As some of you probably know we're two petrol heads called Dave (Welder Dave & 3D Design Dave) that decided to set up a design & fabrication business called DaveFab.
We've both had a few 5's in the past and we use the current one (we've named it the D52, because of the whole stealth bomber thing) to develop parts.
So here's the story so far...
This is the car in all its glory at a recent ring trip (more on that later), it's a 1997 Mk1 1.8 Harvard
We started out making a few bits in our spare time, we were proud at the time, they were very very shiny. Some titanium, most aluminium though.
We were quite proud we'd made a few bits, but they were all a tad raw. Not the understated, functional and clean look we were after, so after countless hours making bits in our spare time and loads of different finishes the engine bay looked like this.
The engine was mostly original at this point, we developed our own scuttle intake that uses the stock size panel filter, a radiator cooling panel and it had a cobalt cat back exhaust.
For the other bits, we developed a tower brace, a rear jacking bar/chassis brace and a brake master cylinder stopper. The car also had Koni suspension, and some sticky tyres.
So it all was pretty sedate at this point.
We did a few track days at Castle Combe which were great fun. Attended a couple of local meets
And then in April we took the car to the ring.
The place amazes every time - Car Friday on the Easter weekend is mental. Lots of German beverages were consumed, many laps were done, and lots of plans were chewed over.
From this point on things started to change in terms of what direction we wanted to go with the car...
So not long after we got back from our road trip (about 4 days to be exact) packages started to arrive.
We decided to go Turbo, we've done TD04/05 in the past. While it was great and we love those set ups, we decided we had to use some modern technology. We've designed bits in the past for these turbos on other cars, and we just couldn't resist.
We had rough power figure in mind for the car so after reading many compressor maps we decided a Borg Warner EFR 6258 in 0.64 trim was going to provide the desired wizzbang we wanted with good response.
After spending an unusual amount of time staring at it, making turbo noises and spinning the compressor we turned our attention to the car.
We had to get a few last pics of the car before we took it to bits.
We couldn't wait to get rid of this.
Quick compression test while we could, all seemed ok.
We then had a long long day. One Dave started to remove bits off the car rather rapidly while the other finalised the turbo location for the manifold.
Got everything ready..
Bit of jiggery pokery..
And its out!
The following morning we got stuck back into it, removing the old 5 speed box getting the engine onto the engine stand.
It's a great small package when you get it on the stand. Looks like the important bits have been cared for too. No sludge here!
The next steps we have to take (the best bit) is to fabricate all the components required.
Starting with the exhaust manifold..
So after a few weeks this turned up:
We've decided on a full 304 Stainless Manifold, all 3mm thick wall, with a billet collector and CNC ported head flange. Primary diameters are 1.5" ID. A lot of people turn their cheeks at stainless because of its bad reputation for cracking. There's a lot of reasons this happens, but it's usually improper gas coverage combined with a lack of turbo support.
We started a 3D model of the design, and then designed the weld fixture around this.
While we wait on laser cutting for the fixture, we started the color change on the D52. We decided on a vinyl wrap using Hexis HX2000 material.
It's certainly different, and seems to vary hugely depending on the angle and lighting.
And that pretty much brings you up to date with where we are at the moment. We'll post more as we get on in the next few weeks - we're hoping to get it ready for JDM Combe so fingers crossed we don't have too many hold ups!
Marc at Skuzzle says if that's for a BW you might find the stud for the brace might interfere with the IWG.
It is for a Borg Warner, you'll have to tell him he need not worry so much. Unless we run 80mm+ studs I don't think it'll be an issue. That's with the actuator & rod clocked round as far as allowed by Borg Warner towards the turbo flange.
In other news, we're pretty much there with the intake/radiator/intercooler/oil cooler design.
We decided to go with a slightly smaller radiator core and use a Garrett intercooler core with our own end tank design to optimise the route. The rule of thumb is every 90 degree bend claims half a psi of boost.
We'll do an update shortly..
3D Design, Fabrication & TIG Welding We have upgrades for your 5 at www.davefab.com
Shout, shout. Let it all out. MX5's is what we're all about.
wannabe: Is there a DaveFab discount code for us? I missed the sale prices that were on the site last week
Mar 26, 2019 9:39:53 GMT
FFS Corders: Have you checked the members discount area on here?
Mar 26, 2019 11:15:02 GMT
wannabe: haha I had looked in the DaveFab area but looked right pas t
Mar 26, 2019 12:58:46 GMT
wannabe: past the members discount section!
Mar 26, 2019 12:58:57 GMT
wannabe: Why is it whenever you place an order online you remember something else once you've pressed submit...
Mar 27, 2019 14:24:01 GMT
atlex: Bought a #Davefab part recently.. the quality is well in excess of the price!
Apr 2, 2019 20:46:10 GMT
Zed.: how long do gearlever gaiters last? bought one last May, fitted probably late June, just looked and it's Jeffed
Apr 7, 2019 19:00:21 GMT
wannabe: Have you been playing with your gearstick a lot? Didn't your mother tell you you'd wear it out if you don't stop playing with it?
Apr 8, 2019 12:02:22 GMT
FFS Corders: Depends where you get it from. Jass ones are decent quality and Drmx5 can be a bit varied but is usually long lasting
Apr 8, 2019 13:29:27 GMT
martiny: I was once told the rubber gaiter lasts longer if you rub talc in before fitting, as it fills the pores (or something). So I shake a new one in a plastic bag with some talc. Don't know if it makes them last longer but I expect 5+ years from a Mazda one.
Apr 8, 2019 15:00:48 GMT
howardb66: Yeah, a bit of talc is surefire to stop chafing.
Apr 8, 2019 18:02:52 GMT
Zed.: new gaiter bought from mosseurope on ebay... will not be buying another I don't mind anual oilfilter replacemement but gearleaver gaiters
Apr 9, 2019 14:22:43 GMT
Crumpets: Random one chaps - Has anyone had any luck running a PAS cooler?
Apr 11, 2019 8:10:37 GMT
wannabe: IIRC someone either on here or on the other site had issues with boiling PAS fluid at autosolo and was considering options (including PAS delete) but I can't remember what the outcome was! I don't see why you could make a PAS radiator, though
Apr 11, 2019 9:49:44 GMT
Crumpets: Think i'll look into a small oil cooler and try and run it in line. Thanks for the input Wannabe
Apr 11, 2019 10:52:44 GMT
wannabe: Everything is fixable with time, skill, money and luck lol. It could maybe be worth considering a thermostat or a manual close-off valve, maybe, in case it's really cold in winter??
Apr 12, 2019 7:11:02 GMT
Crumpets: That's not a problem for me as the car isn't driven in winter hahaha For now i'm going to run without a cooler but always looking towards the next step
Apr 12, 2019 7:28:00 GMT
FFS Corders: It's been done a couple of times, can't think of one off the top of my head mind
Apr 12, 2019 17:55:33 GMT
JamesMk3: Is anyone on here doing JDM Combe this year?
Apr 15, 2019 8:29:56 GMT
FFS Corders: Jackyboy usually does, with the South West lot
Apr 19, 2019 19:28:54 GMT