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While I wait for a water pump and Oil Pressure Switch to arrive I figured it was time to lock it the dash placement. Little bit of trimming on the dash to avoid the OEM mounts, but not as much as I thought there would be. I made two alloy stand off brackets for the LHS & RHS of the car and will use the OEM centre point to pull the dash down towards the windscreen as it sits a little proud at the moment. So it now mounts in 3 positions and then once I confirm the Centre Console it will have another 2 mounting points there as well. :)
Super happy with how it looks with the S15 Cluster in place now too. Handbrake will need to be relocated to the driver side to match up to the S15 centre console but I'll leave that for another day. I also put the Modified VSS into the S5 Gearbox! It fits, seals and uses the OEM hole on the FD transducer.... So that's a win... Now to see if the bloody second hand item works! hahaha And last job of the day was just a quick tidy up and finalise the ECU install into the OEM Casing. Could have done it a bit better but it'll work to keep it secure & stop passengers stepping on my it :) https://cimg5.ibsrv.net/gimg/www.rx7...cfa1a07d38.jpg https://cimg6.ibsrv.net/gimg/www.rx7...f479773281.jpg https://cimg7.ibsrv.net/gimg/www.rx7...f0daacb47d.jpg https://cimg8.ibsrv.net/gimg/www.rx7...a75a8f42d2.jpg https://cimg2.ibsrv.net/gimg/www.rx7...228fdab0b8.jpg https://cimg9.ibsrv.net/gimg/www.rx7...bf89b7169c.jpg https://cimg3.ibsrv.net/gimg/www.rx7...48abe37f74.jpg https://cimg0.ibsrv.net/gimg/www.rx7...0968b6698f.jpg |
Quiet weekend.
I thought I would quickly rip the Water Pump Off the car just to inspect it and see if there was anything sinister than needed attention. Everything looks good apart from having no gasket..... Bit of anti-seize on all the bolts and fresh gasket goo so I'm a bit confused as to why it failed. All good though, new one on the way and I'll throw this one in the bin. Also got to do some Aesthetic work today.....test fit some wheels! So much love for the CR2P's! .... Unfortunately they aren't mine and they are way too big unless I want to run a wide body... and even then the 10.5+18 is too big for the fronts. ahahah Still look porn though! http://www.ausrotary.com/images/smilies/icon_smile.gif https://cimg9.ibsrv.net/gimg/www.rx7...702ed1e59e.jpg https://cimg0.ibsrv.net/gimg/www.rx7...fa03aaaf7e.jpg https://cimg1.ibsrv.net/gimg/www.rx7...4e34b3f45f.jpg https://cimg2.ibsrv.net/gimg/www.rx7...caffb1855f.jpg |
Those New Water Pump Feels! hahaha
Shout out to Kevin from Mazcare at Coopers Plains! Absolute legend. He asked me about ten times if my water pump was an S5 and every time I replied "Yes". Got it home only to discover my car is an S5 Engine/Gearbox with an S4 Pump Assembly! http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif ... Do your damn research Ben. Thankfully Mazcare were kind enough to swap it over, no harm done, although I'm sure I'll be on the wall of shame for ordering wrong parts! Also managed to tax an Oil Pressure switch from a mates Evo 7 that I can use for my new cluster and block that hole in the block... just need a 1/8" BSPT --> NPT adapter. And lastly I got some new spacers lasercut the correct PCD. The old ones were a "universal fit" but were so sloppy I'm not sure how safe they really are, or what they are actually good for?? ... not a fan of using spacers but 5mm won't hurt until I can get some correct offset wheels. https://cimg3.ibsrv.net/gimg/www.rx7...e587fd25d7.jpg https://cimg2.ibsrv.net/gimg/www.rx7...53ef1da5f4.jpg https://cimg4.ibsrv.net/gimg/www.rx7...33d1295fb8.jpg https://cimg5.ibsrv.net/gimg/www.rx7...ab8be54cb5.jpg |
The 5 P's!!
Seeing as though everything on this car seems to take triple the time.. (Might be the shed beers slowing us down hahaha) I decided to get a head start on labelling the S15 Cluster and the Reciprocating RX7 wires so we can have a functioning dash next weekend for when it will move on it's own steam! One thing I've learned.. All Electrical people must have a mild form of aspergers... http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif I can fumble my way through it but I'm glad I have my own rain man to help me out with this shit. https://cimg8.ibsrv.net/gimg/www.rx7...d044dedac5.jpg https://cimg7.ibsrv.net/gimg/www.rx7...53818da84d.jpg https://cimg9.ibsrv.net/gimg/www.rx7...96be805db5.jpg |
News on the Muffler front.... Not one to shy away from my mistakes and this is certainly one of them... Moreso for my wallet.
The Rotaflo I bought arrived in a less than ideal condition but I figured I could bring it back! Re-weld the Hangers, Bit of Sandpaper and a lick of paint... But the minute I started with the grinder it lit itself on fire and the internal muffler stuffing or leaves, or god knows what just internally combusted. http://www.ausrotary.com/images/smilies/icon_sad.gif No chance I can risk putting that on the car.. Downfall of Online Facebook Market Places, I quickly purchased a stainless steel Muffler without even checking the sizing... 2.5".... FARKKKK.. OK, No Drama, I'll have a crack at turning this thing into a 3" so I cut the end off only to realise I screwed up and it would take a lot of effort to actually convert this thing into a 3".... Perforated Pipe, Fully Welded front and Back.. FAIL.. On a positive, I now understand how mufflers work http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif So as it stands, the car is now a Straight Pipe 3" http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif Until I order the AES or a temporary one until I can afford an AES. http://www.ausrotary.com/images/smilies/icon_wink.gif https://cimg3.ibsrv.net/gimg/www.rx7...9642933e20.jpg https://cimg0.ibsrv.net/gimg/www.rx7...54a45abfcf.jpg https://cimg2.ibsrv.net/gimg/www.rx7...6bac870946.jpg https://cimg1.ibsrv.net/gimg/www.rx7...d8b0687379.jpg |
Last update , New Water Pump is installed and also the Evo 7 Oil Pressure Switch... Same BSPT thread as the Mazda so that's a big win, saved me $20 on Aeroflow fittings. http://www.ausrotary.com/images/smilies/icon_smile.gif
https://cimg8.ibsrv.net/gimg/www.rx7...b212385f6c.jpg https://cimg6.ibsrv.net/gimg/www.rx7...b75cbdc380.jpg https://cimg7.ibsrv.net/gimg/www.rx7...3fbcaf5f49.jpg https://cimg5.ibsrv.net/gimg/www.rx7...a8ac7d46e4.jpg |
Some final continuity testing on the S15 gauges/stalk before we kick off with the soldering tomorrow. This stuff is pure wizardry and still amazes me. http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif
All going well I'll post up a video tomorrow with the Gauges working & the green unicorn moving on it's own steam.... touch wood. https://cimg0.ibsrv.net/gimg/www.rx7...1a73c7fc3c.png https://cimg1.ibsrv.net/gimg/www.rx7...a3901985bd.jpg |
She's ALIVE!!! .....and very bloody cranky! http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif She's going to be one mean bitch once the tuner is done with it.. Get her ready for QR Rotary Revival in November.
Big Thanks to Kypreo & Bumpstart for the priceless advice they've given on this build the last 12 months. It's the only reason I've kept some form of momentum going and I'm super grateful they offer their advice freely. http://www.ausrotary.com/images/smilies/icon_smile.gif The car fired up with a bit of light throttle on the old E85 Tune and immediately sounded like a Bridgeport http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif Quick run around to discover we had plumbed up the Microtech and FPR to a pressure source on the UIM not vacuum. Quick check by putting my fingers over the ports to see which one was vacuum, plumbed them back in and voila... she started to Purrrrrr... That sounds more like a street port! Bit of smoke from the greenkeepers oil but it was gone within 10 mins of running. It's definitely WAY too loud with that Straight Pipe but that's an easy fix.... I love it and I can't wait to smash some boost into it! |
First of all huge thanks goes to my mate Rob for being as crazy as I am and entertaining me on this whole Dash Conversion. He was on Deck all weekend lending a hand and smashing out the wiring.
The Dash looks great and 80% of the OEM functions are working via the new S15 Stalk and Cluster & bonus is it's all via the OEM plugs too! I love it and I'm not going back (I can't now anyway if I tried) In hindsight, I should have just put the FC Dash back in and taken it to the Tuner to enjoy the car.. The S15 Dash can be fit/modified within 10 mins....The wiring is a MASSIVE ball ache and unless you are Russell Crowe from the Movie a Beautiful Mind... then just save yourself the headache and sleepless nights. hahaha Now for me to tidy up the Charge harness, Weld a muffler & maybe a hotdog resonator, New Overflow bottle and it's ready for a trailer to Matt & the dyno! http://www.ausrotary.com/images/smilies/eusa_dance.gif http://www.ausrotary.com/images/smilies/eusa_dance.gif https://cimg4.ibsrv.net/gimg/www.rx7...6025c9955a.jpg https://cimg7.ibsrv.net/gimg/www.rx7...0326345496.jpg https://cimg8.ibsrv.net/gimg/www.rx7...ebfab0a510.jpg https://cimg9.ibsrv.net/gimg/www.rx7...5746d89dcc.jpg https://cimg5.ibsrv.net/gimg/www.rx7...f1c1d05da4.jpg https://cimg6.ibsrv.net/gimg/www.rx7...b53a1d3e8f.jpg |
Long time no post... Still been working hard in the background trying to get this car ready for Rotary Revival.... maybe had a sneaky weekend off in there to rest.
Welded in the new muffler and honestly, I don't mind the sound. Will still need a hotdog resonator but definitely a lot nicer than the straight pipe! :) For anyone having a crack at home, don't do what I did and use 3.2 rods on 1.6 wall thickness... it sucks.... got the job done though ;) https://www.youtube.com/watch?v=6qYc...ature=youtu.be Also it seems that fibreglass wrap on the exhaust and the paint on the exhaust manifold came back to haunt me after all.... Been turning key most days trying to burn it all off before I send it to the dyno, Don't want to kill my tuner. :lol: :lol: Luckily the fumes and smoke it almost non existent now & it's been helpful to make sure there's no fluid leaks ...so it's getting close to dyno time.. Just one last day on the wiring and then find some $$ to wind some boost in. Dash conversion is still ongoing (BALLACHE) Managed to find a neat way to attach the Indicator/Wiper stalk using the OEM S15 dock so that was a win... Few action items on the wiring still, such as headlight motors, Tacho Signal and Illumination Dimmer .. also the speedo VSS seems to need 5V instead of Ground so going to give that a crack and hope for the best. https://cimg3.ibsrv.net/gimg/www.rx7...7f118f11a7.jpg https://cimg5.ibsrv.net/gimg/www.rx7...43bd87da8e.jpg https://cimg4.ibsrv.net/gimg/www.rx7...7eafd89fda.jpg https://cimg2.ibsrv.net/gimg/www.rx7...2efa36e6b5.jpg |
Kicking some fkn goals this weekend! http://www.ausrotary.com/images/smilies/icon_cool.gif http://www.ausrotary.com/images/smilies/icon_cool.gif See below for walk around video (taken with phone in low light so not the greatest)
Finally finished up the Dash Conversion. http://www.ausrotary.com/images/smilies/eusa_dance.gif Well the cluster, stalk part of it anyway. Bit of drama with the high beams as the S15 works on a single throw switch ON/OFF to activate the high beams, and the FC works with a successive path, Low Beam on, High Beam On. So we did some beep testing on the front relays & Rob came up with a simple but effective diode switch to be able to activate the High Beams! Other part we were a bit sketchy on was the tacho signal in the S15.. It requires a 12v signal and the Microtech outputs 5v I believe. We ended up hi-jacking a signal from the HKS Boost controller and voila... it works. Reads exactly what the Microtech reads now. http://www.ausrotary.com/images/smilies/icon_smile.gif .... One of the bulbs is out on the cluster but apart from that it is now 100%, except we need to test the Speedo/VSS. Rob also was nice enough to wire in a headlight pop up switch just like OEM so I can have the lights up with no lights. Just need to fully install the dash now and find that bulkhead a home. On top of the Wiring, I managed to find a home for the washer bottle as I stuffed up the FMIC install completely forgetting the washer bottled lived there too. All good. The new spot looks neat and it doesn't look too out of place. https://cimg2.ibsrv.net/gimg/www.rx7...eb55e2ae42.jpg https://cimg8.ibsrv.net/gimg/www.rx7...39ce4af67b.jpg https://cimg0.ibsrv.net/gimg/www.rx7...ead12d61aa.jpg https://cimg9.ibsrv.net/gimg/www.rx7...8214f3c281.jpg https://cimg3.ibsrv.net/gimg/www.rx7...0289e66992.jpg https://cimg2.ibsrv.net/gimg/www.rx7...c864265d45.jpg https://cimg6.ibsrv.net/gimg/www.rx7...9873149b5f.jpg |
You have a great project, full of the trials and revelations that makes the journey worthwhile. I have nothing against piston swaps, but I am glad you didn't give in to the darkside. Really nice stuff - the parts (love the steering wheel :D), the conversions - plus you have a wife and kid that helps you out. Awesome!
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Originally Posted by diabolical1
(Post 12294007)
You have a great project, full of the trials and revelations that makes the journey worthwhile. I have nothing against piston swaps, but I am glad you didn't give in to the darkside. Really nice stuff - the parts (love the steering wheel :D), the conversions - plus you have a wife and kid that helps you out. Awesome!
Nah I'm with you, I had to give the rotary engine another crack so we'll see what the new engine can do soon when we wind some boost in... Can't wait! Have you got a build log running on the forums mate? I'd love to have a read through. |
Originally Posted by Reckless_Panda
(Post 12294111)
Have you got a build log running on the forums mate? I'd love to have a read through.
Anyway, you get back to work. I have live vicariously through you. :) |
Was hoping to tax these wheels from the Evo X... 18X8.5 +38
Rears are perfect, Fronts are hitting the Suspension http://www.ausrotary.com/images/smilies/icon_sad.gif I'm already running 5mm slip on spacers and I'm not about to run 8mm slip on without extended studs. Plus then I have to find some open ended wheels nuts for the BBS. https://cimg8.ibsrv.net/gimg/www.rx7...e968d6c89c.jpg https://cimg7.ibsrv.net/gimg/www.rx7...c8508cbeea.jpg |
If you go looking for trouble, you just might find it... http://www.ausrotary.com/images/smilies/icon_sad.gif
I wanted a nice easy job to do as I was home with my sick son yesterday... figured no better time than to have a crack at these extended wheels studs. Had some left over from the Evo 8 and was hoping they'd fit (spoiler, they are a different knurl diameter and length) After realising I couldn't do anything with the wheel studs until I order some more, I went through some initial checks on brake pads, rotors and bushings. Unfortunately the Bushings are all cooked. Every single one. http://www.ausrotary.com/images/smilies/eusa_wall.gif Was hoping they would be good enough to ignore until later but the pit in my stomach said rip it all out and replace with fresh stuff, so the front hubs are now out of the car. Shout out to the guys on Aus FC Facebook for the cool crown nut hack to get the Tie Rod ball joint out! Worked a treat. Now to piece together some whiteline stuff or genuine mazda gear. or if anyone has a bang for buck aftermarket alternative for wheel bearings, tie rods ball joints, sway bar end links, Lower Control Arm Bushings, I'm all ears cause it's all getting replaced. https://cimg2.ibsrv.net/gimg/www.rx7...1a0246ed60.jpg https://cimg8.ibsrv.net/gimg/www.rx7...baf7a86f9f.jpg https://cimg9.ibsrv.net/gimg/www.rx7...746dea435b.jpg https://cimg1.ibsrv.net/gimg/www.rx7...5e7ecb7c01.jpg https://cimg7.ibsrv.net/gimg/www.rx7...3036e22a9d.jpg https://cimg5.ibsrv.net/gimg/www.rx7...c0d81d5617.jpg |
While I wait for the Bushes and Boots to arrive I thought I would try and tidy up the electrical harness a little bit more... Figure if I keep chipping away at it with conduit, eventually it will become really neat. Couple of rogue wires that need lengthening from the VSS install and the Rad Fans but they will get forced into conduit soon.
Although I'm not sure what to do with the bundle of plugs that all live near the Main Harness Relay... Not sure where they lived OEM but it's a mess. Might make a compartment at the firewall and hide them all inside it to keep it neat. I would love to shove them inside the cab passenger footwell but they won't reach. http://www.ausrotary.com/images/smilies/icon_sad.gif I also ordered a new Undertray / Splitter from Marcus Radtke on the AUS FC Facebook page. Check them out if you're in the market, Quality & price is awesome and it even came with all the stainless hardware needed to install it. Hoping I can run some ducting off the undertray and force air to the FMIC and Radiator http://www.ausrotary.com/images/smilies/icon_smile.gif https://cimg1.ibsrv.net/gimg/www.rx7...6f569610a1.jpg https://cimg2.ibsrv.net/gimg/www.rx7...082ff10aaa.jpg https://cimg5.ibsrv.net/gimg/www.rx7...aace8e8951.jpg https://cimg6.ibsrv.net/gimg/www.rx7...a8a4acc27e.jpg https://cimg3.ibsrv.net/gimg/www.rx7...caa380e788.jpg https://cimg4.ibsrv.net/gimg/www.rx7...6489059f59.jpg |
Really nice project car. Man I miss my fc. It's getting hard to find a decent fc over here in America
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Originally Posted by 007fc
(Post 12300067)
Really nice project car. Man I miss my fc. It's getting hard to find a decent fc over here in America
You in the market for another FC mate? It's getting really hard these days to find decent unmolested imports. Just in the last few years here is AUS they've jumped up in price like crazy for the clean ones as well. :( |
I keep looking but can't pull the trigger on anything now. Wife and 2 kids sure k up all the money lol. But I really want an s5 na or turbo. But mostly just convertibles for sale. And expensive as heck for the ones that are available.
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The absolute worst part of any build is waiting for parts to arrive... and also running out of cash. http://www.ausrotary.com/images/smilies/icon_lol.gif http://www.ausrotary.com/images/smilies/icon_lol.gif
Not a lot to update on car movement wise. Just parts starting to trickle in now. Carpet arrived from Knox Auto. Pretty good quality considering how cheap it was. It's no custom carpet by any means but to cover the floor and match the new dash it'll do great. Will have a crack at installing it this long weekend after covering all the holes left in the floor/firewall from missing pieces. Also worked out a solution to my pod filter problem after copying Scott's setup. (Thanks mate) I grabbed a 2.75" --> 3" reducer and am going to use an old offcut from the Stainless Exhaust to angle it 45 deg away from the manifold. Should do nicely, if it's too heavy or the police complain I'll weld a tab on it and secure it to the chassis somewhere. http://www.ausrotary.com/images/smilies/icon_smile.gif Dash is starting to piece together, spent an hour on my back just to tidy up wires and give them a home so I don't stomp on them when I start driving. Also had to try and lock in the centre console... Unfortunately trying to move the handbrake seems like a massive pain, even if I could re-locate it to the drivers side my Sparco won't allow any more room for fitment. So the only option is to neatly trim the S15 piece and attach the FC Shifter Boot. Hopefully use this long weekend to have the whole dash complete and secured. https://cimg1.ibsrv.net/gimg/www.rx7...38ffabae65.jpg https://cimg6.ibsrv.net/gimg/www.rx7...939da1d6bb.jpg https://cimg5.ibsrv.net/gimg/www.rx7...3c44514293.jpg https://cimg0.ibsrv.net/gimg/www.rx7...4197a81693.jpg https://cimg9.ibsrv.net/gimg/www.rx7...e4770089e5.jpg https://cimg8.ibsrv.net/gimg/www.rx7...d7036997db.jpg |
I made a promise to myself to get the carpet install and wiring all buttoned up this weekend. Job Complete. http://www.ausrotary.com/images/smilies/icon_smile.gif
Not the most fun job in the world. My back and knees are killing me but the black carpet looks great with the new dash. I'll let it settle in a bit before final trim near the doors. 1. I started by covering any open holes with Extra Strength alloy tape. My last carpet was water logged from a few holes in the floor pan and it seeped its way through. Few were OEM, others were straight drilled. All covered up now. 2. Next was the Electrical. Spent another hour with that making sure I was happy with the routing and properly secured under the dash and along the floor. I used some cool zip tie clips with an adhesive backing to run in places I couldn't get a pick up point. 3. I was a bit worried about the ECU and all that important wiring getting kicked by an unsuspecting passenger. Wouldn't be their fault so I fabbed up a small kickplate to protect it all and sit under the carpet. 4. Carpet...Started with the rear carpet, at centre with the Handbrake and worked my way outwards while letting the carpet take it's natural form. Took it real slow before cutting holes for seat bolts & then moved on to the front sliding it over the Shifter and back up. Not the greatest of fits but for $250 it was well worth it in my opinion especially just to give the interior a freshen up. https://cimg8.ibsrv.net/gimg/www.rx7...a59b8fdddb.jpg https://cimg0.ibsrv.net/gimg/www.rx7...88f6ef860b.jpg https://cimg7.ibsrv.net/gimg/www.rx7...1488b2e944.jpg https://cimg8.ibsrv.net/gimg/www.rx7...e840de5c7f.jpg https://cimg5.ibsrv.net/gimg/www.rx7...9b9a3abc31.jpg https://cimg7.ibsrv.net/gimg/www.rx7...835840cb4e.jpg https://cimg9.ibsrv.net/gimg/www.rx7...6cef9e2fce.jpg https://cimg4.ibsrv.net/gimg/www.rx7...2452ddd2f9.jpg https://cimg3.ibsrv.net/gimg/www.rx7...fe749fbae7.jpg |
Slowly getting there mate!
That carpet job you can put in the bin!!! hahaha Oh btw do you have door cards? are they electric or wind? if they are wind I have found THE BEST replacement! :) |
Originally Posted by YLD 78U
(Post 12304914)
Slowly getting there mate!
That carpet job you can put in the bin!!! hahaha Oh btw do you have door cards? are they electric or wind? if they are wind I have found THE BEST replacement! :) And Door cards are 100% needed, I was looking at the LRB Speed ones but the ones you sent through look awesome! Might get a price on postage and see if they can get them to AUS for reasonable postage. EDIT: Seems postage is around the $130US mark so around $400 AUD all up for door cards. That postage really kills the overall price hey. |
What was supposed to be a "quick little job" just replacing wheel studs, ended up with me removing the stub axle and opening the hubs. http://www.ausrotary.com/images/smilies/icon_sad.gif
All good though, Means I could inspect inside the hubs, all looked good, Wheel bearing & rear seal looks great. Pressing out the old wheel studs was a pain, leveraging/securing the hub is difficult cause of the uneven shape on the rear. But I got it in the end by clamping one side of the hub. Ended up using ARP-100-7713 Extended Studs. M12X1.5 @ 3.25". Easy as to press in, used a bit of CHS offcut a little longer than the studs and used that to keep things concentric. Now to give them a deep clean, re-pack with grease and re-assemble the front end over the weekend. http://www.ausrotary.com/images/smilies/icon_smile.gif https://cimg5.ibsrv.net/gimg/www.rx7...2d0c98f39d.jpg https://cimg7.ibsrv.net/gimg/www.rx7...cfec0a09ba.jpg https://cimg2.ibsrv.net/gimg/www.rx7...8ef7998318.jpg https://cimg4.ibsrv.net/gimg/www.rx7...160f9d381d.jpg https://cimg3.ibsrv.net/gimg/www.rx7...0c1bfc6023.jpg |
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