What I Have Been Up To

[tworail]

As some of you may have noticed I haven't been active on the forum for a couple weeks.. that is because I am working on a new project, totally unrelated to trains but something I have been waiting all winter to get started on so it has been exciting for me now that things are happening. And yes, I am a closet car freak, in case you wonder after reading this :)

Anyways, enough hype, it's just the work that I am doing to my Mazda Miata, building it up for some track use this year. I have posted this on a couple forums so I am just going to copy/paste the posts here for your viewing pleasure.


Today was the first official day of starting the long awaited work to my car. I have spent the winter buying up parts and slowly the basement was filling up. I brought the car out of storage a couple weeks ago, and have not done much except wash it a couple times - until now!

http://i252.photobucket.com/albums/hh28/jmack_2008/DSC_0024.jpg

Here is a pic of my car taken last summer, pretty much stock, with a black hardtop courtesy of Rev9.

This saga really starts here - my US postal drop where I have been sending all my parts for the last month or so, in addition to what I had stockpiled in the basement. Long story short, they are really nice folks down there but they were getting irritated with the amount of parcels I had accumulated, so I had to go down on Friday, even before my coilovers and rims arrived.

I saved a ton on duties (still had to pay, but whatever) and delivery costs by doing it this way. I claimed $2200 at Customs. I was super organized, but not organized enough to bring the second page of my bill from Crutchfield, so my $500 stereo components were only put down as $170 - whoo! Customs didn't seem to concerned.

http://usaddressinc.com/usad4.jpg

Since I obviously wasn't taking the Miata, I had to rent a vehicle - I got the largest non-truck I could:

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0254.jpg

Was great for the drive down (in the rain, yay) and held every thing I had down there.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0257.jpg

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0259.jpg

Yup, got some cheap shoes for $72 a piece from Vulcan Tire.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0261.jpg

Everything unloaded on the porch. OEM lip, stereo, Energy Suspension bushing set, Flyin Miata frame rails and high-flow cat, new Hella headlights, Hard Dog Rollbar (which I already wrecked by with my box cutter, hella noob move), some spare parts from Rosenthal Mazda, etc etc. Enkei RPF1's and Tein Flex will be ready for pickup next week, so I will be going down there again.

OK, on to the build. Today's objective was to rip out the stock exhaust, cat and header. All going to the dump, to replaced with these bits:

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0265.jpg

Topping the list of stupid things I have done lately - leaving my brand new jack out for the whole winter, under alot of snow and crud. But it still works great, and I gave it a shot of PB Blaster in some areas:

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0266.jpg

Here's the work area, my back yard. Enough space for the Miata, not much else.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0268.jpg

(continued in next post)

[tworail]

First order of business, disconnect the battery before doing any work. I hadn't really done this before on the car, since I didn't really care for it. However, I want to do things 'right', so I am rewarded with this:

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0270.jpg

And this:

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0269.jpg

Ugh, there goes another afternoon. I'll have to clean it up, seal up the bad spots and get a new connector for the battery, as this one is cleary toasted.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0276.jpg

A look at the stock header before taking anything apart. The nuts all came off very easily, after some PB Blaster was applied. Some of the bolts came out of the block, but that is not a huge deal.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0277.jpg


http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0278.jpg

Old header removed, glad I won't be seeing it again.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0279.jpg

The heater hose was really getting in the way, so like a noob I decided to remove it. Much to my disappointment, coolant started leaking everywhere, duh. I dicked around with it for a bit, taking it out for a second, watching the coolant flow out, fill up a plastic bottle, then I just said screw it - I drained the coolant so I could work without it in the way.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0281.jpg

The 5Zigen header would not go in without this bracket being removed. Some PB Blaster, a PVC extension pipe and a busted elbow was all it took to get the bolts out.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0288.jpg

Test fit of the header. I finally got it on, after some wiggling. There was some speculation that this header would not fit since it appears to be a JDM one, and the steering colum would get in the way. I hemmed and hawwed, came back a couple minutes later and put it right into place with no modifications after some more wiggling.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0289.jpg

Lots of space between the header and steering linkage, so it should work fine. I didn't completely install the header because I had some heat wrap to put on as well. Another noob move, I only got 50 feet of 1" tape, so it's gonna be tight. I got frustrated with the wrapping, which was surprising since I have been doing it to road bicycles since I was 13, so I gave up and left it for tommorow.

[tworail]

Day 2 of my build. Long story short the new header/cat/exhaust is down right evil sounding! Not only that, it pulls alot better, seems much faster. Sorry, butt dyno only, but in comparison to stock this thing just comes alive now. At first it was quite loud in the car and with the hardtop on but seems to have quieted down a bit, but damn when you hit the throttle it snarls. Not ricey sounding either, but hell, I'm sure alot of people who don't know better will shake their heads.

I want to get a video for you guys so you can check it out. I'm sure it's comparable to most of the other RSR setups up there but I'm not sure if there is one with this cat and header rolling around.

OK, back to business this morning with the header wrap. I finally got things going my way, but it still wasn't perfect at the end. Given all the bends and obsructions with this header, I wasn't really surprised and if you look at it the right way (see photos) you can't see the spots I couldn't get. There are only about 2 nickel and quarter sized spots on the #4 pipe that didn't get wrapped. No big deal, I made up for it in other places.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0294.jpg

Frontside

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0295.jpg

Backside

I ended up have to shorten up one of the 2-1 wraps since it interfered with the steering colum, there is not alot of clearance there when getting the header in. The oxygen sensor also sits down further, but is actually easier to get to with the wrench now and there is enough cable.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0296.jpg

All in!!! Only ran into one wrinkle, there was a half-assed bolt used in place of the real nuts and bolts going into the head and I ended up stripping the head by wrenching this little 'orphan' too tight. Oh well, not much to be done and I was not concerned since the other 8-9 bolts are good a tight. I pray for no leaks!

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0297.jpg

Clearance shot with header wrap and clamp.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0298.jpg

Cat. Nothing very exciting here, it all bolted together really well, and no leakage.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0299.jpg

Final shot of the bay with the air box and bits back in. After warming up the header wrapped got a bit darker. Had only some mild smoking as it idled for about 10 minutes. No exhaust leaks either, nice.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0302.jpg

I also added the OEM front lip today. Didn't bother painting it, got too impatient!!!

I'll be back in a couple days as I do more of the build, I'm off to NY to get some more parts on Thursday.

[tworail]

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0285.jpg

Comparo of stock and elite header.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0290.jpg

I went back to the other stuff, since I was glad the header would fit, and proceeded to remove the rest of the stock system from the car. Seeya!

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0291.jpg

Hopefully I can get rid of this somewhere.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0292.jpg

New RSR fitted, very nicely :)

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0293.jpg

Under side shot.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0284.jpg

With the car right up on the jacks I poked around the chassis a bit more. This is the state it's in now, which is not terrible for a 18 year old Canadian car. The control arms and bits have some faint rusting, which I will take care of when I do the bushing install later in the season. They will get cleaned up and painted a fresh coat of black.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0283.jpg

Also noticed this - looks like the slave cylinder is leaking. The clutch feels fine, but I'm no expert, so I plan on servicing or replacing the part before too long.

That's it for today. Tommorow I will finish up, and maybe put on the OEM front lip and the Rev9 rear lip, and some other minor tidbits.

Thanks for reading. I still have a ton of things to do, good thing I am unemployed, there is nothing like wrenching on the car on a Monday during a fine spring day :)

[train4myboys]

Nice - I've thought about a Miata for a while, great little track car. Some time I'll break away from my lifted 88 Jeep and basket case 50 Ford to get one of those to play with.

Thanks for the writeup!

[tworail]

If you guys have got this far, kudos!! It's getting quite long :)

Time for another update. I've been driving the car around with the new exhaust setup and it's working quite well - increased acceleration and it winds out so much quicker than the stock setup. Plus the sound is bad ass for a little car like this. I'm still trying to get some videos together so you can get a better idear of what I'm talking about.

Anyways, on with the build progress...

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0308.jpg

Another trip to Niagara Falls to get the Tein Flex coilovers and wheels.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0310.jpg

Yup, factory black RPF-1s. They are damn sexy in black. There are some red Enkei stickers that need to go on, but I will wait until the tires are mounted before putting on that finishing touch.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0312.jpg

Thank you Y. SUZUKI for your inspection efforts!!

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0313.jpg

Backside. These are 35ET, although the 41 there is somewhat confusing.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0316.jpg

Tein goodness.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0317.jpg

A very unexciting shot of my battery area. I bought some sandpaper and rust paint to fix this up, as well as a new battery tray from Mazda since the old one was toast. The water seems to be coming from an unplugged tube, which the battery uses as well. I plugged it up and it rained all weekend, so far so good, nice and dry. I also installed some new connectors since the old ones were quite corroded.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0320.jpg

Mazdaspeed steering wheel, courtesy of Rev9. It uses a Rev9 hub as well.

I also attempted to install my Mazdaspeed strut bar which I have had since last October, and finally got around to installing a USDM washer bottle so it would fit. However, the stock upper shock bolts were not long enough to install it, so I had to postpone. Thankfully the Tein bolts are much longer so it should not be an issues.

[tworail]

Today was the start of the coilover install. I got the majority of the work done in a couple hours, and will likely finish on Thursday. 3 of 4 shocks are in, I'm saving the right rear until last after I do my paint touch up in the battery area.

Overall, removing the stock equipment was not too painful, just needed some PB Blaster on the bolts and some hemming and hawing. I followed the directions in Keith Tanners book, basically remove the upper control arm bolt and drop the assembly so the shock can be removed. It's easy.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0328.jpg

The undertray needs to be removed so you have the necessary clearances.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0330.jpg

Old shock.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0331.jpg

This is what happens with no shock in. Make sure you keep it elevated, or all the weight ends up on your brake line.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0332.jpg

New shock fitted. Much better!! I left all the bolts loose since I am going to do the final tie down later on.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0336.jpg

On the rear, you need to use a long bar to push the suspension assembly down to remove the shock. I just used the extra long bar that came with my jack.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0337.jpg

Another noob moment. Since there was still tension on the rear sway bar, it ended grinding down the thread a bit. A little is OK, but you don't want too much since you won't be able to get the bolt back in or it may end up stripping the thread in the nut. I cleaned up my mess with a little file before putting it back.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0339.jpg

Since the rear Flex shocks are shorter than stock, you need to push the assembly up in order to have the pillow mounts go into the body properly to be bolted down. I used a couple of bricks and the OEM wheel jack to make this happen easily.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0341.jpg

Stock upper mount. Ugh. There was a small plastic gasket included, but I didn't use that on the new shocks. Shouldn't be a problem.

[tworail]

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0342.jpg

Teaser shot of the new wheels, sans tires. I am hoping to get them mounted up to the Azenis on Thursday.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0344.jpg

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0346.jpg

The growing pile of OEM equipment removed from the car. The stock sway bars will soon join that pile, to be replaced with a set of FM sways, front and rear.

http://i252.photobucket.com/albums/hh28/jmack_2008/miata_build/DSC_0345.jpg

Pic of today's mess.

So, I still need to finalize the shock setup with the new wheels on.. For now, to keep things simple, I will be following the recommendations in the Flex manual for installation and go from there.

[tworail]

Nice - I've thought about a Miata for a while, great little track car. Some time I'll break away from my lifted 88 Jeep and basket case 50 Ford to get one of those to play with.

Thanks for the writeup!

Don't delay :)

They are way too much fun and if you have a regular car as well it helps. I don't, so this little beast will be my 'daily driver' :D

[alfalfa]

Love the Mazda Miata. :thumbsup:

The other thing.................:p

lol

P.S. : Would you marry me?

[Boston&Maine]

That is awsome Tworail, I bet that will be so fun to drive... ROTFL that you took the heater core hose off and coolant spilled out :p

One question though, why did you put a new cat on? Are they super anal in Canada about emissions? I know anything older than an '98 here in New Hampshire does not need to have an emissions test done to it...

[alfalfa]

still Love your ride. :thumbsup:

just kidding about tghe other thing.
:) lol

[smokey]

Very cool, TwoRail :thumbsup: I'm not much on Miatas for daily drivers myself, but for a track car- HELL YEAH!! Great handling little cars out of the box and with the right mods... you'll be railin' for sure :D

Since we're on the car-thing... :D I've been hot-roddin' since way back. Got my first 'script to CarCraft when I was 7. Been spinning wrenches on some level since I was 12 (first big job was a clutch/pressure plate/flywheel with my pa :D). By 14... he didn't get dirty anymore!! It was always, eh, boy....

I had a 70 Chevelle with a 406sb I built basically from the ground-up. Man I miss that car. Also had a 78 Malibu, a 95 ex-FBI Caprice (the FedSled :D) and a few others here and there. I have an 03 Chevy 1500HD CrewCab I tuned that now runs high-15s. Doesn't sound so quick, but that's a full 2seconds quicker than stock :eek: I've snuffed many a little ricer with that thing :D Not bad for 6000+lbs. The thing's killing me in gas right now, tho :mad:

Someone mention Jeeps?! Sitting with a bad transmission right now ($2200 estimate :rolleyes:) is my 96 Cherokee on 33s and 6" of lift. I gotta get that thing going... Too much fun!!!

I also do bikes :D I've got a couple old Kawasaki KZs, a 900 and 1000, an 1100 Yami Virago, a 600 Ninja.... and hopefully soon, a new Ducati. I'm torn, tho... a Hypermotard or the new 1098.... ugghhh... :laugh:

WAY too many hobbies!!!

Anyway, keep us posted, TwoRail. Action shots, man!!!! Is it for SCCA or drifting or just open track days?

[Boston&Maine]

I also do bikes :D I've got a couple old Kawasaki KZs, a 900 and 1000, an 1100 Yami Virago, a 600 Ninja.... and hopefully soon, a new Ducati. I'm torn, tho... a Hypermotard or the new 1098.... ugghhh... :laugh:

That is a nice list... I am into dirt biking though, not street riding... I have not ridden since I was like fourteen though because I out grew my old bike... Part of the old B&M line has become an off road vehicle trail, and then there are smaller trails which stem off from it, but those are one private property :rolleyes:

Once I get settled later in life I am definatly picking myself up a dirt bike, probably a Kawasaki something...

[smokey]

I started on dirt. I'd like to get some little dirt bikes for the whole family. My boy is 6 and my daughter's 17. She'd probably go atv, but the boy's a nut :D He's gonna follow Dad's lead ;)

One of the best family activities around- the outdoors :thumbsup: Whether it's dirtbikes, Jeepin', camping- nothing keeps the clan tighter :thumbsup:

I've been street riding now for 25 years so there's just no denying that :D I think of when the boy turns of-age, how I'm going to feel and what I'll say...It already worries me but I know it's inevetible. Training and gear and... God's blessings :D (Now I think about what myparents went thru !!!!!!! Poor folks!!)

My mom and dad got back into riding a few years back. He rides a new 'Wing and pulls a trailer everywhere. He made a little hut on top of the trailer and they take their dog almost always, too!! They did about 3000 miles last month alone :D (I wish I had the time and $$$ to do what they do :o !!)

I guess it runs in the family :D

[tworail]

One question though, why did you put a new cat on? Are they super anal in Canada about emissions? I know anything older than an '98 here in New Hampshire does not need to have an emissions test done to it...

Dunno, we will see when I get it emissions tested :)

Plus the old cat was about 18 years old! :D

[tworail]

I never really posted the finished pics, taken earlier this summer:

http://i252.photobucket.com/albums/hh28/jmack_2008/IMG_0568.jpg

Roll bar on :)

http://i252.photobucket.com/albums/hh28/jmack_2008/IMG_0584.jpg

[smokey]

Doode... now there's a Miata I'd drive everyday :thumbsup:

Very nice job :thumbsup:

[tworail]

Thanks. Unfortunately she has to go to sleep for the winter, very soon.

Getting frigid up here!

[Boston&Maine]

Those black rims look hawt on that car http://www.contour.org/ceg-vb/images/smilies/ubb/drool.gif

Now all you need to do is post up some videos of it in action :smilie_daumenpos:

[smokey]

Those black rims look hawt on that car http://www.contour.org/ceg-vb/images/smilies/ubb/drool.gif

Now all you need to do is post up some videos of it in action :smilie_daumenpos:

Heh-heh... VIDEOS!!!!!!!
Let's see whatchya got, TwoRail :p :D !!!!

[tworail]

I've actually been meaning to make some.... Haven't gotten around to it yet though.

I do have a video you guys would enjoy, I'm just uploading it to youtube now. Stay tuned.

[tworail]

Video as promised - check it out:

http://www.youtube.com/watch?v=91kwjcF98l4

[T-Man]

I Like the video the cats are funny.
Good job on the car I'm sure the work was worth it.
The pictures were great. I think I missed this thread last May.:confused:

[Boston&Maine]

Have you gotten the car dynoed or anything yet? If you give me some accurate horse power / torque numbers I can race it in Forza 2, although the car they have is technically a 2001 Mazdaspeed Roadster... They even have the same rims in the game :D

http://www.modeltrainforum.com/gallery/files/1/9/0/tworails_miata.jpg