Alchemy - Turning epic failure into a resounding success

aMaff

High Speed Low Drag
:
1992 Miata / 2003 Pathfinder
Over the weekend, I had 4 drivers in 2 classes in the Atlanta Pro-Solo. Had an absolute blast, even if there were some... shall we say obstacles?
Shawn (moxnix) from D.C. pulled a 2nd in CSP in my car (note: in my BROKEN, STS2 prepped car on used, 205/50/15 V710s lol) and actually won some money. The rest of us didn't do so great, but I had an excellent time.

Now the fun story:
The car was great during the morning runs on Saturday, no issues at all. Brett, my regular STS2 co-driver was running 1st in the afternoon. His first run was ok, then spun it twice on his second run. Twice. On a mid-40 second course. Hmmm... He comes back and the only words are "Half way through the run, "something" changed, and it's making a new noise." Fantastic. The symptoms looked very much like a failed front sway bar bracket: oversteer, lots of body roll, TONS of front end bite. Well, we couldn't find anything broken. He finishes his 4 runs and the car was all over the place. My turn... I get in the car and rolling up to grid I hear a creak coming from the front. Huh... that's new. I take my 1st run and the car was all over the place. I felt like I was looking at my back bumper for most of the course. A change to the rear shocks made it better, but still the car was not the same as it was in the morning, or even close. As I'm pulling up to the start line for my 3rd run, that creak from the front is just getting worse and worse, so I forfeit my run and pull to grid so we can jack the car up to start changing tires for the CSP folks and inspect the front end. Long story short, after burning myself on various very hot parts, we couldn't find anything wrong. The only thing I noticed was that the creak would only occur with the car on the ground, when you turn the steering wheel. Is it the rack? Sway bark endlink? Bracket? Still couldn't find anything. So I made the call: "F-it. Drive it til it breaks" and handed Shawn the key.

Shawn made all of his runs (and brought home the goods) and the car was still moving, so we handed the car over to Katie (Katya4me). She proceeded to run her 4 runs, and get 2 re-runs on her last run due to timing issues. Half way through her 2nd re-run, it happened. I had my attention elsewhere and had a "huh... it got really quiet" moment, followed by a "wasn't my car just staging a few seconds ago?" moment. I run to the other side of the trailer and the Miata was stopped on course with a very... odd... stance. The driver's front corner was basically on the ground. Long story short, we get a wheel dolly, jack the car up and get her off course. Ball joint failure. The ball joints that I replaced over the winter. Thanks, e-bay! Not like, it broke. Like, the ball, which should be held completely in the 'cup' at the bottom and worked it's way free, leaving the lower control arm to swing free of the knuckle, with the ball / stud still bolted to the knuckle. The wheel hit the knuckle and wore a few nice grooves into the inside, 1 of which was deep enough to have a couple leaks. Well... no R-Comps on Sunday! (no, those were not the new 6ULs, but my old ATS comp-lites). Upon closer inspection, the ball had a bunch of wear on it, and the grease had turned into metal-shaving-paste. Not pretty.

As bad as this sounds, let's consider the alternatives: 1. Failure during elimination rounds Sunday morning or 2. Failure during the drive home on the interstate at 80 miles per hour surrounded by traffic. I'm HAPPY the thing broke, and I'm not sure what to make of that. I almost feel like one of the 'cool kids' (I know, I'm not) now that I've had a catastrophic parts failure on my car at a National event lol

Anyway, long story short, after calling every parts store, dealership, boneyard, etc within 100 miles at 5:30 on Saturday afternoon, I got a hold of a local guy who's brother runs Spec Miata who had a couple spares (thanks Wayne, aka apexlater, SO much. You are a damn LIFESAVER). Brett and I drove up to Lawrenceville (about an hour from the event site, got the parts when Wayne got home around 9:30 or so, and were back at the event site at 11:00 or so, with a few extra tools from my garage and a headlamp. Thanks to the extreme generosity and willingness to get down and dirty on my car of some of the local miata talent, the ball joint had been removed in the afternoon, so it only took about 30 minutes to get the car back together, change back to my STS wheels/tires, and gtfo. I think I got back to the hotel right at midnight. Shawn, thanks again for coming out to lend a hand and some P5 headlights to the repair process.

Anyway, I did a few figure 8's in an adjacent parking lot the next morning and everything seemed fine. No bad noises, and the car felt ok. We proceeded to put another 8 competition runs on the car throughout the course of the day without issue.


It's been a weekend hahaha. All things considered, all's well that ends well, and you've really got to appreciate the strength and camaraderie within the solo community. I had 2 or 3 people wrenching on the car while myself and about 4 or 5 other folks where calling everyone we knew trying to find replacements. By the time I left the site, I had Plans A, B, C and D (D involved disassembling tinmanms6's car that wasn't competing...) thanks to the extreme generosity of a large number of folks.

For those of you reading this and those who aren't (and a lot of names I haven't mentioned)
THANK YOU so, so much.


EDIT: How could I forget!? Thanks again to Kevin (kcbhiw) who not only helped get the balljoint out (the hardest part of the job), but upon my triumphant return to the hotel, handed me his LAST BEER! That was greatly appreciated :D

EDIT#2: by the time we left the site on Saturday, we had plans A, B, C, D and E. A: Get the part from wayne, B: Rick Cone may have had one (turns out he did), C: $100 for ONE from the 24 hour advance auto, and it was in stock, D: if it came down to it, Todd (tinmanMS6) offered up his NA to be cannibalized or worst case E: Brett and I were offered co-drives in 2 other STS2 cars, and he'd bring the truck and trailer to tow 'er home.
 
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A heart-warming story :)

Glad it ended up working out relatively well! No injuries, downtime, or too much loss of money. Hooray!
 
A heart-warming story :)

Glad it ended up working out relatively well! No injuries, downtime, or too much loss of money. Hooray!

Seriously :)


PS, check out the failure mode this ball joint had in the pics below. I replaced the other one tonight and it too felt crunchy compared to the used OEM one I got from Wayne. Talk about messed up cheapo parts. The wear on the ball and the carrier housing is what allowed the ball to slip out.


Also, I got the tire dismounted from the wheel that got grooved by the rest of the suspension. You can visibly see hairline cracks occasionally along the worst groove. We originally thought that it was just knocked off the bead somehow from the impact, but when we re-seated it with the compressor we were hearing a hissing and I felt air from the inside of the rim. We'll have to see what wheel wizards has to say. I'm actually glad that this thing didn't hold air, because if it had we probably would have driven on it and broken again.
 

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Andrew is the most awesome car owner ever. :D Not only did he let me break his car on Saturday, but he then let all 3 of us drive it on Sunday before getting his competition runs in. Maff, your car was a blast to run and I'm sad/glad that I broke it when I did. Let me know the final status on the wheel.
 
LOL yeah I forgot about it. I was in the last elimination bracket on Sunday. I got in the driver's seat and said "Yay! I finally get to drive my car!" lol. I'm really glad you guys had some fun despite the challenges of the weekend. But hey, I'm still coming up for the D.C. pro next month, so maybe I can repay the favor (peep)

:p

In regards to the wheel, it'll probably be another week or 2 before I make it out there to get it looked at. I need to take a couple nights to relax this week what with starting all over again on Friday for the national tour. Tonight was the ball joint, wednesday is an SCCA social, and thursday night will be preparation for the Tour.

That being said: is it friday yet? :p
 
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I bought a lower control arm off eBay to replace a ball joint as well, so great, now you've put this in the back of my mind... haha

Did you ever fix your gas tank issue? I know it is a stretch since well you know, your car is only similar to mine in the fact that they both have this retarded problem and are Mazdas. But I'm definitely lost on where to start fixing the problem and sick of taking 10 minutes to fill 4 gallons of gas. When you get < 15 MPG it makes for lots of trips to the pump
 
yup, it had a bad vent valve on the tank :). Was your control arm a mazda part or a an aftermarket replacement?
 
Suggested thread title.
W.A.N.G. Racing goes balls out to finish in the money.
 
Looks like a clear sign of lack of lubrication. Did the aftermarket balljoint have a grease fitting?.
 
Looks like a clear sign of lack of lubrication. Did the aftermarket balljoint have a grease fitting?.

No. There was a lot of grease on the ball when it came out but it was wiped off before those pictures.
 
no they don't have a grease fitting, but I lubed the bejeezus out of them before I installed them, and most of it was still there when we pulled it off. As Shawn said, it was cleaned up for the pictures.

They also don't have grease fittings unfortunately, neither do the stock ones.
 
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