83 GSL COVID revival Project
#1
Junior Member
Thread Starter
83 GSL COVID revival Project
Hello all:
I first posted on this site back in DEC, 2019 to introduce myself (https://www.rx7club.com/introduce-yo...-club-1140791/) with high hopes to get my 83 GSL back on the road soon thereafter. Less than a month later the world came to a complete stop, as I am sure ALL of you know, due to COVID-19. As unfortunate as this event has been for the world (millions of people dead, the world economy is trying to recover and many memories lost with our friends and family), I had to make "lemonade" out of the situation. I began my 2 year-COVID-19 journey to bring "Max" to life. After many significant delays on getting parts and a very, very steep learning curve, I have completed the best restoration I could do within my skills set and budget. Below is a very condensed picture diary of this project.
DEC.2019-JUN.2020:
JUL.2020
JUL-AUG.2020:
I first posted on this site back in DEC, 2019 to introduce myself (https://www.rx7club.com/introduce-yo...-club-1140791/) with high hopes to get my 83 GSL back on the road soon thereafter. Less than a month later the world came to a complete stop, as I am sure ALL of you know, due to COVID-19. As unfortunate as this event has been for the world (millions of people dead, the world economy is trying to recover and many memories lost with our friends and family), I had to make "lemonade" out of the situation. I began my 2 year-COVID-19 journey to bring "Max" to life. After many significant delays on getting parts and a very, very steep learning curve, I have completed the best restoration I could do within my skills set and budget. Below is a very condensed picture diary of this project.
DEC.2019-JUN.2020:
- Rx7 Club introduction (https://www.rx7club.com/introduce-yo...-club-1140791/)
- AE_Racer and mazdaerx713b provided some feedback on how/where to start: compression test of the engine. It sounded really rough...really rough
- After much deliberation, I decided that the engine needed to be rebuilt. I followed the "Mazda Engine Overhaul Criteria" book I found on this site to guide my decision
JUL.2020
- The transmission needed new seals and fluid flush
- The engine had about 2 mm of grime, oil, sand and who knows what else on it.
- Once I had the engine on the stand and started to undo the cake layers, it became very clear that rebuilding the engine was the right decision -- just look at the rear rotor and rear housing :-( -- I was surprised to see that the center and rear irons were not damaged at all
JUL-AUG.2020:
- Once I had my shopping list ready and began my search for parts. There wasn't much out there.
- I finally came across an auction on Ebay of a complete 1983 12A engine an hr away from where I live. So, I contacted the seller and he offered to let me see the engine before purchasing. I went over to his garage (yes, I was wearing a mask) to inspect the engine and decided to purchase it - I did some rough measurements of all the parts before cash was exchanged. He added a few other items to sweeten the deal: carb rebuild kit, fusible links and other miscellaneous parts
- Once I got all the parts back to my house, I began the very time- consuming task of ensuring all the parts met the Mazda spec tolerances.
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gracer7-rx7 (03-25-22)
#2
Junior Member
Thread Starter
SEP-OCT.2020:
NOV.2020:
With all the engine parts ready for assembly put aside, I rebuilt the carburetor and cleaned the engine bay the best I could while I waited for many parts to come - the supply chain really slowed down my progress...weeks and weeks of waiting
- Now that I was happy with all the engine parts being within spec, I started the cleaning, sand blasting and painting process
- I chose high heat paint: metal gray and Mazda blue (not an actual color, but the closest I can get to the air horn blue)
NOV.2020:
With all the engine parts ready for assembly put aside, I rebuilt the carburetor and cleaned the engine bay the best I could while I waited for many parts to come - the supply chain really slowed down my progress...weeks and weeks of waiting
Last edited by luv2rdtrip; 03-12-22 at 02:41 PM. Reason: repeated comment
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gracer7-rx7 (03-25-22)
#3
Junior Member
Thread Starter
DEC.2020-JAN.2021:
Measuring the end play
Engine ready to go back in
Engine going back in the car
- Engine rebuild begins!!!
- Yes, it took me about two months to get it put together as I was being very **** about every step - this is not my field of expertise, so I wanted to get it right the first time - this project is not cheap
- Things that are new - mostly from Atkins:
- rebuild engine seal kit
- apex seals springs, corner springs/seals and side pieces
- side springs & seals
- oil rings
- water pump and thermostat
- belts
- NGK spark plugs and wires
Measuring the end play
Engine ready to go back in
Engine going back in the car
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gracer7-rx7 (03-25-22)
#4
Junior Member
Thread Starter
FEB.2021
MAR.2021:
JUN-AUG.2021:
Driver side exterior
Pass side interior
Driver side finished
Pass Side Exterior
Drive Side interior
Pass side finished
- New parts added before the first start up:
- KOYORAD radiator and hoses
- Exedy clutch, clutch cylinder and hose
- transmission dust boot, release bearing and front/read seals
- I checked the compression in both rotors with the "RotaryCompressionTester" prior to first start up:
- Front Rotor = 108-110-112
- Rear Rotor = 110-112-114
- Since both rotors compressed at above ~110 (I ran the test several times and achieved consistent readings) I finished putting the rest of the engine components to get the car started
- Added some fuel to the tank, sprayed a little starter fluid in the carb, closed my eyes and turned the key...it took a few tries, but on the 5th try, the car came back to life and idled at about 800 RPM after the choke released
- I can't tell you how wide my smile was that night!!!
MAR.2021:
- Now that I knew the car started and the engine ran pretty well, it was time to spend some more cash in phase -2 of the rebuild:
- suspension
- new exhaust system from Racing Beat - it took 7 weeks for the entire system + springs to arrive -- supply chain issues
- interior
- I ordered every single piece of the suspension (front & rear) and changed it all:
- bushings
- springs - all 4 corners
- struts/shocks
- and while I was at it, I also changed:
- brake rotors/pads/fluid
- rebuilt all 4x calipers
- wheel bearings
- tie rods
JUN-AUG.2021:
- While doing the suspension, I noticed two critical parts of the rear that seemed to have an excessive amount of rust. It turns out that the car had what I have seen in several places on this site referred to as: "the rust of death"
- The significant amount of rust is located in the rear wheel wells where the upper arms attach to the frame. I really thought this was the end of my journey until a US Marine friend of mine (OORAH!!!) said he could help me fix it. He gave me a shopping list and he got to cutting, and molding and fabricating and welding...and I was back on track! Thanks again Chuck!
- Once all the welding was done, I used 3M heavy-bodied seam sealer, rustproofed and painted black. I think it came out pretty good...
Driver side exterior
Pass side interior
Driver side finished
Pass Side Exterior
Drive Side interior
Pass side finished
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gracer7-rx7 (03-25-22)
#5
Junior Member
Thread Starter
SEP-OCT.2021:
- Since I had to take most of the carpet off to address the rust, I decided to get new carpeting and add some sound deadening/insulation to the interior - I was surprised how well it works!
- I also took the window motors and mechanisms out to give them a good cleaning and add new grease to the gears. The motors work so much better and faster.
- Added the following new items:
- door seals
- window track seals
- rear hatch seal
- sun roof seal
- door handle cups/covers
- rear hatch glass struts
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gracer7-rx7 (03-25-22)
#6
Junior Member
Thread Starter
NOV-DEC.2021:
reconditioned fuel pump
rust proof andpainted
JAN.2022:
FEB.2022:
- The Racing Beat exhaust system finally arrived and it was time to take the old system off
- I followed all the RB instructions of how to remove the air pump and add the block off plates
- Torqued everything to spec and started the car. Well, here is where all my problems began. I spent the next month or so trying to figure out why the car was now backfiring and I could not get it to idle right.
- I finally reached out to a fellow Rx7 owner on this site (thank you Ralph!) and he has been very helpful in guiding me through some ways to fix the issue.
- In trying to pin point the problem, I changed all of the vacuum lines in the rat’s nest and the carb. that did not help
- I made sure the carb was nice and snug to the air intake. that did not help
- I measured the fuel coming into the carb and I was only getting 300 cc/min - the spec is ~1200-1400 cc/min. So, this is something...
- began inspecting the wiring to the fuel pump and I was getting 12 V at the pump. inspected that the lines were not clogged.
- Changed the fuel filter AGAIN, as I had changed it a few months prior to starting the car after the engine rebuild.
- Retested the fuel flow and it was now pumping 1000 cc/min. Better, but the right flow was not there yet. Since I had to change the filter 2x within a few engine starts, I decided to drop the tank and get it cleaned out and sealed.
- When the tank came back, I also changed all the soft fuel lines
- reinstalled the tank, put on another fuel filter (third in a few months), added 6 gallons to the tank and measured the fuel output again...still about ~1000 cc/min
- I really did not want to take that fuel pump out again, but did it anyway. I gave it a good cleaning inside and out, rechecked the pump leads and at closer inspection, they looked a little "green". cleaned out the leads to make sure they are making good contact and retested the flow. That was the solution...the pump is now pushing ~1200 cc/min.
- I put it all back and started the car. Same issues: backfiring, rough idle and stalling
reconditioned fuel pump
rust proof andpainted
JAN.2022:
- I took some time off to think about the issues I was having with the car and finally decided to put the air pump back and all the other emissions crap and see if that would fix the issue
- that, my friends, fixed the issue. The car started right away, idles at ~800 RPM, does not backfire and does not stall.
- I took the car out for a test drive and the car drove pretty well. I did not push it past 3.5K RPM just to give it some break-in time.
FEB.2022:
- The next item on the list is to buy new tires. I really want to get the Bridgestones with RWL, but we all know that is not going to happen.
- I also need to register/insure the car, but I think I will wait until it gets warmer and there is no more salt on the streets. This car will never see rain or snow again as long as I own it.
- As far as future projects for the car go:
- a paint job - the paint looks good on pictures, but up close, you know it needs some love
- LEDs all around - I feel like I need people to see me since this car is so small.
Last edited by luv2rdtrip; 03-13-22 at 02:29 PM. Reason: Spelling
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kiweenis (03-21-22)
#9
Senior Member
Well done....looks amazing.
I did everything you've done.... except the engine rebuild and the sound deadening . .... currently working on get her started...... hopefully will be done next weekend....
I did everything you've done.... except the engine rebuild and the sound deadening . .... currently working on get her started...... hopefully will be done next weekend....
#10
Junior Member
Thread Starter
I got the sound deadening from Amazon: KILMAT 50 mil for $62 for a 50 sqft box. I used about 1.5 boxes. Make sure you clean the surfaces well before putting the sheets on. Good luck!
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raven12aFB (03-29-22)
#11
NZ, the capital of BRAP!!
Have enjoyed reading your build. Thanks for the motivation on my own. Wife got me to do a laundry room and bathroom remodel so the GSL-SE has been neglected in the garage. Inspired!!
#14
Junior Member
Thread Starter
Thank you! I have learned a lot from many contributors on this forum and wanted to give back with some of lessons learned.
#15
Junior Member
Thread Starter
#16
Junior Member
Thread Starter
Update:
I have put 100 or so *EASY* miles on the car since April 9th, 2022 and kept the car under 50 MPH. Last weekend I took it on the highway for the first time and the would not go over 65 MPH and wanted to stall at that speed. So, I would let off the accelerator pedal and the car would normalize. What could be making this happen? Any thoughts are greatly appreciated.
I have put 100 or so *EASY* miles on the car since April 9th, 2022 and kept the car under 50 MPH. Last weekend I took it on the highway for the first time and the would not go over 65 MPH and wanted to stall at that speed. So, I would let off the accelerator pedal and the car would normalize. What could be making this happen? Any thoughts are greatly appreciated.
#17
Full Member
I could be totally off - but I would look at the secondaries to see of they are opening at higher throttle. I think they are opened with a link that's part of the mess at the rear of the carb - maybe that didn't get hooked up right?
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