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-   -   TiVo Rotary Build (https://www.rx7club.com/build-threads-292/tivo-rotary-build-1130224/)

tv4184 09-22-18 01:12 AM

TiVo Rotary Build
 
This build thread is about 7 years in the making. I picked up the car on November 4, 2011. Initially I picked her up to do a track day build so I just wanted a CW and didn't look into the history. I probably should have been a little more patient. Previously a Minnesota car that must have been driven through the winter time, the car had surface rust through most of the underbody, but at least nothing concerning that will damage the frame or body panels. I'll tally the build history in this post as best as I can since it's been 7 years since the majority of the work has been done. I also got to a point where I was ready to sell it and did try to sell it a few years back. At that point, I did part out a few things like my M2 carbon fiber intake and gave my friend my base cloth seats. Another friend got my Stance coilovers and brake track setup (slotted rotors and hawk HP10 pads). This was back in 2016, and I had my car in storage at a neighbors place and then my parents place until I bought my own house last year. Been garaged most of the time I've had her and I was about ready to repost last year but the brake line busted near the separation point in the rear. It took me the better part of the year to get around to fixing it. Took several tries with the flaring tool til my friend said I might be better off getting a new line from Mazda, and thats what I ended up doing. Would have saved like 4-5 hours of work haha. Anyway after reposting the sale ad for less than 12 hours, I re-evaluated everything and figured I might roll with the build for the near future. Thought that if I had remorse and wanted to get back into the FD game, it might be harder down the road. I know that might have disappointed a few people that saw my initial sale thread last night.
Current Installed Mods: PowerFC with OLED commander, Koyo aluminum radiator, Tri-Point Aluminum AST, custom Magnaflow high flow cat, HKS Carbon Ti exhaust, H&R springs on blown stock struts, Powerflex polyurethane bushings in rear suspension arms, Delrin bushings in front suspension / rear diff, Atomic Rex "pillowballs", B&M short shifter, AGM Miata battery in passenger cargo bin

Mods in Storage: 3" mid pipe, Blitz FMIC, Stance GR+ coilovers with 12k/10k Swift springs, Banzai racing rear differential brace, Stoptech F/R slotted rotors, Volk 18" wheels, TurboII Morimoto HID projector retrofit headlamps, Brandmotion Infinity rearview mirror

Mods Planned: 99 front end, Voltex rear wing, LED tail lights, single turbo setup, upgraded fuel system, series 8 transmission or rebuild, new engine harness (OEM or aftermarket), V mount or FMIC, Spirit R seats/RZ seats or base cloth seats

My plans are different now. I've been to a few track events but the time committment wasn't worth it for the amount of time I had to put into prepping the car before and the aftermath. I just want to build a nice looking FD, it doesn't have to be perfect, otherwise I'll be out there looking for another 94/95 base model. That might be in the cards in the future but for now I'll work with what I've got. I just need to clear my garage of excess parts from my track build to get started on my build. I'm already over budgeted for car mods for the year thanks to my 07' 4Runner. For now, though, I do have more than enough parts to work with so I won't need to find much til at least a year from now.

tv4184 09-27-18 06:02 AM

11/05/11-11/06/11 - Intro Part 1
 
In a decision I sort of regret later on and frequently curse myself for, I picked up a second FD RX7 because of my obsession with white cars. If you can't tell by now, I mostly shop for white cars, sometimes settling for other colors depending on the situation. One of these days, I'll learn me some patience and wait for the right car to show up, like my low mileage 5 speed IS300. Shortly after picking up my V8 4th gen, another one popped up with 35k miles at the cost of roughly twice what I paid for mine. :ybrick:

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While still at the seller's garage

So I flew out to Raleigh, where the seller picked me up and we went to the bank for me to get him a cashiers check for the car. Unexpectly, we had to fish a piece of a key out of the passenger key cylinder since that was the only side I could lock the car from. I loaded up my tool box (checked a bag full of tools including my torque bar and wrench), along with my other luggage. Before leaving Raleigh, I promptly made 2 more copies of the keys in case mine broke at any point on the way back. I made the same journey to Asheville like I did with my 4th gen to visit my friends. This was before my friend picked up his own 4th gen.

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Broken key that was fished out

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Spent some time around town visiting local joints that my friend, who had just barely moved there a few months prior to my visit. I also had to dial back in some height because the previous owner had it pretty much slammed. This not only made the ride terrible but it also messed up the front fenders a bit. I'll need to get a shop to fix this in the future, but at least they didn't ultimately become bacon fenders. After a short day and a half trip, I started to make my solo 2 day journey back to Houston.

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12 Bones Smokehouse for lunch

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Thirsty Monk for dinner and a flight

I stopped in Meridian, MS after the first night of driving and stopped at a Holiday Inn Express. It was pretty rough because I ended up doing the Tail of the Dragon three times, which ate 3 hours total. I lost cell signal, this was back when 3G was all the rage, so I had to retrace some steps back to the beginning of the trail to figure out the quickest way back. I ended up having to go back the way I came, hence the third time. Spent only 6 hours on the road because of this slight delay and also trouble shooting a vacuum leak, which was a simple line falling off of a sensor. I did the fix on the side of the road with a flash light and re-installing the spring clip that wasn't in place before.

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Fuel stop before hitting the Tail of the Dragon

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Tennessee border

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Alabama border

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Mississippi border
That concludes day one of the trip back.

tv4184 09-27-18 06:04 AM

11/07/11 - Intro Part 2
 
On day 2, I left early in the morning and made a stop in Louisiana at a hole in the wall for some boudin. This was where the lack of AC in the car started getting to me because of the swampy heat and being mid day. Besides the heat, it was mostly uneventful except for a giant engine on the back of an 18 wheeler. I had the old Minnesota plates on the car the whole time since the car was insured but not registered in Texas yet.

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Holiday Inn Express continental breakfast

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Louisiana border

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Hole in the wall boudin lunch

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Texas border

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One of the few pictures I have of the car with the elusive silver FD and the other cars in the fleet minus the CB7 Accord

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My souvenir from my trip to the Tail of the Dragon. Each car always gets some kind of unique piece to them. I was glad to be home after 2 days on the road and was pretty stoked at the time to swap over all the parts from the old to the "new" RX7. I did note that the car felt loads better, might partly be due to the mileage (85k at the time) and also the freshly built engine. The engine might be questionable because, although it was rebuilt like the previous FD's transmission swap, it was cobbled together with new and old parts. Remember to also note the Minnesota plates, that will come into play later on in my build.

Narfle 09-27-18 12:08 PM


Originally Posted by tv4184 (Post 12303839)
Hole in the wall boudin lunch

Can't get that just anywhere. One of my favorite parts of LA.

tv4184 10-04-18 02:47 AM

11/18/11
 
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Some parts that I had ordered on 10/24/11 prior to picking up the white FD (which was on 11/5/11). Turns out I didn't even need the fuel filter. Looked like someone already did some aftermarket setup for the filters.

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First thing I did when I got her back was to start swapping in parts from the old FD. This was exactly the next day too (11/7/11).

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Went out to Harbor Freight on 11/14/11 to get the smallest shop press they had to start the bushing / "pillowball" replacement project.

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Here's the stock "pillowball" and delrin bushings.

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Barstock I had to get to make most of the weird angles work.

tv4184 10-04-18 02:48 AM

11/18/11 - part 2
 
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Took a few tries after that between my friends and me to push out the first couple of bushings. Took a few trips to the store and iron yard to get the right socket sizes, harbor freight bushing clamps, and iron bars to make the right contraptions to push out the stock / delrin bushings. I think the bar stock I got had slightly rounded edges so sometimes the pressure we had on the bushing from the press would sometimes have the bars go flying. Good thing we practiced safety with goggles and shoes at the time.

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This is the first time I encountered problems where I couldn't get a seized bolt out. The stock bushing just kept absorbing my hammering so I ended up using a hack saw to cut out the bolt. No access to power tools because I was living at an apartment with no nearby electrical outlets. Lived life on the edge working on a car in a parking garage. I used my 3rd gen as a makeshift storage shed for tools and random parts.

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The Powerflex bushings came with some grease but I decided to use Green Grease at the time to grease the bushings. I think I'll probably regrease them with Mobil 1 when I start taking her apart again.

tv4184 10-04-18 02:49 AM

11/19/11 - B&M short shifter greasing
 
The next part I swapped over was the B&M short shifter I got from my friend back in July. I followed another forum member's DIY on how to regrease the shifter. The shifter is known to seize up over time so might as well do it while its out of the car.

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A busted shifter boot is pretty common with the amount of heat build up from the exhaust system and the age. The main side effect from this is the smell of exhaust fumes in the cabin. Most of the time it would be apparant when the car is stopped and less whenever the car is in motion.

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The stock shifter on this car happened to have the Mazdaspeed aluminum bushing. I should have swapped it over to my short shifter but it was more trouble than it was worth at the time.

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I had to drill out the transmission tunnel to get to the bolt since I did the install with the transmission dropped on the old FD.

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Disassembly, clean up, and reassembly was pretty straight forward. The only big deal was to make sure not to lose the shifter springs and magnets.

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Green Grease came in handy again.

tv4184 10-04-18 02:55 AM

11/20, 11/30, 12/1/11 - Steering rack bushings
 
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Next up was the steering rack bushings. Found the usual issues with a car that was lowered more than it should have been. Bent front tow hooks...

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...and trashed sway bar mounts. Also discovered the radiator was meant for an automatic FD. The radiator has the connections for the automatic transmission fluid cooler.

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Removal of the steering rack clamp wasn't too bad. At least I already bought new hardware from Mazda to replace the old one.

tv4184 10-04-18 02:57 AM

Steering rack bushings - part 2
 
The only downside to upgrading to Powerflex polyurethane steering bushings for the FD was that they needed triming. Powerflex makes them square when the stock ones have rounded edges. Superpro bushings actually fit better, but I didn't get them in time so I took out the dremel and spent countless hours trimming away and then test fitting them til they fit properly. Even the Superpro bushings need some trimming, just less because its a small line where the mould comes together.
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The new bushings were more placebo effect than actually any change in feel. Still nice to remove a 85k mile 17 year old set of bushings.
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I'll probably have to regrease these too and maybe recoat that bushing clamp.

tv4184 10-04-18 02:58 AM

12/2/11 - headlight shrouds and shift boot
 
Small workings, painted the headlight shrouds with Rustoleum trim paint.
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Replaced the broken shifter boot with a factory fresh one.
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Also had a nice encounter with the factory alarm. My driver lock is busted so I had to disarm it by unlocking the passenger lock. Gotta refresh the lock set whenever I have a chance to remove the cylinders and find a locksmith that can do it.

tv4184 10-05-18 06:41 AM

12/9/11 - rear toe links & lower control arm bushings part 1
 
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After working on both my 4th gen 4Runner and the FD, these look oddly familiar. The aftermarket replacements for the FD and the long travel kit sold by Metal Tech are quite similar actually. If I ever get around to getting both, I can post a side by side, but I guess thats the thing with suspension parts.

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Ended up ordering some non-powdercoated toe links. I also had the guy sell me a complete set of suspension bolts off a lower mileage FD. I was using some grade 8 bolts from Ace Hardware for about a month until these came in.

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Another trip to Lowes to get a 1.5" socket to press out the bushing in the traction bar. The trick here is to cut off "ears" from the stock bushing so the bar stock can hold the lower control arm in place while pressing out the stock bushing.

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Here's a side by side of the old and new hardware. The old pillowballs were really loose. The new hardware will probably wear out quicker but the miles won't be piling on like before so they'll last long enough until I need a new set. I should have contemplated getting aftermarket toe links and lower control arms but using the factory hardware is always more cost effective though and if I polish up the aluminum everything will look like new.

tv4184 10-05-18 06:42 AM

12/14/11 - toe link bushings part 1
 
It took a combination of sockets available to me, larger ones from Lowes again, and a ball joint service kit from Harbor Freight to tackle the toe links. Some work from the hacksaw was also required.

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The aluminum lined bushing made it more difficult to press out.

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All flaps around the larger bushing had to be removed so there could be a surface to keep the toe link in place while pressing out the bushing at the same time.

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Both the ball joint kit and the bar method did not work for getting the larger bushing out on my first try. I had to throw in the towel and try again a few days later.

Johnny Kommavongsa 10-08-18 09:22 PM

Kudos for all the work. Keep at it.

tv4184 10-08-18 11:25 PM

12/16/11 - toe links part 2
 
After hacking some more of the rubber and aluminum off along with a trial and error of several sockets / ball joint combinations, my friend and I were able to finally press out the larger toe link bushing.
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The new bushing will probably have to be cut off if I ever need to remove it. The polyurethane bushings have a lip that extends around both sides of the toe link arm leaving no room to properly press out the bushing. Next part will be the trailing arms...

tv4184 10-08-18 11:28 PM

12/16/11 - trailing arms
 
Toe links were fun. Taking about 3 separate short days...

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The trailing arms were fairly easy because the previous owner had delrin bushings in so they required very little pressure. The replacement bushing was another two piece, which will be easy to service later on.

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The final product would look nicer if I had the tools to polish up the aluminum arms. That'll be a project for much later.

I'd like to say in retrospect, I would have skipped out on working on the toe links altogether. Aftermarket toe link arms would have retained the 3d movement the stock ones had because I noticed both the Superpro and Powerflex bushings do not flex like the stock bushings were designed to. Now taking into account the time/effort, the replacement arms I had to order, and the cost of the Powerflex bushings for the toe links, it would have been better just to go with the aftermarket toe link arms in the first place. Not to say I didn't enjoy the time I spent on them.

tv4184 10-08-18 11:31 PM

12/22/11 - Depo "JDM" bumper signals
 
I'm not always big on cosmetic upgrades but I did decide to order a set of these on eBay. There was a few weeks delay was mainly due to the seller sending me some MR2 signals by mistake. It's funny because I think I've been buying lights from the same eBay seller since highschool. A set of clear bumper/corner lights both for my old 93' Corolla and first 3rd gen 4Runner.

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I also put in LED 194/168 parking lights instead of the amber light that was included. I initially wanted the smoked ones, but most sites had them for almost 3x the price of these non-smoked ones. I figured if I really want smoked ones, I can do it later on my own. These can hold me over til I decide whether or not I want to do a 99 front end.

tv4184 10-08-18 11:35 PM

12/23/11 - turboII retrofit kit
 
I received this retrofit kit in along with the TRS kit I used to retrofit my 3rd gen. At the time there were 3 options for the FD, one from Sakebomb garage ($$$), one from another forum member ($$), and DIY ($$). I say the DIY option is almost the same as the second option because you still have to get clear headlight housing and the parts to do the retrofit, plus the time involved in getting it done right. Just depends on how much your time is worth.

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In a few years, I might consider redoing this setup with an MLED morimoto projector or just getting a set of RE-amemiya headlights for a sleeker look. The only problems are that RE-A headlights cost ($$$$), out of production, and halogen non-projector lamps. This means a retrofit would be done on some pretty expensive headlamps. The HID retros look and work great, way better than the fluted stock headlamps.

tv4184 10-09-18 12:26 AM

12/28/11-1/19/12: battery relocation project part 1
 
The builder I bought the car from had an Optima red top installed in the hatch area. The car did not originally have a factory spare and I had the seller include it with the purchase. The battery not only took up cargo space but it also blocked access to the factory spare tire area, so the spare had to be carried on top instead of underneath the trunk carpet.

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The factory carpet also had a nice cutout in it after removing the battery.

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I kept the 4 gauge wire they used for the Optima battery. I re-routed the power wire inside the cabin under the carpet and through the firewall. The original route they used was through the fuel tank lid, underneath the car next to the exhaust and up into the engine bay to the factory battery mount. The battery post mount was coupled to the wire using a nut and bolt. Removed the post mount/nut bolt setup and just bolted the positive wire directly to the main fuse. Next thing to do was to modify the cargo bin to take the Miata AGM battery.

tv4184 10-09-18 12:29 AM

1/19/12 - battery relocation project part 2
 
I mostly copied my friend's battery relocation project as far as the tie down method and the use of a circuit breaker. Makes it real easy to service the battery or work on the car without having to actually disconnect the postive from the car.
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I connected the ground wire inside the passenger compartment to the seat belt mounting pount. I didn't take as many pictures of the process but anyone that's done a battery relocation setup would know the basic details.

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Battery was tied down to the car frame using a simple battery strap setup. I'll test the battery voltage from time to time with the terminal wire touching the battery ground. I used a Westco AGM Miata battery from GoMiata. It's been working well for the past 6 years and I keep it connected to a Battery Maintainer most of the time.

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Voltage only looks high because it’s connected to the maintainer.

Future plans include rewiring the engine bay and the fuel pump once I get all the details together. The ground in the engine bay is pretty ghetto looking with the yellow ring terminal. The floating main power source is also just as non-asthetically pleasing.

tv4184 10-09-18 12:31 AM

3/7/11 - M2 intake & XSPower SMIC
 
I decided to do some work with the engine bay with air flow and the coolant system. I decided on an M2 intake, which took a while to hunt down, however it didn't take too long to find one from another forum member. The good thing about rare parts is that someone is always holding on to it and might be willing to sell to fund their new projects.
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Then I also got an XSPower SMIC from a friend in Austin. He spent a good deal of time grinding away the XSPower logo and polished it up. Looks pretty close to an M2 SMIC to an untrained eye.
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The oem SMIC looks like it does very little cooling if anything.

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The only downside is that I didn't realize I needed the Greddy elbow to make this kit work so car was going to be down for a little while til I could make it work.

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Actually if I didn't have the M2 intake box it would have fit fine because I could have shifted it over to fit the smaller connection that was meant for the stock elbow. I should have done more research in the end because I ran into overall fitment issues. My RZ bar wouldn't clear the hot side pipe. I didn't have a proper place to mount my AST anymore after installing this SMIC either. It's not surprising that I used to rush into things before researching. Now a days though I might spend too much time reading and making spreadsheets on information before deciding on anything.

tv4184 10-09-18 12:46 AM


Originally Posted by Johnny Kommavongsa (Post 12306266)
Kudos for all the work. Keep at it.

Thanks for that. Most of these are catch up posts since I didn't post anything when I was working on the car back in 2011 / 2012. I'm almost caught up now though. I have a few more left before I can start actually posting new updates. I haven't done anything significant though besides remove parts because I was about ready to sell the FD like twice, once in 2016 and a few weeks ago...lol


Originally Posted by Narfle (Post 12303924)
Can't get that just anywhere. One of my favorite parts of LA.

Yeah for sure man. I always love eating the local cuisine wherever I go. I make tons of stops on road trips whenever I can to get local craft beers or foods that I can't get back at home.

Narfle 10-09-18 02:27 PM

Do you have a duct? Intercooler wont work without a duct.

tv4184 10-10-18 06:51 AM

3/28/12 - Koyo radiator / Tri-Point AST
 
Decided on the regular flow Koyo radiator. Looked so shiny and new that I almost felt bad installing it into my dirty engine bay. I also went ahead and bought brand new OEM radiator hoses from Ray Crowe.

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This was a time that I wasn't picture heavy and I lost some of my back ups too. The cool thing about the replacement radiator hose clamps were that they came with these red metal ties that you just pull off and they clamp into place. So cool...lol

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I bought an aluminum air separation tank from Tri-Point Engineering to replace the stock plastic AST. They don't make anything now a days but I used to like what FD parts they offered at the time. I never understood the shape of the stock AST being square, seemed like the coolant wouldn't swirl properly to get rid of air in the cooling system. It'd be cool to add something like this to the 4Runner but we don't have any issues with cooling plus a lot of RX7 owners end up deleting this. If you can properly flush your cooling system, you should never have any air bubbles in the first place.

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I also met up with a local forum member to talk about the process for restoring the AC system. He had a pretty cool rotary engined pickup truck with TE37x wheels. He recommended on getting a full MANA set of lines, just in case the ones I had were bad, an extra condenser, new compressor, new expansion valve, and rig up a new drier. The new drier was to replace the MANA drier, which was a pain to find a replacement for. For FDs, there was the MANA (port installed) and a JDM (factory installed) AC setup. Differences were very small but mainly the drier for the JDM setup is very easy to find, while the drier for the MANA setup is pretty much impossible. I guess this is partly the reason why most people just ditch the AC setup altogether. The other reason would be racecar...:lol:

tv4184 10-10-18 06:51 AM

2011 May photoshoots
 
I decided that it was time to clean up everything and do a photoshoot.
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Some last minute touch ups from exhaust carbon build up.

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Exterior was mostly factory, most of the mods were to suspension and engine bay. At least the height was adjustable thanks to the Tokico/M2 coilover setup.

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Also replaced the old PowerFC commander with an OLED commander.

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I liked this shot I did a few days later too. If you're still keeping up, by this time I took off my R1 lip and ziptied on a 99 spec lip to my 94 bumper. A nice side profile of all of my cars at that time.

tv4184 10-10-18 06:53 AM

6/3/12 - paint correction and 99 lip remount
 
At the time, my friend was just starting out with his detailing business so he offered to do a correction and debadge what could be debadged from the rear.

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The SBC RPF1s always looked great when they were cleaned properly.

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I went ahead and fixed the sagging lip. When I first installed the 99 lip, I ziptied the factory holes to the ones on the 99 lip which obviously doesn't line up. So I did the reasonable thing and just drilled a bunch of small holes in inconspicuous areas and just did about 6 zip ties per side to get the lip as close as possible. I plastidipped the lip because initially it was white but the previous owner must have hit something so it had a giant spider crack on the edge. Looks good enough for a track build anyway.

tv4184 10-10-18 07:03 AM

6/21/12 - Banzai differential brace
 
I was still getting some wheel hop, even though I'm only on stock hp and have already installed my new rear end pillowball and poly bushings. I went hunting for a differential brace on the classifieds.

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The PPF nuts were seized, so the studs just came out with the nuts when I tried to loosen them.

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Nothing huge to note, except I was still getting some slight wheel hop so the search for an answer continues. I can tell the rear end has firmed up some or maybe its just a placebo effect. My differential bushings are delrin bushings so I'm sure its not that. I'll have to bring down the differential just to make sure though. I would rather have the new HPP 2 in 1 cradle, but there's still a wait list for that one as well.

tv4184 10-11-18 12:59 PM

7/4/12 - AC refurbishment part 1
 
All the parts for the AC refurbishment came in and I went over to another forums member garage to get started on dismantling the AC plumbing.

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These are a mix of the lines I bought online from Fritz and the lines from my car. One of the lines was weirdly bent. Might have been for an non-stock intercooler setup

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I had returned the SMIC back to stock so I could get at the AC without messing with the nicer couplings from the upgraded SMIC.

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This is why cabin air filters are part of newer cars.

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This was the old expansion valve. This is pretty much it for the disassembly portion. Chunked the deuce on most of the stock lines and some of the new lines. The next day is going to be spent on cleaning the lines for installation.

tv4184 10-11-18 01:01 PM

7/5/12 - AC refurbishment part 2
 
Started off the day cleaning the lines with this AC cleaning spray I bought from the autoparts store.

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Prior to the AC refurbishment, I bought a new medium SMIC setup to replace the XSPower setup. Check out that new SMIC duct. Seems like it'll be efficient.

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Here's the new compressor. It's actually the compressor off of a 93-95 Toyota Corolla. $130 off eBay vs spending $300-400 on an actual RX7 compressor.

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The drier was a retrofit of the stock RX7 lines and lines off of a 1st gen Tacoma. It turn's out the 1st gen Tacoma / 3rd gen 4Runner uses the Denso drier instead of the MANA type. I had a local shop weld the aluminum lines. Turned out great.

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Found some real R12 off craigslist. Held decent pressure. It wasn't perfect and we found out that the schrader valve was bad. Too bad it was after we filled up the system so that'll have to be dealt with later on after I finish my plans with the engine.

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Spent roughly 20 hours refurbishing the system overall. AC works but it only gets super cool while at freeway speeds. Coolant temperature creeps while sitting in traffic or in the city. At least I can leave town with the car if I need to take it anywhere. However, now a days, if needed I can use my 4Runner to tow it with me for track days or if I need to go up to Rotary Performance in Garland.

tv4184 10-11-18 10:52 PM

7/28/12 - M2 medium SMIC installed
 
I moved from the XSPower SMIC to an M2 medium SMIC setup. The fiberglass intercooler duct I installed with the AC refurbishment came from this setup. The new SMIC setup came from allrotor, the same guy that sold me my FD. It just took a while because I was waiting on the Greddy elbow and finding the fabled cast hot side pipe that allows for strut bar clearance.

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Side by side comparison shows a slight difference from the XSPower and M2 SMICs.

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This was pretty much the high point of the engine bay. Only other upgrades would be fuel upgrades, direct fire coils, v-mount intercooler, and single turbo. Not all but at least fuel upgrades would be the next step, behind the scenes upgrade.

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Next up are these Stance XR coilovers on the next update. These are custom valved for the FD with 10k/8k front/rear Swift springs. Received these babies a few days (7/23/12) before the M2 SMIC install.

Narfle 10-12-18 12:23 AM

Yas queen!

gmonsen 10-12-18 05:59 PM

The M2 piece is real history.

tv4184 10-13-18 08:02 PM

8/14/12 - Stance XR install part 1
 
The rear coilover installation went fine..

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Went ahead and replaced some of the old suspension bolts while I was at it.

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It'll be nice to have proper suspension dampening again. Front bushings on the tokico shocks are known to wear out so hammering a seized bushing does nothing except just make it jiggle in place. This is where a BFG would have been useful but I didn't have one back when I was staying at the apartment. I didn't have access to a power saw so I'll be using a hack saw to get it but that won't happen for a few months.

tv4184 10-13-18 08:28 PM

4/10/13 - Stance XR install part 2
 
So 8 months later, finally dusted off the FD and took her to my friends place so we can cut off both front strut to control arm bolts to put in the front Stance coilovers.

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Pretty straight forward, just cut off the strut bolt and chucked the old setup in the trash.

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Although factory settings from Stance has the car pretty low. I can't really tell between the settings on the coilovers. Soft and stiff feel pretty much the same to me.

stevexk 10-16-18 08:02 PM

Bushings were the biggest pain in the ass. I still had wheel hop after coils and that same rear differential brace and bushings

tv4184 10-18-18 01:20 AM

12/5/13 - minor updates
 
Not many updates left before we catch up with the present. Ticked over 90k back in 8/23/13.

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Then I moved out of my apartment back in November 2013, so I had to arrange to leave my car at my friend's house for long term storage.

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Bought a few supplies (12/5/13) to get the brakes ready for track weekend in December of 2013.

tv4184 10-18-18 01:21 AM

12/8/13 - front brake job
 
For a combo of track / street use, I just went with Hawk HP Plus pads with slotted Stoptech rotors. I didn't really think there was a need for larger rotors / BBK calipers like I did with my 3rd gen and 4th gen 4Runners mainly because the stock system felt pretty robust already.

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Ran into some issues trying to break the rotor off of the rusty hub.

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Pads were almost done.

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I like the bite the slotted rotors give. Prefer them over crossed drilled, which was what my RS4 had and my CTR has now. The calipers have seen better days though and looks kind of off with the shiny new rotors. I'll be doing a complete rebuild in the future of the calipers and probably new finish as well. Not sure what color I'll go with though, I already have red on the CTR and 4Runner so maybe black or blue. I was also debating on rebuilding these calipers or just buying rebuilt ones from NAPA or RockAuto.

tv4184 10-18-18 01:41 AM

12/9/13 - rear brakes day 1
 
The rear brakes were a bit of an ordeal. The passenger side gave me some hell taking 2 days to finish the job.

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Check out that crusty goodness.

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Ended up snapping the passenger side bolt that holds the caliper in place as well.

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To end the day, I couldn't get the piston all the way in with long needle nose pliers. Must be some kind of seizure of the piston going on. All I know is, I spent 4 hours going no where and the sun was already going down. Good thing I wasn't in my old apartment parking garage.

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The work on the driver side on the other hand went fine. I should always know that things won't ever go smoothly on this car.

In retrospect, I could have probably left the rears alone since I needed the car up and running for the track day. These setbacks almost cost me my track weekend.

tv4184 10-18-18 04:16 AM

12/10/13 - rear brakes day 2
 
Third day working on the brakes now. Reminds me of my recent venture with the 4th gen, taking 4 days to change out almost all braking components. I pray that the hard lines aren't rusted through like what happened later on with the FD.

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The piston refused to go in, even with the rental tool from Autozone.

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Next up was to drill out the seized bolt. Just cutting through the threads was enough to loosen up the bolt from the spindle. I can't remember if I tried hammering it with a BFH though. I learned alot more with my recent brake work on my rusty 4th gen.

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Fluid looked pretty bad. The rears looked just as bad even though it came out a bit more golden brown.

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The aftermath with all the rust and metal shards that came out from all the work. The new pads have that nice sporty noise that sporty pads have on BBKs. Unfortunately, I can hear the rear passenger brake binding a bit on the freeway, which eventually went away. I'll have to try to rebuild the caliper and if that doesn't work, buy a new one. My friend was telling me to do some soaking in vinegar to get the crustiness off the caliper before rebuilding.

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The car had been sitting for a good while, so I borrowed my friend's battery tender to top it off for my road trip to MSR Cresson.

tv4184 10-18-18 04:48 AM

12/13/13 - alignment / inspection / semi-detail
 
Took her over to brake check for one of those nifty lifetime alignments.

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Turns out I wasted my money because the steering adjustments were all powdercoated like the toe links. They were frozen in place so I'll have to replace them before I can get them properly adjusted. I'll also go to a shop that specializes in alignments for lowered cars. Brake Check just doesn't cut it for this type of work. The guy also messed up and bumped my lip on the end of their alignment rack. Good thing for plasti-dip.

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The next stop was to get the car track inspected.

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Then I had my friend do a semi-detail, even though the track day will just dirty her up again. Needed a nice wash either way.

tv4184 10-18-18 05:29 AM

12/14/13 - MSR Cresson weekend
 
This would end up being my first and only track weekend in the car. Not because the car wasn't up to the job. More on that later.

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Saw some interesting cars out there.

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Including some other FDs, with one being an LS swapped.

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My instructor they paired me up with had a first gen RX7. I didn't get a chance to do a ride along because he didn't have a passenger seat.

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Also turns out the wash before the trip was virtually pointless. Dallas had an ice storm the week before, so I ended up kicking up a lot of salt/dirt on the way to MSR Cresson. I also had an off and luckily did not roll the car in the dirt :lol:

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This was the last time the car was driven any discernable distance before being put into permanent storage for the next 5 years. My friend was nice enough to drive her around every 2 weeks for me while he had her. I drove her on my own once I moved her closer to my parents house.

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By the end of the weekend, I could tell it was pretty good on the track with no brake fade and rotated around corners quite well. FD was very easy to drive. As you can tell, temps stayed within range after 7-8 hard laps. Attribute it to the cold weather but I'm sure all the cooling mods did what they were supposed to. The only thing that bothered me was the time commitment to keep up with the car between track days and spending a whole weekend away to go to the track weekend. I just figured it wasn't for me because between the car hobby, I started to travel more and picked up snowboarding. All the expensive hobbies started to add up. This is when I started to think that my journey with the FD was coming to an end. The brake job ended up being the last major upgrade I did to the car because after this I started to do a part out.

tv4184 10-18-18 06:38 AM

2014/2015/2016/2017 - mash up of updates
 
I'm just gonna mash the next few updates into one post. The only thing I did in 2014 was an oil change. First time I did a semi-long drive in the car since the track weekend, besides my friend driving it around his hood.

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I also got around to finally taking off the track day stuff roughly 4 months after going to the track. It all came off pretty easily though with no damage to the paint.

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In 2015, I moved the car down to Sugarland. My friend has a red FD that I had passed on when buying one. It was the only base model I ever found. He got lucky because this was when I started to part out the car, so he got my slotted rotors and semi-new HP Plus brake pads.

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A month later in February of 2015, I removed the M2 SMIC with the intent to post it for sale but never got to it. It's still boxed up at the moment on my list of things I might sell. My other friend also got my base cloth seats.

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I moved the car to my friend's storage facility, where he stores peoples sports cars and keeps them running as part of his storage fee. In June of 2015, I removed my turboII projector setup and the CF M2 box. I ended up at least selling the M2 intake.

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No huge updates in 2016. I took a trip to Japan for the first time and at the Sega "theme" park, they had a full on car Initial D game where you sit in the car and the car moves around as part of the game play. It was pretty neato. I waited for the FD for my turn.

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I also went on a tour of the Mazda factory. I got to see the assembly line for the ND Miata and the portion where they install the windscreen. The automation process was pretty awesome. They didn't allow for any cameras in the assembly area but I did get to see some pretty cool rotary lineage, including the 4 rotor racing car and a hydrogen rotary powered RX8.

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Here's another oil change in April of 2017. Don't worry I did one in 2016 too, I just don't always take pictures of oil changes.

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A few months later, I bought my house and moved in July of 2017. First house and I at least wanted a 3 car if not 4 car tandem garage. Settled for a 3 but I could definitely use a 4 car tandem for the project work. Having the work space is definitely a nice update. I had the car towed because registration had long expired back in 2016. I'm basically waiting now until 2019 for when I can register the car as a classic. I have one more semi-major update before I talk about future plans for the build.

7_rocket 10-21-18 03:55 PM

Great build. Where did you get the clear lens for the projectors?

tv4184 10-22-18 07:54 PM


Originally Posted by Johnny Kommavongsa (Post 12306266)
Kudos for all the work. Keep at it.

Thanks bro, it was a lot of hours pounding rust and laying in the parking garage back in the day.


Originally Posted by 7_rocket (Post 12308748)
Great build. Where did you get the clear lens for the projectors?

They're Sonar RX7 headlight housings. I didn't do the retrofit though I got mine from turboIIrotary. You can see his work here retrofit. Although you've seen it on my thread too.

Detailed how to here though: Retrofit How-To


Originally Posted by stevexk (Post 12307887)
Bushings were the biggest pain in the ass. I still had wheel hop after coils and that same rear differential brace and bushings

Yeah they are. I got lucky most of mine were delrin bushings so I didn't have to deal with the aluminum sleeve. I plan on adding the HPP 2in1 brace though. And I also have the front bushings to do...yay me.


Originally Posted by gmonsen (Post 12307068)
The M2 piece is real history.

Which one? They all seem pretty real history now haha. I miss my M2 intake though but it wouldn't work in my future setup anyway. Looked real blingy when I had it though. I like tiny bits of CF in an engine bay. My RS4 had like a tiny cover over the oil filter. Really made the engine look good with the red valve covers. I'm not sure what I'll do with the FD bay yet though.

I still have one more update from this past year to post before moving on. Not many pictures to add but lots of frustration that added to my desire to sell. Thanks to all the forum members comments on my sale thread though, it did make me change my mind in a hurry.

tv4184 12-06-18 05:53 AM

2/2/18 - suspension downgrade
 
This will be the last update in reference to past events. My friend came over to swap out my Stance / Swift spring coilover combo for his stock / H&R spring setup. I had agreed to this initially because I had planned to sell the car shortly after removing the suspension. I was going to sell the coilover setup afterwards because my friend had already bought some DFV Ohlins for his so he wouldn't have been needing the Stances anyway.

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The H&Rs sit way lower than my Stances did. I do plan on just putting the Stance coilovers back on, now that I decided to keep the FD. Couldn't justify going out for some HKS hipermax or DFV Ohlins.

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The mileage is still semi low for a 24 going on 25 year old car. In a month, I'll be able to register the car as an antique vehicle and be emissions exempt in Texas. My registration has been expired for the better part of 3 years now. That's pretty much it for the build up and semi-break down of my build thus far.

tv4184 12-06-18 06:22 AM

12/6/18 - updates
 
I decided that I'll make a small update today, the eve of me trading in my CTR for my new daily. Two months ago I picked up a box of brake service parts from a guy on the Facebook RX7 marketplace. It is nice that there is so many avenues of finding parts, but then again you have to be pretty diligent to find good deals. The guy included some speedbleeders, hawk HP plus pads, and front / rear Stoptech SS lines. Going back down the path of focusing on suspension and brake mods. I need to source some new rear calipers, my current ones are pretty frozen.

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He also threw a couple of other parts in the box including a Mazda coolant level sensor. Then I also got in some replacement bolt hardware to replace the rusty bolts on both the FD and my 4Runner. At the same time a Mazda keyring came in overseas courtesy of eBay.

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Looks great, very racer-ish looking.

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Next up, I just got in my HPP 2-in-1 diff brace / cradle last week. Looks very crab like. I'll be installing this maybe next week along with a couple of exhaust mods that have been waiting for a while.

Johnny Kommavongsa 12-07-18 07:44 PM

Cool that you decided to keep the car.

We have similar taste. I DD a blk 3rd 4runner and have a blk FD.

My wife's has a CW FD on RPF1s, lol.

You said your AC still doesn't work all that great? You gonna try change anything to get it to work better?

What's next after the parts install?

tv4184 12-08-18 08:26 PM


Originally Posted by Johnny Kommavongsa (Post 12317923)
Cool that you decided to keep the car.

We have similar taste. I DD a blk 3rd 4runner and have a blk FD.

My wife's has a CW FD on RPF1s, lol.

You said your AC still doesn't work all that great? You gonna try change anything to get it to work better?

What's next after the parts install?

Haha it's probably almost the perfect combination. You have a practical daily driver plus a fun weekend toy. Dang 2 FDs...that sounds pretty awesome. I should have kept the RPF1s. I sold them a few months ago.

I haven't tried anything as far as my AC goes. I already replaced the expansion valve when I did the system overhaul. Only things I can try to do is replace the heat exchanger and the schrader valve. After that I can recharge the system. I'm sure the system is evacuated now because the schrader valve was busted when I charged it with R12. I'll have to settle for ES12a this next go around.

As far as future plans, I drew up a slight timeline and preliminary build of parts. At least plan on updating to 99 front end, some kind of vented hood setup, Recaros or Bride seats, upgrade the fuel system (new pump, injectors, rails, regulator), delete the emissions / airpump, have the 5th gear synchro fixed. Long term I do plan on going single with either a Turblown or Gleaseman manifold with an EFR8374 setup. Probably plan on changing out my PowerFC for an Adaptronic setup and getting the IGN-1a direct fire as well. Engine mods alone are tallying almost up to the price of the car itself...lol I think that's why I shelved the build 5 years ago in the first place but now with the new house, I have space and time to do things right. I'll probably do everything in stages so I'm not taking a huge hit all at once.

tv4184 12-08-18 08:36 PM

Not a real RX7 update but this past Thursday I traded in my CTR to Tesla for a new Model 3.

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Between not having to make regular gas station stops for multiple cars and the enhanced auto pilot features, it was a better move to have this supplement my 4Runner as the daily. I figured having the IS300 / RX7 was enough to satisfy my tuner car / manual transmission needs. Eventually once I build the FD to daily driver-ish status then I might make that hard decision on whether I should keep the IS300 around. Feels that the IS300 would be too redundant, that the manual FD would be more fun and the sedan form would be fulfilled by the Model 3.

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I got one last farewell group picture before bidding farewell to the Type R. It is arguably the best combination for daily driver / fun / practicality in one. If I was a normal person and didn't have multiple cars, that would be the one single car I would own. It's funny, my delivery advisor was like a bit shocked and questioned my decision for trading in the CTR for the Model 3. I'm sure they took it around the block for a spin. In the end, the safety features / accident avoidance was what sold me in my decision. Anyway, hopefully my next update will have something more exciting in relation to the FD build.

tv4184 12-09-18 05:53 AM

Not a real FD update but I traded in my CTR the other day to Tesla for a new Model 3.

https://uploads.tapatalk-cdn.com/201...4eecbf4b00.jpg

Between not having to make regular gas station stops for multiple cars and the enhanced auto pilot features, it was a better move to have this supplement my 4Runner as the daily. I figured having the IS300 / RX7 was enough to satisfy my tuner car / manual transmission needs. Eventually once I build the FD to road worthy status then I might make that hard decision on whether I should keep the IS300 around. Feels that the IS300 would be too redundant, that the manual FD would be more fun and the sedan form would be fulfilled by the Model 3.

https://uploads.tapatalk-cdn.com/201...417f3e679a.jpg

I got one last farewell group picture before bidding farewell to the Type R. It is arguably the best combination for daily driver / fun / practicality in one. If I was a normal person and didn't have multiple cars, that would be the one single car I would own. It's funny, my delivery advisor was shocked that I would trade in the CTR for the Model 3. I'm sure they took it around the block for a spin. In the end, the safety features / accident avoidance was what sold me in my decision. Anyway, hopefully I'll have a more exciting update next time in relation to the FD.

gmonsen 12-09-18 12:50 PM

Continued nice work on the FD. Still a bit confused about Tesla's and other electrics. :)


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