A Few Winter Activities

So I have been working on a few items on the Miata over the past few weeks.  I recovered the seats with custom replacement leather covers, added a new shift knob, sound deadened the doors, and modified the fuel rail covers...

First bottom done...

Back in progress - my hands were sore after this work - lots of pulling, tugging and clamping.

I have ordered a replacement leather boot in Tan that I will install when it arrives.  This is a Karcepts Stainless shift knob that I got as a scratch and dent for $35 and I painted it satin black - I t just didn't fit the scheme being polished Stainless.  This knob weighs in at 1.34 pounds and makes the Pro 5.0 shifter move through the gears like butter.

I modified the fuel rail covers - I like the look, but they hold a lot of heat, so I added ventilation.

Evening Cruise

My son and I were out for an evening drive and the website owner of ImportAtlanta snapped these pictures:

New lights - HID

Working AC - 'Livin Large Now!!

So I fought all weekend with the AC, trying to get it running.  I finally dropped the car off to a professional to make custom lines with the proper connections and tap for the LS1 Sensor (transducer).

So that's it - right?  Working AC - BUT NOOOOO!

The compressor would not come on when the button was pushed.  I thought I had it all wired up, but attempt after attempt proved not.  I finally jumped the compressor and traced the wire from the jumper back to the "bundle-o-wires" that I did not strip from the harness - BINGO!   The location circled in the diagram was the culprit.  I assumed it was spliced in the harness, but apparently, it was spliced in a connector on the F-Body.

After splicing that one connection, the AC and the fans work as designed when the AC is engaged - Ice Cold Air at last!!

Heat Management

I have been suffering with uncomfortable heat on the floor when I take the car for long(er) rides.  The floor around the pedals has to be over 100*F.  So I added some HP Sticky mat 1/8" under the car, above the cats and added some header wrap to the pipes just under that section of the floor.  So far, so good - while I haven't driven the car that far, I have had it to 200* sitting, running whilst working on the AC - and the floor stayed relatively cool.  Fingers crossed - time will tell...

Gauges and lights

Tranny is back

The transmission is back in and the car is back on the road.  I am babying this thing and so far have about 25 miles on it this time.  It rained this afternoon here, so tomorrow morning I plan to drive it to the Caffeine and Octane monthly meet.

Gauge cluster - cluster

So I replaced the gauge cluster with another one I got locally (fewer miles) from a 2005 SE.  After I installed it, the tach reads half what it should - wow - talk about inconsistency...  So, I took the other tach out (older gauge cluster) and put it in, with the face from the new(er) one...  Also, since the gauge faces are green when the lights are on, I added green 5mm LEDs to the new mechanical gauges I just installed (replaced the white incandescent bulbs).

Speaking of the new gauges - I developed a leak with the oil pressure line (nylon), so I replaced it with copper.

Under the dash, I added a couple LED lights to the footwells - they are also green, but the superflux SMD. These only come on when the door is open (courtesy lights).

LEDs

The picture below shows the 2-different LED types I used.  These came from Oznium.com.

The Boomerang Effect

Well, as my luck would have it...  The transmission is coming back out AGAIN.  I have had little time to drive the car, dodging the rain and other things going on.  Friday evening, me and my Son went for a drive - it was the second time I took the car up to 70+.  Along that ride, while in 5th gear, at ~70, all of a sudden, it felt like the drive shaft came out - a couple of kunks and some grinding.  I quickly pulled over and inspected under the car - did not see anything wrong - (neither of us had a cell phone).  I restarted the car and eased out in 1st, then 2nd, and limped to the garage - it now has a rubbing sound in the transmission...

UPDATE:  The reverse needle bearing assembly was trashed...  I assume one (some) of the bearings came out and through the gears.  Replaced bearing and main shaft.  I have it back, and hope to get it in by the weekend.  Repaired under warranty.

Can't cry over spilled milk...  Onward...
In the meantime, I have been thinking that I really want mechanical temp/oil pressure gauges.  I took the NB gauge cluster apart and sunk a couple of 1.5 inch mini gauges into the same holes where the Miata temp and oil pressure gauges were.  It looks pretty good - the colors are a little off - but it works for me...  Its completely reversible if I don't like it in the future...

Finally!

Ok - so I finally have the car on the road!  and it's AWESOME!!...  I still have a few things to workout, like the tach reads double the actual RPM, and I need mechanical gauges for Temp and Oil Pressure, and I still need to service the AC system - but hey, it runs, drives and is fun for sure.

I have been driving around with a scanner attached to the OBDII to capture realtime stats - all is good, except having an issue with the right upstream O2 sensor.  I may have to swap the Bosch for AC Delco.

I built an air box behind the light to capture more of the outside ambient temp air, and less of the heated under-hood air.   

Still needs some body work and paint

Subwoofer to add a little base to the system.  This is a Pioneer low profile sub that fits nicely in the trunk pan.

Exhaust being mocked up

Added a crossover pipe

Performance cats

Testing while waiting

Well - since I cannot drive the car, today, I ran a diagnostic scanner on it to review the functions.  I was able to test the fans to ensure they are wired correctly and blow in the right direction (pull in my case) - all tested as expected.  I was also able to see the AC request signal is working, however, since the AC has not been refilled, I won't test the compressor just yet.

I also buttoned up the underneath and put the starter blanket on, along with some tidying up.

Just WAITING on exhaust...

Plans - what plans?

Plans for driving the Miata next week just took a hit.  I picked up the Transmission today and plan to have it back in this evening, fully expecting to move on to the exhaust by Monday.

Well...  As it turns out, the exhaust guy and shop owner are going to the Grand Prix de Trois-Rivieres 2013 in Canada and will be gone for 10-days...  I might be doing a custom exhaust in my own shop...

Tranny News!

Well - no real good news - I need more parts...

I replaced the clutch because it was not in great shape 50% gone - hot spots on the flywheel and on the pressure plate. The slave cylinder wasn't in great shape either - OEM has a plastic sleeve? - I was shocked.  New one is steel.  included pilot and throw out bearings - Cha-ching - $525 please!

Transmission update - they cracked it open today - stuff it needs:

• 3/4 shift fork (upgrading to steel) 
• 3/4 synchro pack
• 5/6 shift fork
• 5/6 synchro pack
• 5th gear
• Bearings
• Seals
• Putting in billet keys while its open

The good news - it will be ready next week - The bad news - my wallet won't be...  $1200

For those working on their firewall.  The transmission was a bitch to get out with the bell housing, and ultimately I had to unbolt the clutch from the flywheel and drop it straight down.

The problem is that top bolt on the bell housing.  I don't know why the instructions are to cut the wide, but short relief in the firewall...  It should be longer, toward the back of the car, and doesn't need to be 4-inches wide.  Longer would enable that bolt to come out on-top of the bell housing and the transmission (with the bell housing) could come out as a unit.

I fixed it for any future tranny work on my car. 

Two Steps Forward - One Step Back

Well - got the car on the road to the muffler shop today only to find out I have no 4th or 5th gear.  The transmission feels like it is going into gear, but the gear isn't there.  I took the console and boot off the tunnel thinking there may be a clearance issue - but NO.  I will have to drop the transmission to find out what's going on - and I will not be doing that this weekend - I am really mad and totally bummed about it.  I should have opened it up while out of the car, but didn't.  Hindsight is 20/20.

Took a while putting on, jacking up, taking off, adjusting the coil overs, repeat to get the ride height about right - and it looks good.  Before you comment - I already know the directional tires are on backwards only after driving it to the shop - the kid there pointed it out. At least that is a real easy fix.  The transmission - I dunno - crossing fingers and hoping its not fatal.

Almost there

Lots of additional progress towards the end-goal...  I expect to take the car down the street later this week (to the muffler shop) for a new exhaust system and alignment.  I will be using Magnaflow components on the exhaust.

I have completed most of the other tasks:

• Installed all new carpet (what a PITA!).  I got the heavy "mass backing" with Loop Carpet and it is nice, but makes it difficult to work with.
• Seats are back in
• Upgraded the stereo - removed electric antenna - installed stubby
• Installed a NB gauge cluster - rewired dash
• Installed Dakota Digital Speed calibrator
• Installed the Audi CV boots on axles
• Installed FM Little Big Brake Kit
• Put the fenders / nose back on
• Rolled said fenders (front and back)
• Received wheels/tires (Toyo R1R 225/45/15 on J-Speed wheels) 
• Ordered long lugnuts from 949 Racing
• Cut the rear bumper cover for dual exhaust - just made it look like the other side.

Left to do:

• Bleed brake/clutch systems
• Get Exhaust installed
• Alignment
• A/C fill
• Revisit all nuts/bolts to ensure torque
• Fix windows (switch is flaky)
• Install NACA duct on Driver's headlight cover

Pictures:

This is the style switch I'll be building for the windows.  Much more retro and cool than the plastic POS that is came with.

Duct I plan to use on the headlight cover

Major Milestone - It runs!

It Runs!!

No exhaust yet - but it does run...

Almost ready!

So lots of progress on the Miata on July 4.  It was a very rainy day here in the South and I got several things done in the shop.

Installed the completed rear subframe with all new parts, drive shaft, axles, hubs and control arms (new bushings).  I have now filled all fluids in the car (except brake/clutch) and installed the headlights.  Once the new Brake kit arrives, I can install that.  I ordered the Little Big Brake Kit from FlyinMiata.  I thought that kit offered the best value of what I have found.

VMaxx setup.  I installed the coil overs in the car, but the rear units are pretty close to the CV boots (see pics below).  Once I am able to set it on the ground, with the wheels/tires I choose, I will be better able to assess that situation.  Note: I am not calling it an "issue" - yet.

Almost ready to test fire.  Unfortunately, I have not received my PCM back from LT1Swap.com - and I am a bit concerned, as I have not been able to get a response from Brendan.  Today marks 2 business weeks since being delivered to LT1Swap.com via UPS, yet I still don't have it and cannot get a response from them.

Front to back under the car

Rear suspension

Yikes!  that is close!  I am not sure how much more pre-load I need on these springs, but this is the minimum due to clearance of the CV boot.  Currently, the CV boot is pushed back toward the hub.  Either way, it is tight.

Front Coilovers - still need to set the ride height, but that may be driven from the rear setting and the CV boot  situation.

 Items left to complete:

• Address the intake design
• Install brake kit & bleed system
• Decide on Wheels/tires
• Build exhaust
• Re install interior (new carpet - Black)
• Re install doors, fenders, hood
• Alignment