nix
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Post by nix on May 23, 2021 19:29:14 GMT
OK so yesterday after swapping the injectors I changed my mind and decided the driveshaft issue was a problem that I needed to fix sooner rather than later. As such I spent most of yesterday coming up with a solution, I've some more parts which should be in next week and hopefully if all goes well I can make a mock up axle and send of for new shafts to be made. With that issue out of the way I decided to do something a little different to start off with and wanted to progress the bulk of the work on the core support. I decided to be a bit extra here a plasma cut the company logo into the core support.  the holes either end are there so that you can easily get a socket onto the top intercooler bolts. After a lot of careful welding it came out like this:  after a quick hit with the wire brush and a quick coat of red primer it ended up like this. The welding isn't the prettiest but trying to TIG weld 1.2mm sheet to 1.5mm wall thickness tube without anything warping is not a fun job.  After that little detour I figured it was about time to actually crack on with the downpipe. I'd been putting this next bit off slightly as getting the exhaust around the gearbox crossmember was going to be a pain and I'd kind of accepted a while ago that the best solution was oval pipe. So I started by trimming the crossmember slightly to add some extra clearance and then using some dies in the press formed some oval pipe and some oval to round converter thingy's and then started welding. Unfortunately due to the lack of room down that side of the gearbox I couldn't fit the vband so the exhaust is effectively a single piece from the turbo to the back of the gearbox (just before it goes into the CAT). I haven't welded this piece onto the rest of the downpipe yet as I wanted to put in an exhaust hanger somewhere on the gearbox crossmember but here's the next bit:    I am still waiting on some quotes for modifying the propshaft but hopefully in the next week or 2 I can get that sorted as well. Over the next few days though It'll probably be more exhaust work |
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nix
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Post by nix on May 24, 2021 23:01:27 GMT
As promised more exhaust work, It took several test fits and a few sections had to be modified before I was happy but the Downpipe/ front exhaust section is now in one piece and the cat is in position.   Ignore the absolutely terrible harness bolt plates, they are another thing on my list of things to fix at some point and they cable ties on the exhaust are just to help support the sections whilst I build it. So the exhaust is pretty straight forward from here on, although I need to wait until I have the axles in before I can commit to the routing around the diff. I'll probably tac everything up until just before the diff and then switch back to doing the wastegate. I've also ordered all of the fuel system parts and all of the hose and fittings to finish plumbing the turbo so I can get the all tied up this week as well. Its slowly getting there! |
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nix
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Post by nix on May 25, 2021 8:14:38 GMT
No progress and there likely won't be any today as I agreed to help my brother fix his mini cooper. However the postman did arrive early this morning and deliver all of my fuel and oil line fittings:  6m AN-6 Teflon line for fuel feed and return 1m AN-4 Teflon line for turbo oil feed 2x 5/16 (8mm) hard line to AN-6 adapters 2x AN-6 straight fittings 2x AN-6 90 degree fittings 2x AN-6 to 5/17 (8mm) quick disconnect (Tailgate McNoIndicate use quick disconnects on the fuel rail) 2x 14.5mm Banjo to 8mm Barb for turbo water feed/return 1x 14.5mm Banjo to AN-4 for turbo oil feed 2x AN-4 90 degree fittings 1x 7/16-20 UNF to AN-4 for turbo oil feed (for some reason my turbo seems to have a 7/16 UNF thread for oil feed but standard metric for water) Should be a few more deliveries later today as well |
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Post by Zed. on May 25, 2021 9:44:26 GMT
1x 7/16-20 UNF to AN-4 for turbo oil feed (for some reason my turbo seems to have a 7/16 UNF thread for oil feed but standard metric for water) AN threads are UNF   stollen from anfittingguide.com/wp-content/uploads/2014/01/AN-hose-and-fitting-guide-v21.pdfyou may find the turbo will accept an AN4 fitting if you cut the tapered 'seat' off to allow it to seal against the turbo's machined outer surface (copper washer time?) what make fittings have you bought? (looking for recomendations / reviews of brands...) Rich. |
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nix
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Post by nix on May 25, 2021 10:06:09 GMT
1x 7/16-20 UNF to AN-4 for turbo oil feed (for some reason my turbo seems to have a 7/16 UNF thread for oil feed but standard metric for water) AN threads are UNF stollen from anfittingguide.com/wp-content/uploads/2014/01/AN-hose-and-fitting-guide-v21.pdfyou may find the turbo will accept an AN4 fitting if you cut the tapered 'seat' off to allow it to seal against the turbo's machined outer surface (copper washer time?) what make fittings have you bought? (looking for recomendations / reviews of brands...) Rich. I was not actually aware that AN used UNF threads, that is good to know! I've got the 7/16 adapter which has an inverted taper on the turbo side as well as an o-ring to seal against the turbo so hopefully that'll work. I always used to use Aeroquip fittings in the past but they are so damn expensive. The last couple of cars I've built I've used Torques fittings (company that sells via ebay). I've had good experiences with them so far, the fittings are relatively cheap, they have a stupidly large range and free next day delivery. Can't fault the quality either, both fittings and braided line has always been really good quality. their fittings are probably 25-40% less than Aeroquip fittings and of the same/similar quality I previously made a set of high pressure power steering lines for my S14 with the their teflon line and fittings and it held up to some serious abuse and never failed! |
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Post by Zed. on May 25, 2021 10:12:59 GMT
I always used to use Aeroquip fittings in the past but they are so damn expensive. agreed, I like Aeroquip aswell but Speedflow can be a better fitting as more compact radius, sometimes very usefull! I've a few 'Torques' fittings as they came in a bundle of parts I bought but havn't used them so no experience  Rich. |
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nix
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Post by nix on May 25, 2021 11:39:33 GMT
So more parts arrived, Got the oil sump gasket (this is so I can pull the sump off to weld in the oil return fitting) and got my new fuel pump. As this car's primary purpose is as a daily and not a track weapon or drift slag I decided against going for external pumps with swirl pots. Instead I opted for a 340LPH in-tank pump in the form of this AEM unit.  Its not actually listed a straight swap part for an MX5 but it has virtually the same dimensions so I'll make it fit and I think I'll run fresh (and larger) wires to it at some point |
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nix
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Post by nix on May 25, 2021 22:34:52 GMT
So I didn't really got much time to do anything on the car this evening as I was pulling a Mini apart to find out why the clutch doesn't release... FUN... I did get a few more parcels though and I did get time to design some prototype parts. Both of my new driveshafts arrived ready to make a mock up. After a fair bit of googling I found an axle that would work... and once again I've had to resort to VAG parts. So for the inner part of the driveshaft I settled on using the rear driveshaft/cv from an Audi S4. The S4 driveshaft is a similar setup to the MX5 driveshaft with the fixed outer and plunging inner joint and replacement inner joints are easily available and affordable. The only downside is the inner joint is a tripod joint but considering the S4 model the joint is from produces nearly 400hp I'm not too concerned. Obviously Audi driveshafts aren't going to bolt up to a Tailgate McNoIndicate diff so I need an adapter, after taking some measurements I threw something together in fusion and fired up the plasma cutter to create a prototype.  Hot of the CNC Plasma. After a little cleanup they looked like this:  So the inner set of holes bolt to the Tailgate McNoIndicate diff flange and the other set bolts to the driveshaft, the plan was to tap the outer set of holes to an M10 thread. Unfortunately plasma cutting 10mm steel is always a big inaccurate as the plasma stream start to deflect so the edges start to taper. It'll work for prototyping but I'll have to get the final parts either laser of CNC cut. These will however allow me to make my mock up axles to send off to be fabricated.  It's probably gonna be a slow week as I've still got a dissembled Mini in the workshop where my car has been living. Hopefully before the weekend I can roll my car back in and start cracking on. |
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nix
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Post by nix on May 27, 2021 13:04:09 GMT
Ok this is more for my benefit than anyone else's but I thought I'd throw together a sort of To-Do list of what needs to be done still on the car TO-DOFinish exhaust designFinish wastegate piping and feed back into exhaust
Fully weld exhaust and wastegateWrap wastegate and exhaust
Finish welding on manifoldMake turbo oil feed lineFinish turbo oil return and weld fitting into oil panMake turbo water linesFinish mock up of engine coolant hoses and lines for heater coreMake coolant reservoir/header tank/expansion tank.Make fuel linesInstall Fuel PumpFinish lower section of core supportMake Intercooler pipingModify clutch pedal assembly to fit Tailgate McNoIndicate master cylinderMake new clutch lineFinish welding diff mountsMake mock up axle/driveshaftGet custom axle/driveshafts madeGet prop shaft shortenedPaint new steel in engine bay & chassis legsPaint/Powder coat modified subframesPaint/Powder coat gearbox cross memberDe-Power steering rack/Weld pinionReplace outer tie rod ends on steering rackWire up engine with Tailgate McNoIndicate harness and modify to work with existing Mazda harnessChange all fluids/Service engine, gearbox and diffInstall ABS sensor in front wheel hub to use for speedoWire up SGI-100BT to correct tacho signal and generate speedo signal for OEM gauge cluster
I'll no doubt have things to add to this when I remember them and I'll cross them off as I go along and this is in no particular order. |
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nix
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Post by nix on May 27, 2021 15:57:17 GMT
Lets play a little game...
I am bigger than M10, Smaller than M12 and I'm not 7/16-20 unf. What am I?
So my turbo came with a banjo bolt that is about 10.7mm in diameter, both threads and shaft and I have no idea what size or thread it is. I really don't want to use a banjo for the oil feed as it will put the lines in really odd positions. I had planned on using an adapter to adapt it to AN-4 but I need to know what size it is.
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nix
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Post by nix on May 27, 2021 16:54:16 GMT
Lets play a little game... I am bigger than M10, Smaller than M12 and I'm not 7/16-20 unf. What am I? So my turbo came with a banjo bolt that is about 10.7mm in diameter, both threads and shaft and I have no idea what size or thread it is. I really don't want to use a banjo for the oil feed as it will put the lines in really odd positions. I had planned on using an adapter to adapt it to AN-4 but I need to know what size it is. Ok so I think I’ve now got this sussed, I’m like 99% sure it’s a 7/16-24unf fitting (m11x1.0) as that seems to be standard fitting option on some Garrett GT28 and GT30 turbo. I’ve ordered one so hopefully that will arrive next week and it’ll actually fit |
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Post by Zed. on May 27, 2021 18:23:53 GMT
Lets play a little game... I am bigger than M10, Smaller than M12 and I'm not 7/16-20 unf. What am I? So my turbo came with a banjo bolt that is about 10.7mm in diameter, both threads and shaft and I have no idea what size or thread it is. I really don't want to use a banjo for the oil feed as it will put the lines in really odd positions. I had planned on using an adapter to adapt it to AN-4 but I need to know what size it is. Ok so I think I’ve now got this sussed, I’m like 99% sure it’s a 7/16-24unf fitting (m11x1.0) as that seems to be standard fitting option on some Garrett GT28 and GT30 turbo. I’ve ordered one so hopefully that will arrive next week and it’ll actually fit UNeF Rich. |
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nix
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Post by nix on May 27, 2021 21:31:44 GMT
Ok so I think I’ve now got this sussed, I’m like 99% sure it’s a 7/16-24unf fitting (m11x1.0) as that seems to be standard fitting option on some Garrett GT28 and GT30 turbo. I’ve ordered one so hopefully that will arrive next week and it’ll actually fit UNeF Rich. I didn't even know UNeF was a thing. Oh well hopefully this one works |
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nix
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Post by nix on May 31, 2021 11:46:57 GMT
Well things were going smoothly after Friday night and Saturday Morning, but it was clearly all going too smoothly. On Friday after taking some measurements and assessing some things I decided that it might be worthwhile to try and adjust the engines Fore/Aft angle to improve clearances in some places. When I originally installed it I'd had it set at exactly 3 degrees but evidently during the process of making mounts and whatever else it had slid to about 3.5 degrees. so I made some adjustments and adjusted it to about 2.8 degrees and made a new mount to hold it place. This 0.7 degree change makes a huge difference, it drops the top of the engine enough so that it now clears the bonnet without any further modification and it moves the back of the gearbox up by about 23mm! This along with the new gearbox mount adds a lot of extra room to easily run the exhaust without it being the lowest point on the car. This change also changes the propshaft angle up meaning I can mount the diff a lot higher up in the car which is awesome.
This change obviously means I've got to rework some bits, but its definitely worthwhile. So I started work on the new prop centre bearing mount and this is when prarrie canoe hit the fan. I was smoothing it off on the big belt grinder and probably applying too much pressure as the part bit into the belt and was fired out across the room. Well my hand went straight into the belt and I ground through part of 2 knuckles and part of my thumb... Fun . So that's my work on the car done for the weekend unfortunately. Hopefully in the next few days it'll heal up a bit and I'll get some movement back in my fingers and I'll be able to get back too it.
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Post by Zed. on May 31, 2021 12:42:08 GMT
my hand went straight into the belt and I ground through part of 2 knuckles and part of my thumb... Fun Sucks when theres leakage, makes a mess and puts work back a while  much damage or just less skin? also, you've never lived untill you've had a finger glued back on......
or driven up a tree*........
Rich.
* not my finest |
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