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Davidbolam
5th February 2012, 09:52 PM
Nice to see the build pictures coming along.

Did you take any measurements or did you draw a diagram when you made the engine mounts? I am using a 1.6 myself and want to get around the bonet clearance problems.

If so please can I have the details


David

skov
6th February 2012, 05:35 AM
Haha, it does look a bit "Solo Polo Peeper" now you mention it Michael :)

Johno - that rear wheel is only on there very loosely at the moment, which might be why it's sat at that angle.
I'll try to remember to investigate and take some measurements next time I'm out there.

David, if you look through my photos there should be a load with measurements showing my intended engine position.
Essentially I've just got the sump 40mm below the bottom rail, and the engine offset to the passenger side by 25mm.
I've also purchased an inlet manifold from a Mk2 1.6 recently, which may or may not help with bonnet clearance - watch this space!

skov
7th February 2012, 01:17 PM
My lovely shiny protechs arrived from NTS today :D

https://lh6.googleusercontent.com/-aAGSgJPS8Pw/TzEjNqIaTEI/AAAAAAAAIJU/lREdZ4n7GeU/s512/shocks.jpg

skov
8th February 2012, 09:29 PM
I'm now officially rolling :D :D :D

https://lh4.googleusercontent.com/-SgESFxGJB1Y/TzLn2i-jWsI/AAAAAAAAIJ0/XavxMoL_Mu4/s640/S5033187.JPG

Couldn't resist getting in and going for an imaginary drive!

HandyAndy
11th February 2012, 03:20 PM
Looking great :cool:

Nice to see that chassis on wheels :)

Did you make "brum brum" noises ? :p we,ve all done it , well maybe under our breath :D

cheers
andy

skov
11th February 2012, 04:23 PM
Did you make "brum brum" noises ?


I certainly did!
Though to be honest it was a bit more "crazy frog" than "brum brum" :D

Cheers Andy, I have to say it was great feeling getting it on it's wheels, I couldn't stop grinning for a while :)

skov
13th February 2012, 11:20 AM
Got my Battery today. A dinky little Odyssey PC680, which should fit nicely in the passenger footwell without taking up too much leg room (not that I particularly care about passenger legroom!)

https://lh6.googleusercontent.com/-topWAHvZn8Q/Tzjv7eq8PFI/AAAAAAAAILU/XniYbdv9LnU/s800/130212-1109.jpg

mark
13th February 2012, 12:02 PM
Fitted the same to my car last year when I upgraded and its spot on

Reasonably powerful for its size too

Mine came off the road at the end of September and the battery has been disconnected whilst Ive been tinkering, just got it all back together a couple of weeks ago and the battery cranked it over perfectly, as if it had just been charged that day!

skov
13th February 2012, 01:55 PM
Hi Mark, that's good to know thanks!

I've got an optimate kicking around somewhere which I plan to use to keep it in tip top condition. The chances of me actually remembering to use it are pretty slim though :rolleyes:

james3004
13th February 2012, 03:13 PM
Where did you get the battery from john, that's what I've been looking at for my build

skov
13th February 2012, 03:52 PM
Where did you get the battery from john, that's what I've been looking at for my build

Hi James, I got it off ebay for £80 posted. That was the cheapest I could find!
I just checked and the seller I got it from doesn't seem to have any more listed :(

andysredmini
15th February 2012, 01:48 PM
Hi Skov.
Do you mind me asking where you positioned your seat belt anchorages (cp18). I am building a Saturn based mx5 chassis and have come to position them 140mm (from the back edge) from the front face of br12 as per the book but they are clashing with tt6 on the transmission tunnel.
I’m either think of cutting the anchorage down to retain the original measurement or pulling the whole bracket back so that it mates to the rear face of tt6.

Many thanks

Andy

skov
15th February 2012, 02:28 PM
Hi Skov.
Do you mind me asking where you positioned your seat belt anchorages (cp18). I am building a Saturn based mx5 chassis and have come to position them 140mm (from the back edge) from the front face of br12 as per the book but they are clashing with tt6 on the transmission tunnel.
I’m either think of cutting the anchorage down to retain the original measurement or pulling the whole bracket back so that it mates to the rear face of tt6.


Hi Andy, I'm pretty sure I put mine in the book position.
Are you sure you've got TT6 in the right place? It should be in the book position too, so there shouldn't be a clash :confused:

The position of the bottom anchorages isn't critical as far as I'm aware though, so moving them forwards or back a bit shouldn't be a problem.

andysredmini
15th February 2012, 02:53 PM
Thanks Skov. You were correct about tt6 being in the wrong position. I had them 50mm to close to the back.
Luckily its only a drawing i'm working on. hopefully i cut my steel to the guide and not my drawing. Ill check when i get home.

Thanks again

Andy.

skov
21st February 2012, 06:48 AM
Didn't do too much on the build last week what with valentines day :rolleyes: followed by the winter vomiting bug running wild through the household...

I did venture out on Saturday and managed to revisit my steering shafts/linkages.

I've now done it the same as the Saturn guide, rather than my original way which involved bodging a chopped up sierra column in there:

https://lh3.googleusercontent.com/-xfFc1BMomS8/T0K94WivlNI/AAAAAAAAIM8/-54NWbScM_I/s640/S5033239.JPG

https://lh3.googleusercontent.com/-B5vUnQ2uJmg/T0K934jlLZI/AAAAAAAAIM4/YagTPrbYSaM/s640/S5033240.JPG

https://lh4.googleusercontent.com/-TX3GM-sPrI8/T0K93xLeh5I/AAAAAAAAINA/VAhmAd9ZTNI/s640/S5033241.JPG

Worth noting that I used rally design part RD820F for the shaft to rack linkage, rather than the RD850 suggested in version 3 of the Saturn guide (which I suspect might be a typo!)

stew
21st February 2012, 07:43 PM
looks good john. :) gonna be a real tidy car.


ive loads to update on mine, but not had a chance in a while. still wish i was further on, but enjoyin the build i guess!! lol

dying of the flu currently! :(

skov
21st February 2012, 07:58 PM
Thanks Stew :)
Hope you're feeling better soon!
My work place paid for us all to have flu shots back in the autumn, so I won't be getting that thankfully.
Hasn't stopped me getting ill with every other bug doing the rounds though!
Make sure you get some pics up soon, it'd be good to see how you're getting on :cool:

skov
6th March 2012, 11:56 PM
Finally got around to finishing my front diff mount last week.
I started it months ago before it had been added to the Saturn guide, which is why it's a tad different.

https://lh6.googleusercontent.com/-rANr4WQ7IXY/T1aBQ_qAGmI/AAAAAAAAIN0/oFLfMMzrNmA/s512/diff_mount_fitted.jpg

https://lh4.googleusercontent.com/-MVpVJo0hIs4/T1aBQ5HWxBI/AAAAAAAAIN4/aT8R66oMM8Y/s512/diff_mount_fitted_2.jpg

It's bolted to a plate on the chassis via a pair of landrover engine mounts, and to the diff itself using a pair of M12 bolts.
The holes in the diff were a bit bigger than 12mm, so I sleeved them down with some ali tube to get a nice tight fit.
I'm not 100% happy about using the rubber mounts in shear, but I think (hope!) they'll be ok.

On a seperate note I replaced the OEM bushes in the rear uprights with some Strongflex ones this evenning:

https://lh3.googleusercontent.com/-zYdOZX3opJg/T1aBTzxFtnI/AAAAAAAAIOM/68aDtP7pe4k/s640/rear_upright_bushes.JPG

https://lh6.googleusercontent.com/-7jtHAjxfJEo/T1aBUItj3JI/AAAAAAAAIOQ/O8B1lWiVIR8/s640/rear_upright_bushes_fitted.jpg

It didn't seem right leaving them as 15 year old perished rubber when the rest of the suspension uses polybushes!
And as an added bonus Strongflex very kindly supplied them with 12mm internal diameter crush tubes rather than their 10mm MX5 ones.
I got them to do that so they match the 12mm holes in the Saturn wishbones, and mean I can fit M12 bolts.

CTWV50
7th March 2012, 12:42 PM
How much were the bushes and crush tubes John? And have you got a link for the tube you're using on the bottom. Just picked up yet another bottle of gas so I'm back to the grind again literally.:)

Oh and the steering shaft from the column to rack UJ, what are you using?

skov
7th March 2012, 01:00 PM
Glad to see you've come out of hibernation Chris :D

Here's the tube I inserted into the lower holes in the rear uprights (you need 80mm per side if memory serves me correctly):

STEEL PRECISION TUBE 14mm OD x 300mm LONG 1mm WALL (http://www.ebay.co.uk/itm/STEEL-PRECISION-TUBE-14mm-OD-x-300mm-LONG-1mm-WALL-/250692815856?pt=UK_BOI_Metalworking_Milling_Weldin g_Metalworking_Supplies_ET&hash=item3a5e74cbf0)

And these are the bushes I stuck in the top of the uprights (£22.70 for a pair):

Mazda MX-5 Rear Upper Inner & Outer Suspension Bush SPORT poly STRONGFLEX (http://www.ebay.co.uk/itm/270890908367?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649)

My column to rack UJ is rally design part# RD820F (http://www.rallydesign.co.uk/product_info.php?products_id=13769)

Hope that helps!

CTWV50
7th March 2012, 02:44 PM
Glad to see you've come out of hibernation Chris :D

Here's the tube I inserted into the lower holes in the rear uprights (you need 80mm per side if memory serves me correctly):

STEEL PRECISION TUBE 14mm OD x 300mm LONG 1mm WALL (http://www.ebay.co.uk/itm/STEEL-PRECISION-TUBE-14mm-OD-x-300mm-LONG-1mm-WALL-/250692815856?pt=UK_BOI_Metalworking_Milling_Weldin g_Metalworking_Supplies_ET&hash=item3a5e74cbf0)

And these are the bushes I stuck in the top of the uprights (£22.70 for a pair):

Mazda MX-5 Rear Upper Inner & Outer Suspension Bush SPORT poly STRONGFLEX (http://www.ebay.co.uk/itm/270890908367?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649)

My column to rack UJ is rally design part# RD820F (http://www.rallydesign.co.uk/product_info.php?products_id=13769)

Hope that helps!

Yes it's warmer now so I thought I'd get in the garage again and do a bit.

I've ordered the tube, thank you, but for the bushes did you just spec the 12mm int.dia. crush tube or do you have to speak with them first?

Understood you're using the RD820F for the rack UJ but what about the entention between it and the mazda column is it a sierra part or is it an extended mazda part.

Cheers

Chris

skov
7th March 2012, 03:14 PM
For the bushes I sent them a message asking if they could do them with 12mm internal diameter crush tubes. They replied saying no problem, and just told me to add a note saying that when I placed the order.

My steering column/shaft/linkages are pretty much the same as the Saturn/NTS build guide now.
The top part of the steering shaft is from the MX5, and the bottom part is the Rally Design steering shaft (RD849).
The bit joining them together is just some chunky mild steel tube (3mm wall I think). I couldn't tell you the diameter though - I just took the Rally Design shaft to my local steel supplier, and they let me stick it in various bits of tube until I found one that was a snug fit!

CTWV50
7th March 2012, 03:40 PM
For the bushes I sent them a message asking if they could do them with 12mm internal diameter crush tubes. They replied saying no problem, and just told me to add a note saying that when I placed the order.

My steering column/shaft/linkages are pretty much the same as the Saturn/NTS build guide now.
The top part of the steering shaft is from the MX5, and the bottom part is the Rally Design steering shaft (RD849).
The bit joining them together is just some chunky mild steel tube (3mm wall I think). I couldn't tell you the diameter though - I just took the Rally Design shaft to my local steel supplier, and they let me stick it in various bits of tube until I found one that was a snug fit!

You are "THE MAN" ! Thank You. Your Build has moved on somewhat since I last logged in. I am some-what in shock at your progress.:eek:

skov
9th March 2012, 01:23 PM
Yep, you've got some catching up to do :p

Got my NTS pedal box fitted last night, that was a bit of a chore...
If anyone's reading this - unless you have arms like Mr Tickle, make sure you bolt the pedal box in place BEFORE you fit the side panels, scuttle, and scuttle bulk head...
Could I reach both sides of the box at the same time to tighten the bolts up? Could I bugger!

HandyAndy
9th March 2012, 02:32 PM
If anyone's reading this - unless you have arms like Mr Tickle, make sure you bolt the pedal box in place BEFORE you fit the side panels, scuttle, and scuttle bulk head...
Could I reach both sides of the box at the same time to tighten the bolts up? Could I bugger!

:D I remember that scenario too

Also an idea to attach the clutch & throttle cables & fit the master cylinder pushrod to the pedals before fitting the side panel ;) ......otherwise you,ll end up with your upper body in the footwell with legs in the air .....don,t ask how I know :p :D

need some more pics please John, sounds like you are making great progress.

cheers
andy

skov
9th March 2012, 03:31 PM
....otherwise you,ll end up with your upper body in the footwell with legs in the air ...
andy

That position sounds familiar, lol
It wasn't too bad until I tried to get out again and got stuck!
I couldn't figure out how to get my head back past the steering wheel and was starting to worry I'd be stuck there all night :rolleyes:

Davidbolam
9th March 2012, 10:01 PM
Hi Skov.

When you used the diff mount to secure you handbrake cable did you use the existing mx5 brackets of did you make your own?

Cheers

David

ps. can you put some photos up of your pedal assembly.

skov
9th March 2012, 11:40 PM
When you used the diff mount to secure you handbrake cable did you use the existing mx5 brackets of did you make your own?


Hi David, I used the existing brackets on the handbrake cables, and bolted them to the big diff washer things with M8 nuts and bolts.
I then just moved the cables, bending the brackets in the process, until they weren't fouling on anything.

https://lh6.googleusercontent.com/-GQqPoh6rtoQ/T1aBRJxDtnI/AAAAAAAAIN8/o_oHhLQT8BY/s512/handbrake_cable_routing.JPG

I'll take some pics of the pedal box and get them posted up in the next few days.

Johno
11th March 2012, 07:29 PM
Good progress,
Looking good Skov. Bl**dy hell you've been busy.:eek:
Next weekend my engine should be out of the donor so hopefully soon gonna do the sump chop...
Not forgotten our deal....:)

Johno

Eternal
18th March 2012, 07:55 PM
Been searching for these....
https://lh4.googleusercontent.com/-A2LoJwhflmY/TouId__5O-I/AAAAAAAAHxo/JBDbXx1np9w/pipe_clip_drawing.jpg
but cant find any of them anywhere. I dont suppose you happen to have any links for them as going to need some :)

skov
18th March 2012, 09:28 PM
Been searching for these....
https://lh4.googleusercontent.com/-A2LoJwhflmY/TouId__5O-I/AAAAAAAAHxo/JBDbXx1np9w/pipe_clip_drawing.jpg
but cant find any of them anywhere. I dont suppose you happen to have any links for them as going to need some :)

Manufacturer: Jetpress
Part# CAC446-NAT
Supplier: http://www.comdir.co.uk/

They're not listed on comdir's website, but if you give them a call they should be able to sell you some. I think you have to buy a minimum of 100 though!

CTWV50
19th March 2012, 02:15 PM
Can you do me a favour now you're almost finished!:D

Can you measure from the floor to the bottom rails at the front and rear wheels and let me know the ride height please? I'll be using the same shocks and springs so it will give me an idea of ground clearance. Also does it change ride height when you get in? Ta.:)

skov
20th March 2012, 08:52 AM
Almost finished??? I wish!

Here's my current ride heights, just bear in mind I've only slapped the suspension on there and not set it up in any way yet:

Front: 150mm
Rear: 170mm

I can't say I notice any movement when I get in it. I suspect the ride is going to be a little on the firm side!

skov
8th April 2012, 09:21 AM
No progress to report, as I've had bugger all garage time for the last month due to moving house...
I did manage to take a few snaps of the build when we dragged it out to move it:

https://lh4.googleusercontent.com/-kgb7j9hlqu4/T4FE_6I7zQI/AAAAAAAAIO0/4hn59QF7Mw8/s512/moving_2012_1.jpg

https://lh3.googleusercontent.com/-AsenB7UwqaU/T4FFAt_Py_I/AAAAAAAAIO4/TA_pZnKAUEM/s640/moving_2012_3.jpg

https://lh5.googleusercontent.com/-1zpZEYCM_Q4/T4FFCmrhWoI/AAAAAAAAIPI/WGvrwjsTwvs/s512/moving_2012_2.jpg

https://lh5.googleusercontent.com/-qQptUQBgIQE/T4FFCYmCPiI/AAAAAAAAIPE/dCYJSIa6fT8/s512/moving_2012_4.jpg

Only moved half a mile or so, so decided to enlist the help of a couple of friends and push it to it's new home.
Managed to sit in it and steer for a small downhill stretch which felt great!

Sadly my new garage is still a single (and possibly slightly smaller than the last one).
On the upside, it's now within the bounds of the property instead of en block, and has a side door leading to the garden which is a vast improvement, and makes it easier to sneak in there.

Hopefully get back on the build in a week or two once we've finished unpacking and whatnot.

CTWV50
9th April 2012, 08:22 AM
No progress to report, as I've had bugger all garage time for the last month due to moving house...

Hopefully get back on the build in a week or two once we've finished unpacking and whatnot.

I wonder what you were up to. Nice to see your car out in the daylight hey!:)

skov
10th April 2012, 08:58 AM
Yeah, it was great to see it blinking in the sunshine for the first time :)

Back in a dingy garage again now though!

https://lh6.googleusercontent.com/-WOnkxIAjeT8/T4MKmf451xI/AAAAAAAAIPk/4rSElFO-x7U/s512/new_home_2.jpg

https://lh4.googleusercontent.com/-Ww3HiEZTkLg/T4MKmXaHNcI/AAAAAAAAIPg/mX1kOIb28xg/s512/new_home_3.jpg

I'm still very excited about the side door to the garden:

https://lh3.googleusercontent.com/-nvsFZ3hLMmY/T4MKlYyGxOI/AAAAAAAAIPc/aoH9VmeBa6U/s512/new_home_1.jpg

CTWV50
10th April 2012, 10:07 AM
I'm still very excited about the side door to the garden:

https://lh3.googleusercontent.com/-nvsFZ3hLMmY/T4MKlYyGxOI/AAAAAAAAIPc/aoH9VmeBa6U/s512/new_home_1.jpg

:-))

What's with all the new relays? If that's what they are?

skov
10th April 2012, 11:13 AM
What's with all the new relays? If that's what they are?

I felt the MX5 wiring was a bit over complicated for my needs, and didn't like the two separate fuse boxes (particularly as I wouldn't be using most of the fuses!).
So I junked all the original fuses and relays, replaced them with some generic ones, and hopefully simplified the wiring in the process :)

I've mounted them on the scuttle bulk head behind the dash here:

https://lh5.googleusercontent.com/-K1Q6DwY3aWM/T4QIclXW3fI/AAAAAAAAIQI/NM7puI8Pjbg/s512/fuse_and_relay_location.jpg

Going to be a pain if I ever need to change a fuse, but they'll be tucked nicely out of the way there.

CTWV50
10th April 2012, 10:57 PM
Ahh I see.:)

skov
11th April 2012, 09:06 AM
Here's a close up:

https://lh4.googleusercontent.com/-K7-RB_vaBVM/T4U6gIb-MFI/AAAAAAAAIQQ/dzKbHuFiRSE/s576/fuse_and_relays1.jpg

You can probably see why I want them hidden now :D

skov
17th April 2012, 09:08 PM
Starting to find some time to work on my build again now.
Managed to finish off the brake lines over the last few days:

https://lh4.googleusercontent.com/-7xc5kOR9IM8/T43K6uqoy9I/AAAAAAAAIQ0/17VVBbrrdBQ/s512/S5033273.JPG

https://lh5.googleusercontent.com/-WdG9e3qQ81Q/T43K3pWF7tI/AAAAAAAAIQg/Vkt-9Qh2wzY/s640/S5033270.JPG

https://lh4.googleusercontent.com/-jn3-zAZgwZc/T43K4DNu5TI/AAAAAAAAIQk/FCXbO4HnBB0/s640/S5033271.JPG

https://lh5.googleusercontent.com/-5yhKsjwVgKY/T43K_f96QaI/AAAAAAAAIRQ/FrPD7ipPEv0/s640/S5033277.JPG

twinturbo
17th April 2012, 09:11 PM
nice work.

Davidbolam
17th April 2012, 09:38 PM
Hi Skov. Please can you answer these questions

Where did you get your brake hoses from?

What have you installed after the t piece in the brake line above the master cylinder?

Also where did you get your hydraulic switch from? are you using part smd426?

skov
17th April 2012, 11:01 PM
Thanks TT. I'm quite happy with how it turned out, just worried it's going to p!ss brake fluid everywhere when I fill it up :)

Hi David, I had a feeling someone would ask about that bit after the T-piece in the rear line. It's a rear brake reduction/bias valve from a Ford Mondeo (Ford part# 1113275).
The donor one was a bit awkward/cumbersome to use, so I junked it for the Ford one as it's nice and small and simple.
I know the Mondeo weighs twice what the roadster will, but it has two fitted - one for each rear brake, so I figured a single one for both rear brakes would be about right :D

I got the brake light switch from ebay, here's the details:

https://lh3.googleusercontent.com/-4GOmT_1b21s/T43mfc7U-RI/AAAAAAAAIRk/a2vYH5CdKQw/s854/21080.png

And finally, the flexi lines came from Furore (http://furoreproducts.co.uk/). I was very impressed with their service; they were custom made to my specifications and arrived next day! Very reasonable at £15 per line too.

Davidbolam
18th April 2012, 09:28 PM
thanks skov - time for some parts shopping!!

CTWV50
20th April 2012, 09:41 PM
I see you've decided to use new mx-5 track rod ends. How's the clearance with the wishbone and steering boot now? And also may I ask, where did you get your extensions from? I'm waiting on a pair from NTS but I don't seem to be very lucky at being able to get hold of Nathan.

skov
20th April 2012, 10:14 PM
Hi Chris, my extensions came from NTS, and the track rod ends are the same ones I've had all along - the ones on the donor were knackered and I had to angle grind one of them off the upright!

I've still got my dodgy lock stops on the rack, so clearance is fine ;)
I've rumours that Nathan has redesigned the top wishbones to improve clearance, but haven't seen any evidence of it yet (it might have been Johno that mentioned it to me).

Didn't Nathan put a post up the other day to say he'd switched his phone and email off for a while to avoid distractions and concentrate on clearing the backlog of work he has?

CTWV50
20th April 2012, 10:48 PM
Oh right, I didn't know he was THAT busy.:eek:

Booked your IVA test yet?:)

Out of interest how many turns of the SW get you from lock to lock?

skov
21st April 2012, 08:39 AM
Don't think I'm quite ready for the IVA test, lol
I was aiming for about this time next year!

I did have 2.9 turns lock to lock - I've now got about 2.
Going to have fun doing 15-point turns everytime I need to do a U-turn :rolleyes:

skov
25th April 2012, 01:50 PM
Made a start on the wiring this week, and fitted the tunnel loom:

https://lh3.googleusercontent.com/-nEYx8tIQHPc/T5XVf2pKtvI/AAAAAAAAIR4/1bUb0ai7L4Q/s800/S5033274.JPG

https://lh5.googleusercontent.com/-MT5jbqw3Oew/T5XVgaryOtI/AAAAAAAAISA/XBtK-w2PngE/s800/S5033276.JPG

https://lh5.googleusercontent.com/-F2k-8V1fWlQ/T5XVitd9TDI/AAAAAAAAISQ/y3g4fJEbXB8/s800/S5033277.JPG

https://lh3.googleusercontent.com/-3ynOVlDOFCA/T5XVjWlEINI/AAAAAAAAISU/9s_P1qsUgw0/s800/S5033278.JPG

Does that look ok for IVA?

CTWV50
25th April 2012, 02:11 PM
Looks good what have you wrapped the wire in?

skov
25th April 2012, 04:53 PM
I covered it all in heat-shrink sleeving (except for the short bit up to the handbrake where I used nylon braid).

CTWV50
25th April 2012, 04:56 PM
I covered it all in heat-shrink sleeving (except for the short bit up to the handbrake where I used nylon braid).

I may do that myself!:D

Johno
25th April 2012, 08:58 PM
Hi John, Looking good:cool:
Glad to see you have time to get back on with the build after your move. Wish I knew about auto electrics as much as you as I've started to strip my wiring loom a couple a weekends ago (knit one pearl two rings a bell):D
I have been concerntrating on the engine side the last couple of weekends which doesn't come easy to me as I know nothing about cars...LOL:eek: (thats what a garage is for).

Keep up the good work...Johno

HandyAndy
25th April 2012, 09:40 PM
Looks very tidy indeed :cool:

I don,t think the IVA man would have any issues with that tidy work.

cheers
andy

skov
28th April 2012, 10:02 AM
Looks very tidy indeed :cool:

Maybe if you ignore the over-the-top sikaflex, and the masses of swarf and dust :D
Cheers Handy!

Not sure I know that much Johno, I've spent weeks/months figuring out the wiring and stripping the loom. It's been causing me no end of headaches!

skov
1st May 2012, 11:20 AM
Still slowly chipping away at the wiring...
Got the pedal box wired up, and fitted the battery and main fuse over the weekend.
Decided to put the battery into the engine bay rather than the passenger foot-well like I had originally planned (mostly because my lovely shiny battery bracket was too wide to fit in the foot-well :rolleyes: ).
I think I'm going to put the ECU in the foot-well instead.

https://lh5.googleusercontent.com/-ZBduNcjctXg/T51hs10gl3I/AAAAAAAAIS8/7tt1LoAn4X0/s512/S5033274.JPG

https://lh6.googleusercontent.com/-nIjtSox3sik/T576xKQvi9I/AAAAAAAAITM/cau8BKuq9mg/s640/S5033270a.JPG

CTWV50
1st May 2012, 11:49 AM
Oh mounted on it's side! What a good idea!

skov
1st May 2012, 01:16 PM
Not my idea I'm afraid!
I'm sure I've seen someone else mount one of these batteries in pretty much the same location/orientation.
It is nice that you can mount these gel type batteries pretty much however you want :cool:

Davidbolam
1st May 2012, 07:21 PM
hi skov,

i was looking at the picture of your clutch master cylinder and it looks like you have mounted something inline prior to the clutch hose? What is this or it it the slave cylinder.

Thanks

David

Johno
1st May 2012, 07:53 PM
Hi,
Correct me if I'm wrong but I reckon Skov is replicating the clutch switch fitted to the MX5 with a pressure switch. ;)
On the MX5 there is a mechanical switch which the spring often fails and causes problems when the clutch is engaged with regards to engine revs I believe, some sort of emission thingy.

Johno

skov
1st May 2012, 07:57 PM
Hi David,
Here's a slightly better picture of what I've done:

https://lh3.googleusercontent.com/-pjW0VbSVVIA/T51hOMMJuiI/AAAAAAAAISw/sVhx3JeGpEE/s640/S5033273.JPG

I've got the clutch master going to a t-junction, which then goes to a flexi hose to the slave cylinder and a brake pressure switch to replace the clutch switch I lost from the MX5 pedal box.
I'm not convinced there's going to be enough pressure to operate the switch, but it's worth a try!
It won't do any harm sitting there if it doesn't work, and the t-junction puts the flexi hose in a better position anyway :)

skov
1st May 2012, 07:58 PM
Hi,
Correct me if I'm wrong but I reckon Skov is replicating the clutch switch fitted to the MX5 with a pressure switch. ;)
On the MX5 there is a mechanical switch which the spring often fails and causes problems when the clutch is engaged with regards to engine revs I believe, some sort of emission thingy.

Johno

You beat me to it Johno!
That's exactly what I'm trying to do. Still not sure it's going to work mind!

Johno
1st May 2012, 08:15 PM
Hi Skov,
Sorry about butting in....:)
I can't see a problem with the switch idea as I guess it's the same switch as the one used on the brake pedal.
Had another bash this weekend with the wiring and think I have removed most of the redundant wires but only time will tell.
The way you are going you better be booking the IVA soon....;)

Keep up the good work...Johno

skov
1st May 2012, 08:27 PM
Hi Skov,
Sorry about butting in....:)
I can't see a problem with the switch idea as I guess it's the same switch as the one used on the brake pedal.
Had another bash this weekend with the wiring and think I have removed most of the redundant wires but only time will tell.
The way you are going you better be booking the IVA soon....;)

Keep up the good work...Johno

No worries :)

It is the same one I used for the brake, I'm just worried there's not going to be enough pressure in the clutch line to operate it.

Leaving redundant wires in the loom isn't a problem, it's removing ones you do need! Already had to put a couple back in where I got a bit carried away with the scissors :)

Davidbolam
1st May 2012, 10:39 PM
what does the switch in the clutch do? I was hopeing this could be bypassed

skov
1st May 2012, 11:31 PM
what does the switch in the clutch do? I was hopeing this could be bypassed

It's an emissions / fuel economy thing. Most ECU's will stop injecting fuel when you're slowing down on closed throttle - but will start injecting again if it's put in neutral or the clutch is depressed (to stop the engine stalling).
If you just leave the switch out the revs will dip, and possibly stall when you stop.
If you bypass it it'll probably be fine, but use more fuel.

motomaniac
2nd May 2012, 09:58 AM
Skov, i would think there'd be no problem with the switch, i have them fitted to my bikes and you just need the slightest of pressure to get them working and light up the rear light, so it should work ok..

Johno
7th May 2012, 08:59 PM
Hi John,
Looking good as usual..:cool:
My colleagues at work have issues with hydraulic pressure switches saying they will fail but like you I will be fitting them... Good idea about the clutch switch by the way. that's what I will be doing now:D

I believe the only reason they fail on older vehicles is because of debris in the lines built up over the years. With new lines and new fluid this should not be a problem... just my thoughts.

Johno

SeriesLandy
7th May 2012, 10:07 PM
Ash said he has had 3 fail and changed his (brake) switch to a mechanical one.
Also Coozer over on LB Link (http://www.locostbuilders.co.uk/viewthread.php?tid=169898)

Johno
9th May 2012, 09:02 PM
Ash said he has had 3 fail and changed his (brake) switch to a mechanical one.
Also Coozer over on LB Link (http://www.locostbuilders.co.uk/viewthread.php?tid=169898)

So is there a better quality hydraulic brake pressure swith we can fit?

robo
9th May 2012, 09:40 PM
It's an emissions / fuel economy thing. Most ECU's will stop injecting fuel when you're slowing down on closed throttle - but will start injecting again if it's put in neutral or the clutch is depressed (to stop the engine stalling).
If you just leave the switch out the revs will dip, and possibly stall when you stop.
If you bypass it it'll probably be fine, but use more fuel.

I suppose you would lose a bit of engine braking if its just bypassed.

Bob

skov
17th May 2012, 01:21 PM
I decided to separate the engine and gearbox the other night.
Can of worms comes to mind!

The bell housing is full of gunk and engine oil.

There's pretty much zero friction material left on the clutch.

The clutch release and flywheel spiggot bearings are knackered.

and the flywheel is covered in cracks!

:eek:

I think the source of the oil is the cam angle sensor, which sits on the back of the head just above where the engine and gearbox mate.
CAS seal leaks are very common on the MX5 and there's evidence that this one had a massive leak judging by the amount of oil below it. I think it had been working it's way into the bellhousing for quite some time.
Saying that, I'm not 100% sure the crank seal isn't leaking too...

Not sure what to do about the flywheel. I took it to my local friendly garage and they advised me not to put it back as it is.
I might be able to get away with getting it re-faced, but I am slightly tempted to replace it with a lightweight replacement :) Just not sure funds will allow that!

chrisponter
17th May 2012, 02:03 PM
I was thinking of replacing the flywheel eventually too, check these guys out

http://www.flyinmiata.com/index.php?deptid=4531&parentid=0&stocknumber=08-26500%20%2010.30

Not too bad in my opinion

CTWV50
17th May 2012, 03:36 PM
I decided to separate the engine and gearbox the other night.
Can of worms comes to mind!

The bell housing is full of gunk and engine oil.

There's pretty much zero friction material left on the clutch.

The clutch release and flywheel spiggot bearings are knackered.

and the flywheel is covered in cracks!

:eek:

I think the source of the oil is the cam angle sensor, which sits on the back of the head just above where the engine and gearbox mate.
CAS seal leaks are very common on the MX5 and there's evidence that this one had a massive leak judging by the amount of oil below it. I think it had been working it's way into the bellhousing for quite some time.
Saying that, I'm not 100% sure the crank seal isn't leaking too...

Not sure what to do about the flywheel. I took it to my local friendly garage and they advised me not to put it back as it is.
I might be able to get away with getting it re-faced, but I am slightly tempted to replace it with a lightweight replacement :) Just not sure funds will allow that!

Sh*t:eek: , cracks!! How many miles has it done?

skov
18th May 2012, 11:17 AM
I was thinking of replacing the flywheel eventually too, check these guys out

http://www.flyinmiata.com/index.php?deptid=4531&parentid=0&stocknumber=08-26500%20%2010.30

Not too bad in my opinion

Looks good - I could quite easily spend a silly amount of money on that site!

I almost bought the 4kg Ultra Light Weight one from ILMotorsport yesterday:

http://www.ilmotorsport.de/shop/article_detail.php5?aid=3889&oid=12&depth=0&page=0&count=6&PHPSESSID=eb6dbcd7a70582bdd4310ca19a45e67e

But then I stuck a post on MX5Nutz and someone's offered me a standard flywheel plus a low mileage clutch for £30, and being a cheapskate I think I'll get that instead :D

Sh*t:eek: , cracks!! How many miles has it done?

Yeah the face where the clutch mates against it is absolutely covered in hair line cracks! I don't think it's in any danger of failing just yet, but I reckon I'll play it safe and replace it!

The car had allegedly done about 60k, but I'm starting to suspect it had done rather more than that... :rolleyes:

CTWV50
18th May 2012, 12:02 PM
But then I stuck a post on MX5Nutz and someone's offered me a standard flywheel plus a low mileage clutch for £30, and being a cheapskate I think I'll get that instead :D

Nice one. So easy to get carried away with things. Lighten flywheels are one of the many ways to spend more to get less? WTF!:D

BORNXenon
18th May 2012, 01:11 PM
Nice one. So easy to get carried away with things. Lighten flywheels are one of the many ways to spend more to get less? WTF!:D

Like womens underwear. The more they spend, the less material there appears to be. Not that I'm complaining like! :)

Must say though, I had a lightened flywheel on my old Vectra and it was one of the best modifications I ever made. Still have that engine sat in the garage, will be going in my build, some time after I have enough funds to even start! :D

skov
18th May 2012, 08:55 PM
https://lh6.googleusercontent.com/-q_lUyZOg_Yc/T7aoM2MwqgI/AAAAAAAAIVg/2eCiDeCKyZg/s640/flywheel1.jpg

K4KEV
19th May 2012, 12:45 AM
Hi John.....looks like it has been drifted to within an inch of its life, the engine I have displays similar cracks but I have a junshop lightened flywheel and my crank is going to be reground.....dont really think you will get away with that level of cracking but maybe its a case of giving it ago.....nowt to lose is there.:)

Tatey
19th May 2012, 07:51 AM
I have to say I wouldn't want to risk using a cracked flywheel, as when it goes it goes, and with already being cracked it is just a matter of time before the cracks grow long enough until fast fracture can occur.

Not really something you want to risk :eek::

http://www.youtube.com/watch?v=0NYZVLNOXvs&feature=related

Davidbolam
5th June 2012, 03:16 PM
When you installed the brake pressure reduction valve in your rear brake line what size of union was used on the input side? It seems a lot bigger than 10 x 1.

I was trying to work out which way around it went until I came across the question you had asked on the ma5da racing forum.

David

skov
5th June 2012, 03:50 PM
When you installed the brake pressure reduction valve in your rear brake line what size of union was used on the input side? It seems a lot bigger than 10 x 1.

I was trying to work out which way around it went until I came across the question you had asked on the ma5da racing forum.

David

No idea what it is I'm afraid!
My local friendly garage had a dig through their pot of brake unions and found one the right size :)

skov
22nd June 2012, 11:19 PM
I think it must be time for an update!

Haven't had a huge amount of time to spend on the build for the last couple of months, but slowly managed to strip the engine down and replace the head.
Also swapped the scary cracked flywheel with a decent second hand one I picked up via mx5nutz.

The free engine stand I got from the tip came in handy!

https://lh4.googleusercontent.com/-Ci_KK9joke0/T8fl7CEYcII/AAAAAAAAIXY/1ZVhO_oXiV4/s512/S5033269.JPG

Actually got a decent session in the garage for the first time in ages tonight, and managed to get the engine into the chassis:

https://lh5.googleusercontent.com/-LjyihS2pIxE/T-TpOYa_XII/AAAAAAAAIYY/0mLr-yzkw1o/s640/S5033270.JPG

The bonnet fits, which is nice!

https://lh6.googleusercontent.com/-dE33O4Wk36c/T-TpSRFEaCI/AAAAAAAAIYw/tqgJH1F25zE/s640/S5033274.JPG

twinturbo
23rd June 2012, 07:53 AM
Good effort, just need to get it running now ;)

TT

skov
23rd June 2012, 08:52 AM
Good effort, just need to get it running now ;)

TT

Thanks TT. Hopefully won't be too long before I get it running, just need to sort out the spaghetti under my scuttle :eek:

https://lh5.googleusercontent.com/-wip7rdRKh4A/T-TpU9gdjfI/AAAAAAAAIZA/grtaQ24iue8/s640/S5033277.JPG

alga
23rd June 2012, 12:55 PM
Wow, your spaghetti looks super tidy compared to mine. I'm trying to use the Sierra fusebox, and it looks like a tangle of wires.

Davidbolam
23rd June 2012, 07:57 PM
Looking really good skov. I was looking at your photos. In the second album what is the blue cylinder shaped item. It looks like it is the last photo on there.

david

skov
23rd June 2012, 10:15 PM
Looking really good skov. I was looking at your photos. In the second album what is the blue cylinder shaped item. It looks like it is the last photo on there.

david

Thanks David.
If you mean this, it's my fuel pump.

https://lh3.googleusercontent.com/-fDe5v9cBaq4/T-WhwqjPZDI/AAAAAAAAIZs/MXjRPmXf__I/s912/S5033272.JPG

I'm currently figuring out where to stick it!
I think I'm going to do something similar to Alga here:

http://www.haynes.co.uk/forums/showthread.php?t=8197

Davidbolam
23rd June 2012, 10:38 PM
Are you not using the in tank mx5 one?

skov
23rd June 2012, 11:14 PM
Are you not using the in tank mx5 one?

No, but I wish I had now!

Johno
26th June 2012, 06:55 PM
Nice to get back in the swing of things John I bet...:)

Cars looking especially good with the bodykit on.:cool:
So how did you overcome the bonnet clearance issue in the end? I bet you're glad you got over that problem.
Wirings the one part of the build I'm not looking forward to but you seem to be progressing well with yours.

Well hope you keep posting the piccy's...

Johno

skov
29th June 2012, 01:28 PM
Nice to get back in the swing of things John I bet...:)

Cars looking especially good with the bodykit on

Might look good if the colour of the panels actually matched and they weren't covered in scuffs!
The number of times I've dropped/kicked/knocked/scratched/chipped them is unreal :rolleyes:
I would have been well peed of with myself if I'd bought brand new ones!

I stuck with the engine position detailed in my photos (i.e. sump 40mm below bottom rails, engine offset 25mm towards passenger side). Also had to move my throttle cable bracket down slightly by putting the top bolt in the bottom hole and tapping a new hole for the lower bolt if that makes sense :confused:
The bonnet fits, but it's tight. I think its just touching the inlet manifold, which might come back to bite me when it's running an the engine is bouncing around on it's rubber mounts...

CTWV50
30th June 2012, 02:45 AM
Might look good if the colour of the panels actually matched and they weren't covered in scuffs!
The number of times I've dropped/kicked/knocked/scratched/chipped them is unreal :rolleyes:
I would have been well peed of with myself if I'd bought brand new ones!

I stuck with the engine position detailed in my photos (i.e. sump 40mm below bottom rails, engine offset 25mm towards passenger side). Also had to move my throttle cable bracket down slightly by putting the top bolt in the bottom hole and tapping a new hole for the lower bolt if that makes sense :confused:
The bonnet fits, but it's tight. I think its just touching the inlet manifold, which might come back to bite me when it's running an the engine is bouncing around on it's rubber mounts...

I think it'll be all right John! :) Your build progress has kept me going!:cool:

skov
30th June 2012, 07:15 AM
Glad to hear it Chris :D

The build's progressed quite well this week, so should have some more updates soon!

CTWV50
1st July 2012, 12:21 PM
So I see! Just had a nose through your album.:cool:

skov
1st July 2012, 10:47 PM
Time for an update!
Just about finished my fuel routing this weekend:

https://lh3.googleusercontent.com/-OtFFeOKJN-8/T_DADQJ5B_I/AAAAAAAAIcA/GEeVAWnL60Y/s640/S5033288.JPG

https://lh4.googleusercontent.com/-s-np1UpQdTw/T_DAGNYzcWI/AAAAAAAAIcA/K5w6KAjEPes/s640/S5033289.JPG

https://lh3.googleusercontent.com/-vJ7BnutmT94/T_DAIHg2MfI/AAAAAAAAIcA/6TgJn1Fkf74/s512/S5033290.JPG

https://lh4.googleusercontent.com/-yNPdSYsk9QY/T-uBFZgT71I/AAAAAAAAIZ0/3CPLdo0RHTs/s640/S5033280.JPG

Just need to add a few more jubilee clips and connect the fuel pipes up in the engine bay.

The pump is a cheapo Bosche copy off ebay, the red/clear filter is a mesh/gauze pre-filter to protect the pump from the swarf in my tank, and the main fuel filter is a TKF516 (used on loads of cars from a 0.9l Cinquecento to a 4.2l A6).

Johno
2nd July 2012, 08:45 PM
Hi John,
You'll be running out of things to do soon...LOL:)
I see you have a join in your return line, just temporary?
Are you planning to vent your tank with an inline valve with the spare outlet on top of your tank or go or just take the pipe up high and then route it below your tank?
I don't know if you have done it yet but have you fitted your earth strap/wire from your tank to chassis.

Johno

skov
2nd July 2012, 09:11 PM
I can't see me ever runing out of things to do on it!

The join is probably permanant - but I will add a couple of jubilee clips!
It's a reduction joiner to go from 10mm hose for the tank outlet to 8mm hose for the copper line.

Haven't decided how to vent it yet, I think I might still have a valve from the donor kicking about somewhere that might do.

Thanks for reminding me about the earth strap! I've got a threaded hole in the tank ready, but haven't fitted the strap yet.

twinturbo
3rd July 2012, 08:04 AM
I have one of those pumps somewhere, bought about 3 years ago for our golf MK1 EFi conversion and not used,... Have not seen it in ages though :confused:

TT

Davidbolam
3rd July 2012, 09:26 AM
Hi Skov,

The pictures are looking really great there. I have a question. I noticed you had put up a post a few weeks ago showing the accelerator cable. Did you use the original one or purchase a new item. Thanks David

skov
3rd July 2012, 11:16 AM
I have one of those pumps somewhere, bought about 3 years ago for our golf MK1 EFi conversion and not used,... Have not seen it in ages though :confused:
TT

I didn't nick it, honest :)


Hi Skov,

The pictures are looking really great there. I have a question. I noticed you had put up a post a few weeks ago showing the accelerator cable. Did you use the original one or purchase a new item. Thanks David

Thanks David. I was hoping to use the original, but it's a bit on the short side, so I'm going to get a universal one and cut it to the correct size.
I'll post up the details when I'm done.

skov
3rd July 2012, 11:27 PM
This evening I have mostly been playing with hose.

At the rear I've used a Polo expansion tank and T'd it into the heater matrix hoses:

https://lh3.googleusercontent.com/-H9De_k7L2h4/T_NbtZN-xjI/AAAAAAAAIck/HoAhIWf50O0/s640/expansion_tank_routing.jpg

Up at the front I've just about a figured out the routing of the hoses to the radiator.
I'm pretty happy with the bottom one, but the top still needs a little work, and probably some kind of support bracket somewhere:

https://lh3.googleusercontent.com/-kcm6vXWcbv8/T_Nbo8BcnVI/AAAAAAAAIcI/HNgQnEAeqTo/s640/bottom_hose_routing.jpg

https://lh4.googleusercontent.com/-vYEdacpf1Ho/T_NbwJrsPeI/AAAAAAAAIc4/Cvmsxmar6X0/s640/hose_routing_top_view.jpg

https://lh6.googleusercontent.com/-X2iaaMdbHOQ/T_Nbyj3U6cI/AAAAAAAAIdI/0HwHv6p91yk/s640/top_hose_routing.jpg

damn 4 pics per post rule...

skov
3rd July 2012, 11:27 PM
...the routing of the top coolant hose is a bit on the convoluted side in order to make space for my air intake components:

https://lh4.googleusercontent.com/-e0JMbx2RzE0/T_NbxRqDSpI/AAAAAAAAIdA/QVEnzYwc0Zk/s640/intake_side.jpg

https://lh3.googleusercontent.com/-395CAjbZS8U/T_NbsZ1mpmI/AAAAAAAAIcg/td_K-qEE5bw/s640/engine_bay_front_wide.jpg

Still need to finish the brackets for the airflow meter and airbox, and probably add some ducting to bring cold air into the airbox, but it's more or less there.

Johno
6th July 2012, 08:55 PM
You've been a busy bunny haven't you....:)
I bet that's really rewarding putting those components in.
I guess by your photos you routed the air components in first then sorted the cooling side?
She's one hell of an air filter you got there, what make is that?
So come on how long before you bring her to life....:D

Lots of progress there John and excellent workmanship...:cool:

Johno

PorkChop
6th July 2012, 09:48 PM
You've been a busy bunny haven't you....:)
I bet that's really rewarding putting those components in.
I guess by your photos you routed the air components in first then sorted the cooling side?
She's one hell of an air filter you got there, what make is that?
So come on how long before you bring her to life....:D

Lots of progress there John and excellent workmanship...:cool:

Johno

It's a CDA airbox Johno.

The build is really coming along nicely Skov - it'll be up and running in no time :)

twinturbo
7th July 2012, 08:11 AM
Having water in makes a whole difference to the mind set. Mines mocked up and sort of holds water . Would not want to preasurise it though LOL...

TT

CTWV50
7th July 2012, 10:36 AM
Nice Job John, I've been scratching my head over this plumbing for weeks. Think I've got it sorted now though.

skov
9th July 2012, 07:00 AM
Thanks guys.
The airbox is a Carbon Dynamic Airbox (CDA) made by BMC.
A mate at work offered it me for a fraction of the new price, so I thought I may as well use it :)

I wouldn't fancy filling my system with water yet TT, let alone pressurise it!
There's still a couple of small bore hoses I need to fit/replace, not to mention several missing jubilee clips. Oh, and my filler cap doesn't fit, which I'm slightly annoyed about...

I suppose I'm going to have to get around to doing the wiring soon, I keep putting it off, but I'm running out of other things to do now!

deezee
9th July 2012, 12:16 PM
Just a quick observation, but it looks like your inlet / airbox will be sucking in air from around the exhaust manifold? Wouldn't that be red hot air? I know my stainless manifold exhaust runs at a couple of hundred degrees when I shoot a infrared thermometer onto it.
I find the heat soak on that side of the engine is pretty high after I've been driving for even 15 mins. I've had to use some aluminised glass cloth on a few bits and bobs to keep the heat off components.

skov
9th July 2012, 02:19 PM
Yeah, I know it's going to be pretty hot there!
My plan is to bolt some ducting like this to the intake side of the airbox and route cold air into it from somewhere else:

https://lh3.googleusercontent.com/-rXxf1clx7R4/T_rZ3kNCrVI/AAAAAAAAIeg/ecBhPfFZlcM/s480/08-360-005_flex_duct.jpg

skov
10th July 2012, 09:36 PM
Hi Skov,
The pictures are looking really great there. I have a question. I noticed you had put up a post a few weeks ago showing the accelerator cable. Did you use the original one or purchase a new item. Thanks David

Hi David, just finished my throttle cable, here's the details as promised:

The cable I used is a Sytec 1m universal cable, which I cut down to the length I needed.
To link it to the pedal I used a 'classis' trials bike brake clevis (sold on ebay for use on BSA/Norton/Triumph/etc.) which seems to fit both the pedal and the cable nicely.

https://lh5.googleusercontent.com/-PphUD5b0kso/T_qa-Cf-3WI/AAAAAAAAIeA/SR4KsPsAxo4/s576/throttle_cable.jpg

At the throttle body end, I used a 10x5mm solderless nipple.

At the pedal box I used a bicycle brake cable adjuster to hold the cable outer in place, and at the manifold I reused the adjuster from the MX5 cable.

To get it to fit under the bonnet I had to reposition the braket on the manifold by grinding the top hole off the manifold and drilling/tapping a new one futher down.

https://lh5.googleusercontent.com/-hG4TEUNr5Do/T_yMeVPH74I/AAAAAAAAIfU/Q1_3JJ-e1wo/s640/S5033285.JPG

https://lh4.googleusercontent.com/-4ox8EDbEBHo/T_yMd80YMUI/AAAAAAAAIfU/XhuaOOn_168/s640/S5033284.JPG

https://lh6.googleusercontent.com/-UlPsYz7zdDE/T_yMeyyiHfI/AAAAAAAAIfU/zNl1X3OwpIM/s640/S5033280.JPG

One thing I did notice is that you need a massive amount of pedal movement to get the full travel on the throttle body.
Not sure if that's a good thing or not!

Hope that helps.

Davidbolam
10th July 2012, 10:50 PM
Thanks for the update re the cable. I was thinking a shorter accelerator pedal would be better as mine feels like its been designed for a size 15 shoe!

skov
4th August 2012, 07:24 AM
Haven't done a massive amount on the roadster lately, but have been slowly knitting together the spaghetti under the scuttle.
Got to the point last night where I could tentatively connect the battery up.
Well blow me down - no fires, smoke, or blown fuses!
All the relays seem to switch, and the engine turns!!!
Might have to stick some fuel in soon and see if she runs.

https://lh5.googleusercontent.com/-Vg7zbIeH9MM/UBzF3EOgkpI/AAAAAAAAIhI/G16gl7Hgeos/s640/S5033291.JPG
https://lh4.googleusercontent.com/-Wc9nBaPKUFk/UBzF1zFc-rI/AAAAAAAAIhI/SL-sHZ93Sec/s640/S5033289.JPG
https://lh4.googleusercontent.com/-NEsLvU0rywM/UBzF1kyxQAI/AAAAAAAAIhI/BnTZwxZtbrc/s640/S5033288.JPG
https://lh4.googleusercontent.com/-FFGfk3WZyHU/UBzFz5YoHlI/AAAAAAAAIhI/J0vcRkgeWWA/s640/S5033287.JPG

Davidbolam
4th August 2012, 11:58 AM
Don't forget the video!!

The wiring under the scuttle looks really tidy. I am worried that there won't be enough space under mine as there is that much!!

Hope it starts first time for you.

David

skov
4th August 2012, 12:47 PM
Don't worry, I won't forget the video!
Have you managed to get your's started yet David?

Davidbolam
4th August 2012, 08:13 PM
Not yet. The fuel pipes that I got off eBay need to go back as they were just sent in a plastic bag and are full of dents. Looks like the postman sat on it!

skov
4th August 2012, 08:19 PM
Just started her for the first time, woot woot! :D :D :D

Here's the requisite evidence:

http://www.youtube.com/watch?v=vjKb0o9w2Zo&feature=youtu.be

Might have to fit an exhaust before I try again!

Davidbolam
5th August 2012, 07:25 PM
congratulations - it wont be long until you are taking it for a spin up the street!!

Johno
5th August 2012, 08:12 PM
Well done John.....:D
I bet you are well happy with her starting up.
I see you had a big grin on your face on the vid but couldn't see if you had your fingers crossed....:)

Glad to see your hard work is paying off....

Johno

skov
6th August 2012, 11:11 PM
Thanks guys, I did indeed have a big grin :D
I had a little bit of excitment just before that too. Ran the fuel pump to get the fuel rail pressurised in preperation, and it turned out one of my injectors wasn't seated properly, resulting in a petrol fountain!

Tried to make a start on the exhaust today, but the bearings went in my angry grinder... and shortly afterwards I managed to break my last jigsaw blade trying to cut an exit hole in my side panel :rolleyes:

Davidbolam
8th August 2012, 12:02 AM
John,

On the fuel rail which of the fuel tubes is the input and which is the exit?

I was going to select the one with the small regulator as the exit. Hoping this is right. I was thinking that if yours started you must have had them the correct way around.

David

skov
8th August 2012, 06:52 AM
Hi David,
That's right - the one at the rear near the regulator is the exit. I went on mx5nutz and asked that very same question just to make sure!

skov
8th August 2012, 09:34 AM
Oooh, the postman has been kind today :D

https://lh5.googleusercontent.com/-J50MqzxzSjc/UCIj7ettJDI/AAAAAAAAIhw/AL6R8sfjwW0/s640/simmi_exhuast_can.jpg

Johno
8th August 2012, 08:31 PM
Well that looks very nice indeed....:cool:

May I be cheeky:o and ask how much?
Really looks well made, what are the specs of it.
Once shes fitted first test drive looming......????????:eek:

Johno

skov
8th August 2012, 09:06 PM
It's a Simmi Performace stainless steel end can.
Handmade in the North of England apparently, so must be good! It does appear to be very nicely made.
Comes with a removable baffle too which might be handy for the IVA noise test :D

Here's the ebay listing:

http://www.ebay.co.uk/itm/250800426533?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

Still a fair way off the first test drive yet! Hopefully get time to drop the propshaft off for shortening this week, which'll get me one step closer.

motomaniac
8th August 2012, 09:28 PM
bloody hell, simmi, hes just up the road from me.... did the removable baffle for my supermoto.... nice work he does...

Davidbolam
8th August 2012, 10:46 PM
The exhaust looks good and it comes from consent the home of the philleas fogg tortilla chip!

That's only about 10 miles from me so I may use one of those if it works well.

motomaniac
9th August 2012, 01:04 AM
hes just outside if he hasnt moved, somewhere i think near stoney heap.... got mine done a few years ago, so he might have got bigger premises now...

skov
21st August 2012, 09:08 AM
My shortened propshaft turned up from Bailey Morris today.
Looks like they've done a great job, and have even painted it which I hadn't expected!

https://lh3.googleusercontent.com/-wv4erutSlEw/UDM_3ymQZFI/AAAAAAAAIjU/kQ5VaM_mZeU/s640/2012-08-21%252008.54.25.jpg

K4KEV
21st August 2012, 11:21 AM
jeeeez....that looks awefully long....mine will be half that length at least, is the mx5 box really that short?

CTWV50
21st August 2012, 11:28 AM
So when is the first drive? :)

CTWV50
21st August 2012, 11:33 AM
Just started her for the first time, woot woot! :D :D :D

Here's the requisite evidence:

http://www.youtube.com/watch?v=vjKb0o9w2Zo&feature=youtu.be

Might have to fit an exhaust before I try again!

Well done john, made me smile when I saw you crack a smile! My little buy said over the noise "Why is he turning it on when it's not ready?" Haha!

skov
21st August 2012, 09:06 PM
You had me worried all afternoon Kev, turns out my massive shaft fits perfectly though :D

https://lh5.googleusercontent.com/-zwWHvWK-VMM/UDPnrIr5ZZI/AAAAAAAAIjk/MXCABh911PY/s640/2012-08-21%252019.18.19.jpg

I was just thinking this morning I hadn't seen you on here for a while Chris!
I'm still a little way from the first test drive yet. I need to get the clutch and brakes working, make the exhaust system, and stop it p!ssing coolant all over the place :mad:
Really looking forward to blasting up and down my drive though!

K4KEV
22nd August 2012, 12:51 AM
just realized John ...the sierra diff sits a little way into the trans tunnel and its my g/box that sits a long way back ....it had me thinking (worrying too):confused:

CTWV50
22nd August 2012, 01:20 PM
I was just thinking this morning I hadn't seen you on here for a while Chris!


It's that time of year again where I just can't be bothered!:rolleyes:

skov
23rd August 2012, 08:37 AM
I know the feeling, my build time's been fairly minimal recently :rolleyes:

skov
27th August 2012, 08:37 PM
Had a successful bank holiday today.
The wife could tell I was hankering to get in the garage and offered to take all the kids out shopping for the afternoon (in return for a fistfull of spending money of course!).
Managed to fabricate my exhaust system and take her out for her first drive :D
Ok, so I only went up and down the drive (largely because the brakes don't work yet), but it was still quite exciting!
I'll stick up some photos of the exhaust later, but here's the first drive video for now:

http://www.youtube.com/watch?v=vlClgxiGbrQ&feature=plcp

ayjay
27th August 2012, 08:55 PM
Well done;)
Did you use the back wall of the garage as a brake?

twinturbo
27th August 2012, 09:08 PM
Must be a very long time sine I did much productive, and going up and down the drive is blocked by the other two projects :rolleyes:

May have a couple of free days a week for the next few months, so perhaps progress on all fronts.

TT

Davidbolam
27th August 2012, 09:13 PM
Well done. I must get out in the garage tomorrow night!!

David

skov
27th August 2012, 11:04 PM
Thanks Guys :D

Here's some pics of my exhaust set up.
The tubing is just two 90 degree bends, with some strange angles cut into the ends to make it all line up (took a lot of trial and error!).
As mentioned previously, the end can is by Simmi Performance, and I mounted it using the hanger strap it came with and two 'half moon' exhaust rubbers I found on ebay.

https://lh3.googleusercontent.com/-unKPUfr7Tqs/UDvqvYCKjyI/AAAAAAAAIl4/BrwsvQuoELA/s640/2012-08-27%252016.57.37.jpg

https://lh3.googleusercontent.com/-fw_8yeJHhxQ/UDvqxQ-WDII/AAAAAAAAIl4/a9F4XgbWcg0/s640/2012-08-27%252016.58.05.jpg

https://lh6.googleusercontent.com/-NZpWBBWM920/UDvqz9J3RDI/AAAAAAAAIl4/p2CE_iHRQaM/s512/2012-08-27%252016.58.16.jpg

Johno
29th August 2012, 08:27 PM
Hey....:D
First turn of the tyre under its own steam?
One serious goal achieved there John.... my hat off to you buddy.;)

Exhaust looks good too, I see you put it plenty forward of the rear wheel arch compared to a lot of builds, is this to keep heat of it?
Also I've been looking on here regarding exhaust clamps and IVA but not found a lot. Obviously not a good idea to put a plastic cap on one's nuts in this area....:D

Is part of this area exempt to a certain degree as per the front shock area?:confused:

Whats your thoughts John?

Johno

skov
29th August 2012, 09:02 PM
Hey Johno,
I put it that far forward for several reasons.
The official reason is to stop the kids stepping/burning themselves on it getting into the car, and to stop it melting the rear arch.
The real reason is I was too lazy to make it any longer, and too tight to buy the extra pipe (the bits I did use were fished out of the bin at work :) )

Not sure what to do about the exhaust clamp. I might just cover it in exhaust heat wrap, which might then fall off on the way home from the IVA ;)

Johno
2nd September 2012, 06:52 PM
Hi John,
I hate to be the bearer of bad news :( but has anybody pointed out that your green paint on your side panels is looking a bit eeerrrr.... frayed around the edges.....:D:D

Do you plan to put a heat shield around your'e lovely bike can at some point?
Is it true the carbon fibre cans don't heat up as much as stainless cans as black would look good against yellow.
Not that I'm enquiring for my own build of course you know....:rolleyes:

Johno

skov
2nd September 2012, 10:57 PM
Ha ha. I've been trying to keep that protective film on for as long as possible, as I'm bound to scratch my panels to buggery as soon as I do!

No idea if carbon is cooler or not :confused: Does look good though :D
Simmi do a carbon version of my can for another 30 or 40 quid.
I was quite tempted, but was struggling to justify spending a ton on the can, let alone any more :rolleyes:

Hadn't thought about a heatshield to be honest.

skov
6th September 2012, 11:21 AM
Managed to get my brakes working last night, so I can now stop as well as go!

I really hadn't been looking forward to bleeding the system, and was having nightmares about spending days pumping the pedal, but it couldn't have been easier!
I went for the squirting-fluid-into-the-callipers-with-a-syringe approach. A few squirts into each one in turn, tried the pedal and it was pressurised :D
Usually takes me several hours to get any pedal pressure!

Davidbolam
6th September 2012, 01:49 PM
Now I really have to go into the garage and do some building lol!!

You will have to pop a video on youtube of your first blast up the street!

Have you had any thoughts about the front wing stays. I know Nathan produced some and had them available on the NTS site. Have you designed your own yet?

David

skov
6th September 2012, 02:08 PM
I'm not sure I want to post incriminating evidence on youtube!

I have been thinking about how to do the wingstays recently, and have some ideas, but haven't started making them yet.

vmax1974
6th September 2012, 02:53 PM
I'm not sure I want to post incriminating evidence on youtube!

I have been thinking about how to do the wingstays recently, and have some ideas, but haven't started making them yet.

When you do please make a few sets cause I will be wanting some too

Davidbolam
6th September 2012, 10:13 PM
How about 3 sets or publish the plans!

I will see if I can get a picture of Nathan's online. He mounted his similar to the sierra upright but I had been thinking about using the 3 holes that retain the brake dust plate.

David

skov
6th September 2012, 11:05 PM
I aint running a production line, lol :)

I found these pics of how one of the kit car manufacturers (can't remember which one) does it for their MX5 based 7. Probably going to do something similar:

https://lh3.googleusercontent.com/-4KiNeYXp7G0/UEkdAehw88I/AAAAAAAAImI/Kp-Tan6Sz2A/s512/IMG_2172.JPG

https://lh5.googleusercontent.com/-icRfCn4xbVw/UEkc_R-imSI/AAAAAAAAImA/g2VScGWNy74/s512/IMG_2171.JPG

deezee
7th September 2012, 08:55 AM
https://lh3.googleusercontent.com/-fw_8yeJHhxQ/UDvqxQ-WDII/AAAAAAAAIl4/a9F4XgbWcg0/s640/2012-08-27%252016.58.05.jpg

During my IVA test, the radius ball thing was applied to my exhaust brackets and mounts (hence why the exhaust tip has to be rolled). With that in mind I think that bracket might struggle to pass. Obviously it depends on how thorough the IVA examiner is on the day.

skov
7th September 2012, 09:22 AM
Hi Deezee, I did have my doubts about it!
I'm hoping a little adjustment and/or some strategically placed trim might get it through!

skov
8th September 2012, 08:28 AM
Here's a pic of the NTS wingstays:

https://lh6.googleusercontent.com/-JzHh-D5IqtQ/UErzGH7T9mI/AAAAAAAAImc/d9cZjYBycLk/s500/nts_wingstays.jpg

CTWV50
9th September 2012, 11:09 AM
Wow, well done John. Almost enthused enough to get in the garage but I broke my right scapula a few days ago so my right arm doesn't really work well. :rolleyes:

skov
10th September 2012, 06:40 AM
Wow, well done John. Almost enthused enough to get in the garage but I broke my right scapula a few days ago so my right arm doesn't really work well. :rolleyes:

Thanks Chris!
I had to google scapula. Sounds painfull :eek:
Wishing you a swift recovery!!

skov
11th September 2012, 01:16 PM
Not the most exciting progress announcement, but I finally got around to making my tank straps.

Just used some thin steel strips and edge trim:

https://lh6.googleusercontent.com/-vkuB0hkFc2o/UE8qdq58uuI/AAAAAAAAInc/F7rL9g7D8lY/s512/2012-09-10%252020.06.28.jpg

https://lh5.googleusercontent.com/-Bgq4s5nkBwc/UE8qZ2s6AGI/AAAAAAAAInY/9XTeS3-FXJY/s512/2012-09-10%252020.06.35.jpg

Davidbolam
12th September 2012, 08:33 PM
Hi skov any chance of a picture from the rear of the tank. When my straps are in place they won't follow the same line as the tank and I will have a gap. Also wondering how you fastened it to the bottom rail.

David

alga
12th September 2012, 11:54 PM
Oooh, the straps look very neat!

skov
13th September 2012, 01:24 PM
Thanks Alga!
I was just going to have steel strips with foam on the bottom, but I made such a mess cutting the strips I came up with the idea of using the trim to hide the ragged edges :D

David, my straps don't follow the lines of the tank perfectly either (in particularly down the rear!). They are tight against the corners of the tank though, so should hold it in place.
I did take a photo of the rear (it's in my photo album), but it's not very clear.
I'm in the middle of fitting the ali tub at the moment, so can't take another right now. It'll be coming off prior to final fitting, so I'll try to remember to get one then.

skov
16th September 2012, 04:02 PM
That's my rear tub done!
Made a bit of a hash of it where I folded it over the round tubes, but I aint doing it again! (and the tub cover should hide it anyway)

https://lh4.googleusercontent.com/-9m3joff9gAw/UFXlxfjZfBI/AAAAAAAAIp0/gwC_QLsfjHk/s512/2012-09-16%252014.08.59.jpg

https://lh3.googleusercontent.com/-snUZKVAIkws/UFXlhiG_GLI/AAAAAAAAIpc/y1tc-sRp5Jc/s640/2012-09-16%252014.09.25.jpg

https://lh5.googleusercontent.com/-KPqi8EJRG4M/UFXlMl3xJUI/AAAAAAAAIo4/eQns-O4Dces/s640/2012-09-16%252014.09.58.jpg

https://lh5.googleusercontent.com/-8Cm-2S-cb1I/UFXlHlcpW5I/AAAAAAAAIow/evqY7cxJE6o/s640/2012-09-16%252014.10.09.jpg

Dualist
16th September 2012, 06:28 PM
Rear tub looks bloody good mate.

voucht
16th September 2012, 06:35 PM
Look excellent Skov, congratulations :cool:
Aluminium side and rear panel will be my choice too.

skov
16th September 2012, 10:01 PM
Thanks guys!
To be fair it does look loads better in the photos than it does up close!

Johno
20th September 2012, 08:54 PM
Hi John,
Thats looking very nice indeed mate;)
Rear tub looks good in the photo from what I can see. What colour scheme are you going with for the whole car???
Are you going to paint your Alu and your GRP as you said there are some scratches in the GRP.

Cracking stuff:D :D

Johno

skov
20th September 2012, 10:02 PM
Haven't got a clue on the final colour scheme yet :confused:
It's all a bit of a mish mash at the moment!
Going to look even worse when I fit the rear wings - they're red!

I'll eventually get the whole thing either painted or vinyl wrapped depending on cost.

skov
23rd September 2012, 09:57 PM
One of the things I love about building the roadster is learning new skills.
Here's one I hadn't counted on...

Decided to learn how to sew so I could attempt to knock up various bits of trim.
It's not quite hairdressing, but probably more than girly enough to warrant using an MX5 as the donor :D

Anyways, my wife refused to let me near her machine, so I picked up this little beauty off gumtree today for next to nothing:

https://lh5.googleusercontent.com/-OP0gbn76ZHE/UF9v4GuVrWI/AAAAAAAAIqg/jLp72ji5aew/s640/2012-09-23%252021.07.26.jpg

They don't make them like this any more!

Had a bit of a play this evening with some vinyl leatherette stuff I had kicking about (don't ask!).
Didn't go too bad at all, managed flat-fell seams, french seams, and even a spot of welting :D

https://lh5.googleusercontent.com/-RFHOgVcqdus/UF9v0HNpwOI/AAAAAAAAIqY/xJ5W3S4gbL8/s640/2012-09-23%252021.23.00.jpg

robo
23rd September 2012, 10:14 PM
FMB you will be knitting the roadster some wollen wheel warmers next:eek: Thumbs up on the tin work skov its looking nearer to hitting the road by the day:)

Bob

skov
24th September 2012, 11:17 AM
Thanks Bob!
Still not happy with the top of the rear tub, but with any luck I should be able to sew up a tonneau to cover it up :D

Don't worry, I don't intend to take up knitting any time soon...
...not after the scarf debacle :o
(I tried knitting one for one of the babies a few years back. About six inches in I gave up as it looked more like the Indian subcontinent than a scarf!)

CTWV50
5th October 2012, 01:28 PM
Ahaha! My mum had one of them! Nice job, car loks good. You are a very productive person in more ways than one! ;)

skov
7th October 2012, 09:24 PM
Thanks Chris!

Had to man up and get the real power tools out this weekend.
I've done a bit of grinding, drilling, and welding here and there, and whipped the jigsaw out to make a start on the dash:

https://lh6.googleusercontent.com/-qPluYFKcMOQ/UHHfaWsrf9I/AAAAAAAAIs8/mnZhtmiCVss/s640/2012-10-07%252020.56.26.jpg

Davidbolam
7th October 2012, 09:37 PM
Looking good skov. How are you changing the speedo drive from cable to electric? I like the instruments you have chosen.

skov
7th October 2012, 09:46 PM
Looking good skov. How are you changing the speedo drive from cable to electric? I like the instruments you have chosen.

Thanks David. I've replaced the speedo cable with a speed sensor from a Mk2 MX5:

https://lh4.googleusercontent.com/-RARkJpmjCLg/UBzF55JQfOI/AAAAAAAAIhI/vTb_j-VQnIA/s512/speed_sensor.JPG

robo
7th October 2012, 09:46 PM
[QUOTE=skov;7837
(I tried knitting one for one of the babies a few years back. About six inches in I gave up as it looked more like the Indian subcontinent than a scarf!)[/QUOTE]


What Bradford??????


Are you getting any other guages?? glovebox etc.

Bob

skov
8th October 2012, 09:31 AM
Oooh, that's a bit politically incorrect :D

I'm planning to keep the dash nice and simple.
The only additional things I'm going to add are hazard and rear fog switches.

The clocks have all the tell-tale lights I need build into them, and they have a couple of little LCDs which I'm hoping I can use to display anything else I might want.

robo
8th October 2012, 09:52 AM
Sorry I meant to say Southall. :)

So if the clocks have all the lights in ie highbeam,oil,indicators and ignition they would meet the iva standards ????. Seems like the way to go, thats a lot of stuff not to have to mount.:cool:

Bob

skov
8th October 2012, 11:13 AM
They should meet IVA standards, they're all the right picograms and colours and presumably passed type approval in the mini, so hopefully I'll be ok!

The only thing it's missing is a rear fog tell-tale, but I'm hoping I can use a switch with that built in.

Numplumb
16th October 2012, 10:44 PM
Hi skov just read your thread from start to finish, what a brilliant job so far.
I'm a new member I have just bought a part built chassis which I'm going to alter so as I can use an MX5 donor, been reading lots about it and would love to build one half as good as yours.
Keep up the good work Regards Mick.

skov
17th October 2012, 09:15 AM
Hi skov just read your thread from start to finish, what a brilliant job so far.
I'm a new member I have just bought a part built chassis which I'm going to alter so as I can use an MX5 donor, been reading lots about it and would love to build one half as good as yours.
Keep up the good work Regards Mick.

You're too kind Mick!
Are you sure you haven't got me mixed up with someone else (http://www.haynes.co.uk/forums/showthread.php?t=8582) though :p
Good luck with the build.

Numplumb
17th October 2012, 10:49 PM
Hi skov been looking at your build thread, can you give me a bit of advice in the book it shows TT8 as 127mm and Saturn Mx5 alterations show TT8 as 165mm but in there photo it shows top and bottom tranny rails widening from behind TT8 to the new gap of 240mm is this right?.
Also in your picture on page 4 SB5,SB6 you haven't moved them out to line up with the tranny rails, I bought a chassis which has been part built for a Sierra which I will have to alter so I was hoping to cut the tranny top and bottom rails behind TT8 and renew to the new dimensions and leave SB5,SB6 where they are like you have would that be okay or does the tranny widen out further forward as we'll any information would be much appreciated.

skov
18th October 2012, 12:07 AM
Hi mate, that's right - the tranny tunnel is the same up to and including tt8. It's only behind tt8 that it widens out.
I can't remember the numbers for the seat back rails, but the two vertical ones either side of the diff will need to be moved out to match the tunnel. The two diagonal ones above them can stay where they are though.

skov
18th October 2012, 09:41 PM
Thought I'd whip the sewing machine out and have a practice go at the boot cover (the real one won't be red!).
Didn't turn out too bad for my first proper attempt at upholstery, some of the seams are a bit wonky, but I think I'm starting to get the hang of it:

https://lh6.googleusercontent.com/-guEKpDWKL4o/UIBm3KhBJxI/AAAAAAAAIvI/4YUCNh3nuL4/s640/2012-10-18%252021.26.41.jpg

https://lh5.googleusercontent.com/-PCV34HyYPfc/UIBm-BOAYiI/AAAAAAAAIvY/7A9eO4dVR70/s640/2012-10-18%252021.26.02.jpg

robo
18th October 2012, 10:22 PM
Skov that cover is the nuts.

bob

Davidbolam
23rd October 2012, 10:17 PM
Hi skov are you using a polo radiator. If so is it from a mk2?

What type of expansion bottle have you used? All the ones I have looked at seem to have too many outlets.

thanks

David

skov
24th October 2012, 06:54 AM
Hi David,

Radiator is VW Polo 1983 - 1990

Expansion Tank is VW Polo 1981 - 1994

Davidbolam
24th October 2012, 11:18 PM
Thanks.

Does your expansion bottle have more than one outlet? The ones I have searched appear to have 2. I have looked at your photos and I can only see 1.

If there is more than one outlet how did you plumb the second outlet in?

David

alga
25th October 2012, 12:46 AM
All VAG bottles I've seen have a ~16 mm outlet at the bottom and a 8 mm inlet at the top.

Mine's from a Škoda, but exactly the same one has been used in Golfs, Passats for about a decade.

http://locost.lt/pic/625

skov
25th October 2012, 12:58 PM
Mines the same bottle.
I've got the 16mm at the bottom Tee-d into the heater matrix hose, and I think I'm going to link the smaller outlet at the top to the small outlet at the top of the radiator.

skov
25th October 2012, 11:56 PM
I decided to get that top outlet hooked up this evening whilst I was thinking about it.
I used my left over copper fuel line with a couple of short bits of hose either end to go to the tank and rad:

https://lh6.googleusercontent.com/-UpbkhS07rGE/UInAuyoV1YI/AAAAAAAAIws/al_lBR1wPKg/s640/2012-10-25%252023.42.22.jpg

https://lh3.googleusercontent.com/-hbAr1UhCVsA/UInA0m93ZWI/AAAAAAAAIw0/5TywfLUFZiM/s512/2012-10-25%252023.41.51.jpg

https://lh5.googleusercontent.com/-uPFKNKHrMeY/UInA3-4stjI/AAAAAAAAIw8/R1duhtCUUwo/s640/2012-10-25%252023.41.41.jpg

Johno
26th October 2012, 07:23 PM
That's all looking neat and tidy John...:)
Are you still planning to route your air inlet to a cooler part of the car as I see it's near the exhaust manifold at the moment.

Davidbolam
26th October 2012, 07:43 PM
That's really useful as I was wondering how to do it. eBay later I think!

skov
27th October 2012, 06:58 AM
No problem David! I'm actually very glad you mentioned it, as I had originally planned to just vent that top outlet to atmosphere, which probably would have been a disaster :rolleyes:

Tidy :confused: Not sure who's build you're looking at Johno! :)

I will route some cooler air into the airbox at some point, either from the nose cone, or possibly a vent on the side of the body.
Either way it's right down at the bottom of my list of things to do, as I don't think sucking in warm air is an IVA fail!

Davidbolam
5th November 2012, 12:03 AM
Skov

I have just been limiting the lock on my rack an decided to follow your idea. I am finding though that the lock stop seems to be the jubilee clip and not the tube. In your photo album you have a photo of some metal looking items made by Perrin. have you used these? If so where did you purchase them and did they work?

Thanks

David

skov
5th November 2012, 09:25 AM
Hi David,

No, I didn't use the Perrin ones. Can't even remember what they were for, or why I saved the picture of them now!

I'm still using plastic tube with jubilee clips. I think I may have cut them down so they're no wider than the jubilee clip since the pics were taken, so my clips are probably effectively the stop too.
I don't think there's a massive problem with that.

skov
18th November 2012, 10:22 AM
That's my rear wings, rear lights, and fuel filler in place:

https://lh4.googleusercontent.com/-A4BD6rWIavE/UKim6xccihI/AAAAAAAAIz4/PXygwvLcRC0/s640/2012-11-17%252014.24.26.jpg

Starting to see the end in signt now :D

https://lh3.googleusercontent.com/-cCshRDaDDx4/UKinMnpsbsI/AAAAAAAAI0Y/VKLyWy9C0Q0/s640/2012-11-17%252014.23.54.jpg

K4KEV
18th November 2012, 10:29 AM
Good progress John.....I was wondering where you had gone:)

CTWV50
18th November 2012, 10:37 AM
Looking good John. Like the cover. Almost motivated to go in the garage!!:cool: Have you done a video of it moving recently? I think that might do it for me! :lol:

skov
18th November 2012, 11:10 AM
Don't worry Kev, I'm still here :D
I've been beavering away in the garage, but mostly been doing odd little jobs that aren't worth boring anybody with!

Sorry Chris, I don't have any more videos of it moving.
It may or may not have been driven further than the end of my drive, but the event if it did or didn't happen was not recorded to protect the innocent and/or guilty ;)

robo
18th November 2012, 11:24 AM
Don't worry Kev, I'm still here :D
I've been beavering away in the garage, but mostly been doing odd little jobs that aren't worth boring anybody with!

Sorry Chris, I don't have any more videos of it moving.
It may or may not have been driven further than the end of my drive, but the event if it did or didn't happen was not recorded to protect the innocent and/or guilty ;)

That looks like a very nearly finished car you have there skov:cool:

Bob

stew
18th November 2012, 11:55 AM
looks great john! :)

skov
18th November 2012, 02:18 PM
Think you might be right there Bob :D
It's felt like I haven't made much progress lately, but I kind of stepped back and took a look yesterday, and thought bloomin ell, that's not far off being finished!

Still got a massive list of jobs to do, but I'm hopefull it'll be on the road in the next 6 months :cool:

Thanks Stew. Haven't seen any updates from you for ages, are you still building?

stew
18th November 2012, 08:10 PM
Think you might be right there Bob :D
It's felt like I haven't made much progress lately, but I kind of stepped back and took a look yesterday, and thought bloomin ell, that's not far off being finished!

Still got a massive list of jobs to do, but I'm hopefull it'll be on the road in the next 6 months :cool:

Thanks Stew. Haven't seen any updates from you for ages, are you still building?

not done anything since march, :mad: but ive got rose joints ordered, so need to get some free time and get these wishbones done. :)

twinturbo
23rd November 2012, 07:15 AM
last thing i did was put on bonnet latches and look at replacing the top steerin bearing . that was september i think

skov
22nd December 2012, 10:30 PM
Well I've done bu99er all on the build for the last few weeks :rolleyes:
Actually got out in the garage briefly tonight and had a mini break through though.
Haven't been able to start the car for a while now... it'd turn a couple of times, then bog down and stop.
Thought my new battery must have been knackered before I'd even finished the build, and wasn't pleased! Charged it over and over again and it made no difference.
Anyway, had a bit of a play tonight and started pulling connectors out.
Found out it'd crank without bogging down if I had the injectors or ignition coil unplugged, which had me puzzled.
Then had a bit of a brainwave and swapped the spark plug leads over, and it burst into life :D
After a bit more digging it turns out that when I shortened the loom I'd swapped two wires over that went to the ignitor module, and it had been firing all my cylinders out of phase!
Fixed the wiring error, swapped the plug leads over and it's running again.
The enthusiasms flooding back now :D

Hopefully get back on the build properly once xmas is out of the way... Hope you all have a merry one by the way!

will_08
22nd December 2012, 10:54 PM
The progress you've made, you can afford the well deserved break! ;)

Have a good christmas too!

Davidbolam
27th December 2012, 02:29 PM
Hi,

hope you had a good xmas and haven't fallen off your unicycle too much.

A few months ago we talked about getting proof of the age of your engine to avoid having to fit a cat. After a bit of trawling I found this on the westfield ownver site.....

Mazda Engines:

Call Mazda UK on 08457 484848 and ask to speek to the Homologations Manager.

Give him the engine number and then he'll take down a few personal details and ask you to write in with a cheque for £35 (prices correct in 2008)

Send the payment to:
Mazda Motors UK Limited
Anchor Boulevard
Dartford
Kent
DA2 6QH

Then a couple of weeks later you'll get a letter back confirming the engine number and it's manufacture date. If the donor was an import (Eunos/Miata etc) there may be a slightly longer delay as they need to contact Japan to get the necessary details for the car.

I haven't done this yet but it could save having to put an awfull cat on!

Cheers

David

skov
27th December 2012, 02:47 PM
Had a great xmas thanks David, hope you did too!
My legs and ankles are covered in cuts and bruises from falling off the unicycle, but I'm determined to learn how to ride it. It's on my things-to-do-before-I-die list right below build my own car :D

Thanks for the info, I'll give that a try in the new year, really don't want to have to put a cat on it!

robo
28th December 2012, 11:56 AM
Had a great xmas thanks David, hope you did too!
My legs and ankles are covered in cuts and bruises from falling off the unicycle,

So first she buys you a unicyle and then she starts to throw sharp objects at you while you try to master the thing. MMMMMMMMMMMM there might be a message in there somewhere,:)

Bob

skov
1st January 2013, 11:54 AM
Happy new year all!

Today's the two year anniversary of me making the mistake of clicking the buy-it-now button on the book...

Doesn't look like I'm going to quite meet my original target of building it in two years, but I'm fairly confident I'll have it on the road before this year is over!

skov
18th January 2013, 12:40 PM
Got a call from work today to say there's a freshly powder coated roll bar sitting in my cubicle :D
Almost wish I'd gone in today now, it's going to be a long weekend!

skov
21st January 2013, 11:25 AM
Just managed to finish my dash off:

https://lh5.googleusercontent.com/-SOsRF__3U3g/UP0jUxhwaDI/AAAAAAAAI3Q/F9g_w3fMZVc/s640/2013-01-21%252010.59.31.jpg

I'm not overly happy with it, but I'm bu99ered if I'm going to do it again before IVA. That was my second attempt as it is :rolleyes:

Hoping I've got enough padding for IVA - I used two layers of camping mat, a layer of scrim foam, and finished it off with vinyl.
On my first attempt I had some pipe insulation foam along the bottom edges too, but I couldn't get the bloody vinyl to follow it, so got peed off and ripped it all off!

I think I'll move the fog and hazard switches below the clocks if I ever do get around to remaking it again too. Only put them behind the steering wheel to keep them in the 'exempt zone' and to make sure they're clearly visable for IVA.

Davidbolam
21st January 2013, 11:42 AM
I think it looks really good. I wish I had done a bit more on my build before xmas and I could have been doing stuff like this inside in the warmth rather than going outside and coming straight back in again due to the cold!

I also like the mini clocks.

keep putting load of pics up to motivate us all

skov
21st January 2013, 12:18 PM
I'm not convinced, but thanks anyway David!

Know what you mean about the cold, I've been trying to finish off my wiring recently, but my hands soon get too cold to work!
It's been quite nice being able to make the dash in the comfort of my living room.

If it's pics you want, here's a few of the various things I've been working on, none of which I've managed to finish!

Rear cover Mk2 - already needs a good dusting! Also need the roll bar in place to finish it off:

https://lh4.googleusercontent.com/-0CY47rCgG08/UP0u-UEh2qI/AAAAAAAAI30/58FMbB1w7KI/s640/rear_cover_mk2.jpg

Wiring in the rear tub:

https://lh6.googleusercontent.com/-8r6qF3Am2Ng/UP0vNh7i8iI/AAAAAAAAI4U/_buhid6s_ZE/s640/S5033299.JPG

https://lh6.googleusercontent.com/-cGga5y-wOCU/UP0vRw_ZpzI/AAAAAAAAI4k/NtIhm4gazK4/s640/S5033300.JPG

Engine bay wiring:

https://lh6.googleusercontent.com/-YvDA1RqsMWU/UP0vCVWvE9I/AAAAAAAAI4A/72O38hIMJdc/s640/S5033294.JPG

skov
21st January 2013, 12:18 PM
Rear wings are now bolted in place. Used rivnuts and big washers, and some tadpole trim between them and the body (you can see that in the rear cover picture).
Also wired up my rear clusters, and almost finished the wiring to the side repeaters which are going to sit on the rear wings.

https://lh6.googleusercontent.com/-VltdXkcDDqg/UP0vIyXBYsI/AAAAAAAAI4M/wz67YbdgqqU/s640/S5033296.JPG

https://lh6.googleusercontent.com/-TbLqXyCt4sk/UP0vNwgpX7I/AAAAAAAAI4Y/RNLrxtVH6mY/s640/S5033298.JPG

twinturbo
21st January 2013, 12:39 PM
Nice to see you making progress.

TT

K4KEV
21st January 2013, 12:55 PM
By gum John.....you haven't half been busy the last few months ...are you going to try for a spring summer IVA? cos it certainly looks like you are on target;) I think you are right about the switches they do not look right there, but the dash does not look that bad and I am fussy, why not try a bit of buttoning!.
Nice work bud, keep it up.

skov
21st January 2013, 03:28 PM
The strange thing is it doesn't feel like I've done much at on the build for a while. I suppose I have made a fair bit of progress :confused:

The current plan is indeed to get it on the road by the summer, which I think should be just about possible if I pull my finger out.
My original plan was to complete it in two years, but I'm going to miss that deadline next month :rolleyes:
Two and a half years will do though!

skov
22nd January 2013, 09:18 PM
Oh, and another thing I've been working on recently is my roll bar.
Managed to finish it off towards the end of last year and sent it off to the powder coaters a couple of weeks ago.
Got it back home and bolted it in place today :D

https://lh3.googleusercontent.com/-jGMhwNM3V9o/UP7_60RxbqI/AAAAAAAAI5c/g6gWyKMQ8wc/s640/S5033319.JPG

https://lh3.googleusercontent.com/-RlP-heGktiQ/UP8AGXDu-SI/AAAAAAAAI54/N7g2aKSZtv8/s640/S5033323.JPG

Johno
24th January 2013, 07:42 PM
Hi John,
She's all coming together now and looking good.:D
The roll bar looks nice and shiny, it's a nice feeling when you bolt on parts that look as good as that....:cool:

Keep up the pace and you'll soon be putting ink on that VOSA form:eek: :eek:

skov
24th January 2013, 10:25 PM
Ah ha, I was bored at lunchtime and filled the IVA form in today as it happens :D
I don't plan to send it off for a while though!

twinturbo
25th January 2013, 12:11 PM
Don't loose it ;)

TT

skov
25th January 2013, 01:31 PM
I won't lose it, not after all the head-scratching and googling trying to figure out what to put on it!!!

On a related note I called Mazda this week to ask for a proof of engine age letter from them for IVA, I've added a post to the MX5 donor thread here:

http://www.haynes.co.uk/forums/showpost.php?p=88149&postcount=42

skov
26th January 2013, 08:22 PM
This evening I have mostly been cutting out and shaping some mesh for my nose cone grill:

https://lh5.googleusercontent.com/-mFBxDMiQ-1Y/UQQ4HIDQw4I/AAAAAAAAI7Y/iJlcYP_rEyE/s640/S5033328.JPG

https://lh4.googleusercontent.com/-m9BQ66Qbp0g/UQQ4G5pct0I/AAAAAAAAI7Q/UAC1jKEzhJc/s640/S5033330.JPG

Haven't quite decided how to fix it in place yet, I'm tempted to just sikaflex it.


I also decided to give up trying to make my current seats fit and ordered a pair of cub sport L7's from kit parts direct earlier today :rolleyes:

Davidbolam
26th January 2013, 10:04 PM
Drill some holes in the corners and hold it in place with cable ties.

David

skov
30th January 2013, 02:03 PM
That's my side repeaters fitted. I went the little round LED ones in the rear wings:

https://lh6.googleusercontent.com/-bgNgCWwoL5o/UQhIiCdpG3I/AAAAAAAAI8E/zPCdloRe9IA/s512/S5033332.JPG


Whilst I was at it I fibre-glassed in a couple of cable-tie bases each side to hold the wires in place:

https://lh6.googleusercontent.com/-rT8EXaoPx4Y/UQhIiETxfRI/AAAAAAAAI8I/GyxfTcIdzM0/s640/S5033333.JPG

https://lh6.googleusercontent.com/-4X1Q-E0KVps/UQmUtNwIhII/AAAAAAAAI9Q/ObyeD0nLzRg/s640/S5033337.JPG

skov
30th January 2013, 11:12 PM
Got my proof of donor/engine age letter from Mazda today.
Cost of letter: £35
Not needing a CAT: priceless :D

https://lh5.googleusercontent.com/-5jL-BqdU9bY/UQmT9cPiEkI/AAAAAAAAI9I/IcCr0JiPfYQ/s512/mazda_proof_of_age_letter_censored.jpg

Stot
31st January 2013, 09:25 AM
Hi,

Would I be right in thinking you dont need this for a UK model as date first registered on the V5 would be proof the age of the engine?

Cheers
Stot

skov
31st January 2013, 01:18 PM
Hi,

Would I be right in thinking you dont need this for a UK model as date first registered on the V5 would be proof the age of the engine?

Cheers
Stot

Hi Stot,

I've done a bit of googling on this, and the answer is I don't know!

From what I can tell it's down to the individual tester whether they will accept the V5 as proof of engine age or not.
Bear in mind that IVA emissions are based on engine age and not donor age, and it's possible that the engine on the V5 may not have been the engine originally installed.

Personally I didn't have much choice because whoever imported my donor didn't put the full engine number on the V5, just the first two characters of it :rolleyes:

Stot
31st January 2013, 05:17 PM
..it's possible that the engine on the V5 may not have been the engine originally installed.

Yeah I guess thats unlikely but still a consideration the IVA tester might have. :rolleyes:

Cheers
Stot

skov
3rd February 2013, 11:14 AM
I've been playing with the sewing machine again this morning :o

Thought I'd have a go at doing some diamond stitching:

https://lh4.googleusercontent.com/-7HNsQa9AhGs/UQ6Mulwrw1I/AAAAAAAAI_0/IG1Uzi3bGu4/s640/S5033350.JPG

I do like a bit of diamond stitching, but I'm not quite sure whether it's going to look right on the roadster or not :confused:

My current thought is that I'd make panels like this to go between the rails on the chassis sides, and also run it down the sides of the tranny tunnel (with plain black vinyl along the top of the tunnel).

Is it going to be worth the effort, or just look stupid?

Dualist
3rd February 2013, 05:24 PM
I like it, especially as I was looking at the Lucra (http://www.lc470.com/002_images/470_silver/980/008.jpg) cars this morning. The 7's are a little plain on the inside, but this I like :)

K4KEV
3rd February 2013, 06:02 PM
You could earn some dollar doing that John :) it certainly looks rather professional.

flyerncle
3rd February 2013, 09:28 PM
New Lucra on the drawing board with silly HP,tunable Corvette engine's I believe.

Davidbolam
3rd February 2013, 11:10 PM
That looks really good. Very morganesque. I was planning on carpet triangles in there! Will the tubing be ok for Iva ? Ie are the corners not too sharp?

David

skov
4th February 2013, 07:41 AM
Thanks guys! I think I might make a couple more panels before I decide.
It's never going to look anything like as good as that Lucra though :eek:

I'm sure plenty have passed IVA with the frame tubes exposed on the inside haven't they?

skov
17th February 2013, 04:11 PM
Spent the last couple of weeks fitting and wiring my headlights and front indicators.
That took a bit longer than I expected...

https://lh3.googleusercontent.com/-h6VqUjOzmao/USD8Y2p3KqI/AAAAAAAAJC8/0gG0ndoeWYo/s640/S5033371.JPG

Turns out I had originally welded my headlight brackets on in the wrong place and the front wheels hit them on full lock :rolleyes:
After umming and arring for months on what to do I ended up just cutting the end of the brackets off, and drilling new holes in them for the headlight bolts to go through.
To cover the resulting sharp edges I pushed on a couple of rubber end caps before fitting the headlights (still need to put some trim around the headlight bases).

https://lh6.googleusercontent.com/-D2zZTMoF-70/USD8ZHMF-II/AAAAAAAAJDA/X5pul0GCYs8/s640/S5033373.JPG

For the indicator extensions I went locost and used a metal tube from my old bed frame (I kept hold of a couple after dismantling it, thinking they'd come in handy for something!).

Rather than two individual extensions I went for a single tube running the whole width, with a couple of nuts welded into the end to screw the indicators into.
To hold it in place I just used sikaflex on the inside of the nose cone (and sikaflexed my front grill in place while I was at it).

Also fibreglassed some cable tie bases in to the nose cone to keep the wiring tidy.

https://lh5.googleusercontent.com/-c0w2933UXFI/URwEe4k1-0I/AAAAAAAAJBo/Ll9W_Cl4H64/s640/S5033360.JPG

I've changed the wiring slightly since I took the above photo so the wires for both indicators come out of the same hole in the tube, and both run down the side with the tie bases so I only have to disconnect the wires in one place to remove the nosecone.

Johno
17th February 2013, 08:14 PM
Hi John,
Blimey the're some big lamps you got there....:eek:
Looks like you've been spending a few hours in the garage lately...
The diamond infill panels look sweet, are you planning to fit them or are they just work in progress?:) :)

As always a cracking job...:cool:

minicountryman1961
17th February 2013, 10:35 PM
when I bought my headlamps, I wish I had bought these with the builtin turn signals. A friend of mine did, and his car is looking much cleaner on the front.http://www.yogisinc.com/index.cfm/page/ptype=product/product_id=7481/category_id=186/home_id=-1/mode=prod/prd7481.htm

skov
17th February 2013, 11:43 PM
They're not that big Johno!
They're the standard 7 inch ones, they do look a bit big in the photos now you mention it, must be a trick of the camera or summink :)

The diamond panels were a bit of an experiment and I haven't got around to making any more yet.
I'm fairly sure I'll end up fitting them or something similar at some point.

Those headlights with built in indicators area great idea, if not a little late for me!
Not sure I'd want to pay that much for them though :eek:

Stot
18th February 2013, 07:36 AM
when I bought my headlamps, I wish I had bought these with the builtin turn signals. A friend of mine did, and his car is looking much cleaner on the front.http://www.yogisinc.com/index.cfm/page/ptype=product/product_id=7481/category_id=186/home_id=-1/mode=prod/prd7481.htm

Not sure they would IVA would they? They make you put bike indicators on long stalks to make them visible from various angles, cant see ones inside the headlamp being visible from these angles?

Cheers
Stot

skov
18th February 2013, 09:08 AM
The stalks are only needed to get the indicators within 400mm of the edge of the vehicle.
If they were built into the headlights that wouldn't be a problem as the headlights need to be within 400mm of the side anyway.
I suspect where they would fail IVA is with the headlight beam pattern, as presumably they 'kick' the wrong way with them being from the US.
Still a nice idea though!

robo
18th February 2013, 09:34 AM
Davey fitted some all in one units. Not cheap but very neat venom 5, they have side light head/dip and indicator. I think the fronts only need to be visible from the front, the side indicators deal with vision from other angles.

http://i1116.photobucket.com/albums/k577/mypickys/311514_10151087578003816_1697754073.jpg

Bob

skov
18th February 2013, 09:18 PM
That's my mirrors fitted - one more thing ticked off the list :D

https://lh4.googleusercontent.com/-TIyf0zbTH_4/USKYYjkvFWI/AAAAAAAAJEA/ShFsrfvDHjI/s640/S5033377.JPG

https://lh3.googleusercontent.com/-Smzliy_GsnE/USKYYR_z7-I/AAAAAAAAJEE/Ro7bWwl3aDE/s640/S5033378.JPG

CTWV50
27th February 2013, 05:38 PM
Stupid question I suppose but how much fuel pipe did you use? Just ordering some now.

skov
27th February 2013, 09:21 PM
Stupid question I suppose but how much fuel pipe did you use? Just ordering some now.

If you mean the copper lines I bought 10 metres, and probably have about a metre and a half left (I must have wasted a fair bit!).
If you mean the rubber pipes, I've no idea!

CTWV50
6th March 2013, 10:39 AM
Thought I'd whip the sewing machine out and have a practice go at the boot cover (the real one won't be red!).
Didn't turn out too bad for my first proper attempt at upholstery, some of the seams are a bit wonky, but I think I'm starting to get the hang of it:

https://lh6.googleusercontent.com/-guEKpDWKL4o/UIBm3KhBJxI/AAAAAAAAIvI/4YUCNh3nuL4/s640/2012-10-18%252021.26.41.jpg

https://lh5.googleusercontent.com/-PCV34HyYPfc/UIBm-BOAYiI/AAAAAAAAIvY/7A9eO4dVR70/s640/2012-10-18%252021.26.02.jpg

I see you have made a second black cover? Red one looks good, and my car will be red eventually. Do you sell the red one??

skov
6th March 2013, 11:10 AM
I see you have made a second black cover? Red one looks good, and my car will be red eventually. Do you sell the red one??

Sorry Chris, the red one is no more :o
I was running low on red vinyl, and chopped the red cover up the other night to make some more interior panels...

skov
9th March 2013, 09:17 PM
Speaking of interior panels, I've spent the last couple of days in front of the sewing machine making some more :o

https://lh5.googleusercontent.com/-xhQjHSFom4k/UTukcxiWWjI/AAAAAAAAJIE/fU9cdeHivGA/s640/S5033393.JPG

Just finished fitting my seats and belts too:

https://lh5.googleusercontent.com/-IjW6CttfdTk/UTukvqy7dZI/AAAAAAAAJIs/tjhsukaPnFY/s640/S5033403.JPG

CTWV50
9th March 2013, 09:46 PM
Looks ace? What seats are those? There not your original seats are they??