I ended up getting another master cylinder. I bled everything the same way as before and the pedal is definitely better but it's still not perfect. The car isn't running so I decided to leave it so I could start on other tasks. Once the car is running I'll mess with it some more. I have plans to make braces for the MC and brake pedal assembly to eliminate the flexing going on to improve the pedal feel.
magnumP5's RX-7 Build Thread
- Thread starter magnumP5
- Start date
I ended up getting another master cylinder. I bled everything the same way as before and the pedal is definitely better but it's still not perfect. The car isn't running so I decided to leave it so I could start on other tasks. Once the car is running I'll mess with it some more. I have plans to make braces for the MC and brake pedal assembly to eliminate the flexing going on to improve the pedal feel.
I haven't been able to dedicate much time to the car. I've been busy doing stuff around the house, possibly preparing for a move, and doing a lot of traveling. It's also the time of year when it's 90+ degrees outside with dewpoints over 70 degrees so the heat index is 100+ and I just don't like working in that heat. I spent maybe an hour this weekend doing this:
Decided I didn't need windshield wiper sprayers. The car will likely not be driven (willingly) in the rain so I figured that can go.
Vacant spot left over. Not much in the engine bay except the engine now.
I left all the provisions for the system in place just in case I live to regret this decision. In a bit of boredom I stretched the fleece over the frame for my fan shroud.
The flat stock is holding the fleece down where it's glued flat to the frame. This is where the shroud will contact the radiator. I still need to pull the fleece tight in a few places but in general it's turned out well. Still not sure if I want to make the fleece integral to the shroud or turn it into a mold.
Decided I didn't need windshield wiper sprayers. The car will likely not be driven (willingly) in the rain so I figured that can go.
Vacant spot left over. Not much in the engine bay except the engine now.
I left all the provisions for the system in place just in case I live to regret this decision. In a bit of boredom I stretched the fleece over the frame for my fan shroud.
The flat stock is holding the fleece down where it's glued flat to the frame. This is where the shroud will contact the radiator. I still need to pull the fleece tight in a few places but in general it's turned out well. Still not sure if I want to make the fleece integral to the shroud or turn it into a mold.
It generates the complex curves of the shroud when stretched over the frame. It's a trick audio guys have been using for ages to make enclosures. Another approach would have been to use some kind of foam and sand it to shape.
I think I would make the fleece integral. Once it is saturated with resin and it hardens you would only need another layer of resin and glass mat and you would be done. Except of couse the time you take for any smoothing which should be minimal. Keep in mind though, I have never worked with fiberglass so I might be talking out of my ass a bit.
The more I think about it the way I have it glued to the frame makes me think I have to turn it into a mold. I see one of two things happening:
1) The resin melts the glue and I lose my mounting flange and end up with a shroud that's too big, or
2) The glue holds but the resin-soaked fleece is now stuck to the wood frame.
A this point I'm hoping for #2. I'll soak the fleece in resin, let it dry, and seal it then lay the fiberglass over top.
After much debate I said screw it and I decided to turn everything into a mold so my shroud will be completely fiberglass. I became convinced either the spray adhesive would prevent me from removing the resin-soaked fleece from the frame or it would just dissolve when the resin was applied ruining the shape. I stapled the crap out of the border of the shroud and flange to maintain the shape. Everything is ready for resin now:
After a couple coats of resin I'll apply filler to the areas with the staples to prevent the "dimples" from transferring to the fiberglass. Plan is to resin, fill, sand, clear, wax, and coat with PVA before laying the fiberglass.
After a couple coats of resin I'll apply filler to the areas with the staples to prevent the "dimples" from transferring to the fiberglass. Plan is to resin, fill, sand, clear, wax, and coat with PVA before laying the fiberglass.
First layer of resin applied to the fleece:
It's a little thin in a few places (3/4 of the flange and on top) but I went through most of the quart of resin I had and all the hardener. I'll pick up some more tonight and after another good coat everything should be ready for sanding.
It's a little thin in a few places (3/4 of the flange and on top) but I went through most of the quart of resin I had and all the hardener. I'll pick up some more tonight and after another good coat everything should be ready for sanding.
I'm making a mess in my garage is what is going on
Basically I'm making the mold for my fan shroud. The plan is to add another coat or two of resin to the mold, sand, fill, sand, fill, sand, etc. until it's super smooth, cover it with many layers of clear, then wax heavily. Only once this is all done will I start laying fiberglass. I have to admit this fiberglass stuff has me a little excited. I'm already looking for other things I can make/make lighter with it 
I picked upped some more resin, hardener, and some acetone, and ordered some mold release and a roller from McMaster during lunch so I should be good to go.
I've not laid any fiberglass so I'm not declaring success just yet. The concept seems pretty simple. Can't be harder than wrapping vinyl, right? (I kid) What I'm doing is still nothing compared to Corey's carbon fiber fender work.
I got another (thick) layer of resin down on the mold last night. I think that'll do it. Now it's time for sanding. Lots and lots of sanding.
Spent a lot of time on the shroud this weekend. Applied the second layer of resin Thursday night:
Spent most of the day Saturday sanding:
Applied filler and sanded Saturday night and Sunday morning:
Sprayed primer last night:
The plan is to sand again and apply several layers of high-gloss clear. Once that's done I'll apply several layers of mold-release wax and then I can lay the fiberglass. The mold isn't perfect but I'm operating under the assumption the fiberglass and resin of the final product won't take every small imperfection into form.
Otherwise I'm fighting urges to drop the RX-7 chassis and swap everything into something lighter, with a better suspension and aftermarket support: NA Miata.
Spent most of the day Saturday sanding:
Applied filler and sanded Saturday night and Sunday morning:
Sprayed primer last night:
The plan is to sand again and apply several layers of high-gloss clear. Once that's done I'll apply several layers of mold-release wax and then I can lay the fiberglass. The mold isn't perfect but I'm operating under the assumption the fiberglass and resin of the final product won't take every small imperfection into form.
Otherwise I'm fighting urges to drop the RX-7 chassis and swap everything into something lighter, with a better suspension and aftermarket support: NA Miata.
Sanded the mold again last night:
I think my total sanding time is in the double-digits. This is turning into one of the more labor-intensive projects I've worked on during this build. Next step is clear followed by lots and lots of mold release wax.
I think my total sanding time is in the double-digits. This is turning into one of the more labor-intensive projects I've worked on during this build. Next step is clear followed by lots and lots of mold release wax.
No pictures today. Sorry guys. I emptied an entire bottle clear on the mold last night but it's still thin in a few places so I'll have to pick up another. The coating also got contaminated in a few places so I get to sand some more before painting. Yay. In between coats I started working toward what will eventually become my radiator/oil cooler ducting. I removed the factory front crash bar (don't worry it's going back in) for additional clearance. I was also able to relocate the front wiring harness so it won't have to go through the ducting. Fortunately no wire-extending was necessary. It's still going to be a major PITA with the oil cooler support and lines but it's looking easier. I also made the decision to go with a Racing Beat universal pre-silencer and muffler combination for the exhaust. The tech at RB thinks this should keep sound <100 dB even though internet discussions say otherwise. I'll choose to believe RB for the time being.
Still strongly considering it if I can find a clean chassis from which to start. I actually have a lead on a '93 with a blown engine that already has the rear end from a 1.8L car swapped in. I spent some time the last few days doing some research and the swap isn't as straightforward as some would believe but it looks doable. The biggest challenge looks like it would getting an exhaust made as the PPF looks to be in the way. I can say this though, if I do go down this route it will make this build seem like those "high school P5 bolt-on build threads"
Because they're bigger, heavier and have an inferior suspension setup? I remember reading speculation that Mazda originally intended to put a rotary engine in the Miata. When they did it blew the FC away in every aspect during factory testing. Obviously not wanting to undercut more lucrative RX-7 sales they went with a traditional piston engine in the cheaper Miata. It's just speculation but it makes sense.
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