Project 'rotarvette'

[yoeddynz]

I've had two chevettes before this one. My first was a 2.3 slant four job with Piazza running gear which i'd started during my apprenticeship, sold recently whilst back in NZ and is now hopefully going to be raced in the North Island. then here in Blighty Hannah and I bought a black hatch 1256 with a lovely '80s bodykit that we had great plans for which didn't eventuate and it ended up as a runabout. Now its in Scotland somewhere.
I've always fancied having one with a Mazda rotary engine- especially after we had bought a Gen 1, s3 rx7 2 years ago- and fell in love with the engine. I like the simplicity of the engines, the way they rev so smoothly and the sound is very unique (some like it- some hate it!) I kept picturing a little Chevette with a really tidy engine install- the motor sitting right back and low. The RX7 was nice and quick standard and with a chevette weighing 200kgs lighter it should be fun! I will be ditching the standard carb for a Weber IDA and with that and a good exhaust i'm hoping for 160BHP (possibly up to 180) on standard ports.
The g/box sits higher on a rotary so I'm expecting some tunnel raising and the sump will have to be spun around if I want the engine to sit behind the crossmember.

This thread is being posted on both the Mazdarotaryclub.com forum ( a bunch of nutters- very keen on modifications and speed it seems, especially some of the blokes in Aussie) and the Chvettes.com forum..another bunch of of very funny nutters- both forums well used worldwide too. So I'm going to write enough info for both parties to understand the ins and outs of each respective marque- rotarys in particular being not very well known about unless your a fan!

So starting with the RX7 which I bought first from somewhere near Manchester I have been stripping all the crap off the engine. The engine is a 12A which is fitted to all Gen 1 Rx7s. Later Gen 2 and onwards from 1986 have a 13B with slightly bigger capacity9hence the 1.2, 1.3...) and this engine in much moddified form is still being used today in the RX8.
anyway- this 12A is covered with emissions crap so off with that lot and i'm now almost ready to pull the motor out- week nights being dark and no lighting so its just weekends i've got right now till a workshop is built....
http://i57.photobucket.com/albums/g226/yoeddynz/thisintothat.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/needsaclean.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/mywhatalongbonnetyouhave.jpg

[chip-3door]

Interesting project :D

[Dominic]

Like it a lot!!!!! What's the plan for the 'rotorvette' then? Full on slammed + tubbed + caged drag car? Track day monster? Very quick and fun road car? Or a combination of them all??? :chat

Presumably you're not going to rebuild the 12a before the transplant. If you do, it would be a shame not to cut a big bridgeport. :cool

Look forward to future updates and discussions...

[MikeLMR]

looks cool ... look forward to some updates.

[yoeddynz]

Hopefully if all goes well I'll have done enough to just update once a week or so..I dont have the nerd net at home so its a lunchtime mission to the nerd cafe next door to work. Just ordered 12 tonnes of 40mm gravel today to get rid of the mud and then hopefully I've convinced Hannah that we need a workshop. I'd love to have it sorted for summer....but you all know how these things go...

As for what I want it to be.. I'd like to keep it as standard looking as possible- some wider steel wheels will be all thats visible but for some recaros.

Most people who not into chevettes already have said.." why a chevette? they're crap..old mans cars etc etc..."

I've just sold a mint mk1 2 door escort 1600 in NZ and after driving that and loads of other cars I cant think of a another cheap, simple RWD! that actually handles as well as a chevette does standard. Hopefully no one will expect a little chevette....

[travellinbob]

Top idea for a project there. There are sooooo many reasons for putting a rotor into an old skool car. rear wheel drive, light, cheap to buy etc....
I look forward to more updates.
all the best, michael.

[yoeddynz]

Thanks fellas. I got the little chevette running on sunday! I'll post some more up tomorrow.

[yoeddynz]

After all that rain I ordered 12 tonne of stone. I then borrowed a mini digger (which was fun) and now we have a decent place to play with cars on- whatever the weather. And i've got permission to build a garage/carport which when done will make a big difference to work hours possible.
So after a full Saturday of shifting stone etc and getting the MK Bedford next door going again it was back into car mode. The Chevette has been dormant for a long time so first thing was to get some fuel up to the engine but when nothing appeared I checked the fuel pipe between filter and pump- Completely rotten ! So some pipe from the RX solved that. Then check for spark..nothing. There was feed to coil so dizzy next- points buggered! With the car came loads and loads of spares including 4 sets of points! So with new ones in place and set, the little engine eventually sprung into life but only on full choke- as soon as I gave some throttle she died so a stuck needle? Took top off Stromberg and the needle was covered in what smelt like varnish- really old fuel I guess? Cleaned it up and back in place she ran great! YES. pumped tyres up and off for a spin..going great till I applied brakes and rear wheels locked up. Bugger. Rode clutch and freed them off and made mental note not to use brakes again unless a possible tree/truck/old lady could become involved..
So a quick little drive on the lanes here and she goes really well! I'm very happy.
Now up on blocks to free up rear cylinders.

Really good news now. After having a good look over she's even less rusty then I thought. Solid underneath, Waxoil everywhere. The rust I thought was on end of one sill is just a little bit at the bottom of rear arch. Apart from some acne on the rear arches and the front valance trying to make a run for it the worst is four holes along the top of the drivers side sill under the rubber seal. As far as I'm concerned its a good solid car and I love it when I don't have to weld underneath cars !!!!
Even under the battery is solid! My chevette in Blenheim NZ (a very dry area) had more rust!

The RX7 just sat there- hopefully this weekend coming will see all the bits I want plus engine and box out. Then its off to China. So any first Gen people reading this- is there any bits of trim you might require?
some pictures....
Said needle..
http://i57.photobucket.com/albums/g226/yoeddynz/strombergneedle.jpg
My new stone surface making life more pleasent...
http://i57.photobucket.com/albums/g226/yoeddynz/chevetteworkingbee.jpg
The only rust i'll have to risk splatter in my ears for...
http://i57.photobucket.com/albums/g226/yoeddynz/reararchrust.jpg
And finally the nearside arch in all its glory...
http://i57.photobucket.com/albums/g226/yoeddynz/nearsidearchrust.jpg

[kiwimazda]

Blimey, Blenhiem. Last time I was there or there abouts was for a rally. I spent about 3 stages under the bonnet of my mates 106 pug holding some wires together so we could keep going:eek: If you want an HS or HSR kit for the rotorvette give me a shout on zero 1 two 5 2 fifty2 14three. I know were to get them cheapish.
Cheers
Brian

[yoeddynz]

When was the rally? I used to love going to watch the stages up Taylors pass rd.

I'm going to keep the car looking as 'Grandad' as possible for now but thanks very much for the offer...maybe in the future an HS front spoiler would be nice. I like cars that dont look quick but are..

Anyone reading this thread I apologise for lack of photos- I stupidly went and deleted them all from my photobucket account without thinking so will have to repost them tomorrow.
alex

[yoeddynz]

This weekend has been spent buying a ferret for girlfriends little sister and trying to tidy wiring up on a £50 Yamaha Sr 125...
So the chevette has only had a little time spent on it...
The rear drums were locking on. I've now stripped both sides and cleaned out the wheel cylinders and fit a seal kit that came with the car on one side. The rubbers were ok anyway.
I'd love to say weather I've fixed em but now another tyre has blown out on its sidewall. Both tyres that were facing the sun over the last few years are badly perished so its off to get some second hand ones.
I'm going to order a load of timber and build myself a garage these next few evenings.I'm going to beat these less than ideal conditions...till it floods..

[yoeddynz]

well- I have now built a garage. This will stop the rain hopefully.....

http://i57.photobucket.com/albums/g226/yoeddynz/newgarage.jpg

[yoeddynz]

After building the main garage structure its been odd nights here and there filling it up. i built a nice solid bench, chucked some shelves up and moved the Rx7 in. Then I spent a week rebuilding a bus door for our neighbour so that meant no work done to Rx7...
Moving on. I thought it prudent to reinforce the main rafter before lifting out engine. decided to lift out engine and box complete so I know the rafter can handle it.....

http://i57.photobucket.com/albums/g226/yoeddynz/abouttohoist.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/outitcomes.jpg

Once out I built a little cradle to hold engine in and with two handles its really easy to move about...

http://i57.photobucket.com/albums/g226/yoeddynz/holdsenginelikethis.jpg

Now I'm stripping the car of any other useful parts before it finds its way to China...

[shaunwil]

What condition is the back window in, is the heater matrix in tact and wiper motor ok ?? I could do with some of the dash switchs too, mainly the headlight one, but how much would you want for it all ??

Shaun

[shaunwil]

ooh and what condition are the door locks in ???

Shaun

[yoeddynz]

If you are happy to come and remove what ever you need and buy me a pint ( very lucky me as I have a pub but 1 minutes walk from my garage...this could be a problem now as I have just discovered that I can get a wireless signal...there goes work on the car on a cold winter night out the window....) then come and grab the bits.

The window is intact. the demister matrix seems fine. switches are all there and working. the wiper motor works.

alex

[yoeddynz]

door locks fine too- take the whole lot and the keys.

[shaunwil]

oooh sounds like a plan. Only real downside is your 180miles away :( Will have to get back to you ! Doh, Doh, Doh !!!!

Shaun

[yoeddynz]

OK- see what you can do and I'll see if I can get hannah to remove whatever to keep her busy....

Meanwhile I just bought another chevette.... very nice too....I'm very happy. definately only done 25,000 miles and seems really solid! So far I've not found a spot of rust- wicked.
drove it back from london village last night and the auto box was much better then i expected.
interior is mint. tonight i'll messure up and see what room there is for NORMAL pedals...


Its BROWN!!!!!!

Wow- This is now my 4th chevette. Does that mean I have a problem?

http://i57.photobucket.com/albums/g226/yoeddynz/newbrownchevette1-1.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/newchevetteinterior.jpg

[shaunwil]

Not to worry, if you could give me a price for the locks that would be great !

Shaun

[mullins]

yoeddynz, can you email me - hayden at aotearotor.co.uk thanks

[travellinbob]

Yes you do have a problem. But there are people that canhelp you! if you find them let the rest of us know!
If you are not going to use the wiring harness out of the 7 would you be interested in parting it out of the shell and sending it on up to me for a fee? I also need the little black thing that the wires go into, sorry being a ****, think it is called the voltage regulator? Nice wee shed too. Like the way you have personalised it with the hanging baskets!
cheers,michael.

[yoeddynz]

Voltage regulator...hmmmm....I'll have to check as I'm not sure if i'll be needing that bit for the conversion? All the wiring in the chevette will be redone with veiw to hiding it so I've taken out loads of bits in case they are needed. I'll read the haynes bedside reading book and see if I can work out if I need it- or if I have it? I think the alternator has been changed for one with an internal reg though..

Shaunwil... I'll remove the locks and ignition and work out a price depending on how many times I scrape my Knuckles.

I checked over the car last night- climbed all about underneth and looked everywhere and could not find one spot of rust anywhere!!!
Things like rusty stone chips and scratches etc but nothing needing more then a quick sand, neutralize and dab of paint.

I'm so so happy. And I'm warming to the brown- in low light it looks black. I'll just drive it at night.
master cylinder is going and its missing some badges.

I measured between the two and there seems to be about an inch or so less space in the drivers well to the left of the column...so out with a big hammer then.

Now the problem of what do I do with the other one? I'm going to need a few bits and peices off it like pedal box, master cylinder and other little odds and sods but Its too solid to scrap!
My solution to stop me losing sleep over the death of a chevette is to take the bits I need and sell what ever else I can to make up what the first one cost me. Then offer the rest etc to someone who needs a good solid shell for free.
I'll soon have a 25,000 mile motor and a great brown/beige interior up for grabs plus loads of other goodies.

Does this all sound sane?

[shaunwil]

Cheers that would be great !

Shaun

[mr.bishi]

I will be ditching the standard carb for a Weber IDA

Mad project dude......out of interest,where are you getting the Weber and manifold from?

[yoeddynz]

I got the manifold from NZ when I came over and and the Carb I will probably buy new from eurocarb...
cheers
alex

[mr.bishi]

I got the manifold from NZ when I came over and and the Carb I will probably buy new from eurocarb...
cheers
alex


What do you do with the oil metering gubbins when you switch carbs?

[yoeddynz]

sorry for late reply but I dont get on the net that often.
If you check out the old school rotarys section I started a thread titled '13B NA' and its got loaads of great info on there including stuff about metering units. Its been a big learning curve for me- I'm still learning loads!.. and guys like 'old one' seem to know all the stuff so check it out.

Do you have a project in mind?....

alex.

[mr.bishi]

Do you have a project in mind?....

alex.


Nah,nothing specific yet......i've only owned my first rotary for about 3 weeks so far so i'm trying to learn as much as possible and what's possible for what budget..

I've been reading about the use of 2stroke pre-mix rather than the omp but there never seems to be a definative answer..

[yoeddynz]

No posts recently but work on the car has been going well!
Hannah took it out for a day of general hacking about town and even with an autobox she came back well happy with it which is good as shes paying half of all costs...

First thing i did after that was to give it a good clean. Then some Halfords cutting compound to take off the dull paint followed by some really good wax I brought over from NZ.
Looking nice and shiney on the outside- and showing all the dents dammit.
Next step.. the inside- my theory on car projects is that if the interior is a nice to be in then everytime I hop inside I'll just want to finish it and drive it.
And when drinking tea (or whatever else) inside car it'll be more satisfying making brmmm brmm sounds..

So out with the mint but yucky brown interior and in with the grey from the other car. Whille all the cards were out I cleaned out the dust and other crap that accumulates in doors- found a diasbled parking permit - and waxoyled the lot. It looks as if its had some waxoyl or something in the past unless the factory puts some thing in there? Swapped the dashes over- now black not brown. Swapped over pedal boxes.

I removed the carpet and found the factory build sheet under the noise insulation! Among all the info it lists the optional extras that car was to have including heavyduty suspension which explains the US made bright red Gabriel front shocks I spotted.

http://i57.photobucket.com/albums/g226/yoeddynz/frontshocks.jpg
I'd bought some recaros from ebay. Out of some rs fiesta they bolted in really easy- pictures later when its all sorted inside.

Engine bay time. Removed old lump. Then weighed it. 115kgs with both manifolds and alt, starter etc. auto box weighed in at 45 kgs!
I then weighed mazda engine with new inlet manifold but old heavy carb plus starter and alt.....130kgs! I did think it would be lighter but there is alot of iron there. Mazda box weighs in at 35 so overall sod all difference then.
Sod nows what my old 2.3 in NZ weighed then- I know a pintos about 190kgs!
http://i57.photobucket.com/albums/g226/yoeddynz/oldchevetteengine.jpg
http://i57.photobucket.com/albums/g226/yoeddynz/removingyuckymotor.jpg
Removed the front crossmember and with loads of petrol and a big old tray to sit it in removed the 23 years worth of gunk. I cut off old engine mounts- no going back there. Discovered bad surface rust under them so its a good place to check on a rusty car if you've got the crossmember out.

http://i57.photobucket.com/albums/g226/yoeddynz/preppingcrossmemberforpaint.jpg
Treated it all and on with some black hammerite.

Refit crossmember and then cut out all the wiring, removed the master cylinder, vacuum unit and brake lines.
On with cleaning engine bay out- loads of paint gone from a leaky master cylinder. I've now decided that once engine mounts are sorted i'll paint the bay shiney grey as the brown makes the bay seem small and dark.
Removed heater box and found loads of leaf matter lurking. What the hell is the sticky blu-tack like goo used to seal the lot in place? I think i'll use silicon to replace it..
http://i57.photobucket.com/albums/g226/yoeddynz/leafmatterbehindheaterbox.jpg
Today I lowered the rotary in place- then took it out. It seems that compared to the Aussie geminis where they just hammer the hell outta the tunnel my tunnel is lower? Maybe autos have a low wide tunnel but I didnt want to hammer it that much as it would only end up with loads of dents and cracks. So out with mr makita jigsaw and chop the top off.
I didnt like the shape of the tunnel top anyhow...

http://i57.photobucket.com/albums/g226/yoeddynz/Tunnelchop.jpg

Lowered it back in (easy too) and with a jack under the box I have it where its going to sit. Looks nice in there and sits almost smack in the middle.

http://i57.photobucket.com/albums/g226/yoeddynz/Enginehunginplace.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/Loadsofroom.jpg
So the gearbox is long! Gearlever will be to far back but the aussies shorten the linkage and 100 mms forwards would be fine. My haynes RX7 manual shows a different box shape so I'll pull the top off and have a gander...
Tomorrow i'll measure up and build a engine crossmember.

[MikeLMR]

thats looking cool ... inspiring !

[shaunwil]

Wow, looking very interesting, does the car have a weber carb too ??

Amazing the amount of work that your getting sorted in this weather !

Shaun

[antnicuk]

looking good, thats my kinda project. i assume that you cant get the engine further back in the bay then due to the gear lever being too far back? shame as it looks like the engine could go further back otherwise.

Keep up the good work

[oldone]

Great going bud,that ROTOR motor looks like it belonged there in the first place......:evillaugh :cool :guinness

[TwistedHumour]

Looks like it could go back a little bit more ;) Or will it catch the handbrake in its stock position?

[yoeddynz]

Yeah- I'm really happy with how its coming along! As for the weather...its been bloody warm for middle of winter i reckon. I cant believe I used to try and do all this sorta work with no garage though.

As for the engine position...I too thought after sitting it in place that it needs to go back further and down...with the IDA on top and filter I feel a bonnet bulge coming on....
but several things make it tricky;
The manifold will foul the servo unit and the clutch slave will foul the heater if it moves back anymore.
As for the gear lever..I took it all out again yesterday and took all the selector mech apart. I've managed to move it all forwards by 102mm.

Then I made a silhouette of the sump and with some string and lots upside down antics I worked out that the engine with its sump turned around will sit back 80mms further and 25mm down but then the gear lever will be only 20mm in front of hand brake.. and the servo will have to go.
So it would be a right mare! And lots of fabrication work is outta the question as I'm currently getting all my power from a honda generator and it definately won't run a welder.

My 2.3 chevette in NZ was mounted to far forwards and probably weighed half again but still handled great so I'm happy enough with this one.

Photos soon..back to work.

[dubber91]

looking great mate. Nice one :)

[antnicuk]

oh well, we cant say you didnt try. keep it up.

[dubber91]

what about a sidedraft car instead of the IDA? that might give you a bit more clearance.....

Steve

[yoeddynz]

oooohhhhh nooooo....must be IDA, must be IDA...

I thought about one of those bendy over manifolds with a side draft sitting over top of engine but apart from the fact I still think of the bends as potential fuel drop out points- the fuel hitting the wall on the outside of the bend and sticking?...maybe its not the case.. then theres the look...carb sitting over the top of the engine and hiding the bumble bee look.

Maybe Su's? Damn I wish i kept the su setup off the last rx7 I had- I gave to the fella who bought the other '7 not thinking I'd have a use for it. Worked well too.

[dubber91]

or you could go for twins......

Steve

[yoeddynz]

photos for ya of said gearbox work and new lever position....
http://i57.photobucket.com/albums/g226/yoeddynz/newselectorhole.jpg
http://i57.photobucket.com/albums/g226/yoeddynz/Bitsremoved.jpg
http://i57.photobucket.com/albums/g226/yoeddynz/newleverposition.jpg
Today I was let loose in the garage nearby and have started the building of the engine crossmember. My work welder ran out of wire 10 minutes in(should have checked) but anyway its a **** gasless mig so I used the welder in the garage and cracked on. I'm taking a day off work tomorrow while i've use of the garage and should have it all sorted and sitting there without a chain block- which will make the car easier to drive..
http://i57.photobucket.com/albums/g226/yoeddynz/startofenginemounts.jpg

[yoeddynz]

hey 'old one'... can you please measure the height of your 48 ida from the base to the top of the carb body where the trumpets bolt on. And the trumpets supplied with 48s- are they a fixed height or can you get shorter ones? I think i'm going to have around 180-190 mm space under the bonnet so I just want to know the heights so I have no more restless nights with nightmares of chopping holes in my bonnet.....

I'm thinking of a ramflo type filter which might offer more room.
As for a bonnet bulge- anyone know of any old triumph tr4 bonnets kicking about?
alex

[oldone]

hey 'old one'... can you please measure the height of your 48 ida from the base to the top of the carb body where the trumpets bolt on. And the trumpets supplied with 48s- are they a fixed height or can you get shorter ones? I think i'm going to have around 180-190 mm space under the bonnet so I just want to know the heights so I have no more restless nights with nightmares of chopping holes in my bonnet.....

I'm thinking of a ramflo type filter which might offer more room.
As for a bonnet bulge- anyone know of any old triumph tr4 bonnets kicking about?
alex
Will measure the carb tomm for you bud......no probs.:guinness :cool

[yoeddynz]

I took the day off work and cracked on with the engine crossmember and gearbox support. The crossmember came together nicely and is probably overbuilt but doesn't seem to weigh too much so better safe then sorry...

http://i57.photobucket.com/albums/g226/yoeddynz/enginecrossmember.jpg

Once that was sorted and in place I started on the g/box support. I ended up using the old Rx7 one and hacking it a bit shorter then welding some box section to it. I bolted in place some 3mm thick plates I had formed to match the curves in the trans tunnel. Its a bloody pain that I don't have a welder in the garage because it meant marking all the odd shapes, bits and pieces as close as i could then going over to the other garage, weld them and hope it was right. I got it right though- and finally was able to remove the jack, stand back and admire the little motor sitting in place.

http://i57.photobucket.com/albums/g226/yoeddynz/enginemounts.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/lotsofroomforfatexhaust.jpg

While taking the photos underneath I noticed the void where the starter motor should be and thought-oh ****- will it fit?...
It does! phew. It has about 20mm clearance but if i had tried mounting engine further back it certainly would have fouled the chassis rail!

http://i57.photobucket.com/albums/g226/yoeddynz/starterisclosephew.jpg

So now I'll sort out the radiator. I'm hoping the Rx7 one might fit in place with a bit of hacking about to the old rad supports. I'm going to chop another hole in the valance in order to let more air in particularly for the oil cooler.
Then out with the engine again to begin cleaning and painting it and the bay. The fun bit!

[travellinbob]

Nice work there on the engine crossmember. looks really neat! You are steaming ahead on the car these days. makes me think I should stop drinking and get back to work on the morris minor!

[Dominic]

Nice work there on the engine crossmember. looks really neat! You are steaming ahead on the car these days. makes me think I should stop drinking and get back to work on the morris minor!

Drinking gives courage and makes men opt for passion :chat :guinness

Great work Alex

[yoeddynz]

why not drink and build at the same time? and a little bit of herb. just not too much or youll end up with engine upside down and backwards.
And drinks at the end of a good days building to celebrate progress- good too.



hmmmmm- drinking and power tools...ahhhhhh

[ArmyOfOne]

I ended up putting my oil cooler in front of the radiator, right behind the grill. I can definitely see the size difference between a 12A and a 13B in these cars. I really like your engine mount, good that you decided to keep the rubber mounts otherwise it would vibrate your eyes out. I speak from experience on this one.

One more thing I discovered is that since the rear end is a torque arm type suspension the rear universal joint moves back and forth as you load the car so be sure to take that into account. The best way to take the measurement for the driveshaft is to load the rear end as heavy as you dare and then take the measurement. Hope this helps.

BTW it is looking really good!!!!!!

[yoeddynz]

thanks man,
yeah-axles... right now I'm having problems getting parts for my HS(same as Kaddet GTE) axle. I need the front rubberbush thing that supports the front bearing and the bigger pressed steel mount it sit in- my HS axle was missing these bits when I bought it :-(
Standard chevette bit are too small.
Army of one - do you have any spares kicking about? (I think your the best to ask on this forum....)

http://i57.photobucket.com/albums/g226/yoeddynz/axlebits.jpg

[yoeddynz]

well- latest stuff done is chop out all the excess metal that was holding the little rad in place and then with some angle iron in the vice i bent up some new bodywork to hold the rx7 rad. it had to go in at a slight angle but with it all sealed up in front the air has no where to go through it.
mount oil cooler in front- this is important as its responsible for 1/3 of the engines cooling.
Plenty of room behind rad for the electric fan.
Then hoses next. The bottom outlet i had to move so out with the gas and some solder. after lots of searching through hose stocks at motor local factor I actually discovered that the bottom hose from mates wrecked mk3 :censored::censored::censored::censored: chopped in half was perfect for top hose.

http://i57.photobucket.com/albums/g226/yoeddynz/newradmounting.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/bigairflow.jpg

Now the clutch.. a holesaw made quick work and after measuring how far the rx7s pedal moved the master cylinder shaft i drilled the chevette clutch pedal. some panel beating to make a flat area for the master to sit and it all now bolts up nice.
Just bought a nos clutch disc for a tenner inc postage off ebay!

http://i57.photobucket.com/albums/g226/yoeddynz/goodolholesaws.jpg

Axle time- after taking the torque tube off and comparing it to the chevette HS 2300 theres quite a difference to the size of components! As i'm missing the mounting bits for the front of the HS axle I'm now on a hunt for either manta A, mk1 cav or HS bits to get it in place. So in the meantime I've moved onto the exhaust manifold.
The Rx7 pipes come out too far so I chopped 'em off and bought some bends from an engineering firm. Hopefully this weekend i'll get enough of it welded together to get down to the back of tunnel then leave the rest to an exhaust place to build up something - thats if I can find a place in oxford that actually has a pipe bending machine! Apparently it seems that in this city of 120,000 no one actually has said machine!!!! I cannot believe this-coming from a town of 30,000 with two such machines and very competant fellas using them.
If anyone knows of a place that actually builds exhausts in oxford-not just fits them- please..i'd love to know.

[travellinbob]

The whole exhaust thing annoys the hell out of me too. I did a recent trawl on the mainland of exhaust shops and it seems all they sell these days is pre-made stuff and do not manufacture anything themselves.
cheers, michael.

[MikeLMR]

raid all the exhaust places (ask though :-) )for scrap exhausts of the right diameter and lop the bends out with an angle grinder. Some modern cars have some right good quality bends and pipe and they tend to rot out at the box so the pipework is up for grabs.

This exhaust is made 100% of scrap :D

[yoeddynz]

Yeah- just crawled under old 7 which hasnt gone to scrappy yet and removed curved section over axle- its fine so i'll use it. The rest of system on chevette is really straight and same side as manifold so with a little chopping work i'll build my own. Built my manifold last weekend -looks good! pics later...
wondering how far back on stock 12A,stock carb i should join primarys?

[strange_days_uk]

Great thread !!



:guinness

[kiwimazda]

Good stuff youre flying, or will be soon.
Ive got a copy of the Vauxhall Chevette works preparation book in NZ if thats any good for you to have a look at.It might help with some things. Should be here in the mail in the next 2 weeks.
I would love to give it to you but you never know what project is around the corner.

[yoeddynz]

Is it the DTV one? sportspart manual...I think you can buy them on disc via ebay. I've got some pages- very good info.

Recovered trans tunnel yesterday and the pulled out engine/box. Have ground off the seam on top of bellhousing and will clean polish what can be seen. Engine up on bench to be cleaned/painted. Start painting bay soon once all messy bits of tatty seam sealer are smoothed down.

I like all this sort of work as I can freely take beer/other and not muck something important up....

I won't select the colour till well sober though!

[travellinbob]

Ha, ha, ha I know what you mean! Just finished trying to get all the black paint off my hands from painting the engine bay of the moggy and it is nice to be doing the type of work to the car that doesnt require measuring 3 times and cutting once etc.
You should be on the road well and truly before summer by the rate of work you are going at.
nice one.

[yoeddynz]

trouble is that we have a wood stove in the truck and when I get home after work its all too easy to end up chilling in front of that rather then out in the cold. will power..will power!
or another cup of tea..and read classiccar mags

[yoeddynz]

Using some 90 degree bends designed for railings and the old exhaust header pipes from RX7 I was able to finally get something sorted without the need for an expensive trip to Brackley(about the closest good exhaust place I know of to Oxford.
The bends were only £2.50 each and were exactly the right thickness and diameter to match up to the stumps I had left on the original flanges.
Cut a bit here, eye it up, jump on old postie bike and ride down to landlords garage to tack in place, back to car-trial fit and repeat. Many times..15 trips on bike- exhaust getting bigger each time.
The back pipe was a pig as it had to come out with as shallow a bend as possible then duck up, in and down to clear the servo and the steering column. I tried to match the lengths as well as possible and once all painted up and in place I'm very happy with the result!
I'll need to make or buy a two into one collector- if any one can advise a place on the net I can browse as my fears were confirmed when I rang around all the local places and no one MAKES exhausts here in Oxford!

http://i57.photobucket.com/albums/g226/yoeddynz/exhaustpipes.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/newheadersinplace.jpg

Then I covered up the hole in the tunnel. looks alot better and less drafty..
Pulled engine and box out. Engine is up on bench getting cleaned and a minor polish (harder then I thought with only autosol and elbow grease!)
engine bay getting messy seams tidied up and repainted.
Not sure on colours yet- not too zany -has to go well with old man brown.

[yoeddynz]

well I'm very happy as I've spent last week or so prepping the engine bay which is all good fun. I've tried not to get too carried away because its still a dented up car in brown but I did fill in the seam between the shock turret tops and the inner wings- never a nice looking bit as aways looking dirty and as if the factory screwed up in the design stage...
A bit of sanding, some primer, spray putty and finally over the weekend lots of silver and lots of clearcoat.
Very happy with result considering all done with spray cans.

http://i57.photobucket.com/albums/g226/yoeddynz/smoothingtheshockturrets.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/newbaycolour.jpg

Between coats I started on engine. Cleaning up the aluminum bits was harder then I thought and always had me thinking ...why shouild I bother- I dont know how good this engine is and its going to blow up..
Polished it up just enough and painted it. I'm very very happy with the colour! Its going to look cool...well I think so...
So fun removing the masking tape on these engines!

http://i57.photobucket.com/albums/g226/yoeddynz/engineinitsnewcolour.jpg

Next up- tidy gearbox bell housing and then refit engine.

[shaunwil]

That looks awesome, The engine bay is going to be really nice :)

Shaun

[oldone]

Could I please place an order for some exhausts built by your local exhaust shop ???????? heheheheheheheh................... Forking awsome job on the exhaust bud,so pro...:god :D

[antnicuk]

Could I please place an order for some exhausts built by your local exhaust shop ???????? heheheheheheheh................... Forking awsome job on the exhaust bud,so pro...:god :D



agreed, im remaking mine at the mo and it aint easy!

You are doing a great job there but i must say you have too much time on your hands or you are a very quick worker! :spank

keep up the good work

[travellinbob]

That engine bay look sawesome! Just painted the one in the moggy the same way but it doesnt look half as good as yours:god
Engine looks great too, cheers,michael.

[MikeLMR]

Spot ON ! :D inspiring amount of progress

[antnicuk]

inspriation! thats what i need, i am sitting here waiting for the frost to melt so i can go outside and finish making my exhaust! Its gotta be done before Saturday otherwise i defo wont pass the 102 db limit!

[Dominic]

Great attention to detail. I like the way you've smoothed the sus tower joint, looks great. Top job on exhaust too :god

[yoeddynz]

Wow- thanks for the comments guys! I'd better not muck it up now...

As for speed/time- sometimes I feel like I've done nothing over the weekend.
I work in a bike shop so its nice to get home and play with cars! just trying to get it sorted before summer so I can enjoy summertime driving it to my favorite Mtb spots in Wales.

I hope once its done it'll inspire more people into rotarys!!!

Once again..cheers..and hopefully it might be done in time for oldschool meet...(thats jinxed it then..)
alex

[Dominic]

Alex, I go over to Wales quite a lot with some mates to hit the Mtb trails. There's a killa new freeride section at Cwm Carn (only about 1 hr from my gaff in Bristol). Let me know if you wanna meet up and do some trails. Frikin cold this time of year though...

Sorry to hi-jack thread... :D

[oldone]

.and hopefully it might be done in time for oldschool meet...(thats jinxed it then..)
alex

Even if its not done bro,you will have yer ass down this way for a cold one and a tongue wag :cheers :cool

[TwistedHumour]

Alex, I go over to Wales quite a lot with some mates to hit the Mtb trails. There's a killa new freeride section at Cwm Carn (only about 1 hr from my gaff in Bristol). Let me know if you wanna meet up and do some trails. Frikin cold this time of year though...

Sorry to hi-jack thread... :D

Cwm Carn has some really nice trails, although I didnt like all the anti motor bike traps! Havent been there for a long time!

You should make the effort and get down to afan argoed/glyncorrwg. They have some of the best trails you'll find - anywhere!

Back on topic: The car is looking outstanding! Cant wait to see the finished project :Thumbsup!

[Dominic]

Cwm Carn has some really nice trails, although I didnt like all the anti motor bike traps! Havent been there for a long time!

You should make the effort and get down to afan argoed/glyncorrwg. They have some of the best trails you'll find - anywhere!

Back on topic: The car is looking outstanding! Cant wait to see the finished project :Thumbsup!


:D Been to Afan, couldn't agree more. Most fun you can have on 2 wheels :Thumbs-up Planning a trip up to Glentress in Scotland this summer, have heard good things.

Sorry, back to cars....

[yoeddynz]

staying on bikes for a second....yeah dominic- would be good to hook up. I love all those places mentioned above! Afan is favorite probably. Hannah and i for last few years would drive our 'home' over to one of the centres and spend a week there over christmas avoiding the christmas crap and savouring clear trails!!! I well reccomend Glentress too- did that one new years eve in the snow/ice- bloody sketchy but well fun! and cold..water tank froze up under my van so no shower afterwards dammit!
I'd like to do more 'real mtbing' in wales- ie having to explore but the manmade tracks are so good...

righto- back to cars...

Era- we will be there no matter!!! if not in chevette then in triumph estate.

[TwistedHumour]

I'd like to do more 'real mtbing' in wales- ie having to explore but the manmade tracks are so good...

Back to bikes again (perhaps we should make another thread :p). I'm lucky enough to live about 20 mins from afan, and must say we've got some fantastic trails down this way.

You can't beat getting the maps out and going for a nice endurance blast. I can recommend Rhyader/Elan Valley - there’s a few hundred km's of natural trails lurking out there!

[yoeddynz]

cool- I'd love to have a guided tour- I think I know the valleys mentioned. Once summers here and cars done i'll have to contact you and hook up!!!
cheers man
alex

[TwistedHumour]

cool- I'd love to have a guided tour- I think I know the valleys mentioned. Once summers here and cars done i'll have to contact you and hook up!!!
cheers man
alex

Sounds good! We should have a mini meet :D

A day of blasting it through the twisty welsh mountain roads in the cars followed by a day of singletrack!

[Dominic]

Sounds good! We should have a mini meet :D

A day of blasting it through the twisty welsh mountain roads in the cars followed by a day of singletrack!

:D :Thumbs-up :Thumbs-up :Thumbs-up :Thumbs-up

[yoeddynz]

yeah yeah yeah yeah! Welsh roads- wow. We had a 175bhp dolomite sprint track car a few years back and I remember Hannah got to drive it up to Betws y Coed (spelling? I'm a Kiwi- hence even less chance of getting to grips with Welsh place names). We were to sell it but potential buyers turned out to be tyre kickers - not that Hannah complained as she got to drive it back after 2 days mtbing! what a weekend!
More of that please

[yoeddynz]

Project coming along nicely- I'm at that point where its pick up a component, clean it, paint it and fit it! Not having to think too much right now as mostly its just refitting standard mazda or chevette bits. minimal bodging needed :D

My new steering rack bits arrived from TJ motorsport. Thanks Tim. Two extra teeth on the pinion cuts lock to lock from 3.5 to 2.4 turns. Cool.
Stripped rack and with only 25,000 miles on car showed no wear. Swapped bits and all good.

http://i57.photobucket.com/albums/g226/yoeddynz/Newrackpiniontop.jpg

Then just as I was fitting a new clutch disc (Ebay-£10 inc postage-bargin!!!) I noticed the spigot bearing sitting in bits at bottom of its little cave. ****! No seal was present where there should be one. Ordered a new bearing and seal but to remove old required the use of my now very worn Die grinder.

http://i57.photobucket.com/albums/g226/yoeddynz/Removedoldbearing.jpg

By Sunday evening last weekend after some last minute bell housing polishing I had engine and box sitting
in place on my freshly painted mounts.
Phew! Onto the refit.
The master cylinder was failing on the car when I drove it back from london. I checked the one in the spares car and that was just as dire. A local motor factor rang me back after I was asking for a seal kit and informed me they had a new master cylinder complete and I got for only £70 (RRP £120)

http://i57.photobucket.com/albums/g226/yoeddynz/newmastercylinder.jpg

Soooo happy- fitted it in with freshly painted servo and its looking like a new car in there! now doing new brake lines- more photos soon.

[TwistedHumour]

Nice work! Really cant wait to see this project finished - its going to be an absolute stormer!

Looking forward to seeing the fitted pics :D

[yoeddynz]

cheers mate! hope it inspires people to get the grinder out...

Ordered a nice fat shiny 14" dia Moroso air filter today. hmmmm

oil cooler is knackered- all the fins are dropping out. Does any one out there have a spare cooler off a series 2 kicking about?

[MikeLMR]

looking good, got be finished soon eh :D only kiddin, know how long all the finishing off takes, keep up the good work!

[yoeddynz]

cheers- i'm now panicking about thew oil cooler now!!! cant seem to find one.
anyone out there got a spare or no some one who does?
Series 2- the wide one under the rad with inlet/outlets on passenger side.

please please please....

[shaunwil]

You could use one of the mini mocal oil coolers !

Shaun

[MikeLMR]

except that they are about 1/4 the size of one fitted to a rotary and don't come with a thermostat an pressure bypass as standard. If it doesn't leak fit it an replace at a later date. The one I have has a bit of fin rot so I intend to replace it with a better one at some point (it's a Gen2 one)

[shaunwil]

Doh, thought you meant the powersteering one !!!!!

http://www.thermex.co.uk/auto_1.php

http://www.fluidyne.com/pl_hpaccessories.html

Shaun

[dubber91]

ive got some stock coolers IIRC....

Steve

[yoeddynz]

excuse my ignorance but what does iirc mean?

do you have one of the coolers i mean? if so you are GOD and is it possible you can bless me with one?....

alex

[yoeddynz]

i spose that if the fins are still there but now they are alu oxide instead of alu they still might work?...

[dubber91]

lol!
Sorry IIRC means if i recollect correctly. Too much internet time methinks! Ill have a look in the garage this weekend and if i can find one ill bring it to the oldschool meet if your coming?

Steve

[yoeddynz]

yeah- wow that would be really cool if you can ! yeah- Hannah and I will be there tomorrow! Wouldnt miss it!

Gave my oil cooler a clean last night and its passable maybe until I hit one pot hole and all the fins fall out...

http://i57.photobucket.com/albums/g226/yoeddynz/oilcooler.jpg

painted up servo all nice and shiny.

http://i57.photobucket.com/albums/g226/yoeddynz/sexyservo.jpg

Now sorting out air cleaner etc. 14" edlebrock one I ordered was too big and fouled the bonnet. so a 10" one and some bodging should do.

[yoeddynz]

shaunwil- are you still interesred in the door locks off rx7 and if so are you coming to old school meet? i've a heater matrix but its still in car- any other bits- light switch was it?
alex

[shaunwil]

Sorry bud, I got sorted with a full set last week.

I'll be at the meet though to say hi !

Just off to wash and wax the car !!!!

Shaun

[yoeddynz]

hello all- i'm now after any mufflers- anyone got anything kicking about not in use? something to suit a NA 12a...straight through... not too loud..not to quiet..
i'm looking at using 2.5 tubing and yhe car has a nice stright run with enough room in various places for 2 mufflers.
cheers
alex

[MikeLMR]

oil cooler looks better than mine does LoL :D sure it'll be fine

why not DIY a silencer ... I posted some links on here to AusRotary not long back. Perforated tube, stainless steel pan scourers and some high temp rockwool and you are sorted. can make them to suit your car then

[yoeddynz]

I made my own system for my supercharged mr2 back when doing apprenticeship but it was easy then as I had anything i wanted sheet metal wise.
Perforated tube- where can I find that then? When i did mine i just rolled up my own tube out of perforated sheet.
stainless scourers!! wicked idea!!! i used as much stainless swarf i could collect whenever i machined s/s.

thinking cap on then....

[MikeLMR]

jetex sell perforated tube by the meter.

[Dominic]

May also wanna try merlin motorsport and demon tweeks, although the latter can be expensive.

http://www.merlinmotorsport.co.uk/

http://www.demon-tweeks.co.uk/

Both do repackable silencers and demon tweeks sell perforated tube too.

[MikeLMR]

(I've found Merlin Motorsport are quite expensive now as well ... they used to be very reasonable, perhaps it is only on items I have looked for recently?)

[oldone]

hello all- i'm now after any mufflers- anyone got anything kicking about not in use? something to suit a NA 12a...straight through... not too loud..not to quiet..
i'm looking at using 2.5 tubing and yhe car has a nice stright run with enough room in various places for 2 mufflers.
cheers
alex
Hey dude,I got a stainless stock back muffler (twin pipes) and a mid section muffler and a few assorted bits,you are welcome to come and look see and help yourself......:Thumbsup! :Typing

[dubber91]

well your all wrong......bow down:god to me.
observer to wonder of car bulder solutions:

mmmmmmmm bafflage

http://www.nfauto.co.uk/bolt_in_silencer_baffle.htm

and to finish
http://www.nfauto.co.uk/exhaust_paint.htm

built backboxes are a bit pricey, but they are SVA.

pretty sure they do pipe bends too....

ive always wondered about bike stuff too

http://www.4-motorcycles.co.uk/acatalog/Otheruniversal.html

and then of course demon theives:

http://www.demon-tweeks.co.uk/products/ProductList.asp?cls=MSPORT&grp=MP095&pgrp=M029&tlgrp=MS003

hope ya find summat there!

[yoeddynz]

hmmm the EXUTAP 15 on bike site....i'm picturing that sticking out from underneth the drivers door! wow- that'll make the plummy oxford students jump as i rark up high street.

and sod mufflers- i'll use short lengths of 2" tube with those baffles up each all welded together.

but seriously- has anyone seen a side exit exhaust on a rotary?
loud?

[dubber91]

i ran my bug without a backbox for a little bit........2 foot exhaust, no muffler......thats loud
Cops just drove stright past! they expect it from a bug

Steve

[dubber91]

you want those oil cooler fittings btw?

Steve

[yoeddynz]

I've just fitted my old cooler. Sits so nice and in good airflow so i'll run it until all the fins blow out and keep looking for another. Still got those ones you gave me- i'll look after them till some one wants some- the oxford oil cooler storage facility.....

so- side exit exhaust?.....anyone done it?

[Dominic]

so- side exit exhaust?.....anyone done it?

Not sure whether its legal in this country e.g. dodge viper UK model had side exhausts for decoration only and real exhausts out of back i think. Caterhams etc get away with it though :3Confused

It might be tricky with ground clearance too, and how would the mufflers fit?

[TwistedHumour]

The Merc SLR has side a exhaust too – out of the drivers side though (as opposed to the dodge).

My guess would be the reason the dodge has it like that, is because if the exhaust backfired you would end up toasting pedestrian. Rather than complicating the system by adding lots of bends so it can come out of the other side, they left the pipe straight.... like I said, just a guess :)

[dubber91]

No worries running side exit dude. Ive seen bugs with em a fair amount.
Reason for it on OEMs to prevent CO intrusion, where Co enters the cabin under negative pressure gradients (when your driving with a window open a crack).
Nothing in the road safety act IIRC. Only reason you could be pulled would be under a miscellaneous act the bill sometimes use which basically allows them to prevent the car being driven based upon the 'officers' beleifs that your car is unsafe. Why they allow them such privilages given an entirely non-engineering background i will never know.
Even then they have to have SERIOUSLY good arguements for it as the act was overused in the past. The law has clamped down on the law so to speak

:D

far to much information.




In summary:


Do it, it'll look the dogs danglies!
:spank

[yoeddynz]

I think i'll look into it- check the clearance first and then where the muffler/s can go.

It'll be drivers side.

Bonus - keep the very last section of the pea shooter out the back for the OLD MANS CAR EFFECT!

I could pinch an exhaust stack off a Kenworth (actually- i think i've only seen one Kenworth in the UK..at a show) or a Mack and turn it on its side.:D

alex

[yoeddynz]

Work has slowed down as I've got to start getting some miles in on pushbikes. Its now smaller jobs which at first seem easy on paper but turn out to be a right mare in practice!

I fit the radiator and connected up the hoses, fit the oil cooler. Enough room behind rad to fit an electric fan so on the hunt for one of them now.
Cleaned up the dizzy with a new cap and while trying to find a new set of leads found some british brand which you can swap the ends around for different exit angles etc. And they are ORANGE.
Heres a pic of it all less manifolds,carb and some wiring...

http://i57.photobucket.com/albums/g226/yoeddynz/Latestengineshot.jpg

I spent this last weekend under the car with odd bits of 2" tube and various bends eyeing up the exhaust. Mark with tipex, out from under car and cut, re check, walk to other garage and tack, back to car, check, remark another bit and so on- half the time was spent crawling in and out from under car or walking to garage!

Very tight under there- I had bought one big muffler off net and been givin two other smaller stainless ones (Thanks very much Era!!!) and I needed them all to keep it bearable noise wise.
Finally sorted it though- floor needed some clearance (big hammer..) and it might knock in a couple of places which I'll sort with carefully hoseclipped on springs.....me- bodger?

http://i57.photobucket.com/albums/g226/yoeddynz/Myexhaust.jpg

Other night I taped up manifold- keep the heat down in bay.
Its nasty fiberous stuff so did it outside.
Its just like putting tape on pushbike handle bars only bigger.... easy job...

http://i57.photobucket.com/albums/g226/yoeddynz/startingtaping.jpg

After two hours of very careful wrapping and lots of tea I had finished one half and I must say I'm very happy with the result!!! proper job.:InLove

http://i57.photobucket.com/albums/g226/yoeddynz/whatajob.jpg

[MikeLMR]

looking very tidy! the engine looks great painted up like that.

[Dominic]

Looks like its just rolled off the production line. Except for the rotor of course :cool

[yoeddynz]

cheers!

No comments on my beautiful exhaust wrapping? sniff..:(

[travellinbob]

Sorry I hadnt wanted to coment on it as I had thought a professional had done the wrapping:D
looks great. cheers, michael.

[OLSKOOLROTAR]

cheers!

No comments on my beautiful exhaust wrapping? sniff..:(

yeah I got a comment, " will look good when you've finished wrapping it" hehehehehehehehehe!:evillaugh

Seriously though, you've done a top job on your car. You should be applauded mate :Thumbsup! :god

[yoeddynz]

Btw- that wrap does not go half as far as I thought it would! Just had to order more bugger it!
cheers for comments! Itching to drive the thing!!! summer days cruising the blocked up dual carrige ways on the way to yet another service station...

[RotorHeid]

Fall in love with the engine bay, pure simple +brill and a good job!:god
it's kick my own ass on Fri morning:2eek and starting to planning about painting my own bay while waiting for a engine!
Well done and keep it up!!:Thumbsup!

[dubber91]

LMA motorsport in bedford do cheaper exhaust wrap, i know how the cost can really moutn up!

looks ace mate ;) wish i had that attention to detail!

[yoeddynz]

Last few weeks since last post i've been continuing on in between bike rides in the sunny weather.
I fit exhaust in place - not without some hacksawing about the old gbox mounts which i found fouled the exhaust once tightened up. awkward bloody job.

http://i57.photobucket.com/albums/g226/yoeddynz/bitoflatebodywork.jpg

The bend over the axle was going to knock the body so my master bodge (of which i'm very proud) was a transit bonnet spring hose clipped to top of bend. now the exhaust is suspended perfectly.

http://i57.photobucket.com/albums/g226/yoeddynz/bestbodge.jpg

Next step was the axle swap. This picture shows the differnce in size between the standard axle and the HS one- which is bloody heavy...talk about about massive unsprung weight!

http://i57.photobucket.com/albums/g226/yoeddynz/axles.jpg

It went in nice and easy- should do anyway. Just need to get some brake bits for it.

Then turreting- a job I wasnt looking forwards to as it would involve moving car to other garage to welds in the buggers. It turned out an easy job and satisfying. The boot floor has plates spot welded in place where the turrets normally are in saloons/HS's. These spot weld I drilled out and smacked the plates from above with hammer and wood which poped them out. Easy.

http://i57.photobucket.com/albums/g226/yoeddynz/removed.jpg

Then some sheet steel- 1mm thick for sides and 3mm for top. Bent it to shape in vice and cut out top shape with jigsaw. welded Them up inside and out.

http://i57.photobucket.com/albums/g226/yoeddynz/turrets-1.jpg

Removed springs and sat car down on bump stops with shocks fully extended through holes- gave an extra 10mm and marked arch.

http://i57.photobucket.com/albums/g226/yoeddynz/markingshockturretpoints.jpg

I then cut the turrets to the right shape to follow boot floor contour and end up at marked height.
Then towed car around to garage and welded them in. Done.

http://i57.photobucket.com/albums/g226/yoeddynz/turretsfinished.jpg

The alternator had a bloody rough bearing so took it apart, replaced it and gave the housings a clean,paint and polish. Looks really nice on top of engine, all matching gayness...

http://i57.photobucket.com/albums/g226/yoeddynz/strippolishandpaint.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/niceandshiney.jpg

I done the new fuel tank return feed and new fuel line and have now started all the rewiring. Fun with lots of excuses to be anal about tidyness. photos soon.

alex

[dubber91]

will you polish my alternator dude? Theres beer in it for ya!

[oldone]

Alex.........you have been missed bud.! Where ya been ?:rolleyes: Riding those 'Tour to France and see sunshine' bikes again.......you build cars and let Hannah ride the bikes !!!!!!!!!:guinness :rollin

[mikeysrx7]

Nice looking 2.5S estate too!! lol

[yoeddynz]

cheers all. might one day get to drive it....!
Era- hello there! Yeah- i've been sinful and riding bikes too much! soon though i'll be able to combine both driving then riding. Soon..

alex

[yoeddynz]

Fuel system needed a return line installing for standard Nikki carb. I used the standard chev line and fitted a new 8mm main feed to carb. Filled the tank with soapy water and dilled a hole, then punched it bigger which allowed a nice dip for solder to fill in. A bit of copper pipe worked nicely.

http://i57.photobucket.com/albums/g226/yoeddynz/fuelreturn-1.jpg

Now the wiring. I did take any photos of the rats mess created once taking off all the insulation but heres how much I removed..

http://i57.photobucket.com/albums/g226/yoeddynz/lotsoftape.jpg

I had to add in a tacho feed, oil gauge feed and much heftier coil feed(mazda standard has bloody big feed so I copied it- maybe electronic ignition needs more juice?
Ditched the standard chevette 'Resistance' wire which loops from near the ignition all the way down to R/H front light and then back again to the coil to drop voltage down to 7/8 volts for ballest system (bypassed at start up to bump coil feed up to 12volts when it needs it most).
Ran a feed for electric fan too.
I then tidied it all up and hid it right up under wing lips and back through inside car using spare chevettes loom for added length.
I'm pretty happy with result- some wires can be spotted at components but not big fat runs- loads tidier than standard loom anyway.

Moving inside to the dash- I had the mazda dials and chevette dials which i now had to swap.

http://i57.photobucket.com/albums/g226/yoeddynz/workcommencesondash.jpg

The mazda dials are almost the same diameter as the chevette ones so with a knife and file I whittled them down. Whilst cutting the back down on speedo i failed to check exactly where I was cutting and cut right through the odometer drive shaft! ****!!! So I had to shorten shaft down with saw, file and turn it down true in the drill, make a bracket and rivet it back in place. Time wasted because I was too keen with the saw!

http://i57.photobucket.com/albums/g226/yoeddynz/my****up.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/fixed****up.jpg

It all cobbled together ok though- used existing lights from chevette dash but now with see though dial faces it all looks a lot brighter than standard. Looks messy on the back- tacho guts wouldn't fit in place so is now wrapped up and hanging off the back. Lots of odd wires here and there- but I sort of know whats what....

http://i57.photobucket.com/albums/g226/yoeddynz/oilpressuregauge.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/cobbledtogether.jpg

I'm now in the process of making a seperate fuel and temp gauge thingee- maybe sighted under dash- maybe in centre console(which car doesnt have..so i'll have to make one of them too...)

All those little jobs eh...

[antnicuk]

the good work just keeps coming, i love what you are doing....

Would it have been safer to weld the return line to the little cap next to where you welded it? looks like the sender unit

[yoeddynz]

cheers-
the thing next to it is the gauge unit- didn't want to mess about with it. Filling it with water takes away the vapour/ explosion chance.

Excited now- must organise another mini meet of rotarys soon...big classic car meet on 2oth in Wallingford I want to go to with chevette!

[oldone]

:Thumbsup! :Thumbs-up :wiggle Brill work......20th of what month dude,mini meet is in order :yes

[dubber91]

Im hoping the beetle should be running within a month or so.....

Steve

[yoeddynz]

20th of may. I'm also really really keen on going to prescott hillclimb on the 26/27 for bugatti weekend of racing- veyron is meant to be running up there!
I think £20 in advance for weekend- and you can camp there! Maybe a a mini meet watching very oldschool racers could be cool!
alex

[oldone]

20th of may. I'm also really really keen on going to prescott hillclimb on the 26/27 for bugatti weekend of racing- veyron is meant to be running up there!
I think £20 in advance for weekend- and you can camp there! Maybe a a mini meet watching very oldschool racers could be cool!
alex
You are running away with yourself dude,thats 2 weekends you want to do something.........I can do only one,which is the best ?:cheers

[yoeddynz]

hmmm- its got to be the weekend of watching small old cars with stupid big motors burning lots of fuel(and oil) racing up a hill. we should work together and try to pinch the Veyron...

[yoeddynz]

BTW- this is the event....
http://www.prescott-hillclimb.com/events.htm

Lets all get some classic jappa(and maybe a beetle/chevette?) cars along and show what its all about. Picture me in a brwon chevette hanging it out up the climb with that veyron disapearing into distance(behind me..).......




then wakes up...

[yoeddynz]

Well then. Heres the dash...

http://i57.photobucket.com/albums/g226/yoeddynz/revcounterin.jpg

Built a little 'functional' pod for other gauges but didnt take many pictures.
I used ply, cardboard, aluminum and glue. And solder. Painted black.
It works but doesnt look at all sexy.

http://i57.photobucket.com/albums/g226/yoeddynz/gauges.jpg

http://i57.photobucket.com/albums/g226/yoeddynz/gaugesfront.jpg

Then I cleaned Carb up and mounted inlet manifold. Before plonking the carb in place I had to make a choke arrangement and sort the throttle cable.
Using a solderless nipple from a bike brake cable I managed to use the chevette inner in the rx7 outer and the cable pull offered from the chevette accelerator pedal linkage was 2mm more than needed by Nikki carb to open fully! Wow- very lucky and very Flukey!!!

I built a little sheet metal cable outer support for the choke which is now fully manual unlike complex rx7 system. Then it all bolted in place. cool.
Now I got to sit in drivers seat and make brmm brmm sounds properly.
But I have no gear stick...

http://i57.photobucket.com/albums/g226/yoeddynz/carb.jpg

A mate machined up a stepup spacer to mate the end of manta propshaft I bought from some bloke. Nice tight fit and square. I welded it up as evenly i could and with its short length I'm hoping it'll be resonace free but time will tell.

http://i57.photobucket.com/albums/g226/yoeddynz/propshaft.jpg

A manta B axle came with the propshaft which gave me my brake drums and another diff- this one is 3.65 rather than the 3.45 in place- so I might change it over in the future as the Rx7 has a 3.9. Hope fully the chevette being lighter will offset the difference for now till I get bored.

My friend skimmed the drums for me, I fit new shoes, cylinders, spring kit and new brake pipes. So thats the rear brakes sorted. I'm getting there now!
At this point I'm bloody excited actually.

I now made a short list of final things to do. I wanted to drive it to a classic car show in Wallingford on sunday. Cooling it was an important thing I thought and I got mucked about by local auto lecky trition who kept promising me he find this Kenlowe fan he had in attic (which might not be the right size..)
By friday I was well ****ed off and ordered a whole kit from Kenlowe- going with them over other cheaper ones I had seen on internet for that sort off peace of mind and little bit of a thrill I sometimes get when when I splash out on something a bit expensive. hmmm And they could have it to me buy sat lunch.


Got the kit...ohhhh its like christmas- all nicely packaged and exciting.
12" fan size just fit in place with mms to spare. I wired it up and hid the thermostat away under the slam panel next to the headlight. I ran an extra wire to under the dash and fit a little light so I know when the fans on. dont expect to hear it somehow.

http://i57.photobucket.com/albums/g226/yoeddynz/fankit.jpg

The gearstick- its too short so got some 12mm bar and welded an extra foot on then worked out how long it should be. !2mm thread and now I need a pool ball. using the spares chevette knob for now.

http://i57.photobucket.com/albums/g226/yoeddynz/gearstick.jpg

filled up the axle, box and rad....what else...a missing exhaust clamp. Think thats it. Put 100mls of oil into 10 litre jerry and plonked it in. Then checked fuel gauge- will need adjustment.

[yoeddynz]

On saturday night I hadnt got it sorted so I chilled out knowing I had all of sunday to finish the little things, fit some belts, a bit of mesh over the front to protect the oil cooler.
By mid afternoon it was ready- a crowd amassed...well a few hangers about..
I turned it over with no choke for a bit then with a little choke it coughed. Once again, then a bit more choke and away it burst. cool.

let it warm up and checked levels. seemed ok- just smoke from oily hands on the exhaust wrap etc. But once the oil heated up enough to open the thermostat on the oil cooler it started to **** out through a crack on the top outlet boss.
bugger.

So out with it and a friend tig welded it up. I put it back in place this morning but it still leaks a little. So did the next best thing and took the car for a spin. sod the oil for now.

Goes good. very smooth. fast enough for me after driving big ol triumph estate around. quick rack is nice. suspension felt fine but quite loud gearbox. fine in 4th. I cant remember really noticing it in the 7 so maybe some thick carpet for now till I can swap it.

The brakes are unbalanced and pulled to the right. have to check that.

Fan kicks in but temp gauge reads 3/4 whilst driving so maybe I knocked it when building the pod? Can anyone one the mazda forum tell me where the temp gauge sits with ignition off? Mine sits on the bottom bar but maybe it should start from lower down?

So I have now taken the cooler out resealed it with a better seal(hopefully...) but it reall needs grinding roight down through the thread, welding then tapping but its an odd thread..not quite m16 or 5/8 but a 1.5 pitch.

I'd like to find another better cooler then this without such rotten fins anyway. but for now- no cooler- no driving.....:Grrr

http://i57.photobucket.com/albums/g226/yoeddynz/th_MVI_3304.jpg (http://s57.photobucket.com/albums/g226/yoeddynz/?action=view&current=MVI_3304.flv)

[OLSKOOLROTAR]

:Thumbsup! :Thumbsup! :Thumbsup! :god :god :god

Wicked mate, chuffed for you, sounds great to boot :Thumbs-up

Jase

[yoeddynz]

thanks! taken it a few drives- oil cooler still leaks a little but who cares- gotta drive it!
Its very fun- a little high geared but maybe some smaller 13" slot mags....

going to move oil cooler down and use a series 4 one.
more pics and info when thats sorted.
alex

[yoeddynz]

Just finished big job today- after the first few drives(did about 35 miles in total) with leaky oil cooler and noisy water pump I've chopped the middle of the front valance out and fit a later series 4 rx7 oil cooler(WITHOUT CRACKS). I've moved it down so now it has loads of air flow and not passing hot air onto radiator. I fit a new water pump- managed to get a brand new one from local auto factor. It was moisy and loud clicking which had me worried! turns out i'd forgoten to fit the 4 little bolts onto bottom pully! nuts - lucky.

I've also today fitted another Gbox i got from another kiwi ritor bloke here. About lunchtime today I was fittinmg it with two scissor jacks to lift it and it all came crashing down- one jack slicing my forehead open. bugger.

Its all sorted and I drove it into Oxford city centre watching the gauges carefully. It runs loads cooler- I've got to reset the electric fan cutin point.

So i'm well happy now- although its still far too high geared!....maybe some 13" slot mags with 50 series tyres?

now gotta have a shower and get all the blood off my face!

photos soon...

alex

[dubber91]

youve bled over her now bro....its gotta work;)

[yoeddynz]

And she does indeed. Starts really easily and nicely- Thats a good sign isnt it?

Likes to drink but as I have only whacked it all together on the same old timing settings etc that the engine was at when I got it at I think maybe a tune?
alex

[MikeLMR]

likes to drink ... sounds like it's working just fine :D

[yoeddynz]

heres some photos of recent work...

first- what I chopped out of the valance to make way for the new oil cooler..

http://i57.photobucket.com/albums/g226/yoeddynz/afterthechop.jpg

And heres the new cooler in place- a bit of a dark picture but anyway its got lots of space around it and room for air to flow out from behind. I've mounted it on an angle so the air cant just shoot right through- it has to force its way through pulling heat out in the process (at least thats what MY brain thinks)

http://i57.photobucket.com/albums/g226/yoeddynz/newoilcooler.jpg

Heres the new water pump... hmmm

http://i57.photobucket.com/albums/g226/yoeddynz/newwaterpump.jpg

Next up- I had built a heat sheild outta stainless but didnt take any photos of it. Because its nice and shiney I thought i'd take a photo while it was off during the g/box swap....

http://i57.photobucket.com/albums/g226/yoeddynz/heatshield.jpg

So the oil cooler and the box all work fine but with the standard 7 temp gauge I dont know what temp its running at. So I bought a new VDO gauge and sender. I also searched on Ebay and got a VDO voltmeter from a porsche for £4. I built a new box to house them out of ply.

http://i57.photobucket.com/albums/g226/yoeddynz/gaugebox.jpg

Then I had the fuel gauge to sort out. I took the spare chevette one I had out of the other car and ripped out its guts. I found a spray can lid that was just the right size-52mm - and found another that fit inside it snuggly. I sat the guts inside the first lid attached to the other to space it out right. I then holesawed a cover out of the chevette instrument cover.

http://i57.photobucket.com/albums/g226/yoeddynz/gaugecover.jpg

This I held in place with silicone. I wrapped the end of the lid around in insulation tape till it was a few mills thick and sliced it in half to make the rim.

http://i57.photobucket.com/albums/g226/yoeddynz/homemadefuelgauge.jpg

I now know that it sits nicely at 85 degrees and the fan kicks in at about 90.

And yesterday I took it for a nice long drive down the A34 to Eras ( ...for those who dont know him - 'old one' is an old school rotary nutter having been racing RX's in South Africa a long time before emmigrating here)
It ran there and back fine, past the 'Era test drive' with flying colours
and apart from some wheel balance/alignment issue at around 60 I was very happy! Next weekend I'm off to Bromly pagent of motoring.

And then Era took me out in his series one RX7 with a bridge ported motor and IDA webber- very very quick.....hmmmmmm...wheres a spare motor to take apart :wink:

[yoeddynz]

Obviously you'll all know Era but gotta put that bit in there for the all this info is also posted up on the chevette forum.

Yeah Mike- its drinking alright but down and back to Eras it did 25mpg+ at about 60-65 mph so not too bad at all! Now means long trips are in order!

[20B_boy]

And yesterday I took it for a nice long drive down the A34 to Eras
Lol, didnt notice a guy in a blue FD pass you and then trying to look out the back window did you!! Saw the brown mobile and wondered if it was you :driving Looked sweet mate, great work!

[shaunwil]

Your coming to the retro rides event arn't you? Would love to see it in the flesh :D

Shaun

[yoeddynz]

yeah- FD with a wing? sitting behind a bmw? yeah- at the speed I was doing i had time to notice anything interesting! every one seemed to be going faster than me!
Is yours 20b powered(in the name....) - hmmm- that would be fun....

I really want to go to retro show but have to go to friends leaving do with Hannah. bugger!

alex

[TwistedHumour]

Fantasic news and great work! It's been a while since I've checked the forum and had almost forgotten about this thread.

Your hard work really really shows :) Good job mate!

[yoeddynz]

cheers mate,
gotta come over that way for some mtbing sometime soon!

[Brett]

Hows this coming along now? :wave

[yoeddynz]

Hi there- car is going really well! Had it on a dyno and its putting out 115 bhp whch is spot on for a series 2 12A.
Just bouan old honda SL125 so thats taking my time right now. Any one here going to retro rides show eh? I'll be there in the chevette!
alex