did you have no rust in your scuttle box area?

boy.. that whisky and cola must have set you back a bob or two !:-)

Yea I was quite pricey but I got a free turbo and wastegate:302:

Anyway while I was waiting to get my TIG fixed I decided to make a start on removing the dash. I have a crack free replacement to go in and I need to remove the dodgy chopped loom. A mate of mine thinks he might have a unmolested one.

Dash gone.
http://i227.photobucket.com/albums/d...a/IMG_0602.jpg

One loom with some dodgy chops
http://i227.photobucket.com/albums/d...a/IMG_0614.jpg

The connections that plug into the fuse box. Been getting a bit hot me thinks.
http://i227.photobucket.com/albums/d...a/IMG_0613.jpg

Loom removed.
http://i227.photobucket.com/albums/d...a/IMG_0617.jpg

Cracked old dash.
http://i227.photobucket.com/albums/d...a/IMG_0603.jpg

Crack free replacement! :D
http://i227.photobucket.com/albums/d...a/IMG_0604.jpg

New update :D . Purchased a Xtreme Rotaries side mount alternator kit and alternator with twin pulley.

http://i227.photobucket.com/albums/d...a/IMG_0618.jpg

On the down side now have to modify my coil mount as there is slight fouling on the front coil. :ugh2: Oh well that's what ya get when you buy your parts one at a time.

Luv your build, looking great!

Bit of an update, I cleaned up the dash, rust converted and primed the dash frame. Also stripped and repainted the steel cover panel.

http://i227.photobucket.com/albums/d...a/IMG_0633.jpg
http://i227.photobucket.com/albums/d...a/IMG_0629.jpg

Also after finally after getting my TIG back (well they replaced it :D ) I got around to welding the exhaust probe bung in and shaping the dump pipe to give a bit more clearance for the steering box.

http://i227.photobucket.com/albums/d...tredda/007.jpg
http://i227.photobucket.com/albums/d...tredda/008.jpg

Should be able to send it off to get ceramic coated now!

Hey Guys, got my exhaust manifold, dump pipe and turbo exhaust housing back from getting ceramic coated.

http://i227.photobucket.com/albums/d...a/IMG_0750.jpg


The finish is not as smooth as I thought it would be but it looks allright. As long as it holds on an keeps a lot of the heat in.

About half way through fabricating the front crossmember so after Monday I will have a break from my studies for 3 weeks so might be able to get a bit more done. :D

Fabricated the front engine mount crossmember...

http://i227.photobucket.com/albums/d...rossmember.jpg
http://i227.photobucket.com/albums/d...rinstalled.jpg
http://i227.photobucket.com/albums/d...mber_mount.jpg
http://i227.photobucket.com/albums/d.../Newmounts.jpg

Should be able to pull the engine out now and throw a whole lot of money at it :eek: .

Then start paint stripping the engine bay. The fun begins!

Wow this this is going to be incredible.

Pulled the engine out ready to strip the engine bay.

Couldn't help myself and made up and engine stand with some scrap steel I had laying about.:coolgleamA:

http://i227.photobucket.com/albums/d...a/IMG_0773.jpg
http://i227.photobucket.com/albums/d...a/IMG_0772.jpg

Very nice!

Well as my holiday in Sydney was ruined before it even started by the bastard ash cloud, I did get a bit done on the Mazda.

Removed everything from the engine bay.
http://i227.photobucket.com/albums/d...IMG_0774-1.jpg

Looked a bit nasty down here. :eek:
http://i227.photobucket.com/albums/d...IMG_0776-1.jpg

After a coat of paint stripper came to this.
http://i227.photobucket.com/albums/d...a/IMG_0824.jpg

Note how this side was a different colour. Must have taken a hit once upon a time and replaced.
http://i227.photobucket.com/albums/d...a/IMG_0823.jpg

Then got stuck into it with a assortment of wire wheels and finished of with this little beauty.
http://i227.photobucket.com/albums/d...a/IMG_0825.jpg

And came up like this.
http://i227.photobucket.com/albums/d...a/IMG_0826.jpg
http://i227.photobucket.com/albums/d...a/IMG_0827.jpg

A bit of damage on the chassis rail probably when the inner guard was replaced.
http://i227.photobucket.com/albums/d...a/IMG_0828.jpg

Now will throw a bit of rust converted around and finish the front panel. Also when I removed the front guards found this :icon_tdown: but I will leave this for another time.
http://i227.photobucket.com/albums/d...a/IMG_0829.jpg
http://i227.photobucket.com/albums/d...a/IMG_0830.jpg

Those front corners are a common spot for rust. I had to replace mine as well. They actually aren't hard to replace. Just takes some time, a welder, and a BFH. :)

pretty

Very nice!

keep up the awesome work! Looks amazing!!

awesome
 

well to start the build is awesome so far , i have a 73 rx2 2 door with a turbo and i have a couple questions ,1 i have an s5 trans also, how do you do the shortened shifter housing mod and 2 how do those pwr heat exchangers work compaired to a normal intercooler ?and how good are they for street use (daily driving) ?

This is a quote from Bumpstart from Ausrotary....

remove the gearstick
take the cover off the side of the extension housing, and withdraw the grub screw that holds the shifter cup socket to the inner selection rod
remove the shifter assembly from the back of the box
( undo the bolts holding it to the rear of the box )
remove the outer tube..
( it should pull out with rubber seal on the end )
the shifter assembly will have several sets of bolt holes which attach it to the box
the idea is to cut away from this extension housing the entire front set of holes
and move the entire shifter assembly forwards onto the next set of holes
( everything moves forward one set of holes as the front pair are cut off just forward of the next set of holes )

now, the outer tube need shortening this same amount.
( cant recall the dimensions, its been a while , but its easily measured )
hacksaw will do...

now, the inner rod ( that's normally inside the outer tube )
requires this same length removed
and a new hole drilled and tapped for the grub screw
( to hold the cup socket which is the bottom of the shifter )

re - assemble.....
the shifter should now be over the top of the rear of the box
( and not behind it )
pretty easy to do, not easy to picture without some pics...
( and buggered if i am dragging mine out to take pics )

measure twice, cut once

The distance you cut it will be the distance the housing is moved foward, which is in this case the distance between the front and rear hole centers.

Hope this helps.

Holy Shit! Nearly 12 months since last update. :eek:
Well I've had a bit on the go with a few home projects, work, family and serious case of CBF at times.

In the meantime I purchased a Toyota Hilux diff with the mounts already at the correct width for my RX4 with the axles machined and drilled for 4 x 110 studs and SV RX7 disks.

I removed the old diff and as you can see it was painted purple. Only on the rear side and over dirt, grease and grime. :gay:
http://i227.photobucket.com/albums/d...ps0ae2d0a1.jpg
http://i227.photobucket.com/albums/d...ps96824177.jpg

I went to test fit the Hilux housing and found the holes used to locate the housing on the spring spigots was too small. :wallbash:
http://i227.photobucket.com/albums/d...ps87a7867f.jpg

So off to the local tool supplier and bought a 29mm hole saw. I cut a hole in a scrap bit of flat bar and then tack welded centrally around the hole on the housing.
http://i227.photobucket.com/albums/d...psc2653605.jpg
http://i227.photobucket.com/albums/d...psa5d4e77a.jpg

I took the center drill out of the hole saw arbour and drilled a larger hole in the spring mount.
http://i227.photobucket.com/albums/d...ps96af45d4.jpg

I cleaned the spring saddles and repainted them.

Did the same to the otherside then test fitted the housing. Even got to see what my Simmons look like on for the first time.
http://i227.photobucket.com/albums/d...psaf7d615d.jpg
http://i227.photobucket.com/albums/d...ps28bba287.jpg

Now I am planning to duplicate the factory diff torque rods and mounts fitted factory to some rare RX4s but with some adjustability.
http://i227.photobucket.com/albums/d...ps04f16997.jpg

A bit more progress!

I have made my rear caliper brackets to adapt the RX7 calipers to fit the Toyota Hilux diff housing.

First I created a CAD model of the diffhousing, axles, bearing and housing, disk rotor and a rough model of the RX7 caliper.
http://i227.photobucket.com/albums/d...iffHousing.jpg

Then I printed a 1 to 1 drawing of the profile an cut it out of MDF.
http://i227.photobucket.com/albums/d...a/IMG_1513.jpg
http://i227.photobucket.com/albums/d...a/IMG_1514.jpg

Then ground out the step down.
http://i227.photobucket.com/albums/d...a/IMG_1515.jpg

When I was happy with the fit I created a DXF file and had them laser cut and had a mate mill the step into them.
http://i227.photobucket.com/albums/d...a/IMG_0006.jpg

And here is one fitted! :D
http://i227.photobucket.com/albums/d...a/IMG_0009.jpg
http://i227.photobucket.com/albums/d...a/IMG_0012.jpg
http://i227.photobucket.com/albums/d...a/IMG_0013.jpg

I also bought some new rubbers that go top and bottom of the leaf springs. Bought almost the last lot that Mazda had left.
http://i227.photobucket.com/albums/d...a/IMG_0008.jpg

I got the laser cut parts back this week so I started work on the 2 link mounts.....

This is the CAD model.
http://i227.photobucket.com/albums/d...Ddiff2link.jpg

This is the mount for the chassis.
http://i227.photobucket.com/albums/d...assismount.jpg

These are the mounts to go on the diff housing.
http://i227.photobucket.com/albums/d...a/IMG_0041.jpg

And here are they all are with a bit of a mockup.
http://i227.photobucket.com/albums/d...a/IMG_0042.jpg

Can't wait to see the end product.

^Me too. Should be badass.

I found a bit of time to get some welding done this morning.

Welded up the two link diff mounts.

http://i227.photobucket.com/albums/d...ps2cb50525.jpg
http://i227.photobucket.com/albums/d...psc47f4404.jpg

...and the links themselves.

http://i227.photobucket.com/albums/d...ps44347915.jpg


Painted and fitted.:D

http://i227.photobucket.com/albums/d...ps969f6a21.jpg

When I am happy that I have finished with the diff I'm getting it powercoated.

Ok a bit of an update!

Here's my latest investment...
http://i227.photobucket.com/albums/d...psd26afa86.jpg

Tremec TKO 600 5 speed with Carbon Syncros, Brass fork pads and with an Ultimate Street short throw shifter, Quarter Master Hydraulic bearing, slip yoke for the tailshaft, a Direct Clutch twin plate, and a Green Brothers steel bell housing. :coolgleamA:

I have to do a little mod to the box to suit the RX7 turbo starter and fabricate a gearbox cross member, I will detail this later.

im glad to see the project is still going strong. lovin it!!

Had to make a mod to the TKO to clear the starter for Green Brothers bellhousing.

Some of this area has to be removed and a new hole drilled.
http://i227.photobucket.com/albums/d...psb6bd0479.jpg

Marked out the material to be removed and drilled new hole.
http://i227.photobucket.com/albums/d...psc2305ab2.jpg

Chopped! A bit un-nerving on a brand new gearbox:eek:
http://i227.photobucket.com/albums/d...ps3142b10e.jpg

Bellhousing back on.:icon_tup: Just need to get hold of a turbo RX7 starter to double check fit up.
http://i227.photobucket.com/albums/d...psdd569ae3.jpg

Just for interest, this is the difference between my old SV RX7 box and the TKO.

670mm Vs 730mm from belhousing face to shifter position. The RX7 box I had already done the shortened shifter housing mod.
http://i227.photobucket.com/albums/d...psc62648cb.jpg

I put the TKO on the back of the 20B today and dropped them into the engine bay to measure up the gearbox cross member.
Sorry I don't have any pics at the moment as the missus is away and she took the camera and my phone is no better than a potato.

The TKO fits the RX4 transmission tunnel very well and shouldn't need any "clearancing".

I have measured up and modeled the gearbox cross member.
http://i227.photobucket.com/albums/d...ps1a91e617.jpg

Turns out to only need a very simple design :) .

Here's the photos of the fit up...

http://i227.photobucket.com/albums/d...psbc315c2f.jpg
The shifter comes out pretty close to the factory hole. (Already butchered for the early RX7 box when I bought it :ack2: ) The engine is 50mm further back than factory so normally would be spot on.

http://i227.photobucket.com/albums/d...ps1a7a0500.jpg
Good clearance around the firewall.

http://i227.photobucket.com/albums/d...psa457fee0.jpg
Not bad around the trans tunnel either.

As soon as I get the laser cut parts back I'll fab up the cross member.

Wow. This build is great! I really like how much fabrication you are doing on your own. And your rubber isolated transmission crossmember is great!

I added some gussets to my CAD model just to stiffen things up.
http://i227.photobucket.com/albums/d...ps5ccae91d.jpg

Got my laser cut parts back so welded it all together.
http://i227.photobucket.com/albums/d...ps3b64b78a.jpg
http://i227.photobucket.com/albums/d...ps03b2447a.jpg

Bolted in place.:cheers2:
http://i227.photobucket.com/albums/d...ps1e42518a.jpg

Checked the dump pipe for clearance as well. All looks sweet!:icon_tup:
http://i227.photobucket.com/albums/d...ps39c53257.jpg

who are you using for laser cutting?

also, this bell housing is new to me. Is it a one off or a produced item?

I use a local Tasmanian sheet metal company, SERS. They do a lot of work for the Caterpillar factory I work at.

The bell housing is made by Green Brothers Racing in New Zealand, www.greenbrothers.co.nz. They build in batches as they get orders. They make a Supra to Rotary steel bell housing as well as the TKO and some adaptor plates to use the Mazda cast bell housing.

this might sound silly, but the TKO does not share the same pattern as a T-5 tremec correct?

Not sure:dunno: Whizbang

I have T-5s laying around I would love to stick to a rotary.

Just a small update.

Got the tail shaft done by the guys at Jayben. 3 inch, one piece.:)


http://i227.photobucket.com/albums/d...ps5a32959b.jpg
http://i227.photobucket.com/albums/d...psc18a2be2.jpg

i am loving this project

Started work on the sump as the custom one that come with the motor won't fit.:cuss: I had the flange cut then started working on how much room I have.

I removed the old front engine mount cross member as I need a bit more clearance.
http://i227.photobucket.com/albums/d...psc1094705.jpg
http://i227.photobucket.com/albums/d...ps47ad6fcd.jpg

Then I mocked up the lower half in cardboard.
http://i227.photobucket.com/albums/d...ps0e9c15e6.jpg
http://i227.photobucket.com/albums/d...pscf3707b6.jpg
http://i227.photobucket.com/albums/d...psb328ba42.jpg

Next to the old custom sump.
http://i227.photobucket.com/albums/d...psc260fe14.jpg

After that I modelled it up in Inventor.
http://i227.photobucket.com/albums/d...ps610189fd.jpg
http://i227.photobucket.com/albums/d...ps1b4ad7bb.jpg

Even welded it!
http://i227.photobucket.com/albums/d...psecc52ac2.jpg

Should give me a bit over 5 litres capacity.

Now I just need get the lower half cut.