More rust :'(

And yes it's thru and thru

Found it when I was trying to weld the lambda bung

 

And an update


dismantled the plate

Cleaned:


Found a good location for the lambda prob cable


:roll: :thumb: :whistle:

 

I had a week of vacation and was going to do some work on it but I did some electricity in the hangar we renting. Now we have enough power outlets and (hopefully) less problems with the electricity.

But I've got 2 nice 5mm plates that needs to be drilled and 1 large piece of 0.8Zincor plate (2x1m, 1 size bigger is 4x2m).

Made also an small "welding" shield holder, for between the cars. Need to drill more holes to make it sizable.

 

Some pictures
First of the plates:

Yes they're to small

Some cutting and grinding


Ow did I mention the rust speed holes right and left
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The first welds are been made

The big gaping hole

Off-course we use cad*

*Cardboard Aided Design :p

 

Ordered some parts

with this result


Yes only 2, I couldn't find the loctite

 

Ordered something different, so I can cut shapes

If someone in the EU want's to order it: AIR Inverter Plasma Cutter 10 50A Current Range 60 Duty Cycle 1 12mm Thickness | eBay

I only need to get the setup right, but it isn't bad.

 

Yesterday evening I stopped with this

First order of the day was getting some packages
Clamps yeeeey, no more gaskets and hard to reach bolts

Damned ordered the wrong ones, need the 2" not 2.5"
And then the rest, I forgot to make a picture of the rounded corner:

I need to put a small hole in it for the safetyguard, but it had already a pilot hole.

 

Did somebody said RUST?
Right box girder

Left box girder


Suspension Point left I used the Spot weld drill.

Cutted and welded

 

This time I was smart, first I made the corner

Then the plate over it

 

That looks good! Should last for quite a while. Have you checked out the rocker panels?

 

Ha rocker panels, yeah I called them girders (google translate) :p I'm only going to fix that I'm seeing now, but when I start digging I can doe the whole car

 

Google translate is awesome!

Mazda didn't really treat the inside of those girders very well. I could see that they only sprayed inside as far as they could probably from the holes in the bottom of them. The factory rust proofing stops well short of the base of the A-pillars and the B-pillars. The bottom of both B-pillars on mine were rotten pretty good and on the donor car they were similarly untreated, but not as rusty.

It's just something to keep an eye out for. You may (or hopefully may not) have any rust there.

Keep up the good work! Love the LED lights you've made and the patch panels look awesome.

 

Today I finished the left side.

Next step the holes in the rocker panels

 

Small modification of the meter unit
opened it up to see if there is room for improvement


The real test with the original lightbulbs

Voltage + current


Leds + current limiter

Voltage + current

* power supply doesn't like low currents
And the rear

I hope is enough light now and else I can still put some extra led's directly under the meter

I'm thinking of putting a small Voltmeter under the rpm meter, space enough

 

Nice! I've heard Mazda rotaries never sold well in Europe. I'd imagine parts are not easy to get then? Especially body panels. Great job!

 

They sold, but not so much as all the rest and if you find 1 it mostly rusted

Ordered moooooore parts (url's are for ebay belgium)
brake hoses*, v-band clamps en Volt meters, also I dropped the gearbox with a revision company :dance: I don't know a price of it but I know that they only can start end September. No problem I first need to get the v-band and brake hoses before the gearbox can go under.

* yes I know it's for the younger years, but I got 2 hoses more then the 81-84 set for the same price.

Anyway Mooooooooore picture's

test of the counter unit with the led back light in the car, if you don't see your rpm needle in the dark its 4k or 8k


modified the mid console again with 5mm plexi, paint is not definitively layer.

 

Yesterday evening I started with modifying the exhaust, I thought it was rvs because they said it was but it's not quality rvs because a magnet sticks to it.

First I tried with the plasma but that's not a good idea so then the band saw:


Fitment, mmmh not good:

so one more cut and then fitment = AOK




Add new heads


Later today or tomorrow there will be a new update, currently it's to hot to do anything

 

and then, I have 2

 

I ordered some7 segment led Voltmeters format small

Why, to build them in the instrument cluster offcourse


The brake hoses are arrived, only 1 small problem: m10x1.25 (old) and M10x1.00 (new) :x pitch

 

Small welding/coating update

Left side


left rear "corner"


right side


I sold my tig because I said to someone: "if you give 350€ for it, its yours", so after some weeks they said ok and I had forgotten it but a buddy said that I said that, so now a new tig is cumming to me (AC/DC 200A) the exhaust must wait a little bit longer.

 

That looks all too familiar... It looks good; you did a great job getting after it.

 

True, all first gens has the same problem, so if you find one that says rust free, take a screw driver and start poking

 

Bought myself a new tig, because I sold the old one with 50€ profit
Old one:
180A DC with pulse: http://lcdvision-schweisstechnik.de/...r-TIG-MMA-230V (I bought it on a ebay auction for 300€)


New:
200A AC/DC with pulse mode: http://lcdvision-schweisstechnik.de/...ne-5-200A-230V

First passes of aluminum

 

Just ordered some brake line adapters m10x (m) to m10x1.25(f) and m10x1.25(f) to m10x1(m) since I ordered the wrong brake line hoses