KP's Build - Final Assembly

[300tt]

Thanks for the info, Kevin. I just realized I already ordered the new top spring seats when I placed my last Mazda order. So, I guess I'll just decide which one to go with once I see how they fit together since I'll have both options sitting here.

I agree, I think we'll need lower spring rates too. However, I'll give them a try as they are and see how it drvies.

Mark

[Kevin Patrick]

New Exedy clutch and XTD flywheel arrived on Friday.



Reading the instructions on the back of the clutch boxes made me realize that we are going about the MEV build manuals all wrong. Stuart needs to introduce some new cartoon characters with silly facial expressions.

Clutch Disc Instructions


Clutch Cover Instructions

[Kevin Patrick]

Gentlemen, we have a floor. I used a center punch to mark the holes and applied WD-40 to the drill bit after drilling every few holes. The pneumatic riveter worked well and my hands are very thankful today.

[Kevin Patrick]

Worked on the rear too and added the new brake calipers, pads, rotors and stainless steel lines. Also added the forward wing stays that bolt to the top caliper mount.

New right rear pads/caliper/stainless steel brake line


Right rear installed



Left Rear installed



Rear end… now with brakes!

[JimK]

Hi KP
Really liking your build, looks high quality you must be pleased with the results so far.
Looking forward to seeing this one, you are setting a high standard!
Regards
Jim

[sscrow]

Always looks better when you do the job properly!!!!!looks good Kev.

[bobhern]

what on earth is this going to cost ??

[tlight]

Bob,

My target was £2K, including IVA.

To date it has cost £3,990.60 & I have just under £2K of parts to sell (via E-bay))...(I haven't had to sell any EARTH yet!)

So around £2K to £3K should make a nice MEV Exocet.

Tim

[bobhern]

great thanks.

[Kevin Patrick]

Thanks for the kind words guys.

Bob, I'll be posting my final costs when all is said and done, but going with more new/refurbished parts on your Exocet will probably bring the costs more in line with a Rocket build. (I also am in the US, so there was additional cost getting the kit across the ocean and to my door.)

[Kevin Patrick]

Some good progress over the weekend on the engine. Replaced the timing belt, water pump, camshaft seals, crankshaft seal and alternator belt. I had never attempted these jobs before so I took my time at each step. Certainly is easier with the engine out of the car!

Before


All old parts removed


Used a 1-1/2" PVC fitting to press the seals in


New timing belt, water pump, seals and tension pulleys installed


Covers installed and new alternator belt installed


I used the Wite-Out trick to mark the gears, old and new belt to ensure I did not incorrectly install the new timing belt.

Some resources I used to help me through the job:
Factory Service Manual
miata.net/garage/tbelt/index.html
miata.net/garage/timingbelt.html
miata.net/garage/water_pump.html
www.mx5unleashed.com/tech/timing-belt-mx5.html

Videos:
Timing Belt and Water Pump How-To 1 of 2
Timing Belt and Water Pump How-To 1 of 2
Timing Belt and Water Pump How-To Appendix

I also took step-by-step photos of the work I did - see them here: www.flickr.com/photos/thekevinpatrick/sets/72157626088272397/

[Andy888]

Oh great work and thanks for the cambelt etc links there. This is our next job too, though we are tempted to just pay someone to do it for us so we can get on with it!!

[Kevin Patrick]

Installed the new Exedy clutch and XTD lightweight flywheel. The new flywheel is about half the weight of the stock unit - should spin up nicely.








Also installed the new clutch slave cylinder with a stainless steel line that replaces the curly hard line. This should simplify the system and make it easier to bleed the line.



While the engine was on the crane, I drained the engine oil and replaced the filter while it was still easy to get to.

[Kevin Patrick]

It is starting to come together! After the engine/transmission work was complete, I installed the engine and transmission on the front subframe.


Then bolted on the PPF.


Then the driveshaft.


A bit of a milestone - the engine, transmission, PPF and front/rear subframes are now one.


At this point, I took a few moments to step back and do some quality control. Much of the assembly of the subframes/suspension was only hand tightened and not torqued to spec. I went through all the fasteners and made sure each bolt was torqued to the specs recommended in the factory service manual. Also staked the front axle nuts.

[Kevin Patrick]

Exhaust time. Raceland headers, unknown aftermarket catalytic converter from the donor car, and an OBX exhaust.

Headers


Catalytic Converter


Exhaust