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Meet Maisey

NB 1.8 Turbo Gold Evolution Orange Racing Bronze Rot

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#1 willeywilson

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Posted 09 March 2016 - 11:26 PM

Nutz, meet Maisey.

 

I have owned Maisey for nearly a year now and with a couple of mods under my belt things are getting serious.  With this in mind, I thought it best to document my feeble attempts, poor taste and lack of knowledge for you to generally mock and make fun off.  Hopefully you'll see the method in the madness.

 

The first couple of posts will be a general summary of the past year to bring things up to date, so...

 

After a few weeks of searching, looking at every type of sports car available and days of peer pressure from the chaps at work, on the 24/04/15 I became the unfortunate owner of Maisey, an Evolution Orange NB 1.8iS.

 

Now what I actually wanted was an S2000, like all guys do, but after lots of reading and looking at the ridiculous costs of wrote-off examples, I settled on an NB.  Having bought a couple of cars from Car Transplants online auction, lightly restoring them and selling them on, I thought it would be a good place to look for a cheap motor.  1 - This was stupid, 2 - I was taken with the look of Maisey and the guys kept telling me to buy it, it would be fun they said.

 

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Yes, that says £550 with 45 minutes left to go (which I thought was cheap at the time), it also says 31,483 miles! I paid more than that with my poor auction skills and the way that site operates.

 

It's gold, it's covered in chrome, looking closely at the bonnet it has a Merc style Mazda bonnet ornament and it has done seriously low miles, I instantly assumed a granny has owned this, been to the shops in it once a week, kept it in a garage and paid over the odds at the Dealers to keep her in tip top condition - Again, this was stupid!

 

What it actually is, is a tacky, rusty, leaky, odd tired, massively pulling too the left under acceleration bag of crap, which tried to kill me, my better half and my mate on the 100 mile trip back home, after picking it up from a Car scrapper in Yorkshire.  Whom, might I add assured me was a brilliant little car with no issues, he definitely didn't mention the mould, or the random child seat in the boot... Don't ask.

 

Pic's from the drive home:-

Quick stop at a chippy

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That badge  :blink:

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The chrome  :sick:

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It is quite literally everywhere - the vents, the door handles, THE BONNET, the side lights, the headlights, the tail lights, the 1/4 windows, even the bloody door cards.  90% of this was gone that day, however that bonnet badge unfortunately had to stay for a while, you see, some bright spark decided to drill the bonnet (slightly off centre) to fit this monstrosity.  

 

The bonnet sat like this until last week when I finally started with an angle grinder (more of that later)

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Pulling too the left - flat tyres and mismatched across the axle.  Rear Left had a Cheap Winter Tyre which didn't do too well after a quick lesson in donuts on the works car park.

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So a new set of Khumo HS51 Ecsta was ordered and I set about refurbing the alloys in Ford Graphite Grey (I should have just paid someone to do this)

 

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Make shift spray booth.

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Not the best finish but I was relatively happy.

 

I also had a wheel bearing to sort as I felt I was lucky it didn't lock up on the motorway back home given it sounded like there was a Spitfire under the bonnet.  

 

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Noticed a nice bit of rust and damage whilst it was in the air

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It's safe to say this car was not well looked after, or garaged by the granny I thought...

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Radiator on order and coolant topped up I whacked on the fresh boots, took a photo, and an amazingly short amount of time later I was in Wales for a weekend of camping.

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New tires + wet Welsh roads + first RWD car = many "Oh Shit" moments... I loved it!!!

 

Couple of weekends passed, new radiator (Ebay Special) all the junk out of the boot binned and a new carpet made up, I did unfortunately throw away the load space support which means I have a saggy carpet (I am planning to make an MDF replacement).

 

Out with the old

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Ooo Shiny

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I also read about the gear shift boot and set about replacing it, along with an ebay knob and gaitor.

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Wait, where does that wire go? 

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Did I forget to mention there was red LED's everywhere!?  It looks like Stevie Wonder did the wiring on this thing, I'm surprised it didn't set on fire!

 

I also bought this

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But more on that in the next post, including Euro trip, Nurburgring, Curborough, much rot and the introduction of Terry the Turbo.

 

 

Cheers

 

Wilson


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#2 JakeBro

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Posted 09 March 2016 - 11:34 PM

I envy your enthusiasm haha! Will continue to watch this! 👍
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#3 alhendo1

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Posted 10 March 2016 - 07:29 AM

I have to say I like that colour....great job on the wheels....they look really good on the car.
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#4 tomgb

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Posted 10 March 2016 - 10:19 AM

Looking forward to seeing more, especially Terry.

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#5 willeywilson

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Posted 11 March 2016 - 02:57 PM

It's a couple of weeks later, the bargain exhaust has arrived from MX5Parts, (they were having an auction on eBay and I grabbed it at half price) so we set about getting the car in the air and bolting it on. 

 

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This looks safe...

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We thought this would take a couple of hours, it ended up taking all weekend, mainly because of this.

 

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All of the under body bracing bolts are seized to the weld-on nuts, after getting one off with brute strength I broke out the impact wrench, which subsequently sheered the weld-nut off of the sub frame, great!  All bolts cut in half and the under body brace was out, these will be replaced with stainless fixings later.

 

Annoyingly the exhaust was blowing, rotten and all of the bolts were seized as well. Which resulted in the centre pipe sheering off from the mid box and the need to drill out the weld-studs from the flange so we could replace with stainless.

 

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You may have spotted in the photo above that we cut the mid box open as well.  This was because of an incredibly annoying rattle at about 4krpm which after much research we thought was the gearbox and that it was a fairly common thing on all MX5's, but Chris @ Broadspeed kindly took her for a spin and when we got back I looked underneath the car.  When labouring the engine the mid box violently vibrated up & down (due to the split it was blowing from) but there was also something inside it rattling.  With it on the bench for welding back together we took the opportunity to cut it up and look inside, what we pulled out (I can't find the photo's) I can only describe as molten-black-fibreglass-rubbery-pebbles, about 12 of them.  Which when rattling inside the mid box caused quite the racket.  Welding it back up was a difficult to say the least and multiple blow-throughs later it was sort of back together.  This did cure some of the noise issues although I do still have the 4th gear 4krpm rattle on acceleration, I also removed Cat heat shield, boot heat shield and various other bits of metal.  (I will upgrade the system at a later date so the general rotteness of this isn't too much of an issue)

 

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All back together and all going well for a few weeks.  So I decided to take the dash apart to understand why the Indiglo dials (electroluminscent Green/Blue) the car came with weren't all working.

http://www.mx5parts....2-25-p-651.html

Yet more horrendous wiring which I tidied up but couldn't figure out why the Water Temp gauge doesn't light up like the rest, checked all the bulbs whilst I was there, fitted one into the ABS space (strange that there wasn't one there) and put it all back together.  Now I have the ABS light on all the time  :( Dick! 

 

Did the LED trick, checked the resistance of the sensor and ordered a cheapo eBay sensor for the front right.  What a royal PITA this was.

 

So it rounded, it snapped, I dremmelled it and then I started swinging a big hammer at it.

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Finally got the new one in and all was well.

 

This brought us up to the Start of August, within the next 3 weeks we lowered her, tracked her, did a small Euro-Trip and did my first ever lap around a race track at the Nurbugring,  I'll cover that in the next post.

 

Cheers

Wilson


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#6 codemonkey

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Posted 11 March 2016 - 09:02 PM

Surprised at myself for loving the colour! Great with those wheels too, as said :)


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#7 BLiNK Motorsport

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Posted 13 March 2016 - 12:21 AM

Very enjoyable read  :thumb-up:

 

I love the sarcasm and the way you laugh at yourself for the 'old Granny' purchasing decision.

 

Mk2's can be a real battle with rusted fixings  :baseballbat:  Show them who's boss!


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#8 Rocky eunos

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Posted 13 March 2016 - 04:21 AM

Haha and buy shares in penetrating fluid!
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Mk1 Black Eunos 1.8 S-Special - First MX5 (Aug '15)


#9 willeywilson

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Posted 14 March 2016 - 09:01 PM

It's August, it's sunny (sort of) and the Misses and I are loving top down motoring (although she'd disagree).  I've not had any time off work since January and we think a road trip would be a good idea, so I book a week off work and we start to plan a mini break.  Now, I say "we start to plan" in reality this meant I started to plan, with a bit of input from my better half, which turned into a full itinerary with excel spreadsheet and all - obviously we wouldn't stick to this  -_-

 

With ferry tickets booked, insurance covered and the itinerary nailed down I started to panic.  MX5Parts to the rescue with a full interval service kit and I was somewhat happy to set-off.  

 

However, I had purchased some slightly used PI 40mm lowering springs for cheap-cheap a couple of weeks earlier and decided to fit them and get a Wheels In Motion - Fast Road Evo alignment done before we went.  Considering the car had a massive arch gap and understeered like a pig (although still better than my daily), I thought it would be a good idea given I had plans to indulge in Tourist-fahrten at the 'Ring.  Looking under the car it was clear to see that none of the suspension components had been touched since it left the factory, this is where @Rockey eunos' advice comes in and several litres of penetrating fluid later, I brought out the hack saw.  :wallbash:

 

The rear drop links were knackered to say the least, so I ordered a cheap set from eBay and carried on with the job.  I'll let the photo's do the talking (ignore the rust... we're getting there, slowly).

 

Before

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During

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Just dropped so doesn't actually look all that low

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Couple hundred miles on them and time for an alignment.

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Black Boots & Wheels In Motion in Chesham got her on the ramps, told me straight that the underside is that rusty that it might not align properly with the state of the eccentric bolts, managed to get the numbers bang on anyway and sent me on my way! Great service!  I wish I could say I took the back lanes home, but given it was approximately 150 miles away it was boring motorway all the way, she did go in a straight line though for the first time since I owned her. :dance:

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I also completed a bit of vinyl wrapping which came up nicely before the trip.  eBay's finest Carbon 8D.

 

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A thorough clean, tyres pressures checked, boot packed as full as it could possibly go, parcel shelf packed full, big aerial fitted and we were ready.

 

There is more to go on top of this:-

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The trip:-

Saturday 2AM Ferry to Dunkirk

Drive to Ostend to watch the sun come up at the beach and maybe stay for the day if the weather was nice.  The weather was nice, I was not, awake for 36 hours and 6 of them travelling, I had not thought this "holiday" through.

Quick stop at the beach (driving through the little deserted town with my new exhaust echoing off the walls made me a little too excited)

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Back on the motorway and off to Spa for a weekend of Formula 1.  This was my first F1 race (although I had been to Spa before with a British GT team) and it was great, the weather held up for us too, until we got back to the tent after the race finished and torrential rain ensued.

 

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From Spa, through Aachen and to Cologne, an amazing city which we need to go back to as we were only there for a few short hours before we pounded the Autobahn to the Nurburgring.  This, for me, was the first time I would be going around a race track and I had had very little prep time with the XBOX before setting off due to issues at work.  Cue the nerves.  :trigger:

 

Not the best photo's and definitely not the best lines, it's fair to say I was pretty crap on my first lap but on my second lap I followed a fellow MX5 around which gave me a bit more confidence, although I refrained from overtaking even though the door was open... I needed the car in 1 piece for the rest of the week.

 

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The rest of the week was spent visiting family in Germany, visiting Brussels, Brugges and Menin Gate for the last post before heading home.

 

The car performed pretty damn well, except an odd wheel bearing sounding noise on the Autobahn for 20 minutes or so (I think this was the water pump in retrospect), it wobbled at high speed (warped brakes probably to blame) and it struggled to start one day but eventually fired up.  

 

The bank holiday Monday immediately following the trip was spent at Curborough airfield with Rotten Arch Holes (a local club) which was a great laugh. Can't find the photo's right now but this was my opportunity to actually push little Maisey and get the tail out, with big run off area's and relatively close to home.  I cannot describe at this point how attached I had become to this little, gold, rotten, crap, car.  Go figure.

 

What a week, I was completely exhausted, I needed a holiday.

 

More to come.

 

Wilson


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#10 brachunky

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Posted 14 March 2016 - 10:01 PM

Fantastic write up Wilson! Loved reading yer antics and perseverance.Would love to do the ring someday but never even been on a local track before either


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#11 ScORTED

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Posted 14 March 2016 - 11:30 PM

Gingervitis its catching!
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98 JDM, Racing Bronze RS, VVT conv. Racingbeat, GAZ gold pro, Elise seats, project M roll bar, ATS DTCs 
91 JDM, NEO GREEN, Vspec OEM Tan, MX5OC stickers, style bar etc SLEEPER T25 turbo conversion XD 

91 JDM,chaste white,rot free rolling shell, V8? Project bOOOOst

98 JDM,Racing Bronze, 1.8 RS spec; 6speed, TorSen, Bilsteins, Cut slicks, F1R..Dead and buried

 


#12 willeywilson

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Posted 23 March 2016 - 10:28 PM

We're back from the trip through Europe and I have recovered, there were plans most weekends through September so the car didn't receive much love really.  

 

Also, we were busy ordering and having this built:-

 

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5m x 9m worth of workshop heaven!

 

I had taken my brother-in-law out in the car, on a couple of wet rainy nights, to sensibly practice the art of car control, in a safe and secure environment  :whistle:

Couldn't really get the hang of drifting without fear of damaging the car on a kerb so did some cheeky donuts instead and went for a cruise down some twisties and through some tunnels.  Unfortunately, after several donuts & transitions the car began to overheat.  Knowing that the temperature gauge is so overly dampened I cranked up the heaters and headed for home, luckily we weren't far away and the temperature returned to normal pretty quickly.

I allowed the car to cool and topped up the coolant the next day.  With no obvious signs of leakage and the fan working correctly I, incorrectly, assumed it was just the donuts taking their toll. (clue 1)

 

The car was left under the car cover for a few weeks until I was invited to Thunder in the Park at Donnington with Rotten Arch Holes, this was a bit of a rush job and when I got back home after a week at work I started to check over the car and make sure all was okay.  Took her for a spin and the temperature was rock steady.  A bit of steam was coming from under the bonnet which I thought was just condensation from being stood for a few weeks, after a further hooning the steam stopped and all was good (clue 2).  Later that night I had to nip out and thought I'd take the 5, on the way back the temperature gauge rocketed way past red into "STOP THE F*****NG CAR" territory. Bollocks!  

 

I quickly called Donnington off and set out on fault diagnosis instead of racing around the track  :( .

 

Well this could be an issue:-

 

(sorry about the video quality, crappy iTelephone)

 

The coolant hose from the back of the block to the oil heat exchange had decided to develop a small hole and as can be seen, when revving it piddles all of my coolant over the top of the gearbox.  A set of Stoney Racing silicone hoses were ordered and a week later I spent approximately eleventy hours attempting to change them all over.  What a complete PITA this was!  Getting to the hose, getting it off and a new one on, with jubilee clips was a complete ball ache, alternator off, inlet manifold support bracket off, wheel arch out, complete faff, but glad it's done.

 

Took delivery of this ducktail from a chap on Facebook.  Really not sure on it so still haven't fitted it:-

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Also tried this, which I didn't hate as much as I should have:-

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And had a crack at wrapping the wing mirror, several times, could get 90% of it good but couldn't get around the edge properly.  Gave up and not touched vinyl since haha.  These pictures were from one of the early attempts which weren't great, but you get the idea.

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I also started designing these:-

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Which, after a quick chat with a supplier of mine, whom kindly knocked them out free of charge, I ended up with these:-

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12mm mild steel flanges for TD04 Turbo and 1.8 mk2 exhaust.  I reverse engineered these in CAD from some gasket drawings I found online and buying an exhaust gasket from MX5Parts and attacking it with a vernier  :thumb-up:

 

My Brother-in-law then kindly picked up these Schedule 40 mild steel pipes for me:-

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Total cost - £30 - WIN! Now to learn how to weld...

 

I also picked up a TD04 from ebay for the total sum of £45 delivered, minimal play in the shaft and was taken off a low mileage WRX, allegedly, I named him Terry the Turbo :whistle: .  Got a Breaker bar in the Moss sale too

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Test fit proved the flanges fit to the turbo fine (may need a little porting)

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Brother-in-law cleaned it up at work and plugged the pressure take off and I cleaned up the impeller and turbine

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Slightly out of order but I also took delivery of these

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And installed the Megasquirt I bought several months earlier and the Wideband

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A bit rough but it gets tidied up later.  Several weeks of auto-tuning etc. and it was running pretty sweet except the brakes started to bind and I basically boiled the crap out of them.

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Upon jacking up to sort the brakes out I discovered a whole host of rust and general horridness, so that was that, up on the jacks and time to start cutting metal, but more on that in the next post.

 

Thanks for reading.

 

Wilson


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#13 ScORTED

ScORTED

    watch this...

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Posted 23 March 2016 - 11:32 PM

Aha a wild turbo conversion appeared!
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98 JDM, Racing Bronze RS, VVT conv. Racingbeat, GAZ gold pro, Elise seats, project M roll bar, ATS DTCs 
91 JDM, NEO GREEN, Vspec OEM Tan, MX5OC stickers, style bar etc SLEEPER T25 turbo conversion XD 

91 JDM,chaste white,rot free rolling shell, V8? Project bOOOOst

98 JDM,Racing Bronze, 1.8 RS spec; 6speed, TorSen, Bilsteins, Cut slicks, F1R..Dead and buried

 


#14 willeywilson

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Posted 23 March 2016 - 11:38 PM

Its still a work in progress at the minute, only get weekends to work on her. This thread still isn't quite fully up to date with real time (and I've missed lots of stuff, but the next post should bring us slap bang into the middle of de-rusting and turbo-ing.

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#15 ScORTED

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    watch this...

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Posted 24 March 2016 - 03:01 PM

Top stuff and a fellow OPO user I see
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98 JDM, Racing Bronze RS, VVT conv. Racingbeat, GAZ gold pro, Elise seats, project M roll bar, ATS DTCs 
91 JDM, NEO GREEN, Vspec OEM Tan, MX5OC stickers, style bar etc SLEEPER T25 turbo conversion XD 

91 JDM,chaste white,rot free rolling shell, V8? Project bOOOOst

98 JDM,Racing Bronze, 1.8 RS spec; 6speed, TorSen, Bilsteins, Cut slicks, F1R..Dead and buried

 


#16 willeywilson

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Posted 25 March 2016 - 12:11 AM

Cheers ScORTED hopefully she'll be back up and running before June. Yeah I've got the One and convinced my Misses to get the Two last year, as will become apparent during this build, I love cheap Chinese crap ;)

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#17 willeywilson

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Posted 25 March 2016 - 12:13 AM

Also, this keeps happening! More parts to add to the ever growing pile

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#18 willeywilson

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Posted 31 March 2016 - 09:10 PM

Welcome to another long winded ramble about my ridiculously rotten shit-box of a car...

 

As I've eluded to in previous posts, Maisey isn't in the best of health with regards to corrosion.  After jacking the car up to go over the brakes, I started to poke holes in the sills.  I'll let the photo's below show the results.

 

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Basically, she's knackered.  The way I saw it I had two choices, (three actually): 1) Break and scrap her and lose most of the money I had spent on her, 2) re-shell her or 3) plough even more money in and attempt to restore her.

 

Option 1 wasn't really an option.  I had come to far, spent too much time and money just to throw her away as a bad job (even if there were several niggles that still drove me mad, the leaky roof and the binding brakes to name a couple).  I also didn't fancy buying another one, not knowing what I was getting, or paying over the odds for a fairly decent one considering this was supposed to be some cheap summer fun.

 

Option 2 was a viable option, I even found a 'rust free' 2004 Jap import, mk2 shell for the grand sum of £25!!! It was a bare shell and would cost 3 times that much to get it shipped home.  Still, £100 for a decent shell was a bargain.  After a lengthy conversation with the seller and doing an HPI check it turned out it was a CAT C for a small bump it had to the front off-side in 2006.  Whilst the shell was better, safer and newer than mine I didn't want the CAT marker and change of registration that the re-shell would entail and changing the VIN plates over never crossed my mind...

 

Option 3 it was then.  So I started to strip, cut, grind, bend & bash until I got to something that resembled this... so much for cheap summer fun...

 

Drivers side rear arch in poor condition.

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Drivers side front chassis longit. showed some signs or rust inside but nothing serious.

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The passengers side however had really started to corrode on the inside, the outside only seemed to have surface rust, but on closer inspection it had cracked on the underside.

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So I hit it with a hammer, stripped down that side of the engine bay and ordered a repair panel from Junk Yard Dog

 

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Aluminium corrosion under the paint on the bonnet, and finally removed the remains of the Mazda bonnet ornament. Hoorah!!!  :dance:

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Then I cut a bit more, and a bit more...

 

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Remember that old granny that I though had taken good care of the car... Yeah, not so much.

 

I gave up grinding and started to take the brakes apart, I had previously tried to push the front pads back in, with a serious amount of force, but they weren't having any of it.

 

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One piston came out with a bit of twisting action and 8 bar of compressed air up it's arse end.  The other wouldn't budge.  So I had to clamp it in the vice and persevere, hours it took me, but eventually it popped out.

 

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Unfortunately I didn't get any photo's when I got the pistons out, but after a considerable amount of polishing with a diamond slurry compound on a lathe, the fronts turned out like this

 

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Not exactly what I hoped for, so I ordered another pair of front pistons from BrakeParts.  The rears meanwhile came out great, the brother-in-law also fab'd me a Turbo oil drain adapter for the hose tail I had ordered. 

 

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He also got the carriers ice blasted at work, which did an adequate job of removing the 20 year old rust. Before (left) After (right)

 

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Quick wire wheel and many coats of Hammerite red.

 

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Then started to rebuild with the kit ordered from BrakeParts, new seals and bleed nipples fitted and cleaned up all of the bolts.

 

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The rears finished, the fronts are still waiting for another lick of paint but I've been to busy taking care of the rust.  These have been boxed up and hidden away from danger with the HEL braided hoses, MTEC Discs and EBC Yellow pads that also turned up from Stewart @ Freaky parts

 

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Whilst doing this I wanted to do a mk2.5 front end conversion, however, for the time being I thought I'd keep the mk2 front end but tidy it up a bit.  So I split the headlights and painted them black and made a pikey offset number plate bracket from a B&Q joist hanger (holes will be filled and new 8x6 plate ordered).

 

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Back together but very cloudy, a quick restore is in order.

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Still slightly scratched from the sanding but 100% better.

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More cutting has taken place and I have the new rear off-side wing on  :banana: but more on that in the next post.

 


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#19 ScORTED

ScORTED

    watch this...

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Posted 31 March 2016 - 09:25 PM

Your mad, but the good kind of mad!
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98 JDM, Racing Bronze RS, VVT conv. Racingbeat, GAZ gold pro, Elise seats, project M roll bar, ATS DTCs 
91 JDM, NEO GREEN, Vspec OEM Tan, MX5OC stickers, style bar etc SLEEPER T25 turbo conversion XD 

91 JDM,chaste white,rot free rolling shell, V8? Project bOOOOst

98 JDM,Racing Bronze, 1.8 RS spec; 6speed, TorSen, Bilsteins, Cut slicks, F1R..Dead and buried

 


#20 alhendo1

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Posted 31 March 2016 - 09:34 PM

Brilliant work....love it.
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http://www.mx5nutz.c...howtopic=272554
My 1.6 S Special Import Build Thread.





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