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Project Chise. aka. my first rx7
Hello again. Im here today making a build log of my new baby Chise. I Have posted about her in the past but now its time to make a clean log with the build process.
So quick backstory. I found the car as well as an s4 vert off a guy on facebook. He sold me the cars for 500$ total, titles in hand. Only problem is that the vert was seized and Chise has been Out of commission for over a decade i assume. The goal is to get Chise up and running by november and the ultimate goal for this engine is 180hp maybe. https://cimg7.ibsrv.net/gimg/www.rx7...c2080b7959.jpg https://cimg8.ibsrv.net/gimg/www.rx7...1b75e46509.jpg Overall the only thing chise is missing is the Fuel tank, Crank angle sensor connector, All the emission rats nest (which doesnt matter since it was gonna be pulled anyway) and just minor things that are nor either her or there. After getting it back to the house. The first thing is to actually go over the car and see how bad the interior is. Amazingly, the interior is perfectly fine. The only thing missing that i care about is the center trim which i have a spare one anyway so im not worried. https://cimg7.ibsrv.net/gimg/www.rx7...ddb35193fa.jpg https://cimg3.ibsrv.net/gimg/www.rx7...1fcae2676f.jpg and after a quick vacuum https://cimg6.ibsrv.net/gimg/www.rx7...7a6f8b9e09.jpg https://cimg8.ibsrv.net/gimg/www.rx7...c21a5d75e3.jpg All the car is in one piece, the headliner is fine the only things that gonna change inside are the seats. Im 6'3 so headroom is a bit of a problem. Im gonna take the seats out, cut down the mounts and lower the seat about an inch or two so that i can wear a helmet inside if i ever wanna go autocrossing. The other interior things are gonna be the car arm rests since my legs lean against the door and pushed my knee into the wheel. and lastly the wheel itself. Getting a adapter and a deep wheel will give me some extra leg clearance. Onto the engine bay. https://cimg4.ibsrv.net/gimg/www.rx7...03f83469c6.jpg As for as the engine bay. Everything is there.......Kinda. As mentioned earlier, the crank sensor connector is gone so i am gonna splice in one from another s5 shell my grid is letting me pull parts from. Besides that, the egr was taken off so i had my friend cnc some plates for that. The clutch slave is shot so that getting replaced. Then its just an simple systems check and see if the wires are working after sitting for so long. The remaining vacume lines will more than likely be replaces after i get the car running. https://cimg5.ibsrv.net/gimg/www.rx7...5fd3c2b569.jpg Continued in chapter 2 |
Chapter 2
Not begine the process of figuring things out. I recently got a new job so i now have money to dump into her. I started by taking the intake off and hand cranking the engine to see if it has compression. For the most part it still does. i cleaned up the intake and the rest of the engine bay as much as i could. https://cimg3.ibsrv.net/gimg/www.rx7...c5dbe6d67c.jpg I realized that the actuators for the middle intake, as well as the port actuators. So i gotta replace those in the future. https://cimg0.ibsrv.net/gimg/www.rx7...0433785e5f.jpg Once i get it running ill go in and really clean it. A bird managed to make a nest right in front of the radiator so i gotta pull that mess out. Not t mention there are hundreds of snail shells inside the car. I popped the cap off the radiator and im sure that is beyond saving so that will be swapped our soon. |
Back again.
Last week i managed to pull my friends parts car out of the yard. He had an s5 shell that had a tank and a fender that i wanted. Took an hour to pull the shell out of the mud after changing the tires on it. https://cimg8.ibsrv.net/gimg/www.rx7...1009f0fcdd.jpg https://cimg0.ibsrv.net/gimg/www.rx7...08ff42160b.jpg quick clean https://cimg1.ibsrv.net/gimg/www.rx7...267bf2be10.jpg The car hasnt been used in well over 8 years. the gas was long gone but the oil was still in there. https://cimg2.ibsrv.net/gimg/www.rx7...8af8d0e469.jpg https://cimg3.ibsrv.net/gimg/www.rx7...88b87ff99d.jpg Took the fuel pump out of the s4 vert i have. Did a quick power supply test and it still works so in it goes. I have to splice the wires a bit to fit with the s5 lines. https://cimg7.ibsrv.net/gimg/www.rx7...8c7fbe6ed6.jpg https://cimg5.ibsrv.net/gimg/www.rx7...5dd1f3d2a6.jpg |
Very cool!
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Looks like you're making good progress on the car. Keep up the good work!!
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Finally prepping for the steering wheel. I cant even get in the car easily since my knees dont bend that way. Swapping the wheel out and extending it will help me. My thigh pushes against the wheel and its hard to press the clutch. Im so glad its easy to swap it out.
https://cimg6.ibsrv.net/gimg/www.rx7...bb28aec695.jpg Went ahead and pulled the rad off and checked to see if its still good. There was still coolant left inside so thats a good sign.....maybe. Gonna run tests next weekend and see if its still good. I kinda feel like buying a new one anyway just for insurance. https://cimg0.ibsrv.net/gimg/www.rx7...519ae20832.jpg |
You got a sweet deal for $500.
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New update. My new wheel stuff all showed up and now i can fit in my car.
https://cimg3.ibsrv.net/gimg/www.rx7...b1c2b9927f.jpg https://cimg6.ibsrv.net/gimg/www.rx7...45262b8210.jpg https://cimg9.ibsrv.net/gimg/www.rx7...fe3c2ee1d3.jpg https://cimg0.ibsrv.net/gimg/www.rx7...f4562fa273.jpg Now with the new wheel i have about an inch or two of space from the wheel to my thigh. https://cimg1.ibsrv.net/gimg/www.rx7...7301fdceae.jpg https://cimg3.ibsrv.net/gimg/www.rx7...7ccd5a5ae6.jpg https://cimg4.ibsrv.net/gimg/www.rx7...4f7565d378.jpg Now time to fix the crank angle and the fuel pump lines. |
Update.
So i decided this weekend to go and swap the fender out. I was originally gonna shampoo the interior but texas heat came out of nowhere. Getting the fender off was so damn annoying because of the dent right where the bolts were. Since i got the fresh fender off the spare car, might as well put it on. https://cimg5.ibsrv.net/gimg/www.rx7...55f7f818e6.jpg Idk what it is, but almost every fc ive seen has some type of dent right on the fenders. https://cimg7.ibsrv.net/gimg/www.rx7...b4c55cc3e1.jpg You can see how dented in it is more on that angle. https://cimg8.ibsrv.net/gimg/www.rx7...2e597e132d.jpg Some of the bolt mounts were pressed in and the bolts on the front bumper were warped out of place so it took some muscle and unbolting the headlights to get it to fit the other bumper. https://cimg1.ibsrv.net/gimg/www.rx7...b777e2a2a7.jpg It aint perfect, but its there and thats all that matters. |
Great progress! I feel you on the height situation - 6'7" checking in. I took out the rear bins for awhile so I could scoot my seat back, but I didn't like the look so now I kind-of fit...snuggly.
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Originally Posted by GA_Boy_Drew
(Post 12306419)
Great progress! I feel you on the height situation - 6'7" checking in. I took out the rear bins for awhile so I could scoot my seat back, but I didn't like the look so now I kind-of fit...snuggly.
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Went ahead and took the OMP off since it was already snipped and the lines were gone when i bought the car. The plan is to just mill my own block off plate for it.
https://cimg1.ibsrv.net/gimg/www.rx7...09365e8775.jpg I do alot of 3d design work so i went ahead and mocked up a test fit piece that's 3d printed. Gotta shift the bolt holes over just a little but i got the gasket lined up perfect. https://cimg1.ibsrv.net/gimg/www.rx7...d7dee425ef.png https://cimg8.ibsrv.net/gimg/www.rx7...177369e2c2.png |
So... You know when things are seeming good and the car should be up and running in a few days. Well i kinda hit a big snag in my plans.
I wanted to check the water pump and see if there was any chunks in there that could cause problems with cooling and.... oh boy. It aint good. https://cimg3.ibsrv.net/gimg/www.rx7...388fa2df6a.jpg Yup. as you can see, its completely clogged in there. I hope the rest of the coolant passages arent anywhere near as bad. https://cimg6.ibsrv.net/gimg/www.rx7...0274c74610.jpg The opening of the housing didnt look great either. I want to flush it out to see how bad the blockages are. If its really bad then i may have to pull the engine and just rebuild it after cleaning. This is not what i wanted to see. I have no problem tearing it down. Its probably a much smarter idea to do a tear down and rebuild instead of chancing it and having the whole engine overheat. https://cimg5.ibsrv.net/gimg/www.rx7...71b72fd445.jpg https://cimg6.ibsrv.net/gimg/www.rx7...2e2a198dd8.jpg Also. The thermostat is pretty well clogged. I never knew it could get this bad. https://cimg7.ibsrv.net/gimg/www.rx7...45e94a8c66.jpg SO plan A. is to try and clean it out as much as i can today. Im hoping that there isnt any bad amounts of corrosion inside. IM probably gonna buy a new water pump and assembly anyway. I have access to spares so that will happen soon. |
So a little update. I went and pulled the plugs on the car and... Well.. They are pretty new.
Like actually Brand new. Never been fired. I think the previous previous owner started swapping parts into it but then gave up on the project. Its weird but hey, ill take it. https://cimg2.ibsrv.net/gimg/www.rx7...b92a582ef1.jpg The condition of the water pump had me worried about things but after seeing the plugs and being able to hear compression inside when i turn hand turn the engine, i have much better hopes. |
In a previous post, i took the water pump off and its pretty much just junk. I wanted to slush out whatever crud inside and you cant really get a good seal with just a hose.
I went ahead and designed and 3d printed a flange to go over the hole to allow me to connect a hose to it with minimal leakage while keeping the flow. https://cimg6.ibsrv.net/gimg/www.rx7...4db75f9541.jpg https://cimg7.ibsrv.net/gimg/www.rx7...4bcd3c25e8.jpg It worked out pretty well. Not much was left in there since i flushed it a week ago when i first took the pump off. This time it was just a little gunk and then clean water flowed right through with no sighs of interruptions. https://cimg7.ibsrv.net/gimg/www.rx7...4bcd3c25e8.jpg I need to flip the design so i can flood water back out the other way. https://cimg5.ibsrv.net/gimg/www.rx7...f2f1d1fd54.jpg |
can you make that part for me? i want to flush my engine as well.
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Originally Posted by SirCygnus
(Post 12308856)
can you make that part for me? i want to flush my engine as well.
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Just picked up my first rx7 in similar condition
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Slight update. I started replacing the connectors on the crank angle sensor. The previous owner snipped them all the way down to the loom so i had to cu that open and replace the connectors.
https://cimg1.ibsrv.net/gimg/www.rx7...98ab89bbc0.jpg I had a spare s4 fuel pump assembly so i dropped that into the car and had to replace those wire and connectors. https://cimg8.ibsrv.net/gimg/www.rx7...1d77f1b98e.jpg Had to stop because texas decided to start raining. All thats left is to fix some ground lines, replace fuel hoses from the filter, swap filter, buy an air filter, check connections and drop a battery in. Ill probably try and fix the linkage on the shift knob since its wobbly. |
Some great progress there!! I absolutely love that engine flush plate that you made!! What an awesome tool!! The car is really coming along well and I'll look forward to more updates!
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Forgot to post a pic of the CAS connector actually connected. IDK if the CAs actually works since it kinda rusted insoide but Imight as well try and see if it does before replacing it.
https://cimg1.ibsrv.net/gimg/www.rx7...2bc7646dfe.jpg |
Just wondering if you have made any more progress on the car.
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Originally Posted by mazdaverx713b
(Post 12315260)
Just wondering if you have made any more progress on the car.
The meantime here is a photo of my other baby. https://cimg6.ibsrv.net/gimg/www.rx7...ded7fb1466.jpg 2016 vw Gti. Got her fresh off the lot. My first manual car. I want to get her all nice but since i now have the 7 Im gonna keep her stock for the most part. The only thing ive done is lowering springs in the rear, wrapped the roof black, and i made a custom shift knob for her. She has more Hp than the 7 will in her current state but i i want rwd soon. |
Holiday Update.
So I have been away for a while. I recently moved into my first apartment earlier this month so im doing what i can to get used to that. Im short on cash so i cant buy everything i need but i have enough for now. I got lucky and the apartment came with a garage so i finally have a place to park my babies. The plan is to fix the last few things on the car, try and start her up and see how bad things are. ATM the list of stuff that be done is Finish splicing the Fuel pump wires Put the water pump gaskets in Put the Rad back in Drop a battery in Tape off all the cut wires on the harness Add fuel, oil and test Should be able to do all of that pretty soon after the new year so in the meantime here are a few pics. https://cimg6.ibsrv.net/gimg/www.rx7...9b514e80dd.jpg https://cimg8.ibsrv.net/gimg/www.rx7...d4297b32a8.jpg |
Hello all. Im on my last 10% of replacing stuff. I just went and replaced the
Fuel Filter fuel lines Water pump with a s4 water pump new gaskets thermostat rad pipes Here is a pic of the clutch slave with a new one. The ruster one was on the car. the kinda ok one was on the spare vert and i wanted the cable from it. https://cimg6.ibsrv.net/gimg/www.rx7...44a8c6e594.jpg Now thats all thats left that i dread is putting in new weatherpack connectors for the TPS sensor. |
Minor Update. ATm the car starts and runs. I only ran it for a few seconds and realized i had a fuel leak under the car. But other than that, the car is good enough to start.
The problems i have been having is that i believe that the starter motor is going out. It only starts when i have it jumped even with a fresh battery. I bought another air intake from a guy on instagram so i can finally have the port actuators and an air pump. I will be looking to find a way to actuate the ports without the vacume spider. But thats the only concern i have atm. |
VIDEO UPDATE! I started the car up again and it revs up to 5k for a few seconds then slows down. The bad fuel in the tank ended up clogging up my injectors so i took those apart and plan on starting over again this weekend.
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SO...... I caved in and bought a jdm turboII. I spent last weekend pulling my current engine and pulling the auto trans that came with the turbo. I have a few things i need to swap like the body harness and dash cluster.
https://cimg8.ibsrv.net/gimg/www.rx7...442c5ff5b6.jpg https://cimg0.ibsrv.net/gimg/www.rx7...ef4a7fb2b0.jpg Should be getting in the cluster and body harness this monday so ill be back at it this weekend. |
After having the car for over a year, I finally have an idea on how im gonna do the full build for the car and what phase im gonna do
https://i.imgur.com/Tez1Kkk.jpg Phase 1: Get the car started, replace all the basic things that are just old and need replacing new pads and rotors New Rad coilovers Some cosmetic things that will need to be changed and some safety things to make sure i dont die like the front tie rod and the belts. Install new entertainment system Drive the car for a few months/years so i can become comfortable with it and get a feel for her https://i.imgur.com/u9ocL8K.jpg Phase2: Prepare for engine rebuild Buy rebuild kit and new goopy seals Mildish streetport Haltech ecu and harness Larger injectors new oil cooler electric power steering swap Turbo Kit Front Mount intercooler swap Turbo trans New suspension bushings (might do in phase 1) New seats https://i.imgur.com/EtA0Q0c.jpg Phase3: All the cosmetic things New front Bumper roll the fenders Wire tuck New paint job Swapping the carpet swap door cards In all the Build will probably be little over 20k over the course of the next 10 years or so. |
Dude you are amazing. Keep it up
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Sooooo... you know how i said i was doing it all in stages. Well skip the whole first stage. Ive been mia for the past few months sicne i got a new position at work and now i actually have funding for the build.
I decided to pull the engine apart and start the rebuild. I managed to get a double garage at my apartment complex so i grabbed my baby and brought her up. https://cimg7.ibsrv.net/gimg/www.rx7...1b67b8cb5d.jpg https://cimg6.ibsrv.net/gimg/www.rx7...264aef014e.jpg Pulled the engine apart and everything was good except for the rear stationary bearing and the eshaft. I got an fd eshaft and had to buy a clutch kit since the engine i got came with an auto trans so.... thats a no go. Ill probably put bullets into it one day. First thing after pulling it, Porting. I had Brian at BDCmotorsports do the porting and he knocked it out super quick. https://cimg5.ibsrv.net/gimg/www.rx7...f1e1197045.jpg Since im going full engine rebuild and bigger turbo, the goal is 400+ hp so i have to upgrade the whole rear end. So upgrading to a t2 trans and diff. https://cimg3.ibsrv.net/gimg/www.rx7...af489f6853.jpg and while its all out im gonna clean it up, paint, and put in new bushings. So while i was trying to get the axles out. The axle splines seized together so i had to take it off to a place with much stronger tools than i have. Im in an apartment so using air tools would be a dick move. https://cimg2.ibsrv.net/gimg/www.rx7...c6ab3bb54d.jpg The color scheme for the whole car is gonna be black and gold. 90% black 10% gold is what im aiming for. |
Hey yall. Its yo boi!!
So i have been gone for way too long but i have some solid progress. So..... I have almost a completely different car now. So first off i decided to let tear the engine apart and rebuild the whole thing with new internals and Streetport. After that is done, i upgraded the turbo to something.. a little more boosty. SO i went with a Borgwarner sxe362 turbo kit from turblown engineering. https://cimg6.ibsrv.net/gimg/www.rx7...43c2fa3172.jpg and i also went ahead and redid the whole suspension and that hurt my wallet for a few months. https://cimg7.ibsrv.net/gimg/www.rx7...a0803fb9d8.jpg And the best pic with the engine in . https://cimg0.ibsrv.net/gimg/www.rx7...f32365b8bb.jpg ATM its at a shop to get the fabrication work done for the intercooler and exhaust. |
SO i guess its time i filled yall in. I redid everything. I took the motor apart and got it powdercoated. Tore the car apart and painted it. All new brakes and drivetrain. Most importantly i finally am able to drive the car.
this is what the motor looked like before. https://cimg3.ibsrv.net/gimg/www.rx7...d7e69e8a0d.jpghttps://cimg4.ibsrv.net/gimg/www.rx7...d2168d1d95.jpg https://cimg3.ibsrv.net/gimg/www.rx7...4838b0e71f.jpg ATM im getting all the kinks figured out and installed electric power steering so it will be easier to drive. |
I like the new engine color scheme much better :icon_tup:
What's the plan for the electric power steering? Volvo or mazda3 pump? Also, if you still have the CAD for the flush adapter you modeled up, you should throw it up on thingiverse for the rest of us degenerates with printing additions. |
Holy shit that escalated quickly.
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The black and gold theme looks really clean,.
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Did Turblown have to fabricate the kit once you ordered or was it already in stock? I've been looking at them pretty heavily myself.
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So what i ended up going with is a power steering pump out of a early 2000s mini cooper. Its a really easy swap to do if you ave the space. Its about the size of a football and it lays flat.
AS for the car. I am currently around 200 miles on break in. My alternator took a crap on me so i gotta swap that out but besides that, the car is a champ. . |
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