)

Diff brace

(http://www.face2faces.co.uk/RX7/lights/DSC00045.JPG)

Lights
(http://www.face2faces.co.uk/RX7/lights/DSC00046.JPG)

(http://www.face2faces.co.uk/RX7/lights/DSC00058.JPG)

New headlight mocked up:

(http://www.face2faces.co.uk/RX7/lights/DSC00066.JPG)

More pics to come after tomorrows works. Will be working all day every day this week so keep your eyes on this thread!
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 08, 2006, 09:42:03 PM
Well day two has been long and hard, decided to make my own custom bracketry for the sleek headlights as the kit came from ebay and the brackets supplied were utter ****e.

Please note - you do NOT have to do this with proper sleek headlight kits from reputable manufacturers - dont let my pain desuade you!

Anyways, i have the majority of the offside mount mocked up. Everything fits - just needs some adjustment now for clearances, then im going to paint the bracket and bolt it all down. Then comes the wiring - should be simple compared to today!

The nearside mount should be easier as i can copy the offside mount rather than starting with a piece of cardboard and some scissors haha.


The kit:

(http://www.face2faces.co.uk/RX7/lights/day2/DSC00067.JPG)

Cutting the chassis:
(http://www.face2faces.co.uk/RX7/lights/day2/DSC00068.JPG)

(http://www.face2faces.co.uk/RX7/lights/day2/DSC00069.JPG)

Over to the fabricating table...alias my freezer haha

(http://www.face2faces.co.uk/RX7/lights/day2/DSC00071.JPG)

Slowly getting there...

(http://www.face2faces.co.uk/RX7/lights/day2/DSC00072.JPG)

And we are done!
(http://www.face2faces.co.uk/RX7/lights/day2/DSC00073.JPG)

(http://www.face2faces.co.uk/RX7/lights/day2/DSC00074.JPG)

(http://www.face2faces.co.uk/RX7/lights/day2/DSC00075.JPG)

That whole bracket was custom made by me, and a pain in the ass.

MOre to come tomorrow. Hopefully ill get both lights finished tomorrow so i can start pulling the engine thursday.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 08, 2006, 09:43:08 PM
Todays works:

Got the o/s mounts done yesterday, so traced them today for the N/s mount:

(http://www.face2faces.co.uk/RX7/lights/day3/DSC00044.JPG)

Cut chassis:

(http://www.face2faces.co.uk/RX7/lights/day3/DSC00045.JPG)

And got the other side provisionally mounted up:

(http://www.face2faces.co.uk/RX7/lights/day3/DSC00046.JPG)

Started assembly of the final mock up before paint..can anyone spot the mistake?

(http://www.face2faces.co.uk/RX7/lights/day3/DSC00047.JPG)

(http://www.face2faces.co.uk/RX7/lights/day3/DSC00048.JPG)

(http://www.face2faces.co.uk/RX7/lights/day3/DSC00049.JPG)

(http://www.face2faces.co.uk/RX7/lights/day3/DSC00050.JPG)

now the offside is just about done, everything lined up as it should be. Just wiring and finishing up left to do now for this side, and about another 2 hours on the other side.

(http://www.face2faces.co.uk/RX7/lights/day3/DSC00051.JPG)

Progress slower than i would have liked, but thats life.

Tomorrow i hope to finish the lights totally by early afternoon, remove them for paint and then start disconnecting stuff so i can remove the engine.
Title: Sleek headlight install & engine rebuild pics
Post by: davegttph1 on February 08, 2006, 10:39:51 PM
Alot of work gone into the lights, I take it youve made these yourself somehow?

Looks good mate :)
Title: Sleek headlight install & engine rebuild pics
Post by: Jame5 on February 09, 2006, 09:39:04 AM
I\'ve looked at these lights a few times on ebay. I guess they aren\'t worth the hassle then? :xconfused
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 09, 2006, 09:46:00 AM
james, depends what you consider hassle really at the end of the day! for 200 notes i dont mind spending 4 days fitting them.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 09, 2006, 02:14:28 PM
quick update...while i have a well deserved break.  Got the lights on, just fitting the front wings and finalising, then i gotta tidy up and start pulling out the engine.

Made a cover for the lights...well, its just a strip of gaffer tape at the moment but plan is to paint the perspex some more! covers the springs.
(http://www.face2faces.co.uk/RX7/lights/day4/DSC00055.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: RobbieRX-7 on February 09, 2006, 02:43:27 PM
it looks loads better with the black tape on. Good job there lad :Thumbsup! i much prefer these style lights to the more expensive c west lights that are on most tarted up fd`s..i think those tend to make the car look too much like a fiat coupe. Are you going to get the garage to get them aligned or do it yourself? Also dont forget to put some paint on the bare metal that is exposed when you attacked it with an hacksaw..you dont want a car like this to start to rust now do you! :Nono!
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 09, 2006, 05:18:06 PM
Started tearing down the engine bay...

Removed bonnet before starting...

(http://www.face2faces.co.uk/RX7/lights/day4/DSC00057.JPG)

She\'s taking a pee!

(http://www.face2faces.co.uk/RX7/lights/day4/DSC00059.JPG)

(http://www.face2faces.co.uk/RX7/lights/day4/DSC00060.JPG)

Dirty dirty girl...

(http://www.face2faces.co.uk/RX7/lights/day4/DSC00067.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: avityesboy on February 12, 2006, 01:02:23 AM
Nice one mate, keep up the pics and updates its nice watching people actually doing the work themselves!
Title: Sleek headlight install & engine rebuild pics
Post by: PETE SMITH on February 12, 2006, 01:27:02 AM
Bob,
You\'re obviously a practical man and i think that\'s great!
The attached pic.... I presume the "leaflet" refers to owning the FD?!
You\'re doing a good job.
Pete
Title: Sleek headlight install & engine rebuild pics
Post by: M@r]{ on February 12, 2006, 08:06:35 PM
Hi Mate

Hope you dont mind me picking your brains.....

I have that headlight kit and have been looking for some decent lights to go in there - Where did you get yours?

I would love to get some projector style / angel eyes etc but not sure where to get them.  What size are the light units?

Hope you can help

Mark
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 16, 2006, 08:41:22 AM
My lights came with the kit mate...not sure on size just yet.

P.s the leaflet is to stop my mum piling things ontop of the housings.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 16, 2006, 08:43:12 PM
Well tonight i finally got the engine out!

A bit of spannering...
(http://www.face2faces.co.uk/RX7/njin/day5/DSC00074.JPG)

(http://www.face2faces.co.uk/RX7/njin/day5/DSC00078.JPG)

(http://www.face2faces.co.uk/RX7/njin/day5/DSC00079.JPG)

(http://www.face2faces.co.uk/RX7/njin/day5/DSC00080.JPG)

Out she goes....

(http://www.face2faces.co.uk/RX7/njin/day5/DSC00081.JPG)

And put to bed...for a bit, at least
(http://www.face2faces.co.uk/RX7/njin/day5/DSC00082.JPG)

 And here it is, ready for the butchering....

(http://www.face2faces.co.uk/RX7/njin/day5/DSC00083.JPG)

This weekend will be spent mostly tearing the above apart. Quick question though, i plan on painting the engine - is it best to clean the housings while they are apart, or assemble the engine, tape over the ports and go nuts with a wire brush?
Title: Sleek headlight install & engine rebuild pics
Post by: oldone on February 16, 2006, 08:53:01 PM
I go to all the trouble of cleaning the housings properly,then i tape up the face\'s.This way you can paint them the right way.Using a good paint will reward you with great results. :yes
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 17, 2006, 06:26:49 AM
Are we talking plastikote hot-paint as opposed to halfrauds or some specially formulated stuff for engines here? any recommendations of brand?
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 17, 2006, 07:15:13 PM
Well, set to work dismantling the engine this evening, did a good hours work...

(http://www.face2faces.co.uk/RX7/njin/day6/DSC00084.JPG)

(http://www.face2faces.co.uk/RX7/njin/day6/DSC00085.JPG)

The turbos:

(http://www.face2faces.co.uk/RX7/njin/day6/DSC00086.JPG)

One small crack in the housing, but pretty minimal

(http://www.face2faces.co.uk/RX7/njin/day6/DSC00089.JPG)

(http://www.face2faces.co.uk/RX7/njin/day6/DSC00092.JPG)

Shaft play is VERY minimal to non-existant.  If you puush and pull it forward 1 in 10 times youll feel a slight knock, and the secondary turbo has no play at all.

(http://www.face2faces.co.uk/RX7/njin/day6/DSC00094.JPG)


(http://www.face2faces.co.uk/RX7/njin/day6/DSC00093.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 18, 2006, 02:58:15 PM
more pics for your pleasure:

(http://www.face2faces.co.uk/RX7/njin/day7/DSC00001.JPG)

(http://www.face2faces.co.uk/RX7/njin/day7/DSC00002.JPG)

(http://www.face2faces.co.uk/RX7/njin/day7/DSC00004.JPG)


(http://www.face2faces.co.uk/RX7/njin/day7/DSC00005.JPG)


(http://www.face2faces.co.uk/RX7/njin/day7/DSC00006.JPG)


engine torn down now, nearly ready to start pulling it apart once ive got the flywheel nut off.
Title: Sleek headlight install & engine rebuild pics
Post by: Rixio on February 20, 2006, 02:39:05 PM
How did the work go over the weekend then BOB...
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 20, 2006, 02:42:10 PM
Work over the weekend went ok.  Spent most of it cleaning and stuff, tearing down parts into their components.

Now i just need to clean my housings, front cover, the engine bay of the car, OMP and sump - then im going to dismantle the existing engine, start checking clearences and re-assembling.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 23, 2006, 04:11:21 PM
Engine teardown COMPLETE!!

Removing fly:

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00008.JPG)

Tension bolts exposed...

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00009.JPG)

The rotor in the chamber...

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00010.JPG)

Housing removed..

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00011.JPG)

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00012.JPG)

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00013.JPG)

Wear marks on the housing...doesnt look too bad!

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00014.JPG)

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00015.JPG)

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00016.JPG)

Rotor removed...centre plate exposed...

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00017.JPG)

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00018.JPG)

front rotor housing:

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00020.JPG)

I think this is what caused the coolant leak:


(http://www.face2faces.co.uk/RX7/njin/day8/DSC00023.JPG)

The two rotors - one on left has been cleaned.

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00024.JPG)

Cleaned centre plate, ready for spraying:

(http://www.face2faces.co.uk/RX7/njin/day8/DSC00026.JPG)

More pics to come...

State of play now is that i have a few more bits left to clean (couple of hours work) a few bits to spray (engine housings) then i can start building the short block back up.

By the way, engine has done 70k - 2 of which with a blown coolant seal and radweld.

Progress is being made!!
Title: Sleek headlight install & engine rebuild pics
Post by: nikp on February 23, 2006, 04:21:15 PM
Radweld kept you going for a while then? I\'ve heard it can occassionally.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 23, 2006, 04:26:45 PM
yes, it got me through the summer nicely. I had to use it three times (used holts blockweld too, stronger than radweld) but it got me through the summer ok, with no adverse affects that i can see so far to the rest of the engine - turbo banjo bolts arent clogged, nor are any coolant pipes. Only problem i can see is a nasty almost unremoveable red coating on everything that the coolant has touched.
Title: Sleek headlight install & engine rebuild pics
Post by: SCOOMER on February 23, 2006, 07:20:22 PM
Hi Bob,

You getting/doing any porting work while its in bits?

Oh and is this your first attempt at a rebuild?
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 23, 2006, 07:47:46 PM
no im not, because i cant afford a PFC right now, and will probably pull the engine apart before i go for really high HP - porting isnt essential IMO although it helps.

It is my first attempt at a rebuild on a rotary yes.
Title: Sleek headlight install & engine rebuild pics
Post by: SCOOMER on February 23, 2006, 08:01:14 PM
When i got my rebuild i had it ported and ran without a PFC for a year with no ill affects. This was when it was completly standard apart from intake and cat back exhaust.

Anyway keep the pictures coming, your doing a great job!

Scott
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 23, 2006, 08:12:54 PM
how extensively ported though? I could probably get away with it with a cat to be honest, but my reasoning is that if you port the exhaust, you are going to increase the air throughput of the engine (as it breathes better) and because its a MAP based system to car wont detect that. That = lean condition which = bang.

If anyone has any porting templates i might consider it. did you feel any power increase from your porting scoomer? becuase if you did, i dont want to do it. Dodgy logic i know lol but my reasoning is sound.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 24, 2006, 01:20:21 PM
More pics...everythings pretty clenan ow, time to paint!

(http://www.streamload.com/waspishbobfish/rx7pics/day9/DSC00028.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day9/DSC00032.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day9/DSC00033.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day9/DSC00034.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day9/DSC00036.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day9/DSC00037.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: Jono FD3 on February 24, 2006, 01:29:11 PM
Bob, how easy has you unit come apart???? any snaped studs, stripped threads, Etc.???? and is it a fairly straight forward job or is it more complicated than it looks?????

I might have to do this to mine soon you see :(

Keep the pics coming and keep up the good work!!!!

Jono
Title: Sleek headlight install & engine rebuild pics
Post by: nikp on February 24, 2006, 01:44:54 PM
I believe that it can be common for there to be problems on the exhaust manifold with corroded nuts and sheared studs: but if that does occur then at least the engine is out, so it\'s a bit more easy for it to be remidied.

Generally, i understand the process of engine removal to be quite straightforward: but you should label everything (Leads, hoses, etc) so that you know where they connect back up to when putting it all back together.
Title: Sleek headlight install & engine rebuild pics
Post by: Kash_ on February 24, 2006, 02:28:00 PM
Bob, an excellent job and the pictures are brilliant as it gives you an insight into what a rotary looks like from the inside out, something I have not seen before. Your progress makes a rebuild look fairly straight forward and pretty simple
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 24, 2006, 04:26:38 PM
Jono, its pretty straightforward. Some bits are a pain in the ass, but now ive pulled one engine out im confident i could remove another and strip it down totally in a full day.

how far is milford haven? if you need to do yours i wouldnt mind helping ya out.
Title: Sleek headlight install & engine rebuild pics
Post by: Jono FD3 on February 24, 2006, 07:21:30 PM
That\'s a very fine offer there mate, but Milford Haven is prety much the opposit side of the country for you, South West Wales (25 miles west of Tenby)!!! the motor is still running fine at the moment (ahhh where\'s the wood........... Ahhhh there it is!!!!) I thought I droped a rotor tip the other day but it turned out to be the boost gauge!!!!!
What sort of money has your rebuild come to???? When I do mine I\'ll probably need new tips, housings and a full seal kit (obviously!!!)

Cheers mate hope the recontruction goes as well as the deconstruction for you....... pics make it look so easy!!!!

Jono
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 24, 2006, 07:29:36 PM
no probs mate, well if you need a hand to get the engine out ill be mor ethan happy to come down if you pay for my diesel (i got an economical diesel for long trips) or for my optimax and you put me up for a couple of nights i dont mind helping.  Obviously youll have to provide nosh and brew but as long as you can do that i dont mind helping you pull the engine out and break it down at all. I get a week off work every 5 weeks so let me know when your planning on doing it and ill let you know when im free!

so far costs incurred are:

new housings, end plates and seal kit £1350 (thats cheap, youll pay that for new housings and a seal kit)
various gaskets, lambda sensor etc from mazda £250
various paints, chemicals, rags, tools etc probably £200

Its not cheap, feels like you have to continuously spend money but its worth it.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 25, 2006, 03:36:58 PM
A few more:

A terrible picture of my ever helpful girlfriend helping mask up my rotor housings...
(http://www.streamload.com/waspishbobfish/rx7pics/day10/DSC00038.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day10/DSC00039.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day10/DSC00040.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day10/DSC00041.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: SCOOMER on February 25, 2006, 04:14:21 PM
Quote from: Bobfishhow extensively ported though? I could probably get away with it with a cat to be honest, but my reasoning is that if you port the exhaust, you are going to increase the air throughput of the engine (as it breathes better) and because its a MAP based system to car wont detect that. That = lean condition which = bang.

If anyone has any porting templates i might consider it. did you feel any power increase from your porting scoomer? becuase if you did, i dont want to do it. Dodgy logic i know lol but my reasoning is sound.

I asked for the engine to be ported as much as they could without it incurring catastrophic damage, im not sure how much it is ported (not much id expect) because the rebuild details were lost when i came to pick it up and nobody could tell me any details on it. Anyway i really cant say if their was much difference, but id talk to a few of the builders on here and see if they can help you and sort templates out.

Scott
Title: Sleek headlight install & engine rebuild pics
Post by: Jono FD3 on February 25, 2006, 07:21:34 PM
Quote from: Bobfishno probs mate, well if you need a hand to get the engine out ill be mor ethan happy to come down if you pay for my diesel (i got an economical diesel for long trips) or for my optimax and you put me up for a couple of nights i dont mind helping.  Obviously youll have to provide nosh and brew but as long as you can do that i dont mind helping you pull the engine out and break it down at all. I get a week off work every 5 weeks so let me know when your planning on doing it and ill let you know when im free!

Thats a very fine offer you have made ther............ one question......... does your Mrs\'s come too for the masking side of things  :D   :D  :D Looks like she does a good job!!!

I\'ll let you know, if and when mate.

Cheers Jono
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 27, 2006, 08:57:11 PM
(http://www.streamload.com/waspishbobfish/rx7pics/day11/DSC00042.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day11/DSC00043.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day11/DSC00044.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day11/DSC00045.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day11/DSC00046.JPG)

getting there!
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 28, 2006, 09:34:18 AM
This morning i received 2x the below and 2x 9.5 wide....

(http://www.streamload.com/waspishbobfish/rx7pics/day12/DSC00047.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day12/DSC00048.JPG)

Not on my car but:

(http://images10.fotki.com/v197/photos/4/47612/2047213/IMG_3339-vi.jpg)
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 28, 2006, 10:26:14 AM
better pic...shows off the colour better:

(http://www.streamload.com/waspishbobfish/rx7pics/day12/DSC00050.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: allstaruk on February 28, 2006, 10:35:30 AM
Those rims are nice mate. Re-build looks like its going well
Title: Sleek headlight install & engine rebuild pics
Post by: deanflowers on February 28, 2006, 01:00:16 PM
WHERE did you get the housings and end plates from? can you break the costs down for me on these
Title: Sleek headlight install & engine rebuild pics
Post by: Jovic82 on February 28, 2006, 01:23:24 PM
Wow that is cheap cheap cheap for housings
Title: Sleek headlight install & engine rebuild pics
Post by: dandan on February 28, 2006, 02:04:39 PM
Quote from: BobfishThis morning i received 2x the below and 2x 9.5 wide....

(http://www.streamload.com/waspishbobfish/rx7pics/day12/DSC00047.JPG)

I see the shippers were very careless when packaging up your wheels, somebody lost a foot!

BTW the block looks really good in black i reckon. :)
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on February 28, 2006, 02:32:09 PM
Thanks DanDan, i like it in black too, but only because its mine :P

Thanks for the kind comments guys!
Title: Sleek headlight install & engine rebuild pics
Post by: colinrx7surrey on February 28, 2006, 07:06:53 PM
good work mate-on the rebuild and the wheels a wise choice!!!!
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 01, 2006, 03:02:29 PM
Todays progress...started to butcher the interior, and picked up my injectors from the cleaners...what a result! (check the report)

(http://www.streamload.com/waspishbobfish/rx7pics/day13/DSC00051.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day13/DSC00052.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day13/DSC00053.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day13/DSC00054.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day13/DSC00055.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day13/DSC00057.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: Archbish on March 01, 2006, 03:06:58 PM
bloody hell - what are you doing to the interior???
Title: Sleek headlight install & engine rebuild pics
Post by: strange_days_uk on March 01, 2006, 03:42:03 PM
This is a really good thread.  Good work Bob, have you done all that work by yourself ?  You are a brave man, especially for a first time re-build.

And yes, what the hell are you doing to the interior ?
Title: Sleek headlight install & engine rebuild pics
Post by: nikp on March 01, 2006, 04:02:09 PM
I see that new modification is going well: The bonnet on the roof - is that for extra downforce!? :D
Title: Sleek headlight install & engine rebuild pics
Post by: kermit on March 01, 2006, 04:23:58 PM
Have to say, I have been following this thread and I’m finding it really interesting.  It’s inspiring me more and more to do my own project car!  Keep the pics and updates coming.

Martin.
Title: Sleek headlight install & engine rebuild pics
Post by: Grizzly on March 01, 2006, 04:45:08 PM
Watch the Wind don\'t blow that bonnet off your roof mate.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 01, 2006, 06:00:39 PM
car is under a cover all the time, wind dont affect it

im painting parts of the interior a dark grey - the standard FD interior is too black and mine is tatty and scratched anyway.  Had to take alot off to get the gearstick panel, ac panel, gauge cluster, drivers door card and passenger door card off.  Wanted to color code the whole lot, so had to take it all off

ill be going into the garage in about an hour to start dismantling the gauge cluster etc and start rubbing down the panels ready for paint.  Order new vac lines today for a custom solenoid kit im going to be installing for turbo control.  injectors are back from the cleaners as you saw, exedy flywheel should be arriving friday...

work is far from done! haha
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 02, 2006, 08:25:08 PM
more progress today...

(http://www.streamload.com/waspishbobfish/rx7pics/day14/DSC00058.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day14/DSC00059.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day14/DSC00060.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day14/DSC00061.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day14/DSC00062.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day14/DSC00063.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day14/DSC00064.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 03, 2006, 02:57:28 PM
exhaust manifold stud on brand new rotor housing...snapped :(
Title: Sleek headlight install & engine rebuild pics
Post by: Archbish on March 03, 2006, 03:34:06 PM
Is it a replaceable stud??
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 03, 2006, 04:43:13 PM
Exhaust manifold stud - fixed!
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 03, 2006, 04:44:48 PM
yes its replaceable, luckily mine broke with 2-3cm still sticking out so i just used a stud remover, didnt have to **** around drilling etc.
Title: Sleek headlight install & engine rebuild pics
Post by: FD3Typer2 on March 04, 2006, 11:02:32 AM
This is a good thread. Keep up the good work mate! This is what the community needs, more people doing their own work.

I know how much of a pain taking pics while working is (dirty hands etc) but keep em coming.
Title: Sleek headlight install & engine rebuild pics
Post by: Rixio on March 04, 2006, 09:33:46 PM
Fantastic buddy keep it up...

P.S...i want to butcher my interior panels aswell are they hard to take out? Also what sort of work do you need to do before spraying them cos iv never done it before...
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 05, 2006, 10:53:31 PM
Rixio,

It took me about an hour and a half to get all that interior out. Its not particularly hard, as long as you know where all the screws are - its just a bit fiddley.

To spray it isnt that hard either, its all in the preparation of the parts. Pretty mcuh just rub em down good with some 800 grade wet and dry, rub em off with a clean cotton cloth soaked in white spirits or another solvent, wait for em to dry and paint.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 07, 2006, 07:37:04 PM
Hey guys,
sorry for the lack of updates, not had much time to work on the car, and when i have had time ive been doing work rather than on here!

Latest progress....can anyone identify the two circled areas in the photos of the wiring loom? is on a RHD just down by the A/C bracket. The one with a connector im sure will become apparent, but the one thats just a wire ive very worried about.

(http://www.streamload.com/waspishbobfish/rx7pics/day15/DSC00064.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day15/DSC00065.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day15/DSC00066.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day15/DSC00067.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day15/DSC00068.JPG)

(http://www.streamload.com/waspishbobfish/rx7pics/day15/DSC00069.JPG)
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 10, 2006, 08:30:25 PM
Today i received:

(http://www.streamload.com/waspishbobfish/rx7pics/day15/DSC00071.jpg)

Finish painting the interior panels tomorrow, hopefully re-fit the engine sunday... Im off work all week again next week though so hopefully this whole project should be finished by friday...Just about a month and a week from starting!
Title: Sleek headlight install & engine rebuild pics
Post by: jamie_eaton on March 10, 2006, 08:48:08 PM
good stuff mate great to see DIY!!!!
Title: Sleek headlight install & engine rebuild pics
Post by: Ada7 on March 10, 2006, 09:29:22 PM
Great thread mate. keep up all the good work.Wish i had the never to strip my car back like you have done. :)

Adam
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 12, 2006, 03:23:09 PM
ITs been this way for a while now i just havent bothered posting pics:

(http://www.streamload.com/waspishbobfish/rx7pics/day15/DSC00072.jpg)

Picked up my coolant and oil today, will order oil filter from mazda tomorrow. Cant fit engine yet, gotta get interior done first. That should be done today or tomorrow. After thats in, engine and hooking everything up should take one full day if i work quick, lights 2 days to wire, spray, and fit, wheels, brakes and diff brace a day; i\'m determined to get this car finished by the end of this coming week so i can use it for the weekend, so keep your eyes on this thread!
Title: Sleek headlight install & engine rebuild pics
Post by: Rixio on March 12, 2006, 04:36:27 PM
Keep up the good work ;)
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 14, 2006, 12:31:35 AM
Made some more progress today, got engine totally done and ready to go back into car, and sorted some interior pieces.

Drivers door (i hate the colour... :()

(http://www.streamload.com/waspishbobfish/rx7pics/day16/DSC00073.jpg)

What i used to fix the passenger door handle:
(http://www.streamload.com/waspishbobfish/rx7pics/day16/DSC00074.jpg)

and how i fixed it:

(http://www.streamload.com/waspishbobfish/rx7pics/day16/DSC00075.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day16/DSC00076.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day16/DSC00079.jpg)


Before and after:

(http://www.streamload.com/waspishbobfish/rx7pics/day5/DSC00083.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day16/DSC00080.jpg)

Tomorrow more interior parts going in, and so is the engine.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 14, 2006, 03:26:27 PM
All fired up and ready to go now...

i hope this will grow on me:

(http://www.streamload.com/waspishbobfish/rx7pics/day17/DSC00081.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day17/DSC00082.jpg)

Just waiting for help to arrive in around four hours then ill be putting the engine back in.

(http://www.streamload.com/waspishbobfish/rx7pics/day17/DSC00083.jpg)
Title: Sleek headlight install & engine rebuild pics
Post by: Archbish on March 14, 2006, 03:36:51 PM
I\'m really not sure about the fringe in the "Hope this will grow on me" pic...  Reckon you should just stick to the paintwork instead...
Title: Sleek headlight install & engine rebuild pics
Post by: colinrx7surrey on March 14, 2006, 05:30:20 PM
some good work there mate--all in all how long did it take u to carry out the work you have done so far??
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 14, 2006, 06:28:03 PM
LOL yeah the roof fringe was an afterthought :D

All in all so far today is my 17th day working on the car. 10 or so of those days have been full 8 hour days (like 9am till 6pm working on it) as i get time off from the keyboard from time to time (im a network engineer by profession)

That time also includes getting parts etc (the little niggly bits i mean, o rings, circlips etc etc etc.)

Should be beginning to poke the engine back into the car in a minute!
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 14, 2006, 11:47:36 PM
well, just missioned it puttinng the engine in. what a pain!

(http://www.streamload.com/waspishbobfish/rx7pics/day17/DSC00084.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day17/DSC00085.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day17/DSC00086.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day17/DSC00087.jpg)

Start getting stuff hooked up tomorrow :P
Title: Sleek headlight install & engine rebuild pics
Post by: babz_audio on March 15, 2006, 12:00:16 AM
excellent thread, very interesting...bet you cant wait to get it running

The engine is going back into mine next week so cant wait for that either  :p

get some mroe pics up  ;)
Title: Sleek headlight install & engine rebuild pics
Post by: Rixio on March 15, 2006, 12:54:32 AM
Hope all the hard work and elbow grease has paid off for you...are you gona get a comp test and dyno when its all up and running, itl be interesting to see what the results are :)

Good work man...
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 16, 2006, 06:56:08 AM
Yesterdays update below...doesnt look like alot, but got alot done.
Its now 6:53 AM and ive been out of bed 20 minutes. Im gonna play a game or two of age of empires 3, then get out there and get started. Today i want to finish getting the engine hooked up, wire the lights in, get the wheel well liners back on, change the brakes, bleed the brakes and clutch, and generally get the car to a state where it is actually driveable!

Tomorrow will be spent fitting the diff brace, rear brakes, and generally cleaning the car hopefully!

(http://www.streamload.com/waspishbobfish/rx7pics/day18/DSC00088.jpg)
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 16, 2006, 03:49:13 PM
Well, its 15:49 and ive just finished making the loom for the lights (i didnt want to mangle the stock connectors so i used spade connectors to connect to existing loom) and spraying the brackets for them:

(http://www.streamload.com/waspishbobfish/rx7pics/day19/DSC00089.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day19/DSC00090.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day19/DSC00091.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day19/DSC00092.jpg)

I finished hooking the engine up, filled her with coolant and:

Needs quicktime (http://www.streamload.com/waspishbobfish/rx7pics/day19/MOV00031.3gp)

:D :D :D

next up after a small break is fitting the diff brace, rear brake pads, light brackets, and the wheels.  Headlight covers come back from the painters tomorrow, then she gets a full days washing and we are ready to go!!
Title: Sleek headlight install & engine rebuild pics
Post by: Martiny on March 16, 2006, 04:10:17 PM
WOW! , bud, thats a lot of work.

Isnt that a great feeling when it starts up, eh !!

Congratulations!
Title: Sleek headlight install & engine rebuild pics
Post by: Juz on March 16, 2006, 04:19:10 PM
niceone! been following this thread, great to see it finally coming together for you :)
Title: Sleek headlight install & engine rebuild pics
Post by: Freddy on March 17, 2006, 01:08:57 AM
Excellent Bobfish.. good job. :)
Title: Sleek headlight install & engine rebuild pics
Post by: Icesurf3r on March 17, 2006, 07:50:02 AM
Congrats.....  Been following this thread from the beginning.  Great work you\'ve done there :D
Title: Sleek headlight install & engine rebuild pics
Post by: Ricco_04 on March 17, 2006, 01:48:18 PM
Top job there, well done fella :cool
Title: Sleek headlight install & engine rebuild pics
Post by: strange_days_uk on March 17, 2006, 02:18:16 PM
Absolutely top hole old bean !  Have been following this thread, good work there !
Title: Sleek headlight install & engine rebuild pics
Post by: Kash_ on March 17, 2006, 06:32:31 PM
well done mate, you made it look so easy  :Thumbs-up
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 18, 2006, 02:06:19 AM
Some more pics from today:

Light pods all finished up:

(http://www.streamload.com/waspishbobfish/rx7pics/day20/DSC00096.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day20/DSC00097.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day20/DSC00098.jpg)

Just need to get the light surrounds painted now, wash her and im done! Ive got a whole list of stuff that i wanna sort too now though, things ive noticed during the rebuild :( lol more money!
Title: Sleek headlight install & engine rebuild pics
Post by: Ricco_04 on March 18, 2006, 05:26:35 PM
But at least it will be very much sorted for years to come  :cool

Bl00dy hell, that bonned has come up well  :)
Title: Sleek headlight install & engine rebuild pics
Post by: dj_dee99 on March 18, 2006, 06:47:20 PM
This has been one hell of a cool thread. Surely it\'s gotta become a sticky?!!!
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 19, 2006, 07:58:27 PM
and we are done!

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00099.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00100.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00101.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00102.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00103.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00104.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00105.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00106.jpg)

(http://www.streamload.com/waspishbobfish/rx7pics/day21/DSC00107.jpg)

Photos are pretty crappy, they were a bit rushed. Gonna get some more soon, and ill also put up some high res versions later on.
Title: Sleek headlight install & engine rebuild pics
Post by: Gord.R on March 19, 2006, 09:46:38 PM
Awesome mate...glad to see shes finally all back together...

Where did you get the lights form if you dont mind me asking.
Cheers

Gord
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 20, 2006, 01:20:55 AM
well, just done the first 185 miles and all is good! returning an MPG figure of 23.4 lol, motorway, all under 3k, no boost.

Lights came off ebay, ive no idea who sold them to me as it was over 60 days ago now...sorry! Fitment wasnt great anyway, needed alot of fabrication work and tinkering, one still dont fit properly and they arent properly stuck down yet because the perspex is a diff shape to the light covers themselves. Gonna have to take em off and clamp em down for a bit...
Title: Sleek headlight install & engine rebuild pics
Post by: nikp on March 20, 2006, 10:56:46 AM
QuoteFitment wasnt great anyway, needed alot of fabrication work and tinkering

Know what you mean there! I have recently purchased a set of lights, and the general quality of them is not great (If you\'re reading this ScuttleRX - not having a go at you! :p) so I\'m going to have to improve on them a bit. Which is a bit of a bugger.
Title: Sleek headlight install & engine rebuild pics
Post by: Bobfish on March 20, 2006, 07:28:49 PM
yeah deffo, but in the same token it feels good to know you have a set of lights that nobody else has! You made them, put all the effort into making them what they are.

On another note, whats the best way to get scratches out of perspex? P1500 wet and dry?
Title: Sleek headlight install & engine rebuild pics
Post by: Jono FD3 on March 20, 2006, 07:58:16 PM
Best way would probably be cutting past from a body shop, then T cut or brasso to get the finish back!!

Jono
Title: Sleek headlight install & engine rebuild pics
Post by: moakesr on March 20, 2006, 08:35:11 PM
Top job, congratulations on getting it back on the road.

Richard