Monday 29 April 2013

Fuel system, Diff, Panels, bit of everything really

So it's been a while since I managed to catch up with this. It has been reflected in the progress made over the month due to other commitments and struggling for parts from GBS/not planning enough to know what I need, but that is all part of the learning curve. However, the most was made from the weekend just gone as I managed to get available parts from an order sent ahead from GBS instead of waiting for the full order to be completed. That meant I was saved a weekend of looking a the car with no proper direction.

Anyway, a quick recap from the last blog post:


The diff was fitted...with cable ties...so not much good, just finding the right length bolts and the spacers to do so. This resulted in 3 M10 bolts with a handful of thick washers. I drilled down the pre-drilled holes in the chassis to ensure I got the right place, starting with my trusty 3.2mm bit working my way up to 5mm, 7mm then 10mm. Bit of a file and tidy up and job is a good-un.

The middle bolt was far too long and clashed, I could either cut it down or find a shorter bolt. The shorter bolt was the easier option and solved it nicely. The lower bolts, using the existing holes on the diff from the powerplant frame from the MX5 lined up well and bolted in.
A firm push and wiggle about to test the mounting, nothing moved, well the whole chassis moved so I'd say it's in tight. These were torqued to 50nm for the top bolts and 80nm on the side long bolts. ->These are estimated values based on the Mazda Owners Manual and other people's figures gained from other Manuals. These may or may not be the correct values, using them is at your own risk.



A little bit of safety/self preservation:



After jumping in and out, over and under, I soon found that the top of the aluminium panel to be rather rough/sharp. To save myself any injury, plus blood stains on the car, I used some chrome trim I had to cover the top. It looks ok, might swap it for black trim closer to finishing depending on my mood.








Other things I did over a couple evenings was finalising brake pipe flares/unions, tightening/torquing wishbone bolts & suspension bolts and trial fitting the steering wheel. Plus any various other little tasks that have slipped my mind currently...

On to the last weekend. I managed to get most of the fuel system things I needed which I had ordered the previous week. This included: Low pressure fuel pump, low pressure filter, mounting bracket for these, high pressure fuel pipe, high pressure pump and steering rack mounts. Also received was the gearbox and engine mounting kit, but that will be fitted to the engine and used when mouting the engine/gearbox.

To mount the low pressure pump (left) and filter (right) was straight forward in the end. The pump comes with it's own M6 mounting rubbers and nuts, I plan to use the rivnut mounting hole and drilled a new hole. The filter was a little more tricky. Using a 57mm exhaust clamp I drilled two holes and fitted this in. Upon trial fitting, it required a bit of editing moving the holes down slightly to avoid contact with the chassis rails. only 5mm approx, no problem.

 High pressure hose used between the components for ease of fitting. I have found that the high pressure pipe can be used for conenctions with the low pressure stuff going down the chassis as shown below.



 I have found that because the brake pipe is fitted with P-clips securely, plenty of cable ties will satisfy the IVA instead of fitting more and more P-Clips. On the plus side, it kind of hides my "dodgy" brake like and looks alright now.


High pressure fuel pump fitted on the drivers side footwell panel. Again, exhaust clamps were used, these are 54mm however, 51 may have been better, eitherway, its tight and secure so no problem. Missing the swirl pot so it has taken a stop for now.





Next was the steering rack. Just a simple case of fixing it in properly now I have the mountings.












Next, I spent a bit of time looking at the pedal box and preparing the scuttle/firewall. Take a look at the pictures below, see any problems?



This second one is fairly obvious, substantial panel gap? easy fix when fixed in properly I guess. Secondly on the right, the scuttle was bent at the factory and doesn't sit flat, slanting at a greater angle as you move from left to right. See it now?

















Also, with relation to the pedal box. 1. it doesn't fit very well, will require a trim, both the sides and the lid. 2. the brake reservoir cap may be obstructed by the firewall/scuttle, making maintenance tough. IVA fail maybe?

And 3:  I had already spend a bit of time getting the pedal box to fit, increasing the hole to allow the accelerator pedal bolt/pivot to fit through, and filing the sides to get it to fit nicely with other panels. So in essence, the pedal box is not of suitable size, or the lid needs adapting to avoid squeezing it tight over the pedals/brake & clutch reservoirs. But nothing I can't handle! Just boringly time consuming.....



Not the best picture I've taken, was done the morning after before work due to the lack of light when I finished. Dedication to the point that only darkness will stop slow me down! It spent a night clamped thoroughly together so the scuttle looks a little more properly formed.

Sunday 7 April 2013

Starting to take shape

So right about now I've had roughly 3 weeks on the car working a couple hours in the odd evening plus a couple of full days at the weekend, but probably less with various trips to GBS plus a weekend celebrating my Brother's 18th.

I'll start off with the MX5 shell. It's a sad day as the poor thing's body left the operating theatre of the garage and the full body transplant can now begin. Sadly the shell could not be sold or bought so the local scrappy was called. I know that the shell had to be destroyed by an Authorised Treatment Facility (ATL) for legal purposes, eventually finding a company that would pick it up for free after first refusing for the same reason so many had used: "It's not worthwhile for us". However, the DVLA had told me that they are required by law to collect scrap cars regardless if they are a registered ATL! So free collection and scrapping was arranged. Enjoy the pictures below that halted traffic in the street for 15 minutes!

 A bit of rare help from my Dad, mainly to ensure I didn't kill myself or more importantly, damage the garage he is now planning to sell! We dragged the chassis out using hoist and seatbelt trick again, dragging the hoist for the rear and a trolley jack on the front until clear of the garage.



It took a while but eventually got it out and on axle stands again. Hindsight/tip for anyone else! DO NOT put back on axle stands, it will be easier later to just leave it on the floor...




....because to get to this precarious position, it was just dragged accros the drive, lucky it was gravel and can be swept back neatly!


Finally on the back of the truck pinned down. Such a spectacle to watch being done...but not if I was stuck in the traffic jam waiting. Sorry :)















So now that is done, I can crack on with the build. Saturday afternoon was spent going to GBS after the shell had been picked up to drop off my propshaft, driveshafts and steering column for adaptions. This led to an interesting subject of what cars were used. GBS used a 1996 MX5 Miata (I think it was). Pop Quiz! What car did I use? This should be an easy one for those who have been paying attention.....that's right, 1990 MX5 Eunos Roadster, the Japanese version, essentially the same car but mine is a higher spec. For example, mine had a limited slip diff where GBS' didn't. So fitting it is proving problematic with a greater curve on the top bar. GBS were able to grind this flat, however if I were to do the same, I would lose the material to attach bolts.


One of the other tasks I embarked on was the routing and fitting of the brake lines. This looked to be done really nicely at GBS and given me some great ideas....I think they cheated and used proper tools as mine is nothing like it, but I didn't expect it to be anyway, eitherway, they are in and will do the job just fine. All I'd say is take your time and not to get frustrated. Get a cuppa and have a break if you are.

 




Not a awful but room for improvement. Lesson for the next build when I have more time to perfect every minor detail, I've let this slip as it will be covered up....
 Front tunnel bodywork also in, enclosing the footwell areas quite nicely. It's really starting to take shape now. As seen below.




The steering rack is still not properly secured due to waiting on mounts, plus the track rod ends are still being developed by GBS to ensure the right angles etc are used. However, that didn't stop me fitting the rest of the front wishbones and suspension, however the suspension I am working on getting some decent bolts that won't rattle around like all the bolts I currently have.


And the usual sign off photo from the front of the garage. I will probably put all these into a slideshow to show the progression at the end. See how much spare time I get at work!