Garage Takai

Well i went for an ASI radiator, which arrived last night:

[img]http://images.plebeians.net/i.php?/upload/2018/05/31/20180531224943-c8bdc728-xl.jpg[/img]

Look familiar? Yeah, thats a 42mm core with massively oversized end tanks. They are about 4mm bigger than the 52mm unit. Still aint going to fit. 🙁

So i started thinking about alternative mounting mechanisms, and came up with this little semi-dodgy fix. Surprised i didn’t think of this earlier:

[img]http://images.plebeians.net/i.php?/upload/2018/05/31/20180531224934-2c0714f0-xl.jpg[/img]

Thats an M6x75mm bolt with a bunch of washers spacing the radiator forward in the engine bay, away from the swaybar. Sits like this:

[img]http://images.plebeians.net/i.php?/upload/2018/05/31/20180531224928-d2dc2aec-xl.jpg[/img]

The bunch of washers makes me a bit sad, and if i had my lathe i would machine up a little solid spacer for it. But for now it will work.

The top rubber mounts have enough flex to clear fine, but i gave them a slight tweak with pliers to sit flat again. Overall its about a 2deg deflection. But 2deg is all that is needed for this sort of clearance to the swaybar:

[img]http://images.plebeians.net/i.php?/upload/2018/05/31/20180531224920-fdba04ab-xl.jpg[/img]

Still can’t believe that i didn think of it beforehand. 🙁

Now to package up this junk radiator for return.

So the new fans arrived:

[img]http://images.plebeians.net/i.php?/upload/2018/05/27/20180527060641-d8cf88f3-xl.jpg[/img]

But while they clear the ARC intake, it is still no dice on the swaybar:

[img]http://images.plebeians.net/i.php?/upload/2018/05/27/20180527060633-cdf2c43f-xl.jpg[/img]

Bolts up, but rubs on the fans. So i ordered a 42mm unit rather than the 52mm unit. That 10mm of clearance will make all the difference.

While i couldnt get the car out to bed in the brakes i did a few other little bits and bobs. First up, after bleeding the brakes, was fitting the adjustable endlinks for the front swaybar, that also allow me to use the NB sway bar on the NA:

[img]http://images.plebeians.net/i.php?/upload/2018/05/27/20180527060628-f954e759-xl.jpg[/img]

Second thing was to fit ‘Eagle Eye” LEDs to where the sun visors normally bolt in, and wire them into the knee lights. Makes a huge difference to actually being able to see at night:

[img]http://images.plebeians.net/_data/i/upload/2018/05/27/20180527060611-804e9501-xl.jpg[/img]

Third was making a little tiny RAM mount for the centre bolt hole on the dash, so that i can have a nice solid mount for phones and any lap timer:

[img]http://images.plebeians.net/_data/i/upload/2018/05/27/20180527060603-cfab3f62-xl.jpg[/img]

Finally, i managed to organise a 3 way swap to get a new hard top, this one in silver, with a ducktail type wing on the back too:

[img]http://images.plebeians.net/_data/i/upload/2018/05/27/20180527060617-86ccb498-xl.jpg[/img]

Looks quite nice on the car, and the colour match makes it much easier for me.

Now to wait for the 42mm radiator and then it should be game on for getting the brakes bedded in, and start driving it around a bit.

Courtesy of the Telstra outage today i went home early… only to find the internet out at home too. Oh well, to the garage.

Brake upgrade installed, nice and easily with all the NB8C bolt on parts:

[img]http://images.plebeians.net/_data/i/upload/2018/05/20/20180520230432-944c0352-xl.jpg[/img]

Discs, calipers a chunk bigger, and brand new EBC Yellowstuff pads.

[img]http://images.plebeians.net/_data/i/upload/2018/05/20/20180520230539-31b65327-xl.jpg[/img]

Then as i had the wheels off, i gave the wheel arches a quick roll with the guard roller:

[img]http://images.plebeians.net/_data/i/upload/2018/05/20/20180520230414-89e74c71-xl.jpg[/img]

About 10 years ago back in Adelaide a few of us got together and bought a roller for about $300-400 or so. That one is basically identical and cost $50…

Added a brake master stopper from Beavis Motorsport, given the 25yo firewall flexes a reasonable amount:

[img]http://images.plebeians.net/_data/i/upload/2018/05/20/20180520031739-4cda6f73-xl.jpg[/img]

Finally aded a couple of bits of JDM-yo street cred… for amusement

[img]http://images.plebeians.net/_data/i/upload/2018/05/21/20180521000344-68764b8f-xl.jpg[/img]

and mocked up this rear tow hook that i picked up for $5 in a car garage sale. Not sure if ill use it yet:

[img]http://images.plebeians.net/_data/i/upload/2018/05/21/20180521000407-e17c0b38-xl.jpg[/img]

Need to go get some fresh brake fluid and bleed the brakes next, but that can wait for another day. Probably when i do the fans at the same time.

A bit more time spent on the car today, popped the new water pump in place and then timing belt and closed up the front. Nothing exciting there.

Put a Pipercross filter in place of the Ryco one that is who knows how old.

[img]http://images.plebeians.net/i.php?/upload/2018/05/19/20180519045652-79cf0d70-xl.jpg[/img]

New gasket for the AFM:

[img]http://images.plebeians.net/i.php?/upload/2018/05/19/20180519045609-aa455d3c-xl.jpg[/img]

Then popped in the new radiator:

[img]http://images.plebeians.net/_data/i/upload/2018/05/19/20180519045630-6053ff90-xl.jpg[/img]

And that is where it started all going wrong.
Mainly instead of a 42mm rad they sent me a 52mm rad, so it fouls on pretty much everything. First thing it fouls on is the new bling intake:

[img]http://images.plebeians.net/_data/i/upload/2018/05/19/20180519045547-2be18368-xl.jpg[/img]

Secondly it fouls on the sway bar, which was out of the car so i could get easy access to the crank snout. When the new 24mm one went to go back in…

[img]http://images.plebeians.net/_data/i/upload/2018/05/19/20180519052142-d08c6f32-xl.jpg[/img]

[img]http://images.plebeians.net/_data/i/upload/2018/05/19/20180519045512-907bbe16-xl.jpg[/img]

So begrugingly i chucked the old intake in, and left the swaybar out until i could sort it out later.

With all that done i took it outside to bleed the cooling system and make sure there werent any leaks, and this new tool i picked up (thanks to MCM) is bloody amazing:

[img]http://images.plebeians.net/_data/i/upload/2018/05/19/20180519045433-54948c73-xl.jpg[/img]

Seriously, why didnt i have one of these earlier!

While i was waiting for the engine to warm up and the thermostat to open, i tidied up the car, and then decided to put the Raybrigs in. To say that the old headlights were average was a bit of an understatement:

[img]http://images.plebeians.net/i.php?/upload/2018/05/19/20180519045407-e032597b-xl.jpg[/img]

You can see where i tried to have a polish of the outside, but the frosting is actually mould inside the glass. Oh well, the Raybrigs are much much nicer.

What a change:

[img]http://images.plebeians.net/_data/i/upload/2018/05/20/20180520031751-02671e87-xl.jpg[/img]

The final thing to go wrong with the whole cooling setup was actually found while i was waiting for the fans to kick in. They didnt. Every time the fan kicked in the fuse blew, but the fan spins freely in the housing. Quick test with the multimeter and it seems that there is a short in the motor windings somewhere.

More bolt on parts that dont quite bolt on… 🙁

Oh well, time to get a flat alu sheet and some Spals out and make up some low profile fans. While that is happening i may as well get started on the brake upgrade too.

In between a bunch of family stuff this weekend i found a brief 2hr gap to try and get the water pump and timing belt changed. Took about 20msn to rip it all apart and prep it for the new pump, pretty simple compared to many cars ive worked on in the past. But then Murphy reared his ugly head. The timing belt kit i got seems to be second hand or returned, as the pump is an NB unit, and some wingnut has cut off the side mounting tab to get it to clear the alternator bracket. All of that to no avail though, as the NB pumps don’t have a thread in that side for the tensioner.

[img]http://images.plebeians.net/_data/i/upload/2018/05/13/20180513032224-86e3f743-xl.jpg[/img]

Rubbish, and there goes my productive time for the weekend… so i did some other things instead.

Firstly a quick block off plate for the coolant idle valve thingy:

[img]http://images.plebeians.net/_data/i/upload/2018/05/13/20180513032352-e38ea493-xl.jpg[/img]

Then secondly a simple Toyota COP mounting plate:

[img]http://images.plebeians.net/i.php?/upload/2018/05/13/20180513032331-8c4eca96-xl.jpg[/img]

Finally did a bit of further automotive archaeology, and this car is a bit ideosyncratic. Whoever built this engine (or at least did the last timing belt and water pump change) was somewhat paranoid about bolts coming loose:

[img]http://images.plebeians.net/_data/i/upload/2018/05/13/20180513032309-061342ab-xl.jpg[/img]

Every bolt is absolutely slathered in Loctite red and required a ton of cleaning up of the threads.

On the other hand that cardboard gasket looked like this:

[img]http://images.plebeians.net/i.php?/upload/2018/05/13/20180513032414-3d947d0d-xl.jpg[/img]

Shipping cardboard and gaffer tape… really?

Anyway, now to wait for more bolt on parts, that will hopefully bolt on.

Also for the lols. What happens when you are ordering parts at 3am while trying to settle a teething baby:

[img]http://images.plebeians.net/_data/i/upload/2018/05/13/20180513175542-179c069d-xl.jpg[/img]

That would be two front sway bars… and no rears.

Ticking off little things each evening after work while i wait for cam and crank seals to arrive. Last night it was sorting out this monstrosity behind the bumper:

[img]http://images.plebeians.net/_data/i/upload/2018/05/02/20180502190741-903ef991-xl.jpg[/img]

Someone had thought it a good idea to jam an air horn behind there, and not even do it properly, just ziptied and electrical taped in place. What is worse the compressor took about 3-4 seconds to build enough air to make a noise, at which point the soccermum in a Prado has probably just run over the front of the car.

So i decided to embrace the MX5’s Subaru roots, and install Hella Supertones:

[img]http://images.plebeians.net/_data/i/upload/2018/05/02/20180502190753-c2c2fc84-xl.jpg[/img]

One less thing to do later.

[QUOTE=Gammaboy;842980723]What’s the shifter trick on the heater box inlet/outlet?[/QUOTE]

An old guy who worked at a rad shop showed it to me ages ago. You get an adjustable shifter and find a reference diameter from somewhere else on the pipe:

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429014852-37aab973-xl.jpg[/img]

Then you put it around the narrow section of the pipe end, and rotate it around on the pipe end to reshape it to round:

[img]http://images.plebeians.net/i.php?/upload/2018/04/29/20180429014746-4af2bab3-xl.jpg[/img]

Works a treat on softer metals like the heater core or various rad pipes.

Its a pretty neat trick, which i got to show a plumbing apprentice when he was replacing our home HWS. Was fiddling around with a special tool to reround it from the inside etc, and it kept getting jammed in the pipe. 30s with the shifter and all sorted.

So between lots of stressful family stuff this weekend I was very happy to have some garage time on the side to get some stuff done.

One of the reasons i got the MX5 was to muck around and do some stuff i have wanted to experiment with for a while, but too either chicken to do on the AE86 because of costs, or illegality for IPRA.

The first of these was mucking around with flocking. The old dash was pretty munted with several cracks and actually broke in half when i knocked it on the stand. Thats ok, because MX5 dashes are like $50 for a half decent NA one. So after i fibreglassed the bottom of it to hopefully minimise cracking, i got to work flocking.

I built this little electrostatic flocking gun from an electric fly swat that i had lying around.

[img]http://images.plebeians.net/i.php?/upload/2018/04/24/20180424232910-566de31a-xl.jpg[/img]

Not recommended TBH, it would have been better with a pressurised unit, but works well enough (although not for how much effort it was to make).

Nevertheless, it does a half decent job and the dash ended up like this:

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429015031-2f68ee0b-me.jpg[/img]

You can see it looks a little lumpy occasionally though:

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429014923-b9c93fdb-me.jpg[/img]

Still looks good in car:

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013300-642a7877-xl.jpg[/img]

Also jammed an NB heater core in there that needed a little bit of reshaping of the outlets, but that was easy as with the old shifter trick

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013743-e1f7dac0-xl.jpg[/img]

Another thing i have been interested in recently is 3d printing, and given that this is the first build i have done since i built my 3D printer, i figured it was time to knock up some little plugs to seal up the AC box

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013515-481b44f8-xl.jpg[/img]

And also knocked up a mounting bracket for the washer bottle:

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013203-08ca1246-xl.jpg[/img]

Realised afterwards when i was looking on Beavis’ site that it is very similar to what he has done for his setup. Turns out we think alike in engineering terms.

I then started looking around for other things to 3d print, and remembered that my rear valance has a big crack in it and a chunk taken out. So as a second attempt at transferring an irregular pattern to digital and then plastic i figured why not.
First bit is getting the shape:

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013722-d8497bb7-xl.jpg[/img]

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013656-aa19d290-xl.jpg[/img]

Then scanned it in, processed the photo, then converted the image into a vector image, and finally extruded it in Fusion with a little flange lip for attachment. Giving

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013631-2cea9a6b-xl.jpg[/img]

Worked a treat.

Then i went to turn the car around in the garage and hit a snag. Went to put it into first and ripped the entire shifter knob off and tore a chunk of flesh out of my arm. Some previous owner had installed one of those shift knobs with a grub screw, and it had torn up all the thread.

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013334-e5919af6-xl.jpg[/img]

They had then put the stock shifter back in with a hammer. I kind of already knew about this, which is why i had bought a new one already. But still a painful reminder of previous crappy mods.

So short shifter went in:

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429013451-913ca02e-xl.jpg[/img]

Finally i turned the car around, and then got to work on pulling the water pump out and changing the timing belt

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429012702-13677d9b-xl.jpg[/img]

Had forgotten how annoying it can be working on road cars again, and with all of these fiddly little water hoses for random intake junk, its a pain in the bunghole
This one looks like some form of intake heater, wonder if i can delete it

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429012645-f774ff41-xl.jpg[/img]

While this one looks like an IACV

[img]http://images.plebeians.net/_data/i/upload/2018/04/29/20180429012625-451331c5-xl.jpg[/img]

Probably need that one for the moment i guess.

Thats about it for this weekend, should be able to do most of the other stuff on the engine bay area this week or next weekend, but its going well.

Had a few moments this afternoon to pull the heater box out to put a new core into it. It wasnt leaking, but im bloody surprised it wasnt making my feet wet:

[img]http://images.plebeians.net/_data/i/upload/2018/04/24/20180424232528-a50ae79e-xl.jpg[/img]

[img]http://images.plebeians.net/_data/i/upload/2018/04/24/20180424232606-42923554-xl.jpg[/img]

Has leaked and corroded so badly that the corrosion (cupric chloride and efflorescence) has actually sealed it up again. When i put the garden hose on it after coming out of the heater box it was leakier than an incontinent geriatric.

Thankfully i had already started lining up an NB unit which will drop in and make future core changes much easier.

I also added some lightness by gutting the aircon box:

[img]http://images.plebeians.net/_data/i/upload/2018/04/24/20180424232657-541126d8-xl.jpg[/img]

The heat exchanger is easily the heaviest part there, and just gutting it will make for a good weight saving.

Had a couple of hours tonight, so got the biggest thing out of the garage and into the car, the cage.

[img]http://images.plebeians.net/i.php?/upload/2018/04/22/20180422055042-8807c09d-xl.jpg[/img]

Pretty simple install once i got the bloody soft top out, which had a nice little tear down low under the rain rail on the driver’s side, so pretty sure its going to end up being binned.

Mostly fitted the carpet back in too, which will make it a bit nicer place to be in.

[img]http://images.plebeians.net/i.php?/upload/2018/04/22/20180422055014-e8e9505f-xl.jpg[/img]

Found that the heater box has leaked at some point, so im definitely going to change the core and hopefully getting an NB alloy unit to make it easier to work on.

Did a bunch of wiring tidying too, but who needs to see that…