Spooled up Racing's RX7 build thread

[SpooledupRacing]

OK I started this thread on another forum WAY back in August... This is start to finish on my 86' RX7

8-7-08


K as most of you know I have had a bit of problems with my last engine I built.

I did a COMPLETE build on the engine with all NEW mazda parts and I did not replace the oil control rings (hard metal rings). The engine ran fine but smoked and used oil profusly.

I bought new rings and tore the engine down again.. I built it and when I started it I had a miss... after pulling the motor I noticed that the front housing had a LARGE couge in the rotor housing from the apex seal sliding forward on the initial start up..

Now I am out a rotor housing and an apex seal..

So I have decided to start OVER...

I am going to buy:
BRAND NEW rotor housings
Rx-8 Eccentric shaft (1lb lighter)
possibly do lightweight rotors and matching counter weights
etc
etc

I also am going to finish the project by fixing all my electric issues, installing the turbo transmission, turbo LSD diff, new bushings, 5 lug hubs, new wider rims with tires etc.

This is going to be a long journey but I am ready..







8-10-08

Ok so today I cleaned out the shed and the garage... I got the car backed in and up on jack stands..

The wheels are off and awaiting the guy to pick them up...

pics of the car now.

8-11-08

Ok so I came home and walked right to the garage..

in 15 minutes I did the following

removed the intercooler and piping
removed the passenger fender
pushed the bent piece of frame back out where the fender got hit (looks like NEW)
soaked the rear suspension and brakes down with PB Blaster

Not sure if I will go back out and work on it tonight but I do know that I need to put more parts up for sale on ebay!



8-11-08

OK today I purchased the hubs front and rear with calipers. This will swap my car from 4 lug to 5 lug, give me bigger brakes and 4 piston calipers in the front instead of 1


8-12-08

Ok so my store on the other side of the state just received my 4 hubs with calipers and my passenger fender I bought from a guy who lives over by that store..

looks like I will have my first batch of parts come Thursday

pics will follow


8-13-08

First set of parts came today

Energy suspension full kit it is missing 2 sway bar link bushing (no biggie)


8-14-08

Ok so today I got my hubs and my fender.. I have to admit I am a bit disappointed however I got some stuff to work with so its a start

Here are the 5 lug hubs with calipers and just brakes

The rotors obviously are not going to be used the calipers I was expecting to use however they are not worth anything to me because they are in rough shape so I will use them as core money toward a new (rebuilt) set from the shop and the hubs are COMPLETELY rusted to the rotors.. right now they are soaking in PG blaster.. I will coat them again in the morning and if I cant get them off tomorrow I will take them in to the shop and put the torch on them to heat them up and get them apart..

they will take LOTS of cleanup and wire wheels etc to get them back to useable however with some new studs and bearing I am confident that they will be useable.


and here is the passenger fender.. the good part of the deal.. it is in GREAT shape, not worried about the paint because it will be COMPLETELY sanded down put a gel on and primered so I can paint it along with the body in the spring.

8-18-08

OK so the hubs are not coming off the rotors, I have done everything except torch the rotors off the hubs..

So I contcted the guy and he is gonna send me another set of HUBS ONLY I guess when those arrive I can conntinue

Today I bought a set of Urethane transmission bushings so those should show in a few days.

and tonight I will get to working on pulling the rear end apart



8-19-08

Ok so yesterday I pulled the rear spindles off the car, I took them today to have the hubs pressed out and the bushing pressed out of the hubs

Here is what I have and started with

Started with:

Fronts

8-19-08

I just bought a turbo driveshaft.. now I need turbo axles a turbo LSD and a turbo trans and I will be all set to get the drivetrain underway..


8-20-08

OK so I met up with a local guy who is parting a car and well I spent my trans and diff money..

this is what I got with my money

Fluidyne aluminum radiator

Vented pass side headlight cover

8-21-08

Got these the other day

Banzai Racing urethane transmission mounts

8-24-08

I got my driveshaft on friday
S4 Turbo suposidly.. I need to cross the numbers to verify

8-24-08

OK so today I got back to work on the 7..

Here is a few updates..

Front control arms had the bushings removed from them. I then cleaned them up with a wire wheel and painted them with a high gloss black paint.

After that I installed the new energy suspension bushings and put them back in the car.

I then took the rear spindle

removed the backing plate and took them to a shop to have the bushing and the wheel bearing and hub pressed out of it (done mid last week)

I brought it home and also cleaned it up with a wire wheel (again mid last week)

and today I painted them

Next will be to get some new ball joints, and new tie rod ends that way I can get the front spindles back on

then I will have the new rear bearings and hub pressed back together and then get the new bushings put in.

So yeah its progress but until I get a trans, diff and axles I am about done with putting parts back on (oh and new suspension)


9-02-08

ok no pictures tonight just a quick update..

outer tie ends on
ball joints on
front spindles painted black and put on the b joints (awaiting new mounting bolts)

this weekend the trans, diff, axles will come out of the car as well as the rear sway bar and rear suspension


9-06-08

OK so today back to work.. I removed:

transmission
differential
axles
driveshaft
rear subframe

So now that I have everything off I can begin to put the poly bushings in and get the more done..

I also have the front spindles on and the ball joints bolted down to the arms and spindle, and the tie rod end is sitting in the spindle as well..

Today I ordered up:
S4 TURBO LSD
S4 turbo axles
BRAND NEW set of KYB AGX struts

Once everything comes in I will get pictures and get things installed back in the car..

 

[SpooledupRacing]

here are some pics of the rest of the removal..

9-07-08

Ok so I went to the store today and bought a compressor to get things moving a bit quicker..

Then I came home and after getting it all setup, the tools setup and the break in process complete.. I got to work on the rear subframe

Diff is off.

Rear control arms, trailing arms and rear control links are off

subframe is gutted and ready to be cleaned up.

So the next step is to clean everything up rear good, have the old bushings pressed out and the new bushings pressed in and then paint everything black.


9-09-08

I just ordered my springs.

tomorrow I buy my DTSS bushings

9-09-08

just bought rear diff and subframe mounts and dtss elim bushings


TODAY 8/11/08

Ok parts arrived today..

I received:
both rear control arm lower pivot bushings
all 4 rubber seals for the above bushings
both snap rings needed to instal the above bushings

I also received:
both rear control arm upper bushings

Parts

New stuff:

So I did the bottom pivot bushing on my own.. very simple job

old stuff

Anyways when I get the other bushings on I will post pictures..

9-12-08:

OK so I took my control arms in to have the last 2 bushings pressed out and have 1 installed..

I got the call saying they were done and the total was 35.00

I get there and they removed 1 bushing and replaced it but the large bushing that goes to the subframe was still intact.. they said that they could not get it out..

I went hoe and burned it out HOWEVER the new bushings wont go in because there is a collar that needs to be pressed out..

anyways pics of the rubber on fire

OK so I cut some slits in the shells to relieve some pressure and I pounded them out wiht a screwdriver and socket..

Now the new Energy Suspension bushings are in

The shells I had to remove (2 per arm)

The new energy suspension bushings in the arm (crappy pics)

9-15-08

Struts arrived today... KYB AGZ struts BRAND NEW...

tomorrow I should be receiving my other mounts/bushings and then on Wednesday I will be getting my springs..

9-17-08

Ok so I came home today and my next package arrived..

Tanabe Springs TGF032

9-19-08

Well I got the mounts today

I am waiting to hear back from MMR on them because well I received 4 mounts that match IDENTICALLY in size (length, hat depth, diameter, etc) and I go the DTSS elims..

the 4 mounts are 1 pr of diff mounts and 1 pair of rear subframe mounts but even though they are physically the exact same part the subframe mounts were 5.00 more. and I don't know why.

anyways tomorrow I pick up my LSD and axles, I hope to get all the mounts installed and then I can move on..


Today I also received my KYB front strut mounts

KYB front strut mounts:

MMR mounts:

9-21-08

OK the MMR DTSS elims were put in ust a few minutes ago..

I just lined them up and punched them in with a 3lb sledge hammer.

These will be going on my AGX struts. I just need to buy my strut mounts so I can get them assembled

 

[SpooledupRacing]

9-24-08

OK so I got the rubbers out of the diff bushings today but I sill have to get the sleves out of the diff ends so I can add the mmr mounts..


anyways everyone likes fire right?

9-25-08

ok after taking a day off, I went back outside and with alot of hard work and about an hour of time I was able to get the shells out of the diff.

The left over pieces (PAIN IN THE ASS):

9-26-08

I got the front struts all put together and mounted in the car, I got the rear struts all put together but of course not in the car until after I get the subframe in..

Tomorrow I will paint the rear diff, then push in the MMR bushings

pics:

the strut mount perches I needed and the rear mount assemblies:

Struts all assembled:

Fronts in the car:

9-28-08
Ok so today I went outside and installed the MMR bushings in the diff, painted the diff (black) and attempted to get the bushings out of the rear subframe..

PICS!!

10-02-08

OK.. its been a few days.. so now I have some updates..

First of I finally got the bushings out of the rear subframe.. (this was HELL)


Whats left of the bushings

Todays tool to buy:

The end result:

If I have my way.. tomorrow I will clean up the subframe, paint the subframe, slam in the new bushings and then start putting the control arms, diff and other stuff back on it.


I also begun to pull the interior out.. I got the seats out, the rear carpet, all the rear plastic, the front pillars and door sills, the headliner is loose and I still need to remove the front carpet and dash.

I will get pics of the interior once it is all out..

10-4-08
Ok I got the MMR mounts in, painted the rear subframe black and then attached the control arms, trailing arms, and camber links

here is the pics.

Mounts in:

Subframe painted:

All together:

 

[SpooledupRacing]

10-5-08
OK so today I went out and begun painting my trim from red to black using TRIM paint..

no crazy colors nothing special just going to black..

picture of a before and after of an item once I load them up..

10-7-08
OK took these pics tonight of the interior this is after it had sat for 2 days..

the carpet piece is much darker then the pic shows.

chunk of carpet I tested on

trim

10-9-08
Ok so I got out and painted the carpet and touched up the dash.. here is where I am at.

Carpet before:

Carpet after:

Dash:

next will be to put another coat on the carpet (to seal in any red that may come through)

then paint the rear carpet and the carpet around the strut towers
paint the center console (arm rest)
start putting everything back together.


10-13-08

Ok not much to update at the moment.. I have all of the main carpet painted, the dash is back together, the arm rest console was painted and back on, the rear carpet is in the process of being painted (both stores ran out of paint), all of the plastic trip that I have is painted (I will need a couple pieces).

I plan ot pickup some more paint tonight, get the headliner done, the rear carpet done, and hopefully I will get the battery cable I need tonight so I can run that under the carpet before I install everything (battery relocation)

I also got out the sander and touched the drivers rear fender well up.. I havd a 1" bubble spot that I hit with the sander and it cam nice and clean so I got that covered for now untill I get down to doing the actual body work

More pics as things come together..

10-15-08

OK well not much to update with... I sold my seats out fo my RX7 yesterday and in turn turned around and bought my competition diff mount (front) and the adjustable camber bar..

I should have those by Friday so I can install the rear end over the weekend..

BOUT TIME..

then I can finish up the interior and move on the the engine bay and body.

10-17-08

OK so parts arrived today...

Mazda competition front diff mount
and
Mazda competition adjustable camber bar


tomorrow the entire subframe, diff, axles, struts will be put in.

As the parts arrived:

ADJ camber bar:

Comp diff mount:

10-18-08
ok so nobody local had the pinion snubber I will buy one but I don't know how it will mount and if it can be installed with everything back in the car.


Todays progress:

old OEM camber bar out

New mazda comp adjustable camber bar in:

I got the diff mounted to the subframe, the subframe back in the car, the rear sturs put in, the axles mounted.

I just need to get the bearings put in the rear hubs and on forward I can move.


10-18-08

Rear carpet is done

And I have noticed that the paint does wear off the carpet... this kinda bums me out after having probably 150.00 in paint I think I should have just taken the carpet out and swapped it for black carpet.

oh well u live and learn.

I also painted the headliner and pulled the engine harness out of the car.


10-20-08
Ok so today I took my rear spindles/hubs/bearings to have them l pressed together.. I got them back and went home and installed them on the car WOOT WOOT!!

ok so as far as I am concerned get me some wheels and I cna get the car ready to go on the ground..

I still need to buy sway bars and end links and brakes but I plan to set the car on the ground without brakes so I can roll it around during the winter..

anyways here is the pic of the rear spindle on the car !!!

10-22-08
so today I ordered up my front wheel bearing washer, nut, cover, cotter pin, and dust cap so by the weekedn I will have the front hubs on and ready to put wheels under it and get it on the ground YES YES!!!


10-24-08

Ok I got the new frt hub nuts/washer/caps so I installed new inner and outter bearings, new seals, put the hubs on and put on a brand new washer, nut, cap, cotter pin and grease cap

here is a pic of one of the front hub on the car.

10-27-08
Ok no pics tonight but I just spent the last few hour pulling all the un needed brackets off the engine bay, removing some of the wire harness and removing all the straps, removing the coils, oil cooler etc..

Tomorrow I plan to finish all of that up so I can prep it to clean and paint the engine bay..

pics will come up as I get to that point

10-28-08
Did a little more engine bay cleaning.. I ran out of brake clean so I am done for now..

here is what it looks like right now.

Started with:

ended with:

10-29-08
RIKEN!!! whats up man.. good to see you made it over here buddy!!

WE3RX7 this car has no rust in the engine bay or frame rails.. it will get a nice coating done to the engine bay when I do it this weekend.

Today I received some wheels from a friend (free) so I can put this pig on the ground

here they are in the back of my Jeep.

Went home, put the wheels on and dropped it to the ground.. I will get other pics once the car is pulled out of the garage

 

[SpooledupRacing]

TODAY 12-9-08

OK so I have done nothing to the car since the last post.. I have ran short on money and I need to get past the holiday. However just s u guys know I have the engine bay about 80% painted (now its to cold to paint anymore)

I will be buying more parts after the holidays (my plan)

any questions feel free to ask away.

 

[mightyray]

Damn, this is the first time I've seen this post and I'm envious at your ability to work on your car like you do. How did you learn so much?

 

[Vocko]

With what did you paint your carpet ???

 

[KZL_99ES]

with your painted carpet, you should take a wire brush to it lightly, then a broom, then vacuum the leftover paint off; after that put on another coat, that should make your paint last longer and look darker

 

[SpooledupRacing]

Damn, this is the first time I've seen this post and I'm envious at your ability to work on your car like you do. How did you learn so much?

Thank you very much.. I just made this post today...

As for my experience.. I was an ASE certified mechanic for over 7 years..

As for rotaries.. they are easy.. just gotta pay attention.

 

[SpooledupRacing]

With what did you paint your carpet ???

Duplicolor I think it was.. they make a vinyl and carpet paint.

 

[SpooledupRacing]

with your painted carpet, you should take a wire brush to it lightly, then a broom, then vacuum the leftover paint off; after that put on another coat, that should make your paint last longer and look darker

THX I will do that before I put the seats in.. I have had some wear from walking in it but did not seem to be anything that would be to bad.

 

[speedracer]

dam dave you a painting freak!! painted carpet lol
j/k lookin good Dave
soon it will look as clean as my MSP!! lol

 

[SpooledupRacing]

Na.. it wont ever b as clean as your msp...

as for the carpet.. eventually I may pull it and swap it with black stock carpet... who knows.

 

[lil_red_wagon]

glad to see that you could finally get your build thread up here. looks like good progress so far. i will put mine up when the job starts.

 

[MSP2024]

bad ass project, cant wait to see where it goes

 

[SpooledupRacing]

THX Wes..

MSP If you keep an eye on this thread I think u will be enjoying once I get back to working on it.

Dave

 

[InNeedOfBoost]

good build man, this is basically what im gonna be doing with my 1st gen.

keep it up

 

[bazooka joe]

hey dave,,,looking forward to seeing the finished product man!

 

[SpooledupRacing]

OK since my last post I have done nothing with my car alot with my life...

But here is to a new year and another push into getting my car done..

TODAY (15 minutes ago) I just paid for 3 engine IRONS... I am using Cosmo 13B RE Irons on my build.. I did buy my irons used with low mileage and no porting and in the best possible shape from a very reputable supplier of RE parts.

I will be putting my next order in here VERY soon for many more parts.. keep up to the times more to happen in less then 24 hours.

 

[THE Phen]

Nice! Subbed.