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Post by browno on Jun 26, 2017 22:32:12 GMT
So, time for another instalment in my build, and more progress along the road to having something car-shaped rather than a pile of bits in the garage! So the first job from last time was to get started prepping the floor panels for fitting - so firstly I masked up the edges, then with the panels clamped in position, marked out a 10mm line from the edge right round (the tubing is 20mm, so that will get me central). Then I evenly spaced my holes at approx 100mm centres (variation depending on dividing up the spaces evenly and logically!), and then centre punched and first drilled the panels and deburred before remounting and spotting through to drill the chassis rails.  B569DF52-55B2-4D84-85DB-64B08D5F8896_zpsxph9avc3 on Flickr  B831A6D9-D5C7-4703-BAFE-BF677C625978_zpsablebxxb on Flickr Then I also laid out the hard lines for fuel flow and return and also rear brakes, and after mocking up on a bit of scrap ali, started drilling and fixing the lines with p-clips at 150mm spacing (slight overkill compared to the 200mm recommended by many, but again it fitted nicely into the available space). I have made sure to leave plenty of pipe each end for now to be relatively free with routing of the ends...  DE20D261-8B90-4B65-85D2-563A1103C82F_zpscielzgra on Flickr  744A0698-BAE6-4852-9473-0D7F61B3E069_zpstlwpvcg8 on Flickr Then today, I had a great help from a colleague (and former vinyl sign maker) to wrap the floors - with the edges left clear to allow some space for a good bead of tiger seal to ensure the ali is gripped and sealed properly.  9F928DD9-1C54-4996-9937-F1A95045FF75_zps6toxoksv on Flickr Then I applied a thin bead of tiger seal all around the mating surfaces - thinking that less is more here certainly turned out right - I had a little oozing, but only very slight, and which was easily cleaned up with a solvent-soaked rag.  5E5EAE1F-E97D-4A9D-90D7-AFBBAAF7FA06_zpsgdh891eg on Flickr Then having got busy with the lazy-tongs (the cheap silverline ones that I bought having had issues during the line fitting, I used my mate's Clarke ones, which had it all,done super quickly), and I have fitted floors...  1D5247C9-9971-40E0-A807-97F10391E3D6_zpsyfsiaauh on Flickr  98DE7551-9D3A-4957-A372-541F61E40226_zpsh5its87m on Flickr And having debated what to do, I am pleased with how the carbon vinyl works to give a contrast against the green (even with the body still upside-down!)  2A8509D2-8118-4F26-9B86-38AEF9C059C2_zpsipqijqmi on Flickr So, I have front upper ball joints to change over tomorrow, and the upper arms to refit, and then it should hopefully be body-on time this week! Exciting times! |
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Post by gwnwar on Jun 26, 2017 23:40:01 GMT
Get some cheap carpet or rubber pieces to cover the floor while you work on the build..it will save vinyl..
Looks good so far.. Like the color..
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Post by browno on Jun 27, 2017 12:47:00 GMT
Thanks again Gwnwar - definitely want to get something to protect the vinyl to make sure that it doesn't get scratched/damaged during the rest of the build - thankfully I have some old carpet in the garage that should fit perfectly!
If the timings work out right, it might be body on tonight...
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Post by miket on Jun 27, 2017 15:43:38 GMT
Good stuff - things to keep an eye on:-
* the very narrow gap at the rear of the tunnel - mind them lovely new pipes.
* those 2 tabs on the rear of the chassis (if they're still there) may try to trash your rear subframe's brake line if it's in place.
* a rivet head may prevent close union by being jammed between floor and subframe at front unless you've planned to avoid that.
Good luck.
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Post by gwnwar on Jun 27, 2017 17:51:37 GMT
At the front copper tubes, is the center one crimped a little after the turn can't really tell in pic..
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Post by browno on Jul 4, 2017 11:25:05 GMT
Hello again all - and thanks again for your comments - gwnwar your eagle-eyes don't decieve you, there is a slight kink in the top fuel pipe where the bender dug in slightly - I am planning on using that line for the return rather than flow, but will decide as things come together whether to chop at the bend and run a longer flexible hose to overcome that portion - but most likely will just for having a good finish. So, thanks to Photobucket, my thread has been butchered and none of the images are now showing which is a massive pain - but for now I have rehosted everything onto Flickr - HERESo, onto progress, and I have made some! First job was to flip the chassis over and turn it round the right way - and I could admire my floors properly...  9500EF38-9CE6-47C9-8284-F5FEA2865E6E_zpse5kafsex by Gaz Brown, on Flickr Then we lifted the body carefully through the garage and into position, which was pretty straighforward and everything lined up as it should...  8A809374-EF30-49A8-A216-DAB43E31526A_zps880fcpqo by Gaz Brown, on Flickr Then I could build up the rear suspension:  050066AF-BDEE-44CD-A6F8-6646E4CD3420_zpspo0fgroi by Gaz Brown, on Flickr and bolt down the chassis - with one minor schoolboy error when I tightened up this bolt with a ratchet spanner and then realised it was trapped (and of course wouldn't allow me to undo the bolt!) - which was easily solved by wedging a pry-bar in the gap to hold the nut!  17FBEC1A-E840-4E08-BBFD-C880EFE2598E_zps0nnhnajs by Gaz Brown, on Flickr Next, I replaced both front upper balljoints and that also allowed me to build the front suspension up and fit the cycle wings so that I could torque up the front hubs.  C8E34086-06A9-4878-8251-C9A91B9EB58D_zps26rn92uy by Gaz Brown, on Flickr and then I gave my pedal assemblies and steering column a lick of paint to tidy them and started having a go at fitting them. Once I had a feel for what I needed to do re: spacers (I chopped them off the brake pedal and put them on the servo side), and also had removed the stud from the clutch pedal and replaced with a longer nut & bolt, it looked like everything was lining up and the column fitted well with the help of some cable-ties...  Untitled by Gaz Brown, on Flickr  Untitled by Gaz Brown, on Flickr However, the steering column was only just touching the end of the rack fitting:  Untitled by Gaz Brown, on Flickr Having looked online I found reference to this in a few places including the exomotive build guide - exomotive.com/exocet/build-guide/pedals-steering/ which shows that you can extend the lower portion of the column easily... So, having successfully fitted an windscreen to my mate's Tiger kit, we were on a roll and so decided to tackle the column last night. I don't know if there is a difference in LHD and RHD columns (or differences by years) but this didn't work... looking at the lower shaft, we thought it had sealant round the splines - which turned out to be weld... but we persevered anyway, and starting filing away the weld - which revealed the ends of the splines.  Untitled by Gaz Brown, on Flickr  Untitled by Gaz Brown, on Flickr but once we had the weld clear, we discovered that the splines were only really long enough to locate the shaft for welding...  Untitled by Gaz Brown, on Flickr So now, I am going to be buying a replacement column - and having checked a mate's (also a '98 NA) that has the same shaft as mine - should I be looking to extend from the top half of the column, or are there different designs of column out there that have the extendable bottom section (or is this something that was only on LHD cars?)... At the very least - this might act as a reference for others that might come across the same problem not to get chop-happy!) So the saga will continue on this one shortly - but for now, I am really happy to be making good progress - I also now have tyres sorted and being fitted to the wheels at the moment - and have my spacers on order from Freaky Parts too... |
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Post by browno on Jul 4, 2017 12:15:49 GMT
and here is a quick resolution - within minutes of posting my update, I have had an email from Stuart with the following information: I hear you have a column issue. This is resolved with the use of a hammer as in the attached picture. You effectively lengthen the lower part of the shaft by compressing the upper part thus allowing it to protrude further through the bulkhead. Hope this helps, my pictures don’t seem to work on the forum but feel free to use the attached. Hopefully you can get someone to weld it back up. If not send it to me. Stuart  column by Gaz Brown, on Flickr You wouldn't get that level of rapid support from many places! Now that I have seen Stuart's picture, I can see what he has done - effectively shortened the upper half of the outer - meaning that the lower portion will then fit properly. I will try this tonight on my upper column - and I now have a new lower on order, so can hopefully bolt that in once it arrives. I am still intrigued by the US approach though - this certainly suggests a significant difference in the columns across the pond (or all LHD)... |
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Post by browno on Jul 17, 2017 22:03:23 GMT
It's been a little while, but it is time for another progress update! I have managed to sort my column issues - following Stuart's instructions, I managed to bash away at my column and gain that vital extra inch!  Untitled by brownotribbs, on Flickr Which then allowed me to fit up my column properly... and connect up the (replacement) lower shaft...  Untitled by brownotribbs, on Flickr  Untitled by brownotribbs, on Flickr I have then been working to try and begin sorting details - so have the accelerator cable attached, handbrake cables installed and ready to bolt into place and also the clutch plumbed in and bled up, so that is now working. I have also chopped the front end of the fuel hard pipes and have fitted flexible hoses up to the fuel rail (although I have dropped one of the fuel-rail spacers, so will need to sort a replacement if it doesn't turn up on the floor!).  Untitled by brownotribbs, on Flickr I also got my new tyres (Federal RSRs, which I have been very pleased with on my mk3) fitted onto my new wheels and have trial fitted them in advance of my spacers arriving. Although I am not a big fan of black wheels in general, I think that they are the right choice to provide a good contrast to the green chassis and bodywork...  Untitled by brownotribbs, on Flickr And tonight (as I am waiting for my braided hoses to be modified for the brakes, so am holding off on piping them up), I started on the big box of spaghetti otherwise known as the loom!  Untitled by brownotribbs, on Flickr Thankfully, my labels appear to be all intact and legible so far, and I have started lying it all into place as a starting point - which means everything looks a little messy! Thankfully everything that I have come across so far has plugged into the right places, and the other connectors all seem to make sense (I predict this being a statement that might come back to haunt me!)  Untitled by brownotribbs, on Flickr  Untitled by brownotribbs, on Flickr So, it is all coming together - I need to bolt in the handbrake, sort the brake pipes and also the rear fuel pipe connections, but then it should be time to get it started and moving! |
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Post by gwnwar on Jul 18, 2017 18:57:19 GMT
Coming along nicely. Have you thought about a thin pin strip in matching green around the wheels/rims just to break up the black some.. Did you put a small double flare on the fuel tubes to help stop the hose from sliding off.. Fuel supply hose is under 60psi pressure.. Looks like the small seal on top of the trans.. Check for turret being fill with trans fluid 90cc..and plastic bushing being on the end of the shiftier. You may want to get the engine running and lights in place and working before you start chopping the harness. Remember to leave an inch or two at each cut wire just in case you have to hook it up again a piece of shrink tube on ends of cut will seal it.. 1 ground wire can supply ground to a few places/systems.. Same with power.. Go slow.. walk away if you have to.. Remember NAs used power to switch high to low beam headlamps NBs used ground to do switch. If you haven't seen this and printed it off. put pages into plastic sleeves to keep clean and write on them.. For '94>'98 UK MX5s wiring.. www.mx5usedparts.co.uk/media/MX5-Wiring_Diagram_94-98_UK_Mk1.pdf |
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Post by browno on Jul 28, 2017 8:48:46 GMT
Thanks for the tips again gwnwar - you are right that I have double flared the ends of the fuel pipes, and the plan is to get the loom laid in place and get it fired up and working before beginning stripping back the wiring!
The shifter boots do indeed need replacing - another job on the list when I also refill the diff and box with oil.
I have progress though - I have managed to get the fuel lines all in place (but not yet fixed until the tank is fully fitted), and have been finding places to ensure that all earths are grounded (albeit temporarily - a mixture of clamps either holding wires together, or holding them onto the block/ppf was functional if not pretty...).
Having done that, I then jumped the fuel pump and primed the system, and was pleasantly surprised when I tried to turn the engine over...
I only ran very briefly as I have no radiator installed at the moment (a new one is on the way) - but this is another good step forwards...
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Post by gwnwar on Jul 28, 2017 19:30:20 GMT
Bet that start up put a big smile on your face.. now for the list of jobs left.. Good work..
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Post by browno on Aug 15, 2017 9:50:12 GMT
Thanks Gwnwar - yes, it was definitely good to get it to fire up again! I have been making a little more progress, slightly steady as I have been on holiday and also had to replace the brake master cylinder on my mk3 (it was leaking between the master and the servo). The day before my holidays I recieved a package from Freaky Parts containing my wheel spacers, which was good (but I was told in no uncertain terms that they would have to wait until I got home!). They look very nicely machined, and also are not quite as weighty as I thought they might be. So, over the weekend, I fitted the spacers and made sure that all studs were firmly thread-locked into place, at which point, I could then fit all four wheels properly.  Untitled on Flickr which meant that I could remove the axle-stands and drop the car onto its wheels for the first time! It definitely looks a lot lower than the MX-5 did, but I guess that's part of the point!  Untitled on Flickr Then last night I had a bit of time to do some more jobs, and was ably assisted by a friend from work (who has worked building some lovely race cars), and he had also modified my final brake flexi- lines. So first job was to loosely put them into place - with the rears run to the t-piece (now centrally located - will be bolted in place when my rivnut tool arrives!). we also did the fronts, but I didn't take any pics (and need to make up some brackets to hold them in an IVA-compliant position). I do then need to p-clip the flexis in place - but need to wait for a set of new banjo bolts to arrive so that I can get the routing perfected.  Untitled on Flickr We also removed the loom from the car - as I think I was maybe trying to run before I could walk - and needed the space to be able to fit the bulkhead panels and wiring tray. At least I know it runs, and could mark up all of the connectors that were required to make the car fire! The final job was then to fit up the handbrake lever and get that adjusted up - which worked ok after a bit of double checking t hat everything lined up properly. The good news being that once we had adjusted the new calipers and the cable, that I have the beginnings of some working brakes!  Untitled on Flickr So my plan of action now is to get the brake piping/hoses finished and secured then bleed them out, secure the handbrake cables and then start work on getting the bulkhead panels trimmed and fitted up before then fitting and modifying the loom. Oh, and my new (standard) radiator has also arrived, so I have fitted the MEV brackets to it, so I can install that too when I have my rivnut tool. |
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Post by Stiggy on Aug 15, 2017 11:33:58 GMT
great blog, pity about the first few pages with the pictures missing, any chance you could edit these for others to see? I notice the MX5Nutz thread is also corrupted courtesy of Photobucket, I presume it is possible to re host once to get pics back on both forums?
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Post by browno on Aug 15, 2017 12:55:10 GMT
Hi Stuart & thanks for the positive comments - yes, I am planning on editing when i have the chance to do it - along with Nutz and a couple of other forums I have also been posting on! In the meantime (as a fix for those wanting to see the pics) I have rehosted all of the pics (and a few extras) on flickr www.flickr.com/gp/31795518@N05/LYX484. Will also add this to my first post as well for now! Edit - a couple of hours spent redoing links tonight and I have almost got to kit collection day! Getting there slowly! |
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Post by browno on Aug 16, 2017 22:22:43 GMT
Right - that should be the pictures all back for now (assuming that Flickr don't now follow Photobucket's lead!)...
Not much to report today - just got my rivnut tool so have fixed the rear brake t-piece and fitted new banjo bolts to all four flexis.... so with a final check over all fittings, I should be able to give the brakes a first bleed now...
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