New project: 1976 Cosmo RX-5

[djmtsu]

Figured I might well get a jump on things, so this is what's going down. I am picking up a 1976 Mazda Cosmo (RX-5) this weekend. It is partially disassembled, body solid and everything is there. Including a bunch of NOS extras.

Right now here is a teaser of how it sits:

http://lh3.ggpht.com/_OFjbTkyhkOs/TSSiddfhh_I/AAAAAAAACWo/1AOmEymr6ao/s800/mazda%20cosmo%20001.jpg

And here is a pic of how I would like it to end up:

http://lh4.ggpht.com/_OFjbTkyhkOs/TSSid0kIi-I/AAAAAAAACWs/9waFm7fChIc/s800/rx-5.jpg

I am gonna need some help :D

[Prodigy]

That will look great when shes done, are you going for the similar color of white, or another color all together...?

I will be subscribing to this thread :D


J.

[djmtsu]

I like my white Mazda's, so I might try to use the Crystal White Pearl that my Mazda3 had. Bright white with silver in the clear.

Stay tuned.

[TitaniumTT]

NICE... nice find DJ. I want to do an old school rotary. After the FC, and the 'vert, and the FD, and the E46 :rofl:

What are your plans for powa!

[My5ABaby]

You're a crazy bastard. :icon_tup:

[djmtsu]

NICE... nice find DJ. I want to do an old school rotary. After the FC, and the 'vert, and the FD, and the E46 :rofl:

What are your plans for powa!

Ditch the vert and FD and move onto an old school! There is a guy down in North GA with a bunch of old schools for sale. One being an RX-4 with great body and interior with a locked motor. $800 I believe.

Anyway,

The car has a 12a in it that was installed by Mazda back in the early 80's. So no 13B 4 port twin dizzy. It also has the 'better' electronic dizzy in it. This is one of those 'ran when parked' deals. He said it really did run great when he started to take it apart to address some issues. He has put oil in it and turned it by hand a few times a year. So it might be able to be brought back to life.

First off however, I am dealing with the body work and interior. It really just needs a few small spots addresses and to the trim put back on. The interior is in great shape except for the dash. For now, I will get a dashmat until I can redo it myself.

Next, I am addressing the suspension and brakes. I am under the impression that 84-85 from strut/spindle assemblies will bolt in, and give me many more options. From there I can get the RE-Speed FC brake kit. The rear end is where I am in the dark. I know it has factory disc in the rear, but uses a drum inside the rotor for parking brakes. This is not ideal. If I can get an FB rear end under it, I can again go with RE-Speed 5 lug axles and big brakes. From there, a nice set of 15's will be sourced (old school, or meshies).

From there, its power time. If the 12a is healthy, it will get a Weber carb and manifold, direct fire ignition, custom catback, radiator with e-fans and an FD alternator upgrade.

Right now I am debating on whether to keep the chrome bits chrome, or powder coat them black instead.

[TitaniumTT]

There is a guy down in North GA with a bunch of old schools for sale. One being an RX-4 with great body and interior with a locked motor. $800 I believe.

I hate you.... I hate you SOOOOO much right now... I've got 2 13B cores in my garage just waiting to be torn down. Both with water seal failures.... I hate you...

Ditch the vert and FD and move onto an old school!

:rofl: I can't, they're both in my driveway. And per code I'm only allowed to have two unregistered cars on property at any one time. So I'd have to hurry and finish the 'vert, tag it, then move on to old school.... did I mention I hate you :lol:

The car has a 12a in it that was installed by Mazda back in the early 80's. So no 13B 4 port twin dizzy. It also has the 'better' electronic dizzy in it. This is one of those 'ran when parked' deals. He said it really did run great when he started to take it apart to address some issues. He has put oil in it and turned it by hand a few times a year. So it might be able to be brought back to life.

First off however, I am dealing with the body work and interior. It really just needs a few small spots addresses and to the trim put back on. The interior is in great shape except for the dash. For now, I will get a dashmat until I can redo it myself.

Next, I am addressing the suspension and brakes. I am under the impression that 84-85 from strut/spindle assemblies will bolt in, and give me many more options. From there I can get the RE-Speed FC brake kit. The rear end is where I am in the dark. I know it has factory disc in the rear, but uses a drum inside the rotor for parking brakes. This is not ideal. If I can get an FB rear end under it, I can again go with RE-Speed 5 lug axles and big brakes. From there, a nice set of 15's will be sourced (old school, or meshies).

From there, its power time. If the 12a is healthy, it will get a Weber carb and manifold, direct fire ignition, custom catback, radiator with e-fans and an FD alternator upgrade.

Right now I am debating on whether to keep the chrome bits chrome, or powder coat them black instead.

And if the 12A is not healthy? as an aside, 12a's suck... but if it's not.. boosted 13B-RE?? Cosmo for the Cosmo :naughty:

[djmtsu]

And if the 12A is not healthy? as an aside, 12a's suck... but if it's not.. boosted 13B-RE?? Cosmo for the Cosmo :naughty:

Oh, I know, 12a's are not beastly engines, but if it moves it, that is good for now. And they are tough little engines.

I would love to put a 13B-RE in it. You got a spare you want to loan me? Lol (don't forget the EMS). I actually bought an S5 TII engine last week, but plans changed and I sold it to jfaplanet for one of his REPU's.

I am sure I can find another :)

[speedjunkie]

Damn man, this is so ballin. I hate you now too. LOL

Congrats!

[Herblenny]

Cool Project car DJ! Can't wait to see it!

[djmtsu]

Thanks Phil.

Anyone hear from Rotarydave? I haven't seen him post anywhere in a while. I PM's him a few weeks ago and have not received a reply. Wonder if he is in Iraq again.

[djmtsu]

Wow. Info out there for the Cosmo's is so vague, and somewhat cryptic. I read a post where a guy said he uses FC struts in the rear (which doesn't seem possible), and a few references to FB shock in the rear. Nobody has an upgrade spring solution it seems.

Also, the factory bolt pattern is 4x120. Which sucks. Now, if I upgrade the front struts/spindles to GSL-SE, I can get some 4x120 to 4x114.3 adapters for the rear (since there is zero info on an axle swap). However, I have no clue on offsets.

This is going to be fun! I wish I knew if Billy could make his subframe for an FB fit the RX-5. R&P steering would be the shit!

[My5ABaby]

:rofl: Good luck.

[djmtsu]

:rofl: Good luck.

Shouldn't you be off crimping wires? Or cleaning a fuel tank?

[My5ABaby]

Shouldn't you be off crimping wires? Or cleaning a fuel tank?

At 1:30 on a Thursday, I wish. :( Ok, not really since I'm not looking forward to those. At least the fuel tank. The crimping won't be bad as I want to redo my tail lights and clean up the wiring. I'm looking at cutting the wiring in half along with making my reverse lights LEDs. Already have the boards made...

[diabolical1]

well, i don't know you, but i'm thinking i'll hate you, too. :)

on a serious note, i'm anxious to see this lump of coal turn to a diamond in the coming months. good luck.

[FerociousP]

well, i don't know you, but i'm thinking i'll hate you, too. :)

on a serious note, i'm anxious to see this lump of coal turn to a diamond in the coming months. good luck.

and what a lump of coal it is... I can't help but think of Ferris Bueller at a time like this.

[djmtsu]

and what a lump of coal it is... I can't help but think of Ferris Bueller at a time like this.

You go take your hair dresser's rotary to the nail salon.

Speaking of which.......just picked this up today. For a limited time only, then for sale.

http://lh4.ggpht.com/_OFjbTkyhkOs/TSZjp62u9SI/AAAAAAAACW8/l8h6eAagj5M/s800/IMAG0094.jpg

[Buggy]

Welcome to the world of owning one of the obscure old school rotaries. Getting good info is tough. You shouldn't have a problem swapping the GSL-SE front struts in. Just need some of Billy's camber plates and you're good to go. The rear axle is a different story. I know te cosmo's have a 4 link coil spring setup with rear disks. I'd just keep with that setup. Try to hit up some of the aussies for aftermarket parts. I got front coil springs for my Rx-4 from Pedders suspension. They have a lot of products for the old school rotaries. Good luck man. Coming from experience, you'll need it..... But you'll be happy when it's done.

[FerociousP]

You go take your hair dresser's rotary to the nail salon.


weren't you about to buy a non-turbo vert? and what showed up in your driveway again? Oh yes, a cat-printed silver car of salon personnel that only caters to blond hair, blue eyed people and hates jews? This is AMERICA (fuck yeah)... we buy asian cars. :patriot:

[one320fc]

Good find with the cosmo, I will see what info I can get from my dad..he has 4 of them in his back yard!

[djmtsu]

weren't you about to buy a non-turbo vert? and what showed up in your driveway again? Oh yes, a cat-printed silver car of salon personnel that only caters to blond hair, blue eyed people and hates jews? This is AMERICA (fuck yeah)... we buy asian cars. :patriot:

Hey now rapist...the Z3 is only in my driveway for a limited time (like 2 weeks) until it is resold! And you know that!

Yes, yes I admit I was going to buy a stock vert, but then I found my penis and changed directions. You should look into it.

:seeya:

[FerociousP]

I am not a rapist. That's My5ABaby's job.

[My5ABaby]

I am not a rapist. That's My5ABaby's job.:suspect:

[djmtsu]

Car is in Chatt right now. Got a late start today, and didn't want to take it all the way home tonight. So it is still strapped to the trailer, and taking it home in the morning. I will get some pics of the way it sits. I can't friggin believe all the extra stuff that came with it. I even have the original price sticker!



Oh, I never said what I paid for all this goodness........$200.00

[TitaniumTT]

You will rot in hell for that

[djmtsu]

Car is home, and safe in the garage. Time to take stock on what all I have. Here is a little list:
-3 sets of tail light assemblies
-3 front grills
-2 rear bumpers
-2 rear panel between the lights
-2 front lower facias
-2 radiator panels

Some new parts from Mazda
-dome lens
-side glass
-radiator panel
-window trim (with the rubber gasket)
-new door seals
-new random trim pieces
-rear pads
-rear bearings and seals

The engine is complete. It has an aftermarket cruise control set-up. Not sure what carb it is running, I haven't removed the air cleaner yet. I have a ton of receipts, including the receipt for the new engine...in 1987. Back then, a 12a only cost $675. The entire bill was only $1034, labor was $300!!

Oh how times have changed. The original price was $6699.00, with the very few options installed, it came to $6874.00

Lol.

[FC Zach]

Thats pretty cool.

[djmtsu]

Here are some pics of the transport and hasty stashing in my garage. A winter storm was coming, so I had to slam it in there for now.

http://lh6.ggpht.com/_OFjbTkyhkOs/TSswjdt1qjI/AAAAAAAACYA/p-CoAjY4PRY/s800/IMAG0095.jpg

http://lh3.ggpht.com/_OFjbTkyhkOs/TSswnS3C36I/AAAAAAAACYE/0Q5hEc_QxE8/s800/IMAG0096.jpg

Many, many tail lights.
http://lh3.ggpht.com/_OFjbTkyhkOs/TSswuI3nI0I/AAAAAAAACYI/Fdpk0u66aAc/s800/IMAG0097.jpg

Grills, that piece in the lower section of the pic is the factory lip spoiler.
http://lh3.ggpht.com/_OFjbTkyhkOs/TSswzbfeeaI/AAAAAAAACYM/9Mn5ANvde6E/s800/IMAG0098.jpg

Interior. Lovely Velour seats. Lol. Don't mind all the random trim pieces scattered about.
http://lh4.ggpht.com/_OFjbTkyhkOs/TSsw5c_bMLI/AAAAAAAACYQ/4LqgmxonB_Y/s800/IMAG0099.jpg

That is all for now. I will take some more with my actual camera, instead of my phone this week. Including under hood shots.

[Dazed and Rotarded]

Wow great find dj.. can't wait to see what you do with her.. think she will be ready for the gap?

[djmtsu]

Thanks man.

The plan right now is:
-body work and paint
-FB spindle swap with RE-Speed Big Brake kit
-rebuild rear axle bearings and seals
-4x120 to 5x114.3 rear wheel adapters
-new seats, re-dye interior carpet black
-stereo install
-some 15" wheels (can't decide what I want)

Once I find out the condition of the engine, I can go from there with it.
If the 12a in it is good:
-Weber/Holley or some other carb conversion
-emissions delete
-bigger radiator
-e-fan
-FD alternator upgrade

It already has an RB Road Race header on it.

If the motor is bad, well, I will put in whatever I can find!

[djmtsu]

This weekend I am going to try to fire it up. I am crossing my fingers.

There has not been much progress so far. I am getting that Z3 ready to sell, which is paramount since it is providing the budget for the Cosmo.

[-xlr8planet-]

good luck dude, try to make a video if it starts

[TitaniumTT]

Rotary swapped Z3?

[djmtsu]

Rotary swapped Z3?

Lol, you're the second person to suggest that!

No, I picked this up from a friend for an insanely low price. It was a toy he has had for years, and never really used. The slave cylinder went out, and I was going to fix it for him. Well, he asked if I just wanted to buy it, so there it is. It is going to be sold to a co-worker's brother for a healthy profit.

But, if anyone is interested, it is a 2001 Z3 3.0 with 60K.

PS- If it were to be rotary swapped, it would have to be a 20b. There is a massive amount of room under the hood.

[djmtsu]

Well, I picked up some vert wheels. So I guess I have to convert to 5 lug now :D

Two thumbs up for a $100 part requiring several hundreds of dollars to make it work. Sounds like a rotary!

[fire85gslse]

Good luck with that project. Very hard to find parts for her.

[djmtsu]

That is hat people keep saying, yet I found all the missing parts I need in a week.

Funny thing is, when you find one, people start coming out of the woodwork with parts available, and even whole cars. So it hasn't been difficult at all.

And since it isn't being restored to original, it doesn't matter anyway.

[djmtsu]

Tore the engine bay down today. I never bothered to check, just took the sellers word for it, but he was apparently ignorant.

She is still rocking the 13B 4 port!

It is currently stripped down to the block, have some MMO in the housings. It wouldn't budge, and I didn't want to force it to turn over. The oil looks good, and the coolant looked excellent. The plugs were a little oil fouled. I will put up some pics tomorrow.

[fire85gslse]

sweet

[rdgt99]

What a good surprise! Can't wait to see how this turns out.

[djmtsu]

Question of the day:
Weber 45 DCOE or Dellorto 48?

Missed a deal on a Dellorto, 45 DCOE's are everywhere for a good price.

Also, swapping in an FB 3rd member is going to be more of a challenge than anticipated. The springs ride on the LCA's, instead of the axle tube. Also it has a panhard bar instead of a watt's linkage. Charles wants to strip the axle and transfer all the brackets to the FB axle tube. I guess there is no other way.

Measure twice, weld once I guess :)

[ChaserAero]

Mmmmm...this is gonna be fresh.

[rx71king]

what a rare car ..... vary cool......good luck...

[djmtsu]

Just picked up a Weber 45 DCOE with RB upper manifold. Need to either find a 13B 4 port lower, or just buy one new.

Now I need to get a fuel pump an regulator for this carb. Next purchase will be some essentials, most of which I can get from work, like a water pump, wires, coils, distributor cap and rotor, fuel and oil filters.

Next will be an aluminum radiator, and see if I still have my Escort E-fan. I also need an FC alternator, although I think Charles still has my old one. Once the engine is running, the chassis work begins. Then the body work/paint, and last interior.

[TitaniumTT]

How much of that do you expect to have done in time for DGRRXI?

[djmtsu]

How much of that do you expect to have done in time for DGRRXI?

All of it. Sooner if you get your ass out of bed and help. Slacker. :D

[My5ABaby]

Omg what a rust bucket...


J/k. I went and got to check it out and it's fucking pimpin'. I'm really loving the tiny rolling windows. I'm pretty sure the FC needs those on the gigantic b-pillars.

[TitaniumTT]

All of it. Sooner if you get your ass out of bed and help. Slacker. :D

Ambitious, that's for sure.

Sure, I'll be there as soon as the FC is done to help out ;)

[djmtsu]

Ambitious, that's for sure.

Sure, I'll be there as soon as the FC is done to help out ;)

Well, since your FC is NEVER done, I guess I'll just see you at DGRR :)

I get by with a little help from my friends! Honestly, the most difficult part will be transferring all the brackets from the Cosmo axle to the FB axle.

[TitaniumTT]

Well, since your FC is NEVER done, I guess I'll just see you at DGRR :)

:smilielol5: This is very true. I won't deny it

I get by with a little help from my friends! Honestly, the most difficult part will be transferring all the brackets from the Cosmo axle to the FB axle.

Have you looked at Curry Enterprises, or Advanved Adapters, or even Rubicon Express to see if you can just buy the brackets?

[djmtsu]

Have you looked at Curry Enterprises, or Advanved Adapters, or even Rubicon Express to see if you can just buy the brackets?

You know, I had this thought a while ago, then completely forgot. I can probably get the brackets uber cheap from the off road shop here I used to work for. We stocked all that stuff.

[TitaniumTT]

Would be a lot easier than trying to cut everything off and it would save the axle too..... backups are generally a good thing ;)

[djmtsu]

Fo sho.

[djmtsu]

So, now I am considering putting RX-8 seats in it...front and rear.

[TitaniumTT]

I've got a bad back, and bad knees, and after spending 100+ hours in those seats, I never once got out with a sore back. I fucking LOVE those seats. My knees hurt, but that's becuase they just didn't move for hours on end and got locked up. I don't know about the rear, that might be a little wierd.... I'd keep the bench style in the rear which would mean some custom upholstering but would be pretty badass.

They are a tremendous PITA though. The amount of brackets, and mounts, and locating pins that need to come out are ridiculous... got plasma?

[classicauto]

OMG how sexy is that thing??

Not as sexy as the owner.:o16:

[My5ABaby]

OMG how sexy is that thing??

Not as sexy as the owner.:o16:

Sounds like DJ is going to get some Canadian luvin at DGRR this year. :suspect: Bow-a-chika-a-wow-a-wow-a...

[djmtsu]

Sounds like DJ is going to get some Canadian luvin at DGRR this year. :suspect: Bow-a-chika-a-wow-a-wow-a...

Not gonna happen. Our favorite Canuck is going to be hanging with the Mexicans while we're at DGRR.

[My5ABaby]

Not gonna happen. Our favorite Canuck is going to be hanging with the Mexicans while we're at DGRR.

Guess you'll just have to get TT drunk then...

[TitaniumTT]

Good luck... germans don't get drunk... we get even :suspect:

[TitaniumTT]

Oh, and canucks shouldn't go down to mehico... they're generally whiter and then therefore pull in more coin on the mkt..... Joe should reconsider his vacation plans.

[Buggy]

^ I second this.

[djmtsu]

Lol, I'm Swedish so I'm staying out of it :leaving:

Anyway, the Weber is here, the LIM should be here in a day or so. This weekend I am going to wire up the electronic dizzy and install the carb. Hopefully this thing will at least start this weekend.

Also, when I tore apart the engine I was a little concerned. I couldn't turn the main pulley, so I thought it might have seized. Poured some MMO into the plug holes, and let it sit for several days. Went out, put a ratchet on the main pulley bolt, and she turned right over. 3 good whooshes on all faces, so here's hoping it is good internally. At least that is a small victory.

Also, it might not have turned over the first time I tried because it might have been in gear. Maybe....

[TitaniumTT]

:willynilly: :chug:

Nah, if it was in gear it would still move slightly.... unless the tranny or rear end is siezed

[FerociousP]

unless the tranny or rear end is siezed

thats what she said...

[djmtsu]

Zing!

What the fuck has my build thread turned into?

I don't know, but I like it.

[TitaniumTT]

thats what she said...

Your tranny got siezed? That sucks... you filing a petition to get him/her back? ;)

[FIBREMAZ 13 BEEF]

Nice find man!
If you happen to come across anyone that sells new rear brake discs/rotors could you please pm the info as they are unobtanium down here in Australia.

Thanks
BEEFY

[djmtsu]

Nice find man!
If you happen to come across anyone that sells new rear brake discs/rotors could you please pm the info as they are unobtanium down here in Australia.

Thanks
BEEFY

Sorry man, same deal here. I actually joined ausrotary just to see about finding parts and such, and it seems you guys are in the same boat we are.

For being a top selling car in Japan, they sure are hard to find spare parts for. That is why I am doing an FB rear axle swap.

PS- Get me a sweet ass dolphin tail muffler!!!! (seriously)

[djmtsu]

Small parts update:
-ordered rebuild kit and new soft mounts for the Weber
-ordered new gaskets
-new cap, rotor, wires, coils, plugs, filters
-RB LIM will be here tomorrow
-ordered a set of Pedders rear springs from Australia. ETA: 6-8 weeks. Hope they get here in time!

[Buggy]

Ya hopefully Pedders comes through in time for you. I know I had a bit of a delay getting my springs from them.

[djmtsu]

I'm hoping they come sooner than later. The girl said they were placing an order today, and that my springs were in stock in AUS. So, even though they give a 6-8 week lead time, she said they would more than likely be here in 4-5 weeks.

Fingers crossed!

[djmtsu]

LIM is here. Still waiting on the Weber rebuild kit and soft mounts. Jeff20B shipped me a dizzy yesterday.

My tranny is just fine.

[joeywimsett]

Hey,

I own a 76 mazda cosmo and have been searching for different rear end gears, anybody know where to find some?

[djmtsu]

Hey,

I own a 76 mazda cosmo and have been searching for different rear end gears, anybody know where to find some?

Not really anything. I did a ton of research over at ausrotary. That is why my plan was to scavenge the Cosmo suspension brackets and weld them onto a stripped GSL-SE axle.

Oh BTW, the car is gone. Neil (Kansei Rotary) came and picked it up yesterday. It is on its way to Michigan to be restored, instead of bastardized like I was going to do.

Thanks!

[project86]

Hey DJ i didnt see pics of this thing in the start of the thread anymore. Do you still have it? If so you should post a pic or two in my body work thread. Sounds like it might be a fun project :D

[djmtsu]

Nope. The Cosmo is in a new home. Someone who will restore it to its original glory.

It actually was picked up a week ago, and is now in Michigan. Kansei Rotary has it, and hopes to have it back on the road in the next year. He was elated with all the documentation on it and overall condition.

If i would have kept it, it was be a bastardized street machine. Because of its provenance, Neil wanted to restore it. So off it went!

I've seen his other Cosmo, it is gorgeous!

[djmtsu]

To be continued?

[My5ABaby]

Oh lord.

[djmtsu]

Stranger things have happened :-)

[reddozen]

lmao...

[djmtsu]

OK, so I got the Cosmo back.

Time to get to work!

[Whizbang]

so it has come full circle eh?

[djmtsu]

Yep. Worked out well for both of us.

This will be my last "build" for a while. Going to start simple. Put it back together and in good mechanical condition. From there, I'll boost it and the downward spiral will begin.

[Whizbang]

i know how that its. Rally car is getting there. I have a merkur that needs soem things and there is this Rx2 for 400 bucks i really want to pick up.

[djmtsu]

RX-2 for $400 you say...

..where is this located? :D

[Whizbang]

the great state of idaho, in a field behind a farm house

[FerociousP]

Yep. Worked out well for both of us.

This will be my last "build" for a while. Going to start simple. Put it back together and in good mechanical condition. From there, I'll boost it and the downward spiral will begin.

Alright Phil.

[djmtsu]

Update:
Nothing really, although I did pick up another Cosmo, just waiting for it to be brought down here to TN.

Started tearing it apart!

http://rotarycarclub.com/rotary_forum/picture.php?albumid=362&pictureid=2994

Then found some nasty ass rust in a bad spot.

http://rotarycarclub.com/rotary_forum/picture.php?albumid=362&pictureid=2996

This is where the front engine crossmember bolts to the frame rails. A leaky battery has really fucked it up. Notice that nasty looking nut/bolt there? That is a welded nut that has broken free and it seized. Oh, this also doubles as the front sway bar mount.

Now, this is what it is supposed to look like (picture of the other Cosmo). Much better!!!

http://rotarycarclub.com/rotary_forum/picture.php?albumid=362&pictureid=2995

Now, the problem is, I have no idea when the other Cosmo is going to make it down here. It is all based on when my step-dad buys a new truck. Lol.

But there is some light at the end of the tunnel. I have found and test fitted all the trim and such, all there. Also I found the glovebox knob, which was a major source of irritation for me.

http://rotarycarclub.com/rotary_forum/picture.php?albumid=362&pictureid=2993

Other than that, I have replaced the wheel seals and cleaned up the rear diff, including the rear brakes. More to come....