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layabout
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Discussion Starter · #521 · (Edited)
daylight inspection of the new scrap parts


rear setup.


was complete with the brace-frame but I unbolted it to transport as it was an odd shape.


passanger side.


has the later 7" diff.


drivers side.


another view of the complete rear setup.
rear has uncut abs sensors and looks to have been well maintained as theres a 'fresh' rear passanger side caliper and the discs are not worn.


front setup with spare chassis section :ROFLMAO: :ROFLMAO: :ROFLMAO:




handy to have abs hubs.


how many bits of spring?


this will be stripped and hopefully supply usable wishbones, the 1.9 calipers will be for sale (calipers almost definately needing refurb but carriers good to upgrade from early 1.6 size discs?)

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #523 ·
my new Wilwood Forged Dynalite Internal calipers have been delivered, came from somewhere in Texas I believe through Ebay's Global Shipping programme and took 9 days to get here...


photo shows one old design Dynalite on left (balck) and the new Fdli on right (grey ish?)


different appearance. they are mounted on a pair of Supermiata's 'Boxmount' brackets that I bought a while ago.


underside view, slightly different and no spacers to give possible leak positions? also alledgedly stronger and less likely to flex although I doubt I'd notice :ROFLMAO: :ROFLMAO::ROFLMAO:


rear view, these have gone away from Wilwood's brass bleed-nipple bushes and have what looks like steel bushes?

anyway, now to mount on hubs / discs and can finally finish plumbing the front brake syetem in the car....

but I might be rethinking the hose-connections :unsure:

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #525 ·
That's quite possibly the rustiest wishbone/subframe set I've ever seen. Ironically the ABS sensors look great xD
all of the mk1 & mk2's I've seen were somewhat crusty :unsure:


more thoughts on the Wilwood Dynalite calipers.


3 different Dynalite designs, the black anodised caliper @ top is an older design (120-6806) thats been superceded by the rdesigned fdli caliper (grey middle pair & lower black powdercoated).








the newer fdli have different bleed nipples, gone are the brass inserts between the aluminium caliper body and steel nipple.

I will be using the grey pair with the black shiney powdercoated caliper as spare, the older 120-6806 will be sold.

as an aside, I've bought some aluminium 2 piston calipers cheaply and am considering running them as a 'twin-caliper' setup so standard caliper for the mecanical handbrake and the 2pot caliper for foot / handbrake.


Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #526 · (Edited)

had the 2 piston calipers delivered today
 8-)


they are branded as Ginetta but are made by HiSpec - the Ultralite 2 caliper.




billet aluminium and have sectional design so removable / replaceable spacers to adjust for different disc thicknesses, currently setup for 22mm discs but if I decide to use on the rear of the Eunos then I'll machine them to suit the Mazda's thinner solid disc.
also these have the 38mm pistons.


spot the problem???


3 of the same side and 1 of the opposite...



one pair, suppose thats all I need :ROFLMAO:


from Hispec's website.
the bleed-nipples are drilled from one 'end' not both sides so these are made as 'handed', I'm happy & able to drill & tap the caliper to make them ambidextrous(??).
m7 threadded caliper & nipples so an 'odd' / non-standard thread size but nothing impossible....

making bracketry shouln't be too hard, mounting the brackets is a little more complicated as should they be bolted to the rear hubs (from the opposite side of the hub with the origonal caliper bolts or should I weld to the hub?

but first I'm going to strip & inspect them as if these are damaged or need too much work then this project will be shelved as it's based around bein cheap (new pads would be more expensive than the purchase cost!)

more decisions.....

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #527 ·
bit of reserch into the Hispec calipers & it looks like they use / accept the same pad as some Brembo calipers used on the rear of Mitsubishi Evo's, Subaru's etc. so a quick look on ebay and Mintex's finest cheapest pads were delivered...


they fit the caliper so now can run off on another tangent using a stripped caliper half & a pad to look into fitting these on the rear....

probably shouldn't bother but :ROFLMAO:

also, looking into rear drive-flanges - Mr2 spider rears are modified and used in US racecars so ordered a pair to look at 😮

too many ideas!

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #528 · (Edited)
more stupidity & spending, will it ever end?

bought a few ATL fuel tank fittings, these are threadded to allow connection of An6 threadded unions on -6 hose so answering a few questions and removing pushfit / jubilee-clip joins in the high-pressure fuel hose ;)


2 x ATL Fuel Tank -6 JIC Outlet Adaptors.

these will fit in the fueltank's 'lid' and run the feed / return. the threadded side will be 'outside' and the 'pushfit' will connect to some rubber hose inside the tank for both the fuelpump & the return into the bottom of the tank.


1 x ATL Fuel Tank ROV Roll Over Valve, Vent, Bulkhead (TF-475).

this will replace the tank's 'vent' connection that runns to the charcoal-canister / tank breather. the breather system will be somewhat redesigned and simplified in a more competition-car style so open to atmosphere and exiting @ the rear bumper.
I'll be making an adaptor-plate to suit.

now I've the fun of buying An6 fittings and choosing suitable hose - thinking Aeroquip ptfe as opposed to rubber braided types.

more thinking to follow...

ps. don't ask how much😖

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #529 ·

the fuel tank fittings have arrived 😎


the vent / rollover valve seals with an 'O'ring against the top / outside of the tank and supposedly uses a 'Dowty' (bonded) washer between the tank & nut (no Dowty included :unsure:) whereas the feed / return hose stubs have a nylon / plastic sealing 'tophat'.

I'm going to dig-up the spare tank-sender cover & fit the 2 An6/8mm hose fittings in place of the Mazda origonal feed&return pipes then make a disc to replace the 'vent' thats bolted to the tank's top so the rollover-valve can be installed...

more to follow...

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #530 ·
ebay again responsible for more junk 😮


this time its secondhand Aeroquip & Speedflow hose-ends with some braided hose (An6 and An8, also a random turbo oil feed hose)



used but good for mocking-up the fuel system


theres a pair of An8 - 2way An6 connectors, not needed on my car but theres probably some use in the future...


the An8 hose is a good length, I'm too lazy and have no use for this so will not bother measuring :ROFLMAO::ROFLMAO::ROFLMAO:

these probably will be replaced as I don't know their history and fuel leaks can cause all kinds of fun 😮

also, bought a 3J's plate LsD :cool:

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #531 · (Edited)
off on another tangent,


this time exhaust manifolds....

I have 2 designs and a spare 1/4 cylinder branch matching one of the complete manifolds. no downpipe collectors bu these are easily made...


these are made to fit the infamous Ford / Cosworth BDA/BDG engines (4-stud manifold - head joint so commonly the upgraded BDG head (the earlier / BDA head had 3-stud flanges...)

















so, plenty of bits to maybe make a Mazda / Vauxhall conversion as I know theres nothing that will work 'off the shelf'....


Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #532 ·

one of the BDG manifold halves with a mk2 Mx5 manifold for comparison.


overlaid, similar angles so a start in the right direction...


mk2 Mx5 manifold roughly in pace.


BD manifold half roughly positioned.




number 2&3 pair added


as can be seen, the manifold is not sitting against the head, the downpipes are pointing in the right direction....




tried the other design in place...



again, this looks like there could be a chance...

more thoughts to follow.

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #533 ·

found the spare fueltank 'top' so chopped the fuel lines off & drilled some holes 😮




fitted the ATL fittings.




test fit of some hose with 90 and 45 degree 'ends'


the 45 degree 'ends' were tried because I have some, not going to use these on the tank as 90 degree will be used.

next to make an aluminium disc to fit the breather / one way valve into the top of the tank, another job.

Rich.
 

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layabout
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2,433 Posts
Discussion Starter · #534 ·
back to another tangent that started a few years ago, 3J's plate LSD 😉

Shiney...




the outside...

naturally I had ti investigate, also it needs stripping to inspect / clean / deburr etc before fitting new bearings (OK, people do press bearings on complete diffs but thats not my way!)


end plate removed, single bevelle washer as a spring - common practace...


clutchpack & retainer removed to reveal sun & planet gears / crosspins.


I'd opted for the (more expensive!) scintered clutch plates over the 'standard' steel clutches...




test assembled with 45/45 degree ramps as an optional setup (2 way)...


came assembled with 30/90 degree ramp angles (1 way) as recomended...


exagerated ramping, shows the retainers expanding and this increases the preload on the clutches therefore locking more & harder to break traction...

I forgot to order bearings so this will be tonights mission then some diff building to follow 😎

Rich.
 
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