Ok, so I`ve owned my RX7 for about 16 months. I`ve only had it running for 2 of those months. Kind of bad luck I guess. So after the last engine went boom, I though I would do a full REAL build and restoration.

This is my car in it`s former glory...





I started a while ago, so here are some copy pastes from BCRotary.com. I`ll keep updating as things progress.

Rotary rebuild commence! .... again


(October 4th)

Got lots done today

First I spent 4 hours cleaning and organizing my garage.

Then I removed the whole turbo system (unfortunately the exhaust wheel needs to be replace due to damage from apex seal shrapnel), intake system, SMIC, fuel system and un bolted the transmission.

Engine should be out by next weekend.

 

Progress Report - Oct 07 2009


After a solid hour of work today, I managed to get quite a bit done. If you know me, you know I tend to procrastinate and not work for very long before taking breaks ... since I know the cold is on it's way I want to get the old block out and new one in as quick as possible.


Removed the following
-PS pump
-AC pump
-coils
-LIM
-Fuel rails
-undid the wiring harness (broke a few clips along the way)


The block is basically ready to come out. All I have to do is disconnect the pull-type clutch (a big PITA), drain the coolant and oil.



My "work counter" (old deep freezer ). LIM, UIM, Manifold, DP, Wastegate, Turbo


Engine bay as it sits now



My torn apart interior


The space I have to work with (note: I've already completed one swap in this garage). I have to have the car outside to pull the engine, so this is the reason I want to get it done ASAP so I can keep the garage door closed and stay toasty .

 

October 26th

wham bam shazam...

Had some fun today. Got all messy and oily..

Engine is out... and now comes the fun part of taking the flywheel nut off *headbash*











All cleaned up for the day...




New engine is ordered and being built by David at Rotary Rebuild Store. Small intake port and just cleaned up exhaust ports to keep the spool up. ALS 2mm seals going in. Should be ready by December..

Also plan on ordering the RX7Store.com V-Mount kit, fluidyne large 3`` thick oil cooler, PFC, misc gauges (PLX digital for one of them)

Other things I`ve been stockpiling
-Okida Plasma Booster (like HKS Twinpower)
-ALL the Mazda gaskets I need for the swap
-Coil relocation kit
-Spark plug wire kit (to make proper length wires)
-New engine harness modified for Single Turbo

... and other misc things like oil pan studs, fast reacting AIT sensor etc..

 

December 15th...


Did a bit more work...

Pulled shortblock apart and inspected. HUGE gouge from the apex seal. Rotor and housing are both fubar'd.

Pulled front bumper off/rebar , pulled out radiator, and a few other small things.

Cleaned up a bit and prepared for the new shortblock arriving soon. I also went over all of my bolts and brackets etc. and made sure they were all labeled for easy assembly.

Good Shortblock Parts


Front bumper...

Found a nice storage place for it



Like my sweater?

 

TODAY!... Dec 17th..

Busy evening.. did a few things.

Started with removing the oil cooler, power steering rack + pump and lines which led to removing the A/C condenser + pump/lines....


good riddance mr. PS pump. won't be seeing you anymore


steering rack... going to do a full manual conversion on this thing when I get a chance.


The engine bay looks so empty....


parts are starting to pile up.


the obligatory am I in over my head pic





so tomorrow I'm going to pull the trans and the subframe. I was going to have it powdercoated but I think a few coats of some good engine enamel will do.

 

So basically where I am right now...

Subframe is coming out, tranny is coming out. I`m going to undercoat the underbody and clean the engine bay really well.

Engine is finished (courtesy of DJSeven) and I just had the cheque made up today.

 

Good luck with the build hope this one works out well for you so you can enjoy that beauty.

 

Nice!

Its going to look real good when you clean up that engine bay.

 

good work so far! thats a sweet wolf sweater too

 

nice job! I can't wait to see some finished engine bay pictures, and I want to see how clean your underbody will look after this! haha! Good luck with everything buddy!! Do keep us up-to-date with things!

 

Looks like you are well on your way. I think you'll be happy with the engine from David. See my signature for results

 

I've heard nothing but good things from his engines so I'm super excited..

As for the engine bay I'm going to clean that thing with a fine tooth comb. I was going to have it repainted but it's in really good shape and my touch up paint should fix a few small chips here an there. As for the underbody, the whole tranny tunnel and underbody is going to get coated. There is not a hint of rust on it since it was a Cali car and I want to keep it that way.

I'm also removing both subframes as well as the suspension components and having them all cleaned up/painted/cleared. I will also coat the wheel wells.

When you're a bit low on cash for parts it's amazing what you can find to do for cheap!

 

 

Some more updates.

Today I removed..

-Transmission (more of a PIA than I thought it would be)
-Driveshaft
-PowerPlant Frame (this is what causes issues)
-Engine Subframe

I started removing a bunch of the heatshielding in the transmission tunnel to clean them and prep the surface under it for some rubberized undercoating

Before I can really do much more I have to deal with re-coating the subframe and putting that in. Otherwise I can not roll the car outside to clean the engine bay and underbody.





PIA transmission with the PPF.


diiirty subframe is out.


sooper aggressive alignment...

 

Men good luck with the build. Looks like you have a lot ahead of you.

 

Awesome!

 

Good luck, and a great looking build. I know you Canadians are a hearty bunch but barefoot in a garage in December!! It has been single digit cold down here in MA. Just keep thinking of how nice it will feel to be out on the track!!

Jim

 

This is a great build thread. Awesome pics of the part madness... LOL

And yes, the Wolf sweater is a keeper.

 

Man that looks so fun!!!

 

Taking everything apart isn't bad, but re-installing it all is the fun part

Btw, my GF said you look like you're from 1980 with that wolf sweater

 

lol, yes that's what I'm worried about. I've been very diligent to label everything and take pictures along the way. So I think I'll be alright..

As for updates.. I got dirty yesterday with the de-greaser on the underbody. It's amazing how clean you can make it look! It was all red again. I coated the transmission tunnel in gravel gaurd and cleaned all of the heatshielding and re-installed. I also cleaned the transmission and engine subframe, prepped it for paint.

I'll post pics later.

 

So here's a quick shot of the trans tunnel. my camera died so I only got one pic. It was really clean under the heat shielding so cleaning it wasn't that hard. I POR15'd the few spots of bare metal and then coated it with gravel guard. VERY happy with how it turned out. It will keep my car rust/corrosion free for many more years.

I'm doing it in stages... so I only have the transmission tunnel done thus far. I need to clean a few more spots before coating the res.

I'm going to re-do the line where it turns to red. Didn't quite like how that turned out...

 

Has anyone removed the plastic skid guards ont he fuel lines and left them off? Mine are pretty haggard... I'm going to see how much new ones cost. Shouldn't be too much I guess.

 

Some photos of my engine from DJSeven for your viewing pleasure.