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.