Another build thread

[alga]

Aww, very stylish.

[skov]

Looks ace? What seats are those? There not your original seats are they??

No, I got peed off trying to make the original seats fit and treated myself to a new pair :)
They're the Cub Sport L7 ones from Kit Parts Direct.

[Davidbolam]

That looks good. It looks like east coast auto did your panels. Are they gbs seats?

David

[CTWV50]

No, I got peed off trying to make the original seats fit and treated myself to a new pair :)
They're the Cub Sport L7 ones from Kit Parts Direct.

Yes I'm reaching that point of I just can't be arsed messing around with the mx5 seats any more. £160! Not a bad price I suppose. Might just get a pair of those £90 GRP seats.

Are the L7s comfortable?

Edit: Oh wow it's £165 for a pair! Right then. I think I'll get a set. :D Don't suppose you could tell me the height of the belt holes and the width/centres or the holes too. cheers.

[skov]

The bolt holes are roughly 330mm front to back, and 290mm side to side.

The centre of the seat belt holes are about 550mm from the top of the seat base, and about 600mm from the underside.

They're not nearly as comfy as the MX5 seats, but I'm not going to complain too much for the price!
I recon they'll get better with a bit of use. The fabric and foam is quite stiff at the moment, and will probably (hopefully!) give a little over time and mould itself to my behind!

[Johno]

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

Well I must say that looks totally outstanding John.
I'd be well proud of that.
Don't know if I could learn or have the patience how to do that.....LOL

[skov]

Thanks Johno,
I didn't find it that hard to pick up really, I certainly find it easier than welding!
My main problem is dealing with the limitations of my weedly little machine, it was really struggling with the seams along the top of the tunnel and it all went a bit wonky :rolleyes:
Could do with something a bit more industrial for car upholstery really!

[K4KEV]

Those panels do look the dogs John ....nice one on a bit of innovative creativity, keep it going bud.

[flyerncle]

My old man was a tailor and his Singer machines had 1/2 horsepower motors on,not a good idea to put the pinkies near.:eek:

[skov]

My old man was a tailor and his Singer machines had 1/2 horsepower motors on,not a good idea to put the pinkies near.

On the upside you wouldn't need to go to the hospital to get stitches if you did!

Did a bit more upholstery yesterday and made a panel for the seat backs:

https://lh6.googleusercontent.com/-ZZYXO9L5pRM/UT4pkL9XKQI/AAAAAAAAJJM/Xa3HXl8zstQ/s640/S5033407.JPG

[Stot]

I love this stuff, might have to copy some of it.

Cheers
Stot

[skov]

I love this stuff, might have to copy some of it.

Cheers
Stot

Damn, should have copyrighted it :D
Feel free to steal at will!

Here's some more bits I've knocked up on the sewing machine, these are purely to keep the IVA man's balls at bay.

Cover for my relays and fuse box:

https://lh5.googleusercontent.com/-5Q4j9UYZNaI/UT5JG9YbRqI/AAAAAAAAJKc/Dm-mvGKsd7U/s640/S5033418.JPG


Seat belt nut covers:

https://lh4.googleusercontent.com/-zH5YofqPqyU/UT5I8t3j4NI/AAAAAAAAJKI/dw_qffUlxx4/s512/S5033413.JPG


Speaking of the IVA man's balls, these polystyrene ones turned up in the post this morning, should hopefully take some of the guesswork out of what I need to trim and what I don't:

https://lh6.googleusercontent.com/-GmTw50qiTvg/UT4pyxcUgcI/AAAAAAAAJJg/Ce0m7jq4Z6I/s640/S5033408.JPG

[Davidbolam]

Have you got much clearance between the handbrake cables where they come out from the calipers and curve past the rear panel. Mine touch when the suspension is fully compressed. Where the cable is attached to the calliper have you bent 90 degree bracket or have you managed to get enough clearance by attaching the cables to the diff mounting rubbers?

Thanks

David

[skov]

Have you got much clearance between the handbrake cables where they come out from the calipers and curve past the rear panel. Mine touch when the suspension is fully compressed. Where the cable is attached to the calliper have you bent 90 degree bracket or have you managed to get enough clearance by attaching the cables to the diff mounting rubbers?


Hi David,

I haven't got a lot of clearance there, but the cables didn't quite touch the rear panel last time I checked.
I do remember it took me a little while playing with the position of the brackets on the diff rubbers and bending them a little bit until the cable was clear.

[skov]

More bl00dy wiring... (feels like I've spent more time wiring the car, than building it!)
Finally got around to wiring my dash up this week.

https://lh6.googleusercontent.com/-7eZcgs1ZZ5E/UVaphRUuhdI/AAAAAAAAJMY/CC-ZD9bHpuQ/s640/S5033431.JPG

Amazingly, most of it seemed to work when I plugged it into the car.
Just need to make a couple of small tweaks to my CAN interface modules to get everything displayed properly.
Might need to take it for a short drive to test the speedo soon :D

[CTWV50]

Looks very neat. I just spent 4 hours in the garage shortening about 20 wires, I know what you mean!! And I'm just starting!

[skov]

That's pretty good going Chris :D

One tip - if you're ripping out the carbon canister thing, it might be best to leave it's valve connected to the loom.
I removed mine and it's wiring... After running the engine for a while yesterday I checked for fault codes and the only one I have is for a broken evap valve :rolleyes:

[CTWV50]

It would of been good going if I hadn't woke up this morning and had the great idea of changing the position of the ECU. Today I spent 8 hours chopping the loom up and labelling every wire in it! I just couldn't take the debilitating mess of wires any longer!!!!:confused:

[CTWV50]

Oh and thanks for the heads up on the tank valve. I was looking at that just today and wondering if the ECU would care if I deleted it. Did it affect the car at all or was it just a fault code with no ill effects?

[skov]

Oh and thanks for the heads up on the tank valve. I was looking at that just today and wondering if the ECU would care if I deleted it. Did it affect the car at all or was it just a fault code with no ill effects?

It seems to run fine without, and I spent a while googling and couldn't find anything to suggest it will affect the running at all. It'll just bug me slightly knowing there's an error code sitting there :rolleyes:

[Davidbolam]

It seems to run fine without, and I spent a while googling and couldn't find anything to suggest it will affect the running at all. It'll just bug me slightly knowing there's an error code sitting there :rolleyes:

I was told that you can just chop it off loop the rubber tube around to cover the holes and it will run fine however there would be an error code as skov says.

On a different note......

Have you tested to see if the brake switch in the clutch line has enough pressure to operate?

Cheers

[skov]

On a different note......

Have you tested to see if the brake switch in the clutch line has enough pressure to operate?

Cheers

Yep, checked it with a multimeter a while ago, and it seemed to work just fine :)

[CTWV50]

what are you using to read the error codes just an LED kit?

[skov]

what are you using to read the error codes just an LED kit?

Yep, just an LED. Very quaint :D

Spent some more time on the wiring this weekend.
Just need to add a bit more tape and a few cable ties (both of which I've run out of :rolleyes:) and the wiring's done!

Decided to check my indicator flash rate, and was dismayed to find it was too fast for IVA (due to my bulbs drawing less current than the ones in the MX5).
Luckily someone's already figured out how to mod the flasher unit to correct it, which saved me dicking about adding ballast/correction resistors:

http://forum.miata.net/vb/showthread.php?t=335534

Actually the mod was even simpler than the link above, I just needed to remove the resistor and not replace it :D

[CTWV50]

Well done finishing the loom. It's a sneaky little MASSIVE JOB!! Isn't it!

I've spent hours in the garage this long weekend. Slowly putting the loom back together. Bought a clever little wire stripper from Maplin, worth every penny of £14.99. I love it!

On another note, looking at the IVA manual. If I'm on a Q plate and I can prove the engine date. Then they assume the January before as the "Effective Date" of manufacture as it's an amateur built car and then try to fine an exact match in the analyser database. I assume they "obviously??" don't find one and as the date will be pre July 31st 1995, do a Non CAT Test? Correct?

If I can't prove date of manufacture of the engine or donor car then they assume Aug 1997 and do a CAT test using default limits?

Just asking because I know you've probably done your homework on this. :D

[skov]

Well done finishing the loom. It's a sneaky little MASSIVE JOB!! Isn't it!

I've spent hours in the garage this long weekend. Slowly putting the loom back together. Bought a clever little wire stripper from Maplin, worth every penny of £14.99. I love it!

On another note, looking at the IVA manual. If I'm on a Q plate and I can prove the engine date. Then they assume the January before as the "Effective Date" of manufacture as it's an amateur built car and then try to fine an exact match in the analyser database. I assume they "obviously??" don't find one and as the date will be pre July 31st 1995, do a Non CAT Test? Correct?

If I can't prove date of manufacture of the engine or donor car then they assume Aug 1997 and do a CAT test using default limits?

Just asking because I know you've probably done your homework on this. :D


Thanks Chris. It certainly is a massive job, and I'm very happy to have got it out of the way :D
I shot myself in the foot with the wiring too. I thought I'd be clever and replace the fuse boxes, relays, and most of the wiring. All I really achieved in doing that was creating loads more work for myself!

That's how I understand the emissions - except for the Q-plate bit. Whether it's a Q plate or not is irrelevant; the IVA tester doesn't know and doesn't care what plate it's going to have as that's decided by the DVLA afterwards.

Provided the IVA man can't find an exact match for your car in his database (that's the car you've built, not the donor car!) the emissions will be based on the effective date of the engine.

So as long as you can prove the engine was manufactured before the end of 1995 you won't be needing a CAT.
Did you see my post about getting a proof of engine age letter from Mazda? £35 well spent!

[CTWV50]

I did see that post and I will follow that advise for sure. Thanks for clearing that up. At least you know your loom inside out and back to front if you have a fault.:)

[alga]

So as long as you can prove the engine was manufactured before the end of 1995 you won't be needing a CAT.

A small correction: the cutoff date is 31 July 1995.

[skov]

A small correction: the cutoff date is 31 July 1995.

That is the cutoff date, but the effective date for kit cars is moved back to the 1st of January in the year the engine was manufactured.
From the manual:

“Effective Date”
The “effective date” used to determine the criteria applicable is -
the date of manufacture of the vehicle, except for an “Amateur Built” vehicle, a “Vehicle manufactured using parts of a registered vehicle” or a “Rebuilt vehicle” it shall be 1 January immediately preceding the date of manufacture of the vehicle’s engine if this is earlier.

So the engine can be manufactured any time in 1995 and still not need a CAT test.

[skov]

Nearly done now :D

https://lh4.googleusercontent.com/-ind9GAl1QDI/UVvo_u4i9BI/AAAAAAAAJM8/bLZMFA5Yfw4/s800/2013-04-03%252007.31.26.jpg

Just need to paint my bonnet, fit the front wings, add a few bits of trim, and I should be ready for IVA :eek:

[Stot]

Exciting times. :D

Cheers
Stot

[thailoz]

man thats looking sweet:)

[CTWV50]

Brilliant! Just in time for the summer! Well Done that man that must be a record build time! I don't know how you've done it. Congrats!:cool:

[skov]

Brilliant! Just in time for the summer! Well Done that man that must be a record build time! I don't know how you've done it. Congrats!:cool:

Thanks Chris.
Think you must have lost track of time though - it's taken over two years so far :eek:
I'm sure there's been a couple of builds quicker than that!

Not quite there yet, but I can see the end in sight now. I'm almost upset I've got to go on holiday next week, think I'd rather be in the garage finishing the build off!

[K4KEV]

great work and progress John....wish I was at that stage, it is approaching 3 yrs for me....real bummer going on your jolly's at such an important time:rolleyes:

[skov]

Cheers Kev. To be fair I have cut a few corners, done some shoddy work, and not worried too much about cosmetics to get this far :rolleyes:

[Johno]

Good going John...:)
So how many Kit Car mags you taking on holiday then...:D
So I guess you will be absent from the forum for a while whilst on holiday (me thinks the shakes might set in).
Well have a good one and when you get back get the bloody car finished and on the road and tell us how it feels...;)

[skov]

Cheers Johno, we had a great time, and I only had the shakes for the first couple of days!
Spent a chuffing fortune though, and was welcomed home by a couple of large slightly unexpected bills on my door step, so not sure I can afford to get it IVA'd now :rolleyes:

[skov]

Finally made a start on the cycle wing brackets this weekend.
Got the first one more or less done:

https://lh5.googleusercontent.com/-mhP1eoUGuWk/UWsYQURcezI/AAAAAAAAJPE/9vV00pExibY/s640/S5033450.JPG

https://lh5.googleusercontent.com/-ooPGpliNi9M/UWsYQUpYuoI/AAAAAAAAJPI/j37MBps0sTg/s640/S5033448.JPG

[CTWV50]

How have you attached them at the bottom there? Can't quite see. And also, do you have any advise on the front brake line length and positioning? I take it you can use the standard mx5 rear pipes? I'll have to dig them out, think they are still attached to the car! :rolleyes:

[skov]

Hey Chris,
There's an M10 bolt at the bottom that I've used. I think it holds the brake calliper on.
I'll try to get some better pics when they're done.

I didn't bother using the MX5 brake flexis as they were looking a bit beyond their best, so no idea if the rear ones will fit or not.

My front ones are 400mm long with an M10x1 female swivel with 15 degree bend at one end and a straight 10mm banjo at the other.
I'd wait to see if mine passes IVA before copying though as I have a slight concern about them passing...

[CTWV50]

Hey Chris,
There's an M10 bolt at the bottom that I've used. I think it holds the brake calliper on.
I'll try to get some better pics when they're done.

I didn't bother using the MX5 brake flexis as they were looking a bit beyond their best, so no idea if the rear ones will fit or not.

My front ones are 400mm long with an M10x1 female swivel with 15 degree bend at one end and a straight 10mm banjo at the other.
I'd wait to see if mine passes IVA before copying though as I have a slight concern about them passing...

Cheers John I'll hold off. Are all mazda mx5 unions are M10 x 1mm thread pitch?

[skov]

Are all mazda mx5 unions are M10 x 1mm thread pitch?

Yes, I think so.

[skov]

That's the other wing stay welded up :D

https://lh4.googleusercontent.com/-aYlD4l7NFLc/UW5b02a6_-I/AAAAAAAAJXQ/BzT-TEJCX54/s640/2013-04-17%252007.21.54.jpg

https://lh6.googleusercontent.com/-7gAp9UX7qH8/UW5b01JQe9I/AAAAAAAAJXM/mujSY-4eKPc/s640/2013-04-17%252007.22.22.jpg

[flyerncle]

One thing to be aware of with jap pipe fittings is that the threads are usually all the way to the bottom and have op 2 on the pipe not like normal 10x1mm fittings with a few threads missing at the bottom and of course only op1.

(never could remember what was convex or concave):eek:

[skov]

Borrowed a sound meter from work this weekend to check my exhaust noise.
Even with the dB killer thing in my end can I'm still 6dB too loud!

[CTWV50]

Oops! Hahahaha. It is the shortest/smallest car exhaust in the world though! Want to borrow my special creation? Lol.

[skov]

Want to borrow my special creation? Lol.

Haha, that thing certainly is special!
Thanks for the offer Chris, hopefully it won't come to that :D

I think I might actually have a fix for IVA. I took the dB killer thing out and wrapped it in wire wool. Put it back and I'm down to 96dB! (and probably 50 less bhp!)

[CTWV50]

I think I might actually have a fix for IVA. I took the dB killer thing out and wrapped it in wire wool. Put it back and I'm down to 96dB! (and probably 50 less bhp!)

:D So you basically blocked up the exhaust with wire wool!:D If it works, brilliant!

[skov]

:D So you basically blocked up the exhaust with wire wool!:D If it works, brilliant!

erm, more or less, yes :D
Actually it's not quite as bad as it sounds...

I haven't completely blocked the exhaust; the dB killer insert thing has a 1"-ish tube down the middle which is still completely unrestricted.
I've wrapped the wool around the outside of that tube, so I think what I've effectively done is reduce the outlet of the can from 2" down to about 1".

I should be alright as long as it doesn't shoot a scorching hot bundle of wire at the IVA man during the test :D

[CTWV50]

I should be alright as long as it doesn't shoot a scorching hot bundle of wire at the IVA man during the test :D

I don't think that's a fail anyway so you should be fine!:eek:

[skov]

I don't think that's a fail anyway so you should be fine!:eek:

I'm not so sure... I suspect maiming the tester is covered by point 1 in the General Construction section:

1. All aspects of the design and construction of the vehicle must be such that no Immediate danger is caused or likely to be caused to any person in the vehicle or to other road users

[CTWV50]

I'm not so sure... I suspect maiming the tester is covered by point 1 in the General Construction section:

1. All aspects of the design and construction of the vehicle must be such that no Immediate danger is caused or likely to be caused to any person in the vehicle or to other road users

But is it an immediate danger? ;)

How did you get on with your brake pipes up front? I see another member was failed for not having them clipped to the wishbones. Is that our worry with them failing?

[skov]

But is it an immediate danger? ;)


It is if it's flying towards your face!


How did you get on with your brake pipes up front? I see another member was failed for not having them clipped to the wishbones. Is that our worry with them failing?

The strange thing is I'm sure I've seen people fail FOR clipping them to the wishbones! :confused:

I think mine should be ok, but I'd better check them again next time my wings are back on the car. I'll add that to my "to do" list...

[CTWV50]

The strange thing is I'm sure I've seen people fail FOR clipping them to the wishbones! :confused:

I think mine should be ok, but I'd better check them again next time my wings are back on the car. I'll add that to my "to do" list...

I guess the point is they can't be chaffed or damaged by other parts of the car. If you just zip tie them to the wishbones then it's as bad as having them rubbing anyway. But it's all down to tester interpretation I suppose. Caterham's don't appear to clip them so....

I've clipped mine because they came with a metal collar for a support and I might as well use it.

[skov]

I guess that makes sense if they came with mounting collars.
I think I'll leave mine dangling in the wind and hope for the best (and take some clips and cable ties with me just in case!).

Slight change of subject, I think I promised to put up some more pics of my front wing stays.
Here's a couple of the passenger side.
It's made from 3mmx25mm strip, a bit of scrap 3mm plate, and some round tube from an old bed frame :D

https://lh5.googleusercontent.com/-5xtTfrELPv4/UX9d1IEVIFI/AAAAAAAAJaE/YClr9NatzCc/s640/S5033461.JPG

https://lh6.googleusercontent.com/-qBBIwqaHRoA/UX9d1J8KklI/AAAAAAAAJaA/V7hHhu8FXWs/s640/S5033463.JPG

[CTWV50]

I guess that makes sense if they came with mounting collars.
I think I'll leave mine dangling in the wind and hope for the best (and take some clips and cable ties with me just in case!).

Slight change of subject, I think I promised to put up some more pics of my front wing stays.
Here's a couple of the passenger side.
It's made from 3mmx25mm strip, a bit of scrap 3mm plate, and some round tube from an old bed frame :D

https://lh5.googleusercontent.com/-5xtTfrELPv4/UX9d1IEVIFI/AAAAAAAAJaE/YClr9NatzCc/s640/S5033461.JPG

https://lh6.googleusercontent.com/-qBBIwqaHRoA/UX9d1J8KklI/AAAAAAAAJaA/V7hHhu8FXWs/s640/S5033463.JPG

Excellent. If it rains this weekend I might have a go at making a pair of these.

[skov]

Not been a great day in the garage today :(
I thought I only had trim left and was seriously considering sending my IVA application off next week...
Then today I found out that my engine's leaking oil, one of my rear calipers is siezed, and one of my driveshaft boots is leaking. I'm not amused :mad:

[CTWV50]

I've got to find the oil leak on my engine. Not looking forwaed to that job.

[Davidbolam]

Not been a great day in the garage today :(
I thought I only had trim left and was seriously considering sending my IVA application off next week...
Then today I found out that my engine's leaking oil, one of my rear calipers is siezed, and one of my driveshaft boots is leaking. I'm not amused :mad:

I think I've got a spare set of rear callipers in the garage somewhere. You can have them if your cover the postage.

Let me know if you need them and I will pop them in the post

David

[skov]

Hi David,
Thanks for offer, but I've already ordered a new one.

What really peeves me off is that I've already replaced both rear calipers and driveshafts and thought I'd fixed the oil leak!

[skov]

Arrghhh! I've got a coolant leak too!!!

I've stripped everything off the front of the engine and it looks like it was leaking where the water pump seals against the block.
It was a new waterpump and gasket, but the gasket was a very thin metal one and the sealing face on the block is slightly corroded.
I bolted it back on again with a load of sealant this time so hopefully should be ok now!

Also looks like my oil leak is coming from leaky cam seals. I'd already replaced both of the seals... but it looks like the cams have a groove worn in them from the original seals, so not sure they've ever going to seal properly again :(
I had a spare pair of seals and have replaced them again, but I'm not very confident...

[alga]

You're supposed to polish the groove out when changing seals, otherwise they're not going to last long.

[skov]

You're supposed to polish the groove out when changing seals, otherwise they're not going to last long.

Doh! :rolleyes:

One step forwards, two steps back...

https://lh6.googleusercontent.com/-UJRrzE8xVUY/UYkNOOV0ajI/AAAAAAAAJbw/Y70RNzqvflY/s640/S5033461.JPG

I've lost count of how many times I've had that bl00dy cam belt off now!

Managed to find my CV gaitor leak, took me a while as it's only a tiny split. It was virtually invisible before I squeezed it in the right place and the grease came out:

https://lh5.googleusercontent.com/-iItDVTGMWRk/UYkNOM6rPdI/AAAAAAAAJbs/ocBqJ93h2jE/s640/S5033462.JPG

Really not looking forward to changing that...

[CTWV50]

You're supposed to polish the groove out when changing seals, otherwise they're not going to last long.

I normally just tap the seal in so it's slightly recessed and no longer sits within the groove.

[skov]

I had a dig through my spares and found I had another two pairs of cam seals. No idea how or why I ended up with so many!
Anyway, one of the pairs appears to be a slightly different design to the ones that were leaking and seals further along the shaft, so I stuck those on. They were a tighter fit too, so fingers crossed!

[Johno]

Hi John,
You don't seem to be having too much luck lately...:( :(
Chin up matey your doing a cracking job and all will become good in the end.;)

[skov]

Right, that's the cam seals and CV boot replaced, water pump (hopefully!) sealed, engine back together, bonnet vaugely the same colour as the rest of the body work, front suspension components trimmed, and a few other bits and bobs completed.
Might have to send the IVA application off soon!

https://lh5.googleusercontent.com/-kgQd-Lr9dHg/UZgGQ8klGiI/AAAAAAAAJhc/gQv_7xueFws/s640/2013-05-18%252023.36.44.jpg

[Davidbolam]

The car is looking great there!

Did you find what was causing the engine to run unsmoothly?

Noticed your YouTube vid earlier.

Are you going to put some stripes on???

[skov]

Thanks David. I'm pretty sure it's going to get a red stripe down the middle at somepoint :D

I still don't know why the idle is a bit crap, but I'm sure I'll get to the bottom of it!

[skov]

Ah ha, I think I may have fixed the idle surge problem (or at least covered it up!)

There's a hidden adjustment screw on the air flow meter (you have to drill out a metal plug to get to it).
Wound it all the way in (about a turn and a half), then out 4 turns and the surging has gone :D

The air flow meter is a crappy ancient vane flow type and I think the screw adjusts the amount of air that's allowed to bypass it when the vane/flap is closed.
My suspicion is that is wasn't allowing quite enough air through at idle and the surging was something to do with the vane opening and closing. I guess it could be a bit sticky at it's closed point, or possibly upset by me not putting it in the correct orientation.
Whatever the case my bodge will do for now :)

[skov]

I've gone and blooming done it - just sent off my IVA application :eek:

Need to pull my finger out and get it finished now!!!

[K4KEV]

Well done John......hope I am not far behind you:o

[CTWV50]

I've gone and blooming done it - just sent off my IVA application :eek:

Need to pull my finger out and get it finished now!!!

Well done John! Hopefully I'll be ready for the IVA this time next year!:)

[CTWV50]

Just looking through your photos John, are use using those lock stops now?

clicky (http://uk.rs-online.com/web/p/collars/6918124/?searchTerm=691-8124&relevancy-data=636F3D3126696E3D4931384E525353746F636B4E756D6 265724D504E266C753D656E266D6D3D6D61746368616C6C267 06D3D5E5C647B337D5B5C732D2F255C2E2C5D5C647B332C347 D2426706F3D313426736E3D592673743D52535F53544F434B5 F4E554D424552267573743D3639312D383132342677633D4E4 F4E4526)

Good find!

[skov]

Sadly they weren't quite a good a find as I'd hoped :rolleyes:
The passenger side works well, but it restricts the steering a bit too much on the drivers side...

[CTWV50]

Sadly they weren't quite a good a find as I'd hoped :rolleyes:
The passenger side works well, but it restricts the steering a bit too much on the drivers side...

Oh, bummer. :(

[skov]

VOSA just phoned to relieve me of my bank balance!
They recon it'll take two weeks to process the application and get back to me with a test date.

[skov]

Not much to report, but here's a few pics I took of her out in the daylight this morning:

https://lh3.googleusercontent.com/-wRkDn0l3kmQ/UaCTjwebVZI/AAAAAAAAJig/5DcEZwj3LSs/s640/S5033461.JPG

https://lh4.googleusercontent.com/-aG3SaEhDkTk/UaCTjxdkJHI/AAAAAAAAJik/dC0Fgk7dMqQ/s640/S5033462.JPG

https://lh3.googleusercontent.com/-3igjXuBwlc4/UaCTsCI6VuI/AAAAAAAAJi0/8iu1E7aiktE/s640/S5033463.JPG

https://lh5.googleusercontent.com/-s3IIjpI_T54/UaCT7vG6cbI/AAAAAAAAJjg/jHqTTeyNZbU/s640/S5033470.JPG

[deezee]

Build is looking good. Lets hope you fly through the IVA and we'll have another on the road.

[skov]

Thanks Deezee, hopefully won't be too long now!

[skov]

I phoned VOSA today because the receipt for my IVA payment said N1 (light goods vehicle!) instead of M1 (passenger vehicle).
I think I got that sorted, but whilst on the phone asked if they had a date for me yet...
They said they've got a 3 week back log of applications and it's going to be at least two weeks before they look at mine and probably July before I get a test.
Got a little while to wait yet then :rolleyes:

[CTWV50]

I phoned VOSA today because the receipt for my IVA payment said N1 (light goods vehicle!) instead of M1 (passenger vehicle).
I think I got that sorted, but whilst on the phone asked if they had a date for me yet...
They said they've got a 3 week back log of applications and it's going to be at least two weeks before they look at mine and probably July before I get a test.
Got a little while to wait yet then :rolleyes:

You'll have to start another while you wait! You could have the chassis done by then end of July! :D

[CTWV50]

Not much to report, but here's a few pics I took of her out in the daylight this morning:

https://lh3.googleusercontent.com/-wRkDn0l3kmQ/UaCTjwebVZI/AAAAAAAAJig/5DcEZwj3LSs/s640/S5033461.JPG



https://lh3.googleusercontent.com/-3igjXuBwlc4/UaCTsCI6VuI/AAAAAAAAJi0/8iu1E7aiktE/s640/S5033463.JPG

https://lh5.googleusercontent.com/-s3IIjpI_T54/UaCT7vG6cbI/AAAAAAAAJjg/jHqTTeyNZbU/s640/S5033470.JPG


Looks really good John! :cool:

[skov]

Looks really good John! :cool:

Thanks Chris :)
To be fair the camera's quite flattering and it doesn't look half as good in the flesh!
Particularly since I decided to polish the bonnet and managed to go through to the primer... :o

You'll have to start another while you wait! You could have the chassis done by then end of July!

There's no way I'm going to build another bl00dy one!!
It's been fun, but I'm not sure I'd want to do it again. I'm starting to look forward to having some spare time and cash again.
Plus I recon my wife would pack her bags if I started another one!

[K4KEV]

Thanks Chris :)
To be fair the camera's quite flattering and it doesn't look half as good in the flesh!
Particularly since I decided to polish the bonnet and managed to go through to the primer... :o



There's no way I'm going to build another bl00dy one!!
It's been fun, but I'm not sure I'd want to do it again. I'm starting to look forward to having some spare time and cash again.
Plus I recon my wife would pack her bags if I started another one!

lol lol lol:D

[CTWV50]

Thanks Chris :)
To be fair the camera's quite flattering and it doesn't look half as good in the flesh!
Particularly since I decided to polish the bonnet and managed to go through to the primer... :o



There's no way I'm going to build another bl00dy one!!
It's been fun, but I'm not sure I'd want to do it again. I'm starting to look forward to having some spare time and cash again.
Plus I recon my wife would pack her bags if I started another one!

HAHAHAHA!!!

[Johno]

Hi John,

I notice in your photos the rear wheel seems to be quite a way in from the edge of the wheel arch, are they standard MX5 wheels?
I believe the standard offset for a MK1 is 45mm so are the ones you have on different.
As I don't have my rear arches yet I'm intrigued to know what offset to get to suit the car.
What size rims and tyres are fitted just out of curiosity..

[skov]

Mind the gap... :rolleyes:
No idea what the offset is, but they're standard Eunos wheels with 185/60-14 tyres.
I recon they need to come out another 40 or so mm to look 'right'.

[skov]

Come on VOSA pull your finger out and give me a test date, the cars ready and I'm sat twiddling my thumbs now!

[skov]

Phoned VOSA today. Apparently they processed my form and sent it to the test centre (Leighton Buzzard) two days ago.
They checked with the test centre and they got it this morning, and should be phoning me shortly with a test date :D

[CTWV50]

Phoned VOSA today. Apparently they processed my form and sent it to the test centre (Leighton Buzzard) two days ago.
They checked with the test centre and they got it this morning, and should be phoning me shortly with a test date :D

OOoooo exciting!!:D

[skov]

OOoooo exciting!!:D

Even more exciting - the test centre just phoned and booked me in for the 25th June!
Less than 2 weeks to go :eek:

[K4KEV]

Don't waste those two weeks John.... go read iva manual then read it again, then go over your car with a fine toothed comb or magnifying glass, then go over it again ...read iva manual then go over the car again ...oh and once more for good measure ....there you go your two weeks are filled.:D :D

[skov]

I'm already sick of reading that bl00dy manual!
I recon I'll be able to recite it word for word by the end of next week :D

[Johno]

Well it's good you got your test date at last...:)
So what stress level would you compare it to when the time comes do you think?:eek:

Getting married.
Having children.
Moving house.
Anyways good luck and I guess you will be the first MX5 roadster on the road with any luck.:cool:

[K4KEV]

I think his wife had better hide all blades and just say were using plastic ones for two weeks:p :p

[CTWV50]

Great news, plenty of summer sun to enjoy the car. :D Have you made enquires about insurance? Any quotes yet?

[skov]

The quotes so far have been surprisingly reasonable:

Adrian Flux - £186
2gether - £185 for parts only, £202 including labour
Graham Sykes - £220
Frank Pickles quoted £108 for parts only, but sadly don't insure on the chassis number any more.

I'm pretty happy with that considering the renewal for my tin top just came through at £480! (although after a brief discussion they managed to knock it down to £280 :D ).

[skov]

Just sorted my insurance out ready for IVA.
Cost me £156 from Adrian Flux (their original quote included 30 quids worth of optional bollox :rolleyes:)

[CTWV50]

So you plan on driving to the test centre? I didn't think you could? Can you explain?

[Davidbolam]

you can drive to iva centre. the car is insured on the vin number

David

[skov]

So you plan on driving to the test centre?

Yes, I'm that stupid!

I didn't think you could? Can you explain?

You're allowed to drive to and from the test centre as long as you're insured.

Also if you fail the test you can drive to and from a pre-booked appointment at a garage to fix any of the items that have failed.

[skov]

It's covered under the Vehicle Excise and Registration Act 1994, Chapter 22, Schedule 2 (Exempt Vehicles), Section 22 (Vehicle testing etc).

You can have a read here if you're really bored:

http://www.legislation.gov.uk/ukpga/1994/22/schedule/2

[CTWV50]

Wow! Better take a print out of that for when your average copper stops you for not having a number plate or tax. I'll take a read of that link, one day. Great price on the insurance though. Why so low though? Your car will do 0-60 in under 6 seconds for sure. I'm not complaining just shocked. I thought an insurance company would get their fantasy calculator out for sure!:)

[skov]

I was pleasantly surprised, but having looked on the locost forum £150 to £200 seems fairly average for a kit car.
I guess it must be because kit cars tend to spend 350 days a year tucked away in a garage and only come out during the half a dozen days of sunshine we get each summer!
And after investing several years of blood, sweat, tears, and vast amounts of cash building it you're probably going to try your best not to crash it!

[CTWV50]

And after investing several years of blood, sweat, tears, and vast amounts of cash building it you're probably going to try your best not to crash it!

More likely that you won't want to crash it because you'll end up maimed or dead!!! Lol What is the euroencap rating for these cars again?

[skov]

I belive that would be zero stars Chris!
Frontal impact might not be too bad with that nice long engine bay to take the brunt of it.
I dread to think what would happen in a side impact though :eek:

Changing the subject I think I'm almost ready for IVA now. Just been printing out directions for the test centre and wishing I'd had the foresight to fit a fag lighter socket and somewhere to mount my gps :rolleyes:

[CTWV50]

Excited for you! :D Duck tape!

[skov]

I don't think IVA man will be impressed if I turn up with things strapped to my car with duck tape :D

Just checked the forecast for test day, looking good :cool:

https://lh3.googleusercontent.com/-WHR5gdTh7h0/Ucc5RrdhrwI/AAAAAAAAJpw/9xoYMgFC8jk/s375/iva_forcast.jpg

[alga]

Zip ties then!

[CTWV50]

What time is your test?:)

[skov]

What time is your test?:)

8.00am :eek:

[CTWV50]

You must be done by now!:)

[Nismo1982]

Must be taking the long route home from the test station :cool:

[skov]

Must be taking the long route home from the test station :cool:

Only because I got lost :D

[skov]

Luckly I made it to the test centre in one piece, and with plenty of time to spare (I had my doubts!).

https://lh4.googleusercontent.com/-D4mJkdflT3c/UcmarHvuT_I/AAAAAAAAJq0/PeLbEftrzoY/s640/2013-06-25%252007.21.59.jpg

Sadly a first time pass wasn't to be though :(

The car was tested by the main tester (Doug), his trainee, and a sort of supervisor that goes from centre to centre checking tests are done to the same standard. So it got quite a thorough looking over!

They are all good blokes, very friendly, and generally very positive about the car. The supervisor was a bit of an MX5 enthusiast so we had a good old natter on all things MX5.

First test was emissions, which passed without trouble (they were quite happy with the letter from Mazda for proof of angine age).

Next was interior/exterior projections, and a good look around the car.
They liked the fact I'd stuck lots of bits of rubber on there and couldn't find any nasty edges (unusual for Leighton Buzzard apparently!).

Next they stuck it on the ramps to check underneath. This is where it started going wrong...
They spotted one of the rear brake lines and both handbrake cables were rubbing on the chassis. They weren't last time I checked, so they must have settled/bedded-in during the drive there.
They also spotted there was a bit of play between the UJ and steering rack which they didn't like. I tried tightening it up, but there's still too much play.

The ramps came down and they checked all the lights. Head light aim was way off (and still is), but everything else was fine.
Interestingly they didn't seem to measure any heights or distances of the lights.

After that they weighed it then did the brake and speedo test.
The speedo over-read by quite a bit, but was still within IVA spec.
I'll come on to the brakes later...

Next test was exhaust noise, passed with a comfortable 95dB, followed by rear vision, which passed easily.
They liked my Furore e-marked IVA wing mirrors and the position of them saying a lot of people fail by putting them too low and getting too much rear wing in the way.

Next the trainee tester had a blat round the car park to do some more brake testing and to check self centering. Both were fine.

Finally they took a few measurements with a tape measure before dissapering into the office to enter all the figures into their spreadsheet.

Sometime later they emerged with my fail sheet...
This had the fails I knew about above, along with a fail for brake efficiency, and a fail for a big mismatch between each side on the handbrake.

https://lh5.googleusercontent.com/-RwlokFC7NzE/Ucms6al-3NI/AAAAAAAAJrM/edNB2awmMNw/s512/iva_fail.jpg

https://lh4.googleusercontent.com/-q8MdRvRR1N0/UcmaA_L3eWI/AAAAAAAAJqs/9mFo3j16joM/s512/iva_brake_fail.jpg

Not too bad a fail really.
Not quite sure what to do about the brakes yet, but the rest should be easy enough to fix.

[Davidbolam]

thats not too bad John. I am now worrying about my handbrake cables!! The handrake balance can be adjusted easily with a allen key so that shouldn't be a problem.

Let me know if you think of a way to make the cable not hit the back of the car!!

How much does the universal joint wobble by? Is it from Rally design?

Was the balance between the from and rear braking well within limits as I haven't installed the reducer valve yet.
Was it a fun drive there and back?

David

[K4KEV]

Al relatively easy to sort out John, so yes it is a "good" fail:( ...were you able to chase up a retest from them there and then?

[skov]

thats not too bad John. I am now worrying about my handbrake cables!! The balance can be adjusted easily with a allen key so that shouldn't be a problem.

Let me know if you think of a way to make the cable not hit the back of the car!!

Was it a fund drive there and back?

David

I'll let you know what I do David; I'm currently thinking I might attack the cables supports at the caliper end with an angle grinder and re-weld them at a slightly different angle. I tried bending them at the test centre, but they're pretty tough and wouldn't budge!

The drive there was terrifying. I pootled along at 40mph with lorries overtaking me scared it was going to fall apart or blow up :eek:

I was rather more confident on the way home though, and took a slightly more scenic route. Still terrifying, but in a good way!
It feels a bit dull and flat below 4000 rpm, but I found if I kept the revs above that I couldn't stop grinning! Flooring it in second then third had me squealing like a girl :D
The most striking thing is the way it corners though, the steering's nice and direct, and the lack of body roll feels awsome. It's almost like driving a go kart :D

The only things really I want to change at the moment are the accelerator pedal which has far too much travel, and the clutch pedal which doesn't have nearly enough.

[skov]

Al relatively easy to sort out John, so yes it is a "good" fail:( ...were you able to chase up a retest from them there and then?

No, I didn't bother sorting it out there and then, I'll give them a ring once I've sorted out my plan of action. They recon they should be able to fit me in withing a week or so of calling up with it being a fairly quick re-test.

I was always worried about the brakes as it's one of the few things I couldn't check myself.
At least I'm allowed to drive it to a garage for remedial work now, so I might book it in at the place accross the road from work so they can test it once I've had a fiddle with them.

[CTWV50]

A shame it was a fail but sounds like you had a good day out! Did it fail on front to rear balance? Or left to right rear balance? Did you get much bump steer? Regarding being scared driving it. I always say to people when they ask why about my build, " I want a car that will scares me! " looks like I'm going to get my wish!:D

[skov]

A shame it was a fail but sounds like you had a good day out! Did it fail on front to rear balance? Or left to right rear balance? Did you get much bump steer? Regarding being scared driving it. I always say to people when they ask why about my build, " I want a car that will scares me! " looks like I'm going to get my wish!:D

It's certainly scary enough for me in my old age!
I'm sure it won't take long to get used to it, but there's always the option of fitting a turbo if I really want to poop my pants :D

On the handbrake it failed on the difference between left and right sides.

On the brake pedal it didn't exactly fail on front to rear bias.
Mine are heavily based to the front, but what it failed on was combined efficiency. It needs to be 60% (whatever that means:confused: ) and I got 57%.
He said the rears looked particularly poor (they currently give about half the braking force of the fronts). I suspect I would have passed if I didn't have quite so much bias.
I'm currently hoping just bleeding the brakes again and bedding the new discs/pads in will get me that extra 3%.

I'm a bit reluctant to take the bias valve out in case it ends up going too far the other way.

[CTWV50]

Are you using the mx5 brake bias valve? Did you get much bump steer? How much is the retest! Dont remove the bias valve to much rear will have the back locking up and overtaking you if ever needed to actually stop! Not much fun doing 360s under braking!

[skov]

Are you using the mx5 brake bias valve? Did you get much bump steer? How much is the retest! Dont remove the bias valve to much rear will have the back locking up and overtaking you if ever needed to actually stop! Not much fun doing 360s under braking!

No, I junked the MX5 one as I was too lazy to figure out how/where to mount it and connect up all the different pipes on it :rolleyes:
I stuck a Mondeo bias valve inline with the rear brake line instead:

https://lh5.googleusercontent.com/-1ru3_N2DRGs/TzElw9CUU2I/AAAAAAAAIJg/8us10XKLu3g/s720/bias.jpg

[CTWV50]

Well I don't know much about brake lines and master cylinders but when I read that, I had the mx5 master cylinder in front of me off my build and it has a weird setup where one line comes out the bottom and goes to the front right I think. Then two pipes exit the side, one near the rear and one near the front both going to the bias valve. Front one goes off to the front left and the rear one goes off to the back to the right rear brake line and then off to the left rear. I don't understand why it's like that or how you have done yours but I hope something in the above helps you find a solution.

[CTWV50]

This any use to you?

http://www.flyinmiata.com/tech/stock_bpv.php

[Stot]

I'm going to fit one of these to my rear line, pretty good price.

http://www.ebay.co.uk/itm/330946373690

Cheers
Stot

[CTWV50]

I'm going to fit one of these to my rear line, pretty good price.

http://www.ebay.co.uk/itm/330946373690

Cheers
Stot

Adjustable bias valves aren't allowed under IVA regs as far as I'm aware.

[Stot]

Adjustable bias valves aren't allowed under IVA regs as far as I'm aware.

This is a good point. :rolleyes: RTFM. :D

Cheers
Stot

[skov]

I really don't want to be changing the bias valve at this point if I can help it.

I was so close to passing overall efficiency (3% below the limit), that I'm sure just giving the brakes a damn good thrashing and getting them bedded in properly will be enough to get through the test.

Just spoke to my friendly garage across the road from work and he said he'll check it on his MOT rollers for my free of charge :D
So a drive to work next week with plenty of left foot braking might be in order!

Forgot to mention in my write up yesterday. You NEED a bike helmet with these cars. I set off with just sunglasses on, but had to stop and switch to my helmet a few miles in because I was struggling to breath above 45mph :eek:

[Stot]

I really don't want to be changing the bias valve at this point if I can help it.

I was so close to passing overall efficiency (3% below the limit), that I'm sure just giving the brakes a damn good thrashing and getting them bedded in properly will be enough to get through the test.

Just spoke to my friendly garage across the road from work and he said he'll check it on his MOT rollers for my free of charge :D
So a drive to work next week with plenty of left foot braking might be in order!

Forgot to mention in my write up yesterday. You NEED a bike helmet with these cars. I set off with just sunglasses on, but had to stop and switch to my helmet a few miles in because I was struggling to breath above 45mph :eek:

I did a bit more research and if you do find you need a new valve a Fiat Uno valve (http://www.ebay.co.uk/itm/310588485437) seems to be a good choice and used on quite a few builds. It can be modified to be adjustible after IVA too just by changing the way you mount it.

Cheers
Stot

[Johno]

Hi John,
Sorry about the fail....:(
Well I guess you can now concentrate your efforts on the things it failed on and should be an easy fix.
So come on what's it like to drive one on the road for real...:D
To be honest I don't think I would have the b**ls to drive it to the test.

[skov]

To be honest I don't think I would have the b**ls to drive it to the test.

It wasn't balls, it was because I too cheap to hire a trailer :rolleyes:
I was terrified I wasn't going to make it there!

[skov]

Fcuck it, I've took my Mondeo bias valve out and replaced it with a bit of plain pipe.
Got it booked into a garage next week to check it's not biassed too far the other way now...

Decided to do some work on the clutch as it was rediculously heavy and hard to control.
Changed the master cylinder from 0.7" bore to 0.625" and cut and shut the pedal to add an inch or so to it. Feels nice and light now!

New steering UJ turned up today, hopefully get that fitted tomorrow.

Sorted out my handbrake cable interference issue by cutting and rewelding the brackets that hold the cable ends on the caliper. Should bring the cables away from the chassis by about 1/2 and inch.
Only tacked together in the photos, but you get the idea:

https://lh5.googleusercontent.com/-CBSwR-S2TdQ/Uc4OtTUdFqI/AAAAAAAAJsM/iZmT5G7yPi4/s640/S5033461.JPG

https://lh4.googleusercontent.com/-Hr9Rtu3BiEc/Uc4O08VyRxI/AAAAAAAAJsc/qf4Yl94QvvE/s640/S5033463.JPG

Tried to book my re-test earlier, but no one was answering the phones at Leighton Buzzard :rolleyes:

[Davidbolam]

Fcuck it, I've took my Mondeo bias valve out and replaced it with a bit of plain pipe.
Got it booked into a garage next week to check it's not biassed too far the other way now...

Decided to do some work on the clutch as it was rediculously heavy and hard to control.
Changed the master cylinder from 0.7" bore to 0.625" and cut and shut the pedal to add an inch or so to it. Feels nice and light now!

New steering UJ turned up today, hopefully get that fitted tomorrow.

Sorted out my handbrake cable interference issue by cutting and rewelding the brackets that hold the cable ends on the caliper. Should bring the cables away from the chassis by about 1/2 and inch.
Only tacked together in the photos, but you get the idea:

https://lh5.googleusercontent.com/-CBSwR-S2TdQ/Uc4OtTUdFqI/AAAAAAAAJsM/iZmT5G7yPi4/s640/S5033461.JPG

https://lh4.googleusercontent.com/-Hr9Rtu3BiEc/Uc4O08VyRxI/AAAAAAAAJsc/qf4Yl94QvvE/s640/S5033463.JPG

Tried to book my re-test earlier, but no one was answering the phones at Leighton Buzzard :rolleyes:

Which universal joint are you / were you using. I have checked mine (from rally designs) and there is quite a bit of movement.

David

[Stot]

Which universal joint are you / were you using. I have checked mine (from rally designs) and there is quite a bit of movement.

David

I have the RD forged one too and I don't think much of it. One end of mine has the slit machined on the wrong side, the thru-holes for the pinch bolts were no where near where they needed to be to locate in the spline recess and yes its sloppy even when fully tightened.

Think I would plump for a pressed steel one if I cant do something with this one.

Cheers
Stot

[Stot]

Hi Skov,

Looking at that I cant help but think it would be a safer option to shorten it this way. It looks like it would still line up ok.

https://lh6.googleusercontent.com/-ZAaJK3DXXdc/Uc8ddcOxUyI/AAAAAAAAFmc/0-xeG9E55Ws/w800/handbrake.jpg

Cheers
Stot

[Johno]

Hi John,
So was the hand brake cable touching the chassis seat rail all the time or just when the shock was loaded?

I had a similar problem with mine when I fitted the cable. I ended up fitting a angle bkt to pull the cable away from the chassis seat rail.

http://i1199.photobucket.com/albums/aa472/JohnoSS1/2012-07-08-293.jpg



http://i1199.photobucket.com/albums/aa472/JohnoSS1/2012-07-08-295.jpg



The cable cleared just:eek: when I removed the shock spring and moved the damper through it's full range.
I know it looks close to the drive shaft and suspension arm but it clears these as well.

[skov]

I have the RD forged one too and I don't think much of it. One end of mine has the slit machined on the wrong side, the thru-holes for the pinch bolts were no where near where they needed to be to locate in the spline recess and yes its sloppy even when fully tightened.

Think I would plump for a pressed steel one if I cant do something with this one.

Cheers
Stot

I was using forged Rally Design one and it's sh!t. Sounds like like yours is even worse!
The problem I was having is that it wouldn't clamp tigh enough on the steering rack spline. Not happy considering they charge around £20 for it :mad:

I swapped it for a pressed steel one off ebay last night and it's nice and tight with no play now.

Hi Skov,

Looking at that I cant help but think it would be a safer option to shorten it this way. It looks like it would still line up ok.

https://lh6.googleusercontent.com/-ZAaJK3DXXdc/Uc8ddcOxUyI/AAAAAAAAFmc/0-xeG9E55Ws/w800/handbrake.jpg

Cheers
Stot

lol, don't know why I didn't think of that!


Hi John,
So was the hand brake cable touching the chassis seat rail all the time or just when the shock was loaded?

I had a similar problem with mine when I fitted the cable. I ended up fitting a angle bkt to pull the cable away from the chassis seat rail.


It wasn't touching at all when I checked (but was damn close!), by the time I got to IVA they were hard up against the seat backs all the time.
I had the cables pulled away similar to you, but they still managed to move and settle upagainst the chassis.

Seems to be sorted with the shorted brackets anyway.

[Johno]

Hi John,
So what was it like to drive on the roads. Did you have a big grin all the time...:D
Was the handling ok or is there something you would change?
Seeing as my car is virtually the same as yours I'm curious to know what you would do different.
You said the clutch was heavy so that's something I need to look at for a start.

[skov]

Hi John,
So what was it like to drive on the roads. Did you have a big grin all the time...:D
Was the handling ok or is there something you would change?
Seeing as my car is virtually the same as yours I'm curious to know what you would do different.
You said the clutch was heavy so that's something I need to look at for a start.

It's a bit early to say yet. For the most part I was driving to IVA and back like a granny, and to be perfectly honest it's not a particularly pleasant or comfortable place to be when you're just cruising along.
When I did have a bit of a play I wasn't exactly performing a critical assessment of its handling abilities...
I was however grinning from ear to ear and shouting wooooooo quite a bit :D

The clutch was a fricken nightmare though, so much so that I didn't want to drive it again before I sorted it. It was rediculously heavy and hard to control smoothly, which got a bit tiresome in traffic.

I've got a 50 mile round trip to my local friendly garage tomorrow, so I might have some more to report after that.

[Davidbolam]

I was using forged Rally Design one and it's sh!t. Sounds like like yours is even worse!
The problem I was having is that it wouldn't clamp tigh enough on the steering rack spline. Not happy considering they charge around £20 for it :mad:

I swapped it for a pressed steel one off ebay last night and it's nice and tight with no play now.



lol, don't know why I didn't think of that!




It wasn't touching at all when I checked (but was damn close!), by the time I got to IVA they were hard up against the seat backs all the time.
I had the cables pulled away similar to you, but they still managed to move and settle upagainst the chassis.

Seems to be sorted with the shorted brackets anyway.

Is the pressed Steel UJ the same length as the one you took out?

Thanks

David

[skov]

Is the pressed Steel UJ the same length as the one you took out?

Thanks

David

Yes, the one I got off ebay is :D

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=121134330162

[skov]

Arrrrgghhh!
Fixed everything for IVA... booked my re-test for Thursday morning... broke a wingstay on the way home from the garage :mad:

[CTWV50]

Arrrrgghhh!
Fixed everything for IVA... booked my re-test for Thursday morning... broke a wingstay on the way home from the garage :mad:

Well Done! You don't hang around do you! How was the drive?:)

[Davidbolam]

Arrrrgghhh!
Fixed everything for IVA... booked my re-test for Thursday morning... broke a wingstay on the way home from the garage :mad:

How was the brake balance without the mondeo valve in?

David

[skov]

How was the brake balance without the mondeo valve in?

David

The rears are much stronger now and should have got my overall braking efficiency high enough to pass.

I tried replicating the IVA dynamic braking test several times and couldn't get the rears to lock before the fronts so I think it should be fine.

Westfield SDV builds seem to get through IVA without any kind of bias valve too.

[skov]

Passed my IVA re-test this morning :D
I'm a very happy bunny indeed :D

Stopped by the DVLA on the way home, submitted the forms, handed over the cash, and they did the inspection while I was there.
Should get my reg and tax disc in the poast sometime next week, can't wait!

[K4KEV]

Good timing for the nice weather dude:D :D

[CTWV50]

Well Done! And....relax! :)

[Davidbolam]

Yes, the one I got off ebay is :D

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=121134330162

Can I check what bolts you are using on the joint. I had m8 bolts in the old version but now the seem too small. I also cannot get the spanners to fit as the casing is in the way.

Cheers

David

p.s well envious yours is on the road!!

[skov]

Thanks Chris and Kev!

David, I did use M8 bolts, they were a bit of a tight fit, but went in with a some persuasion.
The spanner clearance issue did have me swearing a bit...
I ended up packing the nuts out with a handful of thick washers so I could get a socket on them. Had to grind a bit off the washers to get them to fit too :rolleyes:
Still, it's better than having a UJ that fails IVA!

[CTWV50]

I got a replacement uj (free) from rally design and it's just the same! Except both ends don't clamp up on this one! WTF!! :mad:

[skov]

Got my Reg number and tax disc through this morning!
Just about to knock up some temporary plates so I can have a play tonight :D

[Stot]

I got a replacement uj (free) from rally design and it's just the same! Except both ends don't clamp up on this one! WTF!! :mad:

I think I will be slitting the opposite side and using 2 bolts each end to secure like this. You can slit it with an angry grinder just try and emulate the original slit.

https://lh5.googleusercontent.com/-nSTOYvNW4_8/Udq3jegg93I/AAAAAAAAGBY/AO6hNVQlxX4/s300-no/RDCoupling.jpg

The extra bolt hole doesnt need to be exactly in the spline recess, just gives you extra pinch and the original bolt provides the positive location.

Cheers
Stot

[Stot]

Got my Reg number and tax disc through this morning!

Dang you beat me. :p :D

Cheers
Stot

[skov]

Dang you beat me. :p :D

Cheers
Stot

Only just! Have you got your IVA booked yet? :D

[CTWV50]

Got my Reg number and tax disc through this morning!
Just about to knock up some temporary plates so I can have a play tonight :D

Hottest day if the year too! Have you got a Q plate?

[CTWV50]

I think I will be slitting the opposite side and using 2 bolts each end to secure like this. You can slit it with an angry grinder just try and emulate the original slit.

https://lh5.googleusercontent.com/-nSTOYvNW4_8/Udq3jegg93I/AAAAAAAAGBY/AO6hNVQlxX4/s300-no/RDCoupling.jpg

The extra bolt hole doesnt need to be exactly in the spline recess, just gives you extra pinch and the original bolt provides the positive location.

Cheers
Stot

I think I'll get the one off eBay, all for making stuff work but not that bit!

[CTWV50]

I think I'll get the one off eBay, all for making stuff work but not that bit!


Actually looking at the original cut it looks like it's not been cut deep enough. Might have a go at filing it a little deeper on the original and see if that solves it.

[skov]

Hottest day if the year too! Have you got a Q plate?

Nope, J-reg :)

[CTWV50]

Actually looking at the original cut it looks like it's not been cut deep enough. Might have a go at filing it a little deeper on the original and see if that solves it.

Yep this worked for me!:D

[CTWV50]

Got my Reg number and tax disc through this morning!
Just about to knock up some temporary plates so I can have a play tonight :D

How was it Legal Eagle?

[skov]

How was it Legal Eagle?

Fooooooooking AWESOME!

[Stot]

Yep this worked for me!:D

Good news, ill give it a go on mine too.

Cheers
Stot

[CTWV50]

If you need any bits of bodywork let me know! I know you where admiring my nosecone a while back.:p

http://www.haynes.co.uk/forums/showthread.php?t=12782

[skov]

If you need any bits of bodywork let me know! I know you where admiring my nosecone a while back.:p

http://www.haynes.co.uk/forums/showthread.php?t=12782

If you had a full set the same colour as your nosecone I might have been interested!

[CTWV50]

Nevermind, provisionally sold now just tryiing to sort courier. :-) I bet you can't believe your luck with this weather. Are you driving to end from work in it each day?

[skov]

Nevermind, provisionally sold now just tryiing to sort courier. :-) I bet you can't believe your luck with this weather. Are you driving to end from work in it each day?

Well done, didn't think they'd hang around for long at that price!

I had to drive the tin top yesterday (which now feels like a soft slow soggy old sofa!), but I've commuted in the Haynes every other day this week :cool:

[skov]

Speaking of commuting in the Haynes, I strapped an £8 ebay camera to my front grill for the drive home last night to see how good/bad it was:

http://www.youtube.com/watch?v=s-r9JsjHD8A&feature=youtu.be

Not the most exciting video I know!

[Davidbolam]

Speaking of commuting in the Haynes, I strapped an £8 ebay camera to my front grill for the drive home last night to see how good/bad it was:

http://www.youtube.com/watch?v=s-r9JsjHD8A&feature=youtu.be

Not the most exciting video I know!

It looks like it goes fast enough!

Has you mx5 steering wheel dropped off and been replaced by something fancy yet?

How about stripes on the bonnet

David

[CTWV50]

Speaking of commuting in the Haynes, I strapped an £8 ebay camera to my front grill for the drive home last night to see how good/bad it was:

http://www.youtube.com/watch?v=s-r9JsjHD8A&feature=youtu.be

Not the most exciting video I know!

Two things to say....

Looks and sounds awesome.

Have you written a will?:D

[SteveMX5]

Not too bad for 8 quid I reckon.

Wish that was my commute home, mine is lots and lots of M5 every day :rolleyes:

[Johno]

Wow looks like fun.......:D :D
Looking at the vid I guess the she handles very well?
Sounds awesome to, guess the wire wool fell out somewhere along the line:rolleyes:
All I've got to say is Lucky Bugger... can't wait to get mine on the road now.

[PorkChop]

Speaking of commuting in the Haynes, I strapped an £8 ebay camera to my front grill for the drive home last night to see how good/bad it was:

http://www.youtube.com/watch?v=s-r9JsjHD8A&feature=youtu.be

Not the most exciting video I know!

Nice to see that the cars 55 years from now will look exactly the same as they do now :D

[skov]

It looks like it goes fast enough!

Has you mx5 steering wheel dropped off and been replaced by something fancy yet?

How about stripes on the bonnet

David

She certainly feels nippy enough!
I thought it looked a bit pedestrian in the video - it feels loads faster when you're actually in the car. Could have sworn I driving twice that speed!

I haven't sorted out the stripes or wheel yet, but they're both on my growing list of things to do.
I'm a bit skint after IVA/Insurance/Tax and trying not to spend any more on her for a while :rolleyes:

Two things to say....

Looks and sounds awesome.

Have you written a will?

Ha ha, cheers Chris. I thought you'd enjoy the exhaust note!

Not too bad for 8 quid I reckon.

Wish that was my commute home, mine is lots and lots of M5 every day

I suppose it's not too bad a commute really.
To be fair I did edit out the 15 minutes of queuing at either end, and a load of long boring bits.

Not the best quality, and does some odd things at times, but I certainly can't complain for 8 quid - it even came with a load of different mounting brackets!

Wow looks like fun.......
Looking at the vid I guess the she handles very well?
Sounds awesome to, guess the wire wool fell out somewhere along the line
All I've got to say is Lucky Bugger... can't wait to get mine on the road now.

She is quite entertaining as it happens :D
I was surprised just how well she does handle, particularly considering I haven't really done any suspension set up yet!
Seems to have tons of grip too, even on the donor tyres.

My first lot of wire wool did actually fall out all by itself on the way home from IVA! Had to re-pack it for the re-test, and when I checked it afterwards it had pretty much turned to dust and crumbled away.
I've currently got the dB killer in, and it's possibly a tad antisocial. Tried briefly without and I thought my ears were going to bleed :eek:


Nice to see that the cars 55 years from now will look exactly the same as they do now

lol, must be getting old, as I can't seem to figure out how to change the date! Might have to ask one of the kids to do it for me. If I still had a VCR I recon it'd be flashing 00:00 :D

[skov]

My lovely shiny solid diff mounts turned up today - thanks Stot!

https://lh4.googleusercontent.com/-N5sIjm7WyeY/UfjjJB6ngMI/AAAAAAAAJvU/uUALDdPsvK8/s923/2013-07-31%252010.55.47.jpg

[skov]

No pic, but my repaired propshaft just turned up.
Hopefully pick a new diff up tonight and I can start putting her back together over the weekend.

[CTWV50]

No pic, but my repaired propshaft just turned up.
Hopefully pick a new diff up tonight and I can start putting her back together over the weekend.

Cracking! :D Excuse the pun!;)

[ayjay]

That vids quite good for a cheapo camera;)

Post a link please I am looking for one for use on my bike.:cool:

[james3004]

Was good to see the finished article in the flesh last night John!

Looks s great and I'm well impressed with your sewing skils ;)

Thanks again for lending me the timing light

[alga]

Ayjay, just search for 'md80 camera' on ebay. :-) £4.99+£1.99 shipping!

[skov]

Was good to see the finished article in the flesh last night John!

Looks s great and I'm well impressed with your sewing skils ;)

Thanks again for lending me the timing light

Cheers James! If only my metalworking skills were as good as my sewing skills :D

That vids quite good for a cheapo camera;)

Post a link please I am looking for one for use on my bike.:cool:

Ayjay, just search for 'md80 camera' on ebay. :-) £4.99+£1.99 shipping!

Yep, that's the one. I don't have a link handy, but there's loads of MD80's for around £7 delievered on ebay.

[skov]

Popped over to Porkchop's last night and came back with one very orange diff!

https://lh6.googleusercontent.com/-8yhWHIRcOt0/UftphQ6Bu8I/AAAAAAAAJvk/ji_rPbCCwLc/s640/orange_diff.jpg

The picture doesn't do it justice, it's far more vivid and 'orangey' in reality!

Great to meet you last night Porkchop, and thanks for diff!

[jason 82]

You know when you been tango'd !!!! Lol:D

[PorkChop]

It was my pleasure John - cheers for bringing the stuff over for me :D

That pic makes the diff look totally different, I had to wear sunglasses when I removed it!

[skov]

It was my pleasure John - cheers for bringing the stuff over for me :D

That pic makes the diff look totally different, I had to wear sunglasses when I removed it!

No worries Dave. I've just about got over the trauma of my GPS packing up whilst trying to find your house!

I think my car's going to look like something out of fast and furious with the orange glow coming out of the bottom :D

In other news I was well peeved off last night.
I got Northwest propshafts to fix my propshaft. They couldn't repair the original UJ so had to fit a brand new one along with a brand new tube (at great expense).
Offered it up to the diff and the new flange they fitted doesn't clear the chuffing nut on the end of the diff. One is not amused...

https://lh3.googleusercontent.com/-Gi0xLpd8yec/Ufv4ZVB2pFI/AAAAAAAAJv8/soa7yk8knKc/s640/S5033466.JPG


EDIT: I'd just like to point out it's the same with the old diff too, so I can't blame porkchop or the technicoloured diff!

[CTWV50]

That's annoying!

[james3004]

Very not good!

[Johno]

John's right, it's a lot more orange in real life...:eek: :eek:
Well it's been sandblasted then at least two coats of etch primer and a couple of coats of polyurethane so should last a while.
Not good news about your prop John..:(
I got mine shortened at Dunnings and Fairbank which in the end wasn't a bad price I guess at £69 shortened, balanced, painted and delivered.:o

[skov]

Got hold of Northwest Propshafts, they were a bit surprised saying they had never seen that problem before.
They're sending a courier to pick it up and will see if they can rework it to make it fit.
The front diff mount's taking me a bit longer to fabricate than I had planned anyway, so hopefully the propshaft issue won't set me back too much if at all.

[Davidbolam]

I have spent some time trying to adjust my handbrake cables so they clear the rear bulkhead. I think I have made them even worse.

I have shortened the bracket and pulled the cable up attaching it to the diff hangers.

Skov / stot? - how much have you chopped out of the bracket?

Any ideas of how I can increase the clearance.......

I am starting to loose the will to build my car. Once this is done I will commit to paying for bodywork and the last few bits.

David

[skov]

I have spent some time trying to adjust my handbrake cables so they clear the rear bulkhead. I think I have made them even worse.

I have shortened the bracket and pulled the cable up attaching it to the diff hangers.

Skov / stot? - how much have you chopped out of the bracket?

Any ideas of how I can increase the clearance.......

I am starting to loose the will to build my car. Once this is done I will commit to paying for bodywork and the last few bits.

David

Don't lose heart David, you've come too far to give up now!

I chopped about half an inch out of the brackets, and bolted the cables to the diff bracket things and that was (just!) enough to pull the cables away from the chassis.
I also raised my rear ride height slightly for the re-test to give me that little extra clearance ;)

[CTWV50]

I am starting to loose the will to build my car.

I know that feeling, I'm approaching hibernation once again.:D

[twinturbo]

I am selling an engine and tidying the garage, which means there will be another small push soon....

TT

[Davidbolam]

I've been out in the garage again....

I now only have one knuckle with skin left in it but my rear cables are now well clear of the rear chassis.

I will post a photo in my build

Thanks for the inspiration to keep going!!!!!

David

[Stot]

I have spent some time trying to adjust my handbrake cables so they clear the rear bulkhead. I think I have made them even worse.

I have shortened the bracket and pulled the cable up attaching it to the diff hangers.

Skov / stot? - how much have you chopped out of the bracket?

Any ideas of how I can increase the clearance.......

I am starting to loose the will to build my car. Once this is done I will commit to paying for bodywork and the last few bits.

David

On mine in the photo you can see where the old hole was.

https://lh3.googleusercontent.com/-sLjpZ-uEmxM/UfVQhEcHUuI/AAAAAAAAGtA/sKYCNwSvv5Y/w800/Handbrake+CaliperBrackets7.JPG

The slight change of angle helped more than how much I took of to be honest. I will likely take them off again and fill that hole with weld and grind it so that it butts up all the way along as it could swivel a bit if the bolt came loose.

Cheers
Stot

[skov]

Finally got my propshaft back yesterday. It fits this time which is nice :cool:
Just bolted it all up with my new front diff mount and Stot's solid diff arm mounts.
Here's some pictures for what it's worth:

https://lh5.googleusercontent.com/-S5pv9i1RMKc/UgqOGt8AnlI/AAAAAAAAJzw/d5h1hdjZLU0/s640/S5033461.JPG

https://lh4.googleusercontent.com/-y5J6Ojd9Smc/UgqOGdhIV7I/AAAAAAAAJzs/eAnRc_h24YU/s512/S5033462.JPG

https://lh6.googleusercontent.com/-VrvcAqvt7KE/UgqOEAkTx4I/AAAAAAAAJzg/nR8U9gs3Ano/s512/S5033469.JPG

I'll report back when it breaks (assuming broken wishbones or the awful handling doesn't put me in a ditch first).

[CTWV50]

Great, lets us all know if it feels any different.

[twinturbo]

looks solid, certainly an improvement

[Dualist]

Looks good mate, I'll doing the same to my diff.

[skov]

Just had a quick blast. The diff survived which is a good start.
Can't say I notied any additional vibration.

[skov]

250 miles on and the diff is holding up so far...

Some new roadster related goodies turned up in the post this morning.
I got mixed reviews from other road users on the way home, but I think they were mostly positive :D

https://lh6.googleusercontent.com/-Q45Bl3UTV_g/UhecGhtUiWI/AAAAAAAAJ0M/y_dwoCk1zEE/s640/S5033466.JPG

Chocks away!

[CTWV50]

Wow huge goggles! Must of given everyone a good laugh! :D

[skov]

Wow huge goggles! Must of given everyone a good laugh! :D

Think it might be small head rather than big goggles, and yes, hilarity did prevail :D

[ayjay]

Looks like "The fly":D :D

[Johno]

Glad to hear the "Tango diff" is holding up.:)

Do you think the failure was purely because the rubber mounts where in shear like you say?
Obviously a bit concerned as I'm using the same mounts but in compression and tension.
What did you wear before your new goggles?

[skov]

Glad to hear the "Tango diff" is holding up.:)

Do you think the failure was purely because the rubber mounts where in shear like you say?
Obviously a bit concerned as I'm using the same mounts but in compression and tension.
What did you wear before your new goggles?

Yes, I'm pretty sure it failed due to my half ar5ed job using rubber mounts in shear :rolleyes:
I had a look at your mates chassis when I visited Porkchop's and I can't see your diff going anywhere the way you have it sandwiched with one in compression and one in tension at all times.

Before I got my rediculous hat and goggles I was switching between sunglasses and a full face motorcycle helmet.

These are the shades I use (PM me if you want a 20% discount code):

http://www.uksportseyewear.co.uk/product.php/38/kit-car-glasses-biker-glasses

They're great for short trips and slow/town driving, but I find the bike helmet much more comfortable if I'm going to be driving above 40mph for any length of time.

[skov]

My odometer passed 1000 miles today!
Only one major malfunction during that time can't be too bad can it :o

[Johno]

That's good to hear:)
You've said in another post you have changed you're shocks about. What setup are you currently running.

[skov]

That's good to hear:)
You've said in another post you have changed you're shocks about. What setup are you currently running.

I'm currently running 400lbs on the rear and 250 on the front.
The rear feels about right to me, but the front is a tad too soft.

I'm going to fit some 325lb springs on the front next week.
I was going to go for 300lb, but I managed to pick up the 325lb springs second hand (but unused), for less than half the price of a pair of new 300lb springs :o

[skov]

Ah ha, I found my old build thread! Time to resurrect it.

My tax ran out on the 1st of January, and I won't bother re-taxing it until spring, so it's winter rebuild time.

I did have a list of things I wanted to improve, but seeing as it's been burning a litre of oil every 100 or so miles I'd better fix that first :rolleyes:
Not 100% sure what's wrong, but googling suggests I probably need to replace my oil control rings.
Started tonight by unbolting various bits from the engine in preperation for removal.

Just need to decide whether to rebuild it, replace it with another 1.6, or replace it with something a little more potent.

[Davidbolam]

Ah ha, I found my old build thread! Time to resurrect it.

My tax ran out on the 1st of January, and I won't bother re-taxing it until spring, so it's winter rebuild time.

I did have a list of things I wanted to improve, but seeing as it's been burning a litre of oil every 100 or so miles I'd better fix that first :rolleyes:
Not 100% sure what's wrong, but googling suggests I probably need to replace my oil control rings.
Started tonight by unbolting various bits from the engine in preperation for removal.

Just need to decide whether to rebuild it, replace it with another 1.6, or replace it with something a little more potent.

Supercharger or turbo charger!

David

[skov]

Supercharger or turbo charger!

David

I've got a turbo, a spare manifold, and some bigger injectors sat under my desk at work as it happens :cool:
Don't want to stick it on an engine that's already burning silly amounts of oil though!

[Davidbolam]

I've got a turbo, a spare manifold, and some bigger injectors sat under my desk at work as it happens :cool:
Don't want to stick it on an engine that's already burning silly amounts of oil though!

Sounds like a good plan. Have a look at the mx5s running in the ma5da cup. They manage 250bhp reliably from their 1600s

[CTWV50]

Sounds like a good plan. Have a look at the mx5s running in the ma5da cup. They manage 250bhp reliably from their 1600s

Ooooh I'm getting all excited! :D

[loony]

I was always told that it's cheaper and better to swap engine to something bigger than turbocharging smaller engine...
But... I turbocharged my BMW with M50B25 6 cylinder engine ;) I'm still glad I made it... with old Volvo 850T5 turbo, without lowering CR... great experience...

But... if your engine needs rebuild or similar it's easier to swap than rebuild and turbocharge it...

[PorkChop]

Sounds like a good plan. Have a look at the mx5s running in the ma5da cup. They manage 250bhp reliably from their 1600s

Eh?

Both Ma5da (when it was still running) and the BRSCC equivalent run near standard 1600s.

The torque equivalent of 250bhp would be about the limit for both the gearbox and the conrods. Plus I wouldn't want that much torque going through a 90-93 1600 diff, it will, more likely than not, break.

Personally, I'd rebuild rather than replace. The youngest 115bhp 1600 will be 21 years old after all. The chances of finding another engine needing some form of rebuild will be more likely.

[skov]

Eh?

Both Ma5da (when it was still running) and the BRSCC equivalent run near standard 1600s.


That's what I thought :confused:
I seem to recall they're only allowed a head skim and a bit of porting, and have to run on the standard ECU.
I'd be surprised if they got 150bhp, let alone 250!


Personally, I'd rebuild rather than replace. The youngest 115bhp 1600 will be 21 years old after all. The chances of finding another engine needing some form of rebuild will be more likely.

My thoughts exactly! I can pick up a 1.6 for less than £100, but chances are it's going to need a load of work too.

The other option I was thinking of was sticking a 1.8l Mk2.5 lump in there (~150bhp standard).
That's going to be a fair bit of work though, and even those are 10 years old and starting to go bang now...

[Davidbolam]

That's what I thought :confused:
I seem to recall they're only allowed a head skim and a bit of porting, and have to run on the standard ECU.
I'd be surprised if they got 150bhp, let alone 250!



My thoughts exactly! I can pick up a 1.6 for less than £100, but chances are it's going to need a load of work too.

The other option I was thinking of was sticking a 1.8l Mk2.5 lump in there (~150bhp standard).
That's going to be a fair bit of work though, and even those are 10 years old and starting to go bang now...

Got the races mixed up. I know a company caled AK Automotive who ran a 1.6 in the Northern Sports and Saloon Car Championship that had been tubocharged to 250 bhp. they have now put in a 2.0 turbocharged engine and it has 350bhp. the car they run in the Ma5da races car no 90 which is a different car.

[james3004]

I would say 250bhp out of a 1.6 would make it fairly unreliable!

Go for a 1.8 john ;)

[skov]

I would say 250bhp out of a 1.6 would make it fairly unreliable!


I would have thought so too, but lots of people seem to manage to get that sort of power out of the 1.6 (or at least claim they do!).

I think I'm just going to rebuild the 1.6, then possibly think about adding a small turbo. I won't be trying to get anything like 250bhp out of it though!

Almost ready to get the engine out by the way James. Just need to undo the gearbox and engine mount bolts, so the sooner I can borrow your crane the better ;)

[james3004]

Are to going to decompress the engine or just run really low boost?

I best get a wriggle on.....:rolleyes:

[skov]

Are to going to decompress the engine or just run really low boost?

I best get a wriggle on.....:rolleyes:

There's no need to decompress unless you're going for silly boost.
Mazda used a slightly modified engine from the 323 turbo for the early MX5's, so they're already fairly low compression, and ideal for bolting a blower on :cool:

Don't worry about rushing, I've got plenty of other things to be getting on with!

[james3004]

You make it sound so easy;) :D

[skov]

Only because I've never done it before, and I'm still blissfully unaware of what's really involved :D

[james3004]

Only because I've never done it before, and I'm still blissfully unaware of what's really involved :D

:D how hard can it be!?!??

[skov]

:D how hard can it be!?!??

Harder than I thought - just spent an hour trying to get a broken stud out of my turbo and I still haven't got the c**t out :mad:

[johnl63]

https://www.youtube.com/watch?v=vUKgKtMXec8&list=TLil82oG2EAA9IhFf5HLzs0U59RxFKwHWq
aussie boys run you through the process
john

[CTWV50]

https://www.youtube.com/watch?v=vUKgKtMXec8&list=TLil82oG2EAA9IhFf5HLzs0U59RxFKwHWq
aussie boys run you through the process
john

That Turbo Manifold design looks great, cheap and easy. I'm already browsing ebay for a TD04 turbo! :D

[skov]

That Turbo Manifold design looks great, cheap and easy. I'm already browsing ebay for a TD04 turbo! :D

I had something very similar in mind for the manifold :D

Just been offering up the turbo to the side of the engine. It's looking a bit tight!

[CTWV50]

I had something very similar in mind for the manifold :D

Just been offering up the turbo to the side of the engine. It's looking a bit tight!

What turbo have you got again? That manifold is tiny though, surely with something like that you could make it work.

[skov]

What turbo have you got again? That manifold is tiny though, surely with something like that you could make it work.

I didn't say I couldn't make it work :D

I've got a TD04L-12T off a Volvo:

https://lh3.googleusercontent.com/-fePTGugGn2k/UtcMfAfzwMI/AAAAAAAAKWQ/Jwa3iI_qh3Y/s640/S5033477.JPG

https://lh3.googleusercontent.com/-KkSl5loqnlg/UtcMeFTPK9I/AAAAAAAAKWI/FUAoz9yaDG4/s640/S5033478.JPG

[CTWV50]

That looks fine! There's loads of room! ;)

What is the melting point of fibreglass again?? :D

[jason 82]

Tidy job. That you tube video is going to get us all divorced, & bankrupt ! :D well done for this skov, pioneering the way for us mx5 boys. I smell competition with the fix or repair daily boys !:D :D

[flyerncle]

I smell brown trousers :p

[james3004]

Have you not got the turbo upside down in the pic john?

Mine went the other way up:confused:

[skov]

Have you not got the turbo upside down in the pic john?

Mine went the other way up:confused:

Erm sort of... but if I put it the other way round the exhaust comes out the wrong side :rolleyes:
I have however removed the locating pegs in the housings so I can rotate the centre section round 180 degrees so it's the right way up.

[K4KEV]

its called "clocking" when you turn the cartridge....ideally you want oil feed at the top and drain at the bottom...drain usually goes straight into the sump. things look like they are going to be tight in there use plenty of that heat shield stuff on the back of any fiberglass near hand.

[CTWV50]

I nearly bought a TD04 this week! Fortunately I came to my senses and bought some aluminium sheet! :rolleyes:

What engine management are you thinking of using John?

[skov]

I nearly bought a TD04 this week! Fortunately I came to my senses and bought some aluminium sheet! :rolleyes:

What engine management are you thinking of using John?

There's no point resisting, you know it's inevitable :D

Haven't quite decided on engine management yet. I've got a half baked plan to modify/enhance the OEM ECU, but chances are I'll get stuck or lose interest and buy something instead!

[skov]

In other news, the turbo project's on hold whilst I rebuild the engine.
Stage 1 is complete - got the engine out this evening:

https://lh4.googleusercontent.com/-VVEfxsTyRr4/Ut7w2-uO4HI/AAAAAAAAKWs/AzQ50BOjWaY/s640/S5033478.JPG

Thanks for the loan of the crane James :cool:

[james3004]

You have been a busy boy this week! ;)

Glad to help mate :)

[skov]

I suspect the rest of the week will be somewhat less productive.
I woke up with a severe case of man-flu this morning... :(

[james3004]

Funny you should say that I can feel the onset of the dreaded man flu!!:(

[skov]

Funny you should say that I can feel the onset of the dreaded man flu!!:(

Oh no! Apologies if it was me that infected you :o
Hope for your sake it wasn't - this has got to be the worse case I've had in years :(

[twinturbo]

I used to have a load of TD04-HL15G's when I had my T5...

All long long gone now...

TT

[CTWV50]

Look at this!

http://www.homemadeturbo.com/fabrication-14/mx5-miata-td04-13t-turbo-flange-120190/

I'm still looking at turbos on ebay! :D

[skov]

It was a bit touch and go at times, but it looks like I somehow survived the dreaded man flu!
Managed to drag myself out in the garage the last couple of nights and got the engine stripped down.
The block's currently waiting to be picked up for a honing before I treat it to a new set of piston rings and bottom end bearings:

https://lh4.googleusercontent.com/-aadhpy5sdp4/UuotUUbk21I/AAAAAAAAKag/sEQYfJhjC8A/s576/2014-01-30%252010.18.35.jpg