AFGMOTO1978 Build Thread
11-04-12, 04:07 PM
#76
Adam it is an Allison / Rolls Royce C-20B insulation blanket. It goes between the fuel control / governor system and the turbine. We use to scrap them when the center lower section wore badly. I cut it in half and eliminate the bad section. I may be able to find one for you.
Barry
Barry
11-04-12, 04:21 PM
#78
9/9/07
Finished the dash, had to eliminate the plugs for the SPA gauges and solder the wires directly, I did mil spec connectors though, so it's good. I used plastic rod, spacers and nuts to attach the gauges to the dash, required a lot of trimming original gauge structure in order to fit, but the finished product turn out awesome.
[imghttps://www.rx7club.com/attachments/nw-rx-7-forum-33/257247d1189372429-fd-restoration-%24%24%24%24-damnit-dsc06969-jpg[/img]
Finished the dash, had to eliminate the plugs for the SPA gauges and solder the wires directly, I did mil spec connectors though, so it's good. I used plastic rod, spacers and nuts to attach the gauges to the dash, required a lot of trimming original gauge structure in order to fit, but the finished product turn out awesome.
[imghttps://www.rx7club.com/attachments/nw-rx-7-forum-33/257247d1189372429-fd-restoration-%24%24%24%24-damnit-dsc06969-jpg[/img]
11-04-12, 04:41 PM
#79
9/9/07
Well, put fluids in, cranked it over for oil pressure and found that I have a crack at one of the fittings on one of my mocal oil coolers. Need to fix that and find out why my fuel pump isn't turning on, will need to trace that issue too.
Well checked the wiring for the fuel pump and everything looks good, may be a supporting accessory that causing the pump to not kick in initially when starting. Will figure it out when I can get back to starting the motor. Since I'm dead in the water because of the oil cooler, I worked on other things like getting my rear diffuser fitted. Will need some more work at the corners and getting rid of the aero drag pocket in the right rear tire well.
Well, put fluids in, cranked it over for oil pressure and found that I have a crack at one of the fittings on one of my mocal oil coolers. Need to fix that and find out why my fuel pump isn't turning on, will need to trace that issue too.
Well checked the wiring for the fuel pump and everything looks good, may be a supporting accessory that causing the pump to not kick in initially when starting. Will figure it out when I can get back to starting the motor. Since I'm dead in the water because of the oil cooler, I worked on other things like getting my rear diffuser fitted. Will need some more work at the corners and getting rid of the aero drag pocket in the right rear tire well.
11-04-12, 04:46 PM
#80
9/11/07
Well not much progress yesterday, didn't have the necessary materials to braze the oil fitting back on, notice the DO NOT EXCEED 30Nm tag, yeah, I wish I noticed that sooner, doh. Will have to go to a rad shop to aluminum braze the fitting back on.
So I read up on Chuck Westbrook's tuning guide, good read if you ever plan on tuning your own car.
Well not much progress yesterday, didn't have the necessary materials to braze the oil fitting back on, notice the DO NOT EXCEED 30Nm tag, yeah, I wish I noticed that sooner, doh. Will have to go to a rad shop to aluminum braze the fitting back on.
So I read up on Chuck Westbrook's tuning guide, good read if you ever plan on tuning your own car.
11-04-12, 04:51 PM
#81
9/13/07
Got a Setrab unit, a lot nicer oil cooler.
I put motorcycle turn signals in the oil cooler duct on the plastic fenders; this will show a little light through the vent, which should look pretty cool. Spyder and I hashed that one out.
And I made a pretty big mistake somewhere in my wiring, will have to take the harness out and do a check, I have a feeling its two simple wires that I’ve crossed that goes the ecu that causing all my problems. Stay tuned to starting this bitch.
9/14/07
I made the accessory mount bracket last night for the BOV control valve, Spal fan controller and my modified relay box. Off to paint it goes to get a nice high gloss black finish.
Got a Setrab unit, a lot nicer oil cooler.
I put motorcycle turn signals in the oil cooler duct on the plastic fenders; this will show a little light through the vent, which should look pretty cool. Spyder and I hashed that one out.
And I made a pretty big mistake somewhere in my wiring, will have to take the harness out and do a check, I have a feeling its two simple wires that I’ve crossed that goes the ecu that causing all my problems. Stay tuned to starting this bitch.
9/14/07
I made the accessory mount bracket last night for the BOV control valve, Spal fan controller and my modified relay box. Off to paint it goes to get a nice high gloss black finish.
11-04-12, 05:10 PM
#82
9/18/07
After looking at the wiring harness, it looks like the wiring was correct for the engine control, but I was getting excess current draw from the added accessories and was popping a few fuses along the way. I did have other wiring issues though and after reading Chuck Westbrook tuning guide I relocated a few things per his recommendations. So I rerouted some wires, fixed a few leads and relocated the secondary injector controller for better access. Hope this will be it. Oh, and I didn’t have my leading coil plugged in, that explained why I wasn’t getting spark, Doh!
9/19/07
Well with a jump and a little cajoling with the starter, she RUNS!!!
Welded in the new air temp sensor bung and in the process of checking everything before I do the final wiring harness wrap. The fan setup I have is pretty effective, may go one step further and put fans on the oil coolers. Enjoy to vid.
http://www.streetfire.net/video/its-alive_134520.htm
After looking at the wiring harness, it looks like the wiring was correct for the engine control, but I was getting excess current draw from the added accessories and was popping a few fuses along the way. I did have other wiring issues though and after reading Chuck Westbrook tuning guide I relocated a few things per his recommendations. So I rerouted some wires, fixed a few leads and relocated the secondary injector controller for better access. Hope this will be it. Oh, and I didn’t have my leading coil plugged in, that explained why I wasn’t getting spark, Doh!
9/19/07
Well with a jump and a little cajoling with the starter, she RUNS!!!
Welded in the new air temp sensor bung and in the process of checking everything before I do the final wiring harness wrap. The fan setup I have is pretty effective, may go one step further and put fans on the oil coolers. Enjoy to vid.
http://www.streetfire.net/video/its-alive_134520.htm
11-04-12, 05:47 PM
#84
9/27/07
With my frustration level at a all time high, I took a few days off this week to decompress.
I still have electrical issues, but these are due to removing a few to many items on the original wiring. I need to wire in some resistors where the emissions control valves used to be so my air pump will work and I need to add piggyback relays to the after market fan setup so signals can be sent to the ECU so it knows at what level the fans are running.
I also have pretty major fuel leaks. Looks as thought the primary pulsation dampener gave up the ghost and my custom primary rail fitting had a hair line crack at the weld. Probably caused by a moment from the fuel line to the pressure regulator. At least it happened during buildup and test and not after I had completed the car and see it go up in flames a few days later. Redid the fitting and Spyder's getting me a new fuel dampener.
The passenger rear fender well has a plastic liner in place now to get rid of the aero drag pocket the Re street diffuser would have caused. The liner came from an old driver side front fender liner.
10/2/07
Fixed some fuel leaks still have others.
Wiring diagram for the fan setup done, waiting for the Spal temp sensor to come in.
10/8/07
Finally fixed all the pinhole fuel leaks, had to abandon some fittings and weld on permanent AN fittings on both the primary and secondary fuel rails. The last pin hole leak was so small that I was getting ~1 mm bubbles every 2 seconds.
Anyways, got the fan setup done, with all the ecu integration and I got my 5.2 inch fan for the oil cooler. Need to figure out a clever mounting arrangement for it.
Still have an issue with the air pump not turning on, even with all emissions sensors connected. So I need to figure out what wrong or figure out an alternative control, maybe something connected to the 9 volt resistor for the fuel pump.
With my frustration level at a all time high, I took a few days off this week to decompress.
I still have electrical issues, but these are due to removing a few to many items on the original wiring. I need to wire in some resistors where the emissions control valves used to be so my air pump will work and I need to add piggyback relays to the after market fan setup so signals can be sent to the ECU so it knows at what level the fans are running.
I also have pretty major fuel leaks. Looks as thought the primary pulsation dampener gave up the ghost and my custom primary rail fitting had a hair line crack at the weld. Probably caused by a moment from the fuel line to the pressure regulator. At least it happened during buildup and test and not after I had completed the car and see it go up in flames a few days later. Redid the fitting and Spyder's getting me a new fuel dampener.
The passenger rear fender well has a plastic liner in place now to get rid of the aero drag pocket the Re street diffuser would have caused. The liner came from an old driver side front fender liner.
10/2/07
Fixed some fuel leaks still have others.
Wiring diagram for the fan setup done, waiting for the Spal temp sensor to come in.
10/8/07
Finally fixed all the pinhole fuel leaks, had to abandon some fittings and weld on permanent AN fittings on both the primary and secondary fuel rails. The last pin hole leak was so small that I was getting ~1 mm bubbles every 2 seconds.
Anyways, got the fan setup done, with all the ecu integration and I got my 5.2 inch fan for the oil cooler. Need to figure out a clever mounting arrangement for it.
Still have an issue with the air pump not turning on, even with all emissions sensors connected. So I need to figure out what wrong or figure out an alternative control, maybe something connected to the 9 volt resistor for the fuel pump.
11-04-12, 05:56 PM
#85
10/12/07
Wiring mostly done, buttoning up everything back together. Got my tires in and mounted, Bridgestone RE-01Rs, 265 Rear and 255 Front.
Relocated the fuel pump idle resistor to under the car and closer to fuse box and fuel pump. This sucker gets hot, therefore it stays outside.
Also found a mounting location for my XS engineering ignition amplifier. And I need to route the cluster F in the driver foot well.
Wiring mostly done, buttoning up everything back together. Got my tires in and mounted, Bridgestone RE-01Rs, 265 Rear and 255 Front.
Relocated the fuel pump idle resistor to under the car and closer to fuse box and fuel pump. This sucker gets hot, therefore it stays outside.
Also found a mounting location for my XS engineering ignition amplifier. And I need to route the cluster F in the driver foot well.
11-04-12, 06:02 PM
#86
10/16/07
Alright, dash is in (thanks to the help from Mitch), wiring complete, added an accessory outlet plug in the glove box (like to F-up plug above it?) and will be modifying the glove boxes strike to get rid of the annoying gap present on all 93's. Also started installing the Race Shop roll bar, unfortunately all the hardware that went with this kit is MIA, so I have to source equivalent replacements. Had a massive migraine yesterday; felt like I was going to puck every time I moved; no fun.
10/17/07
Glove box striker modified, Roll-bar installed (will need to remove to install the rest of the interior), it was bit of a jigsaw puzzle, but it's in, and started figuring out how the Sparcos will fit and be setup.
Alright, dash is in (thanks to the help from Mitch), wiring complete, added an accessory outlet plug in the glove box (like to F-up plug above it?) and will be modifying the glove boxes strike to get rid of the annoying gap present on all 93's. Also started installing the Race Shop roll bar, unfortunately all the hardware that went with this kit is MIA, so I have to source equivalent replacements. Had a massive migraine yesterday; felt like I was going to puck every time I moved; no fun.
10/17/07
Glove box striker modified, Roll-bar installed (will need to remove to install the rest of the interior), it was bit of a jigsaw puzzle, but it's in, and started figuring out how the Sparcos will fit and be setup.
11-04-12, 06:16 PM
#87
10/17/07
The Sparcos are super tight and the stock rails will not work. Will have to modify the door panels for sure and maybe the kick plate, seat belt buckle will be an interesting one too. The seats will have to be solid mounted, I will need to find an alternative seat belt bucket (which I have an idea were I'm going to get it from ) and my knee still hits the steering wheel when do a heel-toe operation , I'm thinking the Nardi wheel will need to be made into a D wheel later this year.
10/18/07
The pictures I've attached that shows the side blinkers in action really don't do it justice. It looks way better in person.
10/21/07
While I was finishing buttoning up the engine bay, I went ahead and added check valve bypass filters to the BOVs on the currently non-utilized pop-off fittings. Don't want contaminants to get in there.
Got my rear Tein EDFC stepper motors in, it's going to be a tight fit with the cage, but it will fit.
Front bumper is on and starting the process of painting the sleek headlight lens, once I get a contour I like finished.
The Sparcos are super tight and the stock rails will not work. Will have to modify the door panels for sure and maybe the kick plate, seat belt buckle will be an interesting one too. The seats will have to be solid mounted, I will need to find an alternative seat belt bucket (which I have an idea were I'm going to get it from ) and my knee still hits the steering wheel when do a heel-toe operation , I'm thinking the Nardi wheel will need to be made into a D wheel later this year.
10/18/07
The pictures I've attached that shows the side blinkers in action really don't do it justice. It looks way better in person.
10/21/07
While I was finishing buttoning up the engine bay, I went ahead and added check valve bypass filters to the BOVs on the currently non-utilized pop-off fittings. Don't want contaminants to get in there.
Got my rear Tein EDFC stepper motors in, it's going to be a tight fit with the cage, but it will fit.
Front bumper is on and starting the process of painting the sleek headlight lens, once I get a contour I like finished.
11-04-12, 06:26 PM
#88
10/22/07
Sanded and buffed the lens to improve the clarity and it worked. The lens did not exactly have smooth surfaces.
Started to install the hood pins, will have to drill the hood....may have to wait for cut and buff.
Got some stereo equipment yesterday; JL Audio A4300 four channel amp, 5.5 inch Focal speakers, Focal tweeters and a 10 inch MTX Thunder 5500 sub that was a gift from Bobby (Thanks Bobby). Will be making a custom sub box in the now unused spare tire wheel; same with the amp. May also have my water injection tank in the spare tire well as well, but will have to make sure everything is properly sealed.
Sanded and buffed the lens to improve the clarity and it worked. The lens did not exactly have smooth surfaces.
Started to install the hood pins, will have to drill the hood....may have to wait for cut and buff.
Got some stereo equipment yesterday; JL Audio A4300 four channel amp, 5.5 inch Focal speakers, Focal tweeters and a 10 inch MTX Thunder 5500 sub that was a gift from Bobby (Thanks Bobby). Will be making a custom sub box in the now unused spare tire wheel; same with the amp. May also have my water injection tank in the spare tire well as well, but will have to make sure everything is properly sealed.
11-04-12, 06:38 PM
#89
10/28/07
First initial cute and buff done, stereo is being installed and doors being trimmed. Since I need to be out of the shop by the end of this month I went ahead a just added filters for the turbos for a temporary setup. Will be making an air box and the cooling system ducting. All those items will be made outta CF.
First initial cute and buff done, stereo is being installed and doors being trimmed. Since I need to be out of the shop by the end of this month I went ahead a just added filters for the turbos for a temporary setup. Will be making an air box and the cooling system ducting. All those items will be made outta CF.
11-04-12, 07:08 PM
#92
11/2/07
Finished the temporary air filter setup.
11/6/07
Well she's a runner, did my first 100 miles today on the stock ecu. One small issue that scared the **** out of me, but all is well now.
"Cough"
Differential bolt feel out....I didn't install it, but should have check the bolts anyways. Pic's and video's to come.
200 hours! Since when did you work on my car! LOL Bobby, did however and I really appreciated his help, people make mistakes, that's life, so you can't condemn them for it. Though, if it wasn't for you letting me use your shop John, I would have never been able to do this project, so I am truly in your debt.
Here's a sample pic to wet you peoples palettes, need to get to a computer without corporate intranet limitations to put the remaining coast pic's in photobucket.
I can tell you one thing, this thing is eager to rev. It's a good thing I'm running the stock ecu, because it's imposing a good rpm limit leash on me. Really sucks in traffic though.
11/7/07
Okay here you go. Looks like my PowerFC is dead, so I am in need of a PFC soon. Just did the 500 mile oil change everything looks good.
Finished the temporary air filter setup.
11/6/07
Well she's a runner, did my first 100 miles today on the stock ecu. One small issue that scared the **** out of me, but all is well now.
"Cough"
Differential bolt feel out....I didn't install it, but should have check the bolts anyways. Pic's and video's to come.
Here's a sample pic to wet you peoples palettes, need to get to a computer without corporate intranet limitations to put the remaining coast pic's in photobucket.
I can tell you one thing, this thing is eager to rev. It's a good thing I'm running the stock ecu, because it's imposing a good rpm limit leash on me. Really sucks in traffic though.
11/7/07
Okay here you go. Looks like my PowerFC is dead, so I am in need of a PFC soon. Just did the 500 mile oil change everything looks good.
11-04-12, 07:26 PM
#94
11/11/07
Started building the Sub box today. This sub calls out for .75 ft^3, I'm at .69 ft^3, close enough. Have some carbon/kevlar that I will be using as a top layer for some show. Need to finish cutting the top panel and get more resin to finish the job.
Found a used PFC that I bought today, should be seeing it sometime next week. Can't wait to start tuning this thing.
11/14/07
Sub box mostly done, decided to save the CF/Kevlar for some ducting I will be doing and will just paint the sub box once I’m finished with the setup. Need to finish the wiring and make a mounting tab at the spare tire center hold down point. Also need to do some more sanding to get rid of the roughness of the glass work, but so far it’s turning out nice.
Started building the Sub box today. This sub calls out for .75 ft^3, I'm at .69 ft^3, close enough. Have some carbon/kevlar that I will be using as a top layer for some show. Need to finish cutting the top panel and get more resin to finish the job.
Found a used PFC that I bought today, should be seeing it sometime next week. Can't wait to start tuning this thing.
11/14/07
Sub box mostly done, decided to save the CF/Kevlar for some ducting I will be doing and will just paint the sub box once I’m finished with the setup. Need to finish the wiring and make a mounting tab at the spare tire center hold down point. Also need to do some more sanding to get rid of the roughness of the glass work, but so far it’s turning out nice.
11-04-12, 07:27 PM
#95
11/16/07
Got the amp and sub all connected and damn it's nice. If I set it for a fair amount of bass I get a back massage while I'm driving, hehe. Anyways it turned out really nice, just need to finish the sub box. After thinking through it some more I will be using the carbon Kevlar, but will make two storage divisions out of the remaining spare tire well. One of them will be where the AI tank will reside.
Also Finally got my ARC titanium shift **** in, very nice.
Got the amp and sub all connected and damn it's nice. If I set it for a fair amount of bass I get a back massage while I'm driving, hehe. Anyways it turned out really nice, just need to finish the sub box. After thinking through it some more I will be using the carbon Kevlar, but will make two storage divisions out of the remaining spare tire well. One of them will be where the AI tank will reside.
Also Finally got my ARC titanium shift **** in, very nice.
11-04-12, 07:44 PM
#96
12/3/07
Well, I found one of my boost leaks, but I think I still have more. One possible one is at of all places my SARD boost controller, may be auditorial delusion though .
Also started making the plug for my intercooler duct. Need to finish shaping and cover the plug surface with body filler. Once done I will use this to make my carbon intercooler duct.
Need to do the same for the oil coolers, air box and radiator block off plates.
Well, I found one of my boost leaks, but I think I still have more. One possible one is at of all places my SARD boost controller, may be auditorial delusion though .
Also started making the plug for my intercooler duct. Need to finish shaping and cover the plug surface with body filler. Once done I will use this to make my carbon intercooler duct.
Need to do the same for the oil coolers, air box and radiator block off plates.
11-05-12, 01:47 PM
#98
Full Member
Superb work on this, I'm looking forward to seeing how the ductwork comes out.
How has the Teins and the edfc been working out for you? I'm interested in those myself, would you be able to measure how far above the strut tower the edfc motor sits on the rear? I have a cage mount there myself, different than yours, more of a height clearance issue for me.
Richard
How has the Teins and the edfc been working out for you? I'm interested in those myself, would you be able to measure how far above the strut tower the edfc motor sits on the rear? I have a cage mount there myself, different than yours, more of a height clearance issue for me.
Richard
11-21-12, 07:48 PM
#99
Superb work on this, I'm looking forward to seeing how the ductwork comes out.
How has the Teins and the edfc been working out for you? I'm interested in those myself, would you be able to measure how far above the strut tower the edfc motor sits on the rear? I have a cage mount there myself, different than yours, more of a height clearance issue for me.
Richard
How has the Teins and the edfc been working out for you? I'm interested in those myself, would you be able to measure how far above the strut tower the edfc motor sits on the rear? I have a cage mount there myself, different than yours, more of a height clearance issue for me.
Richard
The top of the EDFC stepper motor is roughly 50mm measured at the top most flat surface on the rear shock tower. As far as teins function, they're a pretty good bang for the buck coil-over. Hand they've held pretty good.
Photo from an earlier post, missed a symbol.
11-21-12, 09:20 PM
#100
12/26/07
The car is being prepped for the 500R that will be coming soon. Need to modify and remove redundant vacuum line and control valves. Also received new primary injectors and will be installing soon. Efini's gave up the ghost after one to many 17psi pulls.
The car is being prepped for the 500R that will be coming soon. Need to modify and remove redundant vacuum line and control valves. Also received new primary injectors and will be installing soon. Efini's gave up the ghost after one to many 17psi pulls.