Project Old School - 1988 Mazda RX7 Convertible - with added turbo!

Discussion in 'Reality Check' started by Jenn, Jul 17, 2015.

  1. Lex Lucas

    feels good.

    Joined:
    Jun 6, 2003
    Messages:
    14,966
    Likes Received:
    129
    Location:
    Nova Scotia
    What kind of carpet cleaner do you have?
     
  2. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
  3. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Got my o2 sensor bung welded up over the weekend by a friend of ours. Now just waiting on a few gaskets to reassemble the exhaust system. I also need to clean up the wastegate.

    [​IMG]
    [​IMG]
     
  4. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Replaced the rad hoses with a set of Racing Beat hoses I had laying around.
    [​IMG]

    Took the glass out of the convertible tops to strip out the good headliner and clean it.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Cleaned up the Waste Gate while I have it out.
    [​IMG]
    [​IMG]
     
  5. Dewie

    Well-Known Member

    Joined:
    Nov 6, 2008
    Messages:
    5,102
    Likes Received:
    1,232
    Location:
    N.S.
    What's taking so long??? gosh!!!

    :P Looks good - I find the updates entertaining
     
  6. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    We also got the map loaded on the new computer last night. :lol:

    It was a productive night. I need to take one of those rad hoses off the car and trim it a bit tonight. Waiting for a bunch of parts to come in now too - block offs for the 2 o2 sensors that were in the downpipe, seat upholstery, gaskets to reassemble exhaust.

    I'm waiting for the headliner to dry - I cleaned it with the shampoo machine - then I can glue it back in.

    Also need to wire in the wideband controller and see if I can fix the passengers side power window switch.

    To do list (tonight's tasks in bold)
    • Reassemble exhaust with gaskets and new resonator
    • Replace turbo coolant hose
    • Reassemble Injectors/Fuel rails/Upper Intake Manifold
    • Tie up fuel pump wiring
    • Rewire window switch power source
    • Install Innovate Wideband controller
    • Install Innovate Wideband gauge
    • Block off old O2 sensor holes
    • Install Adaptronic ECU
    • Take apart seats and rebuild foam
    • Install new upholstery
    • Repaint seat rails
    • Reinstall seats
    • Install headliner on good top, reinstall top
    • Reinstall all interior
    • Fabricate trunk floor panel
    • Replace tires on two wheels
    • Repaint interior pieces that are still granite finish
    • Replace springs on front of car
     
    Last edited: Jul 28, 2015
  7. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Wednesday, I expect I will be able to install the headliner on the top, and Thursday install the top on the car. I'm also hoping my turbo/exhaust gaskets/o2 sensor blockoffs will be here by the weekend as well as the silicone couplers to build my intake.
     
    LMAC and Dewie like this.
  8. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Window switch started working on its own, so I put the door panel back on. Removed the stock computer last night and installed the aftermarket one - ran into another cable I need to connect my wideband. Fixed the turbo coolant line and the lower rad hose. Got the wiring set up for the Wideband controller/gauge, installed the gauge, just need to finish connecting all of the wiring tonight.

    Still waiting for parts to reassemble things... :( I think I'll work on reattaching the headliner on the convertible top tonight.

    Remaining to-do list:

    Engine:

    · Block off old O2 sensor holes
    · Reassemble exhaust with gaskets and new resonator
    · Reassemble Injectors/Fuel rails/Upper Intake Manifold
    · Tie up fuel pump wiring
    · Install Innovate Wideband controller (IN PROGRESS)
    · Install Innovate Wideband gauge (IN PROGRESS)

    Seats:
    · Take apart seats and rebuild foam
    · Install new upholstery
    · Repaint seat rails
    · Reinstall seats

    Top
    · Install headliner on good top
    · Reinstall top

    Interior
    · Reinstall all interior
    · Fabricate trunk floor panel
    · Repaint interior pieces that are still granite

    Chassis
    · Replace tires on two wheels
    · Replace springs on front of car
     
  9. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Headliner is glued on and drying. Wideband and ECU in the car and wired up. Trying to get one stupid broken seat bolt out, Dave was drilling forever, still in there.

    Next is re routing the fuel pump power wire, reinstalling the convertible top/window, and hopefully reassembling the exhaust this weekend if all the parts arrive.

    At some point I need to tie up the rats nest of wires under the dash and tidy it up.

    To Do:

    Engine:

    · Block off old O2 sensor holes
    · Reassemble exhaust with gaskets and new resonator
    · Reassemble Injectors/Fuel rails/Upper Intake Manifold
    · Tie up fuel pump wiring


    Seats:
    · Take apart seats and rebuild foam
    · Install new upholstery
    · Repaint seat rails
    · Reinstall seats

    Top
    · Reinstall top

    Interior
    · Reinstall all interior
    · Fabricate trunk floor panel
    · Repaint interior pieces that are still granite
    - Tie up all wiring.under the dash
    - Drill out broken bolt from when we removed the seat

    Chassis
    · Replace tires on two wheels
    · Replace springs on front of car
     
  10. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Blocked off the two spots where the O2 sensors were previously and re-wrapped the downpipe. 2 weeks and $35 for these two little plugs....
    [​IMG]
    [​IMG]
    [​IMG]



    Got the headliner back on the top and the top is somewhat installed on the car. Going to do the window last once the top is completely in.

    [​IMG]
    [​IMG]
    [​IMG]

    Out comes the computer to make way for the Adaptronic.

    [​IMG]
     
  11. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    To do:

    Engine:

    Reassemble exhaust with gaskets and new resonator
    Reassemble Injectors/Fuel rails/Upper Intake Manifold
    Tie up fuel pump wiring

    Seats:
    Take apart seats and rebuild foam
    Install new upholstery
    Repaint seat rails
    Reinstall seats

    Top
    Reinstall top (IN PROGRESS)
    Reinstall rear window

    Interior
    Reinstall all interior
    Fabricate trunk floor panel
    Repaint interior pieces that are still granite
    Tie up all wiring.under the dash
    Drill out broken bolt from when we removed the seat (IN PROGRESS)

    Chassis
    Replace tires on two wheels
    Replace springs on front of car
     
  12. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Had a pretty productive weekend.

    Top is on the car and moving on the motors again. Just need to put the window in it.

    Reinstalled a bunch of the interior. Repainted all the parts of the interior that had the fugly faux granite finish on them. They're black now.

    Drilled out that broken bolt - then discovered my seat rail is like rotted on the drivers seat - now need to modify a new one I have at home that doesn't quite line up.

    Replaced the springs on the front of the car to take out the redneck lowering kit (cut springs). The car no longer sits like an '87 Camaro.

    Still waiting on gaskets to reassemble the exhaust. Put the fan and shroud on yesterday, and ready to do the fuel injection stuff.


    Engine:
    Reassemble exhaust with gaskets and new resonator
    Reassemble Injectors/Fuel rails/Upper Intake Manifold
    Tie up fuel pump wiring

    Seats:
    Take apart seats and rebuild foam
    Install new upholstery
    Replace drivers side seat rail
    Repaint seat rails
    Reinstall seats

    Top
    Reinstall rear window

    Interior
    Fabricate trunk floor panel
    Tie up all wiring under the dash

    Chassis
    Replace tires on two wheels
     
    LMAC likes this.
  13. Dewie

    Well-Known Member

    Joined:
    Nov 6, 2008
    Messages:
    5,102
    Likes Received:
    1,232
    Location:
    N.S.
    ... and thennnnn?
     
  14. LMAC

    _

    Joined:
    Aug 25, 2003
    Messages:
    15,961
    Likes Received:
    216
    Location:
    Ottawa
    After seeing this doing anything with a soft top is a nope.. haha
     
  15. Dewie

    Well-Known Member

    Joined:
    Nov 6, 2008
    Messages:
    5,102
    Likes Received:
    1,232
    Location:
    N.S.
    JennJenn?
     
  16. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Recent pics:

    Top done (except window)
    [​IMG]

    Finished assembling wheels:
    [​IMG]

    Upholstery has arrived! Just need to install it now.
    [​IMG]




    Engine:

    Reassemble exhaust with gaskets and new resonator DONE!
    Reassemble Injectors/Fuel rails/Upper Intake Manifold DONE!
    Tie up fuel pump wiring DONE!

    NEW! Install Electronic Boost Control Solenoid
    NEW! Install Dual Belt Alternator Pulley

    [​IMG]

    Seats:
    Take apart seats and rebuild foam
    Install new upholstery
    Replace drivers side seat rail (waiting for this to arrive in the mail now)
    Repaint seat rails
    Reinstall seats

    Top
    Reinstall rear window

    Interior
    Fabricate trunk floor panel
    Tie up all wiring under the dash

    Chassis
    Replace tires on two wheels DONE!
    NEW! Install 2 brake flex lines on front
     
    Last edited: Aug 26, 2015
    Dewie likes this.
  17. v-mac

    Fire / Hazmat / GSAR

    Joined:
    Apr 1, 2011
    Messages:
    3,572
    Likes Received:
    291
    Location:
    Antigonish, NS
    NEW! Bleed Brakes!

    :lol:
     
    Dewie likes this.
  18. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    yeah, that too. LOL Goes without saying.

    We also found some wiring that should be going to the transmission that was hacked off by the original owner. I think I figured out where the heck they go though, so that's something at least.
     
  19. Dewie

    Well-Known Member

    Joined:
    Nov 6, 2008
    Messages:
    5,102
    Likes Received:
    1,232
    Location:
    N.S.
    Reverse lights maybe?
     
  20. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    yeah, and neutral switch, 5th/reverse lockout, that kind of stuff.
     
  21. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Seat rail arrived! Just need to clean it up and paint it.

    We put coolant/fuel in the car last night and tried to start, but 2 things happened:

    1) We had a fuel leak at the Fuel Pressure Regulator - I need to find a couple of fittings for this because the type I had were wrong.
    2) The starter didn't engage - could be a trigger wire or a sticky solenoid. Tried to draw the power but it never kicked over.


    Once I sort out these fuel fittings, I'll be in better shape.
     
  22. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Just ordered the fittings I need for this from Australia. Should be here in September. :(
     
  23. Daliah

    Member

    Joined:
    Feb 26, 2015
    Messages:
    198
    Likes Received:
    66
    Location:
    Nova Scotia
    September starts on Tuesday! :lol: Not that far off.
     
  24. Dewie

    Well-Known Member

    Joined:
    Nov 6, 2008
    Messages:
    5,102
    Likes Received:
    1,232
    Location:
    N.S.
    you didn't try strictly hydraulics in Burnside for the fittings??
     
  25. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Here's the issue:
    Anything I buy around here is going to be brass or steel. The part it's going into is Aluminum. These expand and contract at different rates.

    I called Hose & Fittings Canada (which has just as much stuff as Strictly) and they didn't have it and didn't carry what I need (a weird reducer fitting to to go another adapter I already have).

    So to make it work, I have a fuel rail adapter with a female 1/8 NPT fitting, then I have a male-to-male 1/8NPT, then a -6ORB (O-ring boss fitting) to 1/8NPT Female. Plus, I needed another -6ORB plug for the other side.

    Says they'll be here in like 10 business days so I'll just do everything else first. Plus, these are purpose-built fittings for a fuel system that are CNC aluminum.
     
  26. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    I should also note: On rotaries, you never cheap out/mess around when it comes to the fuel system. It can cause a serious engine fire very quickly.
     
  27. Dewie

    Well-Known Member

    Joined:
    Nov 6, 2008
    Messages:
    5,102
    Likes Received:
    1,232
    Location:
    N.S.
    You really shouldn't cheap out/mess around with fuel fittings on any engine in my experience... and always check that your "new" whipper snipper's gas tank isn't cracked before you fill it and start it and use it for 5 minutes only to realize that funny feeling on your arm is fuel pouring out all over you...

    *ahem*

    Excellent reasoning behind why you did what you did - I wasn't trying to shoot you down; I was simply trying to help! Sounds like you certainly have your bases covered!
     
    Boots likes this.
  28. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Hahah yeah, it's not my first rodeo. And the last time I gave someone advice about their fuel system and they ignored it, their car caught on fire.

    I guess building race car stuff for years has made me value quality parts and doing things right. :lol:
     
  29. NotASteer

    Active Member

    Joined:
    Jun 7, 2012
    Messages:
    894
    Likes Received:
    196
    Location:
    Texas
    Very impressive, Jenn. I admire your dedication to doing things the right way as well as your craftsmanship. I can't wait to see the finished product. :)

    (I do hate the offset on the wheels though, but I understand the rarity and dedication to period correct design)
     
    Boots likes this.
  30. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Thanks Pat. :)

    Update: Still waiting on fittings from Australia.
     
  31. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Parts arrived from Australia, only to find out I have a clearance issue between the regulator and the coolant neck. Just ordered more parts to fabricate a stainless AN line to relocate the Fuel Pressure Regulator to the firewall.

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Started taking the drivers seat apart - no wonder it was saggy. New foam acquired to refoam it and new springs bought for it as well! Now to carve the foam.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  32. Dewie

    Well-Known Member

    Joined:
    Nov 6, 2008
    Messages:
    5,102
    Likes Received:
    1,232
    Location:
    N.S.
    Yup that's pretty close - you can't get a nipple without the hex fitting for a wrench on it? or is it rubbing more that I can't see?

    Whatever the case - yay progress!
     
  33. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    The issue is that I have to use ORB fittings, so there is a limited supply of that, plus the adapter I have to use in the fuel rail. It's just millimeters in the difference, enough that I can't bolt down the fuel rail on the injectors. Relocation it is!
     
  34. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Supplies arrived for the great fuel pressure regulator relocation.

    [​IMG]
    [​IMG]

    Got one end on the hose:
    [​IMG]

    Had to build a bracket to mount it on a lip on the firewall.
    [​IMG]
    [​IMG]


    Current state of the car:
    [​IMG]


    Next is to mount the FPR, cut the hose to length, and attach the other end. Then on to brake lines, putting in the old coupe seats, putting the wheels on, and the back window in the top.
     
  35. Jenn

    Jenn
    [OP]
    Left Shark

    Joined:
    Jun 26, 2003
    Messages:
    18,032
    Likes Received:
    273
    Location:
    Middle Sackville, NS
    Here was my weekend:

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]


    [​IMG]

    And the car still doesn't start... :(

    Here are the facts:
    - It's getting fuel - lots of it. I checked the fuel pressure with my gauge and adjusted it to around 35-38 psi. When we take out the plugs to de-flood, they're wet, saturated actually. It's like it floods immediately after you turn it over a time or 2, and is dumping lots of fuel in there.
    - We re-stabbed the Crank Angle Sensor to ensure the timing was correct, done according to factory spec.
    - Checked for spark outside of the engine - there is lots. Arcs very well from the end of the plug to a ground source hooked to the body.
    - All plug wires have been triple checked to make sure they're connected to the right plugs.
    - All plugs are brand new.

    When we de-flood it, and put some oil in the spark plug holes, then turn it over without the fuel on, then replace everything and try to start it, it kicks a couple times in the way that it would if you were bump starting it - you know when it feels like it's "catching", not the traditional sputter.

    Here are the things that are done to the car so you can see the setup:
    - 6-port S4 NA engine
    - 88 Turbo injectors (550CC)
    - Adaptronic Standalone ECU with Turbo 2 basemap
    - Innovate LC-2 wideband (have calibrated it and connected to ECU)
    - AEM adjustable Fuel pressure regulator
    - New Walbro 255 fuel pump
    - Cartech turbo kit with intercooler
    - Removed emissions including solenoids/vacuum rack, BAC valve, EGR valve, Air control valve, and air pump. Blocked off or removed all un-used vacuum lines
     

Share This Page