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Another week another head…

A couple of weeks on and I have made a bit of progress between work things that needed to be done.

First up was stripping the head from the Hilux to see if I could figure out what was wrong. Out comes the Snap On valve tool:

[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823050007-9ec4d87e-xl.jpg[/IMG]

This thing is a bit of magic and can be used easily for removing and installing valve collets. Just place ontop of the valve retainer (black bit is the installation tool) and hit with hammer:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823045959-9f033d04-xl.jpg[/IMG]

A little magnet in the recess pulls out the collets and lets it pop off the valve:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823045952-dbd961b3-xl.jpg[/IMG]

Installation is basically the reverse, will show that when the time comes.

Do that a few times—16 to be precise—and you are left with this:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823045946-72542190-xl.jpg[/IMG]

And this:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823045929-7c1907a6-xl.jpg[/IMG]

Everything looked reasonable at that point, so i took all the valves over to the bench grinder to wire wheel off the carbon deposits, and there i found this:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823045906-919ce86c-xl.jpg[/IMG]

Went back to the head and cleaned up that port (Intake 4) and valve seat and presto:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823045805-65970d47-xl.jpg[/IMG]

And a backlit comparison with the valve in the other port:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823045732-49b4cac0-xl.jpg[/IMG]

That would be the source of low compression on the second pot. Now in a normal situation i would just get a new valve cut for the head and have it matched in with stem length. But being in lockdown makes that more difficult.

However, I do have an entire spare engine…. so onto that head. Before i pulled the valves on that head though i rebuilt my vacuum tester and checked all the ports on that one to see if there were any significant leaks:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823033949-c272cc8f-xl.jpg[/IMG]

All tested fine at around 24inHg so that should be fine for lapping back and sealing up again.

So here we have it:
[IMG]http://images.plebeians.net/_data/i/upload/2021/08/23/20210823165522-9137d070-xl.jpg[/IMG]

Another head stripped and ready for a quick clean up and reseal.

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The end of a path…

Now that we have finished the arduous process of moving we have started looking at the back yard and sorting things out.

The first thing was that a couple of plants had to go. Nopics hated the succulent:

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030532-10230338-xl.jpg[/img]

and the other tree next to it was diseased in the core and rotting from the inside, so off it went:

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030519-3af6a4e0-xl.jpg[/img]

Next thing is that the path had to come up for the workshop and deck to go in. I want to reuse part of the pavers to make a new path, so i took most of those up with the demo drill fairly easily:

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030421-7e1610e5-xl.jpg[/img]

But then i started breaking up the concrete and was in for a surprise. The pavers had been laid over about 150mm of concrete, basically a 100mm path and then another 50mm topper plus mortar and then pavers.

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030341-62130b17-xl.jpg[/img]

What is worse is that i could spot some reo bar throughout the thing. In response i bought a cheap jackhammer and set to work:

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030242-85a60d7e-xl.jpg[/img]

Sure enough there was a TON of reo in lots of the concrete:

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030257-c16dc2ec-xl.jpg[/img]

Most of the path had 2-3 layers of 8mm, and some bits had layers of 10mm and 12mm as well. It was a fairly high aggregate mixture, probably 25 or 32mpa concrete. An absolute pain to tear up. But we got there in the end:

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030158-7ceea3e5-xl.jpg[/img]

All of that path basically filled a full skip, along with a bit of rubbish:

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030126-6a016f24-xl.jpg[/img]

After that it was a bit of a tidy up and try to make the place look vaguely respectable. Well as respectable as it can be with a non running track car in the backyard

[img]http://images.plebeians.net/_data/i/upload/2020/09/13/20200913030023-d0f22577-xl.jpg[/img]

Things will probably slow down a bit now. Lockdown makes it a bit hard to get materials for working on stuff, but ill try and dig out the foundation for the workshop over the next weeks, and put down drainage aggy for behind the workshop. Also need to paint the shed and put another coat on the garage to keep it looking good.

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MX5 Fun Car – Slow and fiddly progress

So after 6 months of working on pretty much everything else (workbenches, mill and lathe stands, welding stand, storage units and the Hilux) and now getting prepared to move house I thought it would be time to at least revisit this a little bit to at the very least prepare it for transport.

I couldn’t really remember where I was up to though, as I had left it thinking i was going to get it back together by Christmas… and well time got away. Instead i just spent half a day pottering around on it and sorting out things as they came up.

First up was tapping and resealing the overflow can:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034519-4860c6d6-xl.jpg[/IMG]
Hopefully that will be the last time i have to modify that ‘bolt in’ component.

While I was over on that side of the engine bay I fitted up the fuel lines, and added some abrasion protection:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034451-78766019-xl.jpg[/IMG]

Might also add some brackets for ziptie or P-clip mounts later on down the track, but will do for now.

I also mounted up the cold side reroute pipe properly:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034425-5292af7f-xl.jpg[/IMG]

[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034415-61f03b39-xl.jpg[/IMG]

32mm Narva P-clips to little alloy brackets (cue the funk) sorted that out pretty easily.

That side of the engine bay now looks like this:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034347-e0007a16-xl.jpg[/IMG]

At some point between the last update and now I had also tapped a 1/8NPT thread into the intake manifold and ran an 4AN fitting on it for the BOV feed.

On the other side of the engine bay I plumbed up the 4AN hose for the wastegate MAC valve:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034512-976184de-xl.jpg[/IMG]

And sorted out all the catch can fittings:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034504-dd43a749-xl.jpg[/IMG]

Drilled and added a 4mm barbed bulkhead fitting to the firewall to feed the onboard MAP sensor:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034438-5d7271fd-xl.jpg[/IMG]

That side of the engine bay now looks like this:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034220-b6ca0956-xl.jpg[/IMG]

Then mounted the ECU and bundled up the spare loom wires out of the way:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034315-f46287a7-xl.jpg[/IMG]

You can also see the LSU4.9 WB1 sitting there too, which I upgraded to from the old LSU4.2 sensor

This connector needed a date with the depinning tools then:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034303-0ca69900-xl.jpg[/IMG]

So that this grommet could be added:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034230-f8b989be-xl.jpg[/IMG]

Now the WB wiring runs out of the old AC drain bung into the trans tunnel to the exhaust:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034338-87396fbd-xl.jpg[/IMG]

Its a tight fit, but it fits. I had spaced it based on the LSU4.2 sensor, which has a slightly shorter body. Should be fine though as it should move with the engine/gearbox.

While I was under there I filled the gearbox oil and checked on the diff oil.

Overall the engine bay now looks like this though, after fitting the air filter and the turbo coolant hose
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034402-94a5be90-xl.jpg[/IMG]

Few more fiddly bits to go now, need to sort a lower rad hose:
[IMG]http://images.plebeians.net/_data/i/upload/2020/06/28/20200628034207-a7dd3941-xl.jpg[/IMG]

Plus have to get some fuel for it and pressure test the fuel system, which I may get a chance to do this week.

Then it is just a matter of setting up the ECU maps and trying to get it going on base map. Might even do that before we move house!

Posted on

MX5 Fun Car – More Things Off The List

Ticked a few more little things off the list. First up was wrapping the dump pipe:
[img]http://images.plebeians.net/_data/i/upload/2019/10/30/20191030042221-642ede9c-xl.jpg[/img]

Should keep the heat down a little bit. Some is better than nothing anyway.

Then made up my MSD ignition leads, and mounted the coil packs:
[img]http://images.plebeians.net/_data/i/upload/2019/10/30/20191030041452-9a1bad63-xl.jpg[/img]

Got some Norma Cobra clamps for the oil and water drains:
[img]http://images.plebeians.net/_data/i/upload/2019/10/30/20191030041710-3bcc204a-xl.jpg[/img]

Will be able to slip heat sleeve over them later when im sure its not leaking.

Speaking of leaks though, i found a pinhole in the aluminium coolant hard line, that just refused to seal up. So i rebuilt it in stainless.

Built a little testing rig:
[img]http://images.plebeians.net/_data/i/upload/2019/10/30/20191030044756-cb53c0f5-xl.jpg[/img]

Just used some 32mm OD (25mm ID i think) PVC plumbing pipe and end caps, with a threaded wheel valve in one end.

Found a couple of pinholes:
[img]http://images.plebeians.net/_data/i/upload/2019/10/30/20191030044808-06fa8756-xl.jpg[/img]

Welded them up and it holds 60psi, or 4 bar.
[img]http://images.plebeians.net/_data/i/upload/2019/10/30/20191030044819-75083d0c-xl.jpg[/img]

Given its only a 16psi cap I think it will do just fine.

And test fitted:
[img]http://images.plebeians.net/_data/i/upload/2019/10/30/20191030041850-744558ad-xl.jpg[/img]

Waiting on some 32mm P clips to be able to build the mounting brackets for it, and then it should be good to go.

Once i can get it mounted up Ill be able to run the wiring harness and finish off some fiddly bits ahead of first start.

Posted on

MX5 Fun Car – Wiring Check


Had a chance today to bench test the wiring loom and make sure it should all work properly. Snapped a few pretty pics when i did that too:
[IMG]http://images.plebeians.net/_data/i/upload/2019/10/20/20191020211030-3063cac6-xl.jpg[/IMG]

Biggest pain was the LS2 coil plugs:
[IMG]http://images.plebeians.net/_data/i/upload/2019/10/20/20191020211037-9f6117e7-xl.jpg[/IMG]

Just less flexible wire, and having to overlap the heatshrink made for a bit of a tight fit. But worked fine.

Made up a bracket for the ECU and wideband:
[IMG]http://images.plebeians.net/_data/i/upload/2019/10/20/20191020211044-496e0a7d-xl.jpg[/IMG]

Some people have asked me what sort of connectors I have used. Well, some are factory for ease of swapping parts over:
[IMG]http://images.plebeians.net/_data/i/upload/2019/10/20/20191020211024-22d04e77-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2019/10/20/20191020211017-1fdc22d1-xl.jpg[/IMG]

While some are DTM or DT for various items. All the body connections (all 8 wires worth) are Deutsch DT, and the IAT and Coolant temp are DTM.
Plenty of room on the Cas and Cnk sensor wires to be able to shorten and swap to potted DTM/DT connectors if the need arises.

Injector of course are standard Bosch:
[IMG]http://images.plebeians.net/_data/i/upload/2019/10/20/20191020211011-95c60559-xl.jpg[/IMG]

All up its not as nice as some i have seen and worked with, and its certainly not motorsport/milspec quality. But its functional and will work well enough.

Posted on

MX5 Fun Car – More Little Bits

Definitively in the 20% of stuff that takes 80% of the time, and no one wants to see more photos of boring wiring and neatening things up.
Managed to get the fuel filter in though, with a fairly simple alloy mount:

[IMG]https://images.plebeians.net/i.php?/upload/2019/10/02/20191002210005-e1d00c27-xl.jpg[/IMG]

Plumbing it in up there is a sweet pain though.
Sorted out my coolant and oil drains:

[img]https://images.plebeians.net/_data/i/upload/2019/10/02/20191002210028-19bc22e9-xl.jpg[/img]

Then sorted out the oil catch can:

[img]https://images.plebeians.net/i.php?/upload/2019/10/02/20191002184716-99d5d561-xl.jpg[/img]

Need to run a few more wires, and finish of some various bits and then its pull down and reassemble for real time.

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MX5 Fun Car – More Fiddly Bits

Another weekend of little bits and pieces, and not much time to work on the car. Got the welder out again and baked the cast pipe to get the contaminants out. Welded up ok after that:

[img]http://images.plebeians.net/_data/i/upload/2019/09/22/20190922042930-c8cfb1b6-xl.jpg[/img]

Then sorted out the new battery mounting in the boot. Thanks to kabab at Automotive Superstore for the Fullriver:

[img]http://images.plebeians.net/_data/i/upload/2019/09/22/20190922042907-a11acffc-xl.jpg[/img]

The bracket is from Techno Toy Tuning in the US, brought it back last year with all the other bits.

Started sorting out hot side piping, and finalised the clocking of the turbo.

[img]http://images.plebeians.net/_data/i/upload/2019/09/22/20190922042818-d117a31d-xl.jpg[/img]

Oil drain needs new bolts, as the socket heads I have interfere. But will all work well.

Then painted and inked the cam cover:

[img]http://images.plebeians.net/_data/i/upload/2019/09/22/20190922042722-0ecbd203-xl.jpg[/img]

Seems to be a massive oil spot that I cant get out on the intake side 🙁

Inking was done with some left over Tamiya enamel paint and a 12ga blunt needle:

[img]http://images.plebeians.net/_data/i/upload/2019/09/22/20190922042538-b03b9398-xl.jpg[/img]

Essentially just dribble the ink in, and voila. Done.

[img]http://images.plebeians.net/_data/i/upload/2019/09/22/20190922042644-3c9c1dec-xl.jpg[/img]

Need to get the fuel filter in, and then I can start on final assembly. Perhaps even this week!

Posted on

MX5 Fun Car – The 80:20 Rule

Very much in the 80% phase of the 80:20 proportion currently. Lots of niggling little things taking up large amounts of time.

First up was changing out the fuel pump. The car had a bit of a hesitation at high RPM and I think I now know why. The in tank fuel filter was basically folded over ontop of itself, blocking flow. 
[img]http://images.plebeians.net/_data/i/upload/2019/09/18/20190918192843-eee9bfc4-xl.jpg[/img]
[img]http://images.plebeians.net/_data/i/upload/2019/09/18/20190918192730-19affaa1-xl.jpg[/img]

Replaced that with a DW200 pump, which drops in nicely.
[img]http://images.plebeians.net/_data/i/upload/2019/09/18/20190918192816-7c1d6ca6-xl.jpg[/img]

After this I started swapping out the fuel lines for ethanol compatible ones, these two in above the tank were an absolute pain. No direct way to get to them, and not much room while leaning over the car.
[img]http://images.plebeians.net/_data/i/upload/2019/09/18/20190918192431-4f29e764-xl.jpg[/img]

Still need to add a new fuel pump relay to take the load off the circuit opening relay in the engine bay, that often pops, and so the fuel pump is directly controlled by the Haltech.

I then mostly sorted out the fuel lines in the engine bay, using PTFE lined 200 series hose and 6AN hose ends; and mounted the regulator to the brake stopper:
[img]http://images.plebeians.net/_data/i/upload/2019/09/18/20190918192616-89f64ee7-xl.jpg[/img]

Made a bracket for the flex fuel sensor, and mounted it up too:
[img]http://images.plebeians.net/_data/i/upload/2019/09/18/20190918192707-d631b676-xl.jpg[/img]

Finally i sorted out the coolant reroute pipe and mounting points to the chassis:
[img]http://images.plebeians.net/_data/i/upload/2019/09/18/20190918192501-66f49993-xl.jpg[/img]
Still need to pressure test it, but it should work rather well.

Almost getting to the point of being able to assemble everything properly, but for now im just getting everything in place and then going to do a full assembly run at the end so I can be sure that everything is done correctly at one time.

Posted on

MX5 Fun Car – Wiring Harness

All but finished the wiring loom tonight. Just waiting on a couple of extra connectors where I had ordered the wrong ones, and to finalise placement of the fuel pressure reg.

[img]http://images.plebeians.net/i.php?/upload/2019/09/11/20190911050827-6279d364-xx.jpg[/img]

This is what Mazda should have done originally, like Toyota, a nice separate engine harness that just links into the body loom in key places. Not the silly integrated harness that ties back to the body in five different places.

Now that it is done I can move to the battery setup, and put in the new fuel pump/filter as the fittings arrived today.

Posted on

MX5 Fun Car – Welding time

Got a few more things ticked off the list, or should i say TIGd off the list. First up was getting the IC piping welded up, which wasn’t too bad except for two spots which seemed to have a ton of contamination that kept screwing up the weld.

Its all in there now though, and the 2″ BOV fits fairly well even with the coolant hard pipe:
[img]http://images.plebeians.net/_data/i/upload/2019/09/07/20190907032955-532eb94e-xl.jpg[/img]

Next up wast starting to work on the coolant hardline, which is a bit finicky with where it runs. But with a bit of massaging of brake lines it ends up looking like this:
[img]http://images.plebeians.net/_data/i/upload/2019/09/07/20190907032749-c10b58a2-xl.jpg[/img]

Welded in a pie cut elbow to redirect it 90deg at the firewall and its close to a straight pipe to the back of the head.

Towards the end of that the welding was starting to get a bit weird, and then I found this:
[img]http://images.plebeians.net/_data/i/upload/2019/09/07/20190907032741-6242d0e5-xl.jpg[/img]

Nasty crack in the torch, which isnt doing any favours. Time for a new torch, and this one was annoyingly not very old.

Without being able to weld stuff I went on to start on the turbo oil line and pressure/temp sender. Did some head scratching and came up with this for mounting the AN4 oil filter:
[img]http://images.plebeians.net/_data/i/upload/2019/09/07/20190907032415-f2d98cd2-xl.jpg[/img]

Its part of a bicycle seat clamp for a 31.8mm seat tube, fits the 32mm filter perfectly.

Added the Bosch sensor and lines and it sits like this:
[img]http://images.plebeians.net/_data/i/upload/2019/09/07/20190907032408-a3e4b288-xl.jpg[/img]

Will have to pop that clip out and put a P-clip in for the feed line.

Also have been working sporadically on the ECU wiring, which—because of Mazda’s infinite wisdom—is a complete replacement for the stock harness. Cue one tray full of Deutsch connectors, a brand new loom, and some braided sleeving:
[img]http://images.plebeians.net/_data/i/upload/2019/09/07/20190907033650-d4528328-xl.jpg[/img]

Picked up a Dymo to do heatshrink labels with too, which makes things much nicer:
[img]http://images.plebeians.net/_data/i/upload/2019/09/07/20190907033636-26efb5af-xl.jpg[/img]

Bit stuck on that stuff for now though, will need a new TIG torch to finish off the welding, and it turns out I ordered LS1 coil plugs not LS2 coil plugs. So more waiting for post.

Until then I’ll get started on the fuel pump and wiring harness there, plus new battery and tie down.