My RX-8 resto build

[djmtsu]

Here is the new rotary.

Specs-
2004 Mazda RX-8 Grand Touring
6 speed
196,115 miles
Navigation
Leather
Heated seats

I got this RX-8 for stupid cheap. The dealer said they just wanted to get rid of it. They thought the clutch was toast, and their local Mazda dealer quoted them $1800 to replace it. Compound that with the mileage, a busted tail lens, and a few minor dents and it wasn't worth it to them to fix it.

So yesterday, it was finally delivered from Miami to Murfreesboro. We had to push it to the driveway, since you can't get the car into gear when running.

The first thing I noticed was the clutch pedal looked skewed towards the brake pedal. I have done my research, and know that the pedal bracket is prone to failure. After they helped push it into the driveway, I got down on the floorboard and check it. Yep! Broken!

That is really good news, as this means saves me a TON of work, and money.

Here are some pics:
http://lh6.ggpht.com/_OFjbTkyhkOs/S22PFVCL74I/AAAAAAAAB6c/iGVmVj2Us24/s800/DSC00525.jpg

http://lh3.ggpht.com/_OFjbTkyhkOs/S22PFchUNqI/AAAAAAAAB6g/yiyGzDmS6RE/s800/DSC00527.jpg

http://lh4.ggpht.com/_OFjbTkyhkOs/S22PFizEJXI/AAAAAAAAB6k/lGo3KhYrclo/s800/DSC00528.jpg

http://lh5.ggpht.com/_OFjbTkyhkOs/S22PFrEl6nI/AAAAAAAAB6o/KFXbbZ2TBYo/s800/DSC00529.jpg

http://lh4.ggpht.com/_OFjbTkyhkOs/S22PFooAqTI/AAAAAAAAB6s/eXX4HYIdjwA/s800/DSC00547.jpg

http://lh3.ggpht.com/_OFjbTkyhkOs/S22PLrmLsiI/AAAAAAAAB64/4QkvrhIUoNM/s800/DSC00559.jpg

http://lh3.ggpht.com/_OFjbTkyhkOs/S22PLrmLsiI/AAAAAAAAB64/4QkvrhIUoNM/s800/DSC00559.jpg

http://lh6.ggpht.com/_OFjbTkyhkOs/S22PLlwGjKI/AAAAAAAAB7A/ynQSXV87s1g/s800/intrx8.jpg

I have already ordered the clutch pedal assembly, a new shift knob, and steering wheel from Tom at partsgroup.com (thanks man!!!)

Today I am going to the salvage yard to get a tail light, and pick over some other parts.

Plans are:
-PDR the dings
-gangsta tint
-Tein S-Tech springs
-RB sways
-tires
-BHR Ignition upgrade
-Cobb Accessport
-catless mid-pipe

Nothing too gnarly right now. Both the wife and baby are going to get rides, so I have to keep it comfortable. I would like to get an MS front bumper and skirts, as well as a catback system. We will see.

[Max777]

how the hell did someone get 200,000 miles on a 2004 RX-8?

Holy hell, and I thought that 200k for an 1980's FC was excessive!

[djmtsu]

The owner was in sales all over South Florida. He drove it ALOT!

It has had a Mazda reman, but it was a long time ago!


And I go agree, my FC only has 140K, and its 20 years old.

[TitaniumTT]

Nice find DJ. So what's the final verdict on the FC? Keep, sell, upgrade :suspect:

Beautiful car. So when you planning on doing the BHR Ignition upgrade? Want me to test it out for ya first :D

[djmtsu]

Unfortunately the FC is gonna have to go. :(

It does make me sad, but I know if will go to a good home. I won't sell it to drifters (no arguments in my thread please). I am just waiting on the UIM gasket to fix it. Then I might spot paint the flaked areas to get a little more $$$ out of her. The good thing is it has excellent compression (like I always knew).

With 196,000 miles on this thing, and the current engine with unknown miles, I need to have the cash available to rebuild if necessary. Add to that the guarantee that it will need several suspension upgrades, etc.

I can still drink beers at DGRRX with you guys right :)

Oh, and you buy the BHR kit, and I will test it for you.

[djmtsu]

Oh, and in case anyone wants to know how much I paid.............

































$5000

[JDriftM]

$5000? Ok, I'll be the first to say it.......I hate you.

[MrsJoff]

I know it has already been said, but damn, 200,000 miles on an 8. That is a lot of miles for such a new car. The car looks to be in really good condition.

Once you are done with the suspension, the next project should be slapping a supercharger on there. They are a lot more fun with one of those :driving:

Good luck with it and hope you enjoy your new toy.

[TitaniumTT]

Nah, skip boosting a renni and drop an REW in there with the GZ MIN and put 500hp to the wheels and not think twice about it.

But send me the BHR ignition upgrade first or no beers at Deals ;)

[Max777]

why even bother rebuilding a renni? Just get a better engine. You have plenty of other cars to drive, so it's not like this is your daily. Though, judging from the amount of work you did on the fc over the period of time you had it broken, maybe this aint such a good idea after all....:leaving:

And did I mention you suck for not selling it to "Certain people" cause a lot of them would take just as good a care of it as anyone else. How bout you change that statement to "i wont sell this car to irresponsible, clueless teenagers who don't know wtf they're getting themselves into and have little to no cash"... which is exactly what we all were at some point in time.:D

Good day, sir.

[mazdadude7]

you jerk! lol I saw that car on ebay I think and I was thinking about it. Im glad it went to a good guy. my plans were a re swap or something similar if I bought it

[TitaniumTT]

If anyone is thinking about swapping the renni out of an RX8 to go with a turbo engine, talk to Dave @ KDR, seriously. He's done a few of them and has a way of doing it that is pure genius.

[djmtsu]

why even bother rebuilding a renni? Just get a better engine. You have plenty of other cars to drive, so it's not like this is your daily. Though, judging from the amount of work you did on the fc over the period of time you had it broken, maybe this aint such a good idea after all....:leaving:

And did I mention you suck for not selling it to "Certain people" cause a lot of them would take just as good a care of it as anyone else. How bout you change that statement to "i wont sell this car to irresponsible, clueless teenagers who don't know wtf they're getting themselves into and have little to no cash"... which is exactly what we all were at some point in time.:D

Good day, sir.

Hey! I did do some work to it, but I also had two other Mazda's plus my DD's I had to take care of all at once.

No more. I will only have this, the Jeep and the Volvo for a long time. I am not in a rush to do an engine swap. Although the power would be nice, I think the wife wants to drive it every now and then as well. I wouldn't boost the renny, but there is no reason to not rebuild it and wait for a while to swap in an RE.

Tomorrow it should be able to drive it!

[TitaniumTT]

REW > RE for an RX8. There are a few products out there that coupled with the REW make it virtually plug and play as far as the electronics go. Still need to fab up engine mounts, dp's etc etc.

[djmtsu]

Find me solid information on an REW swap. Details, I don't wanna hear about this person did it, or this shop did it. I want to know what goes into it 100%

Otherwise, I'll just keep my renny.

I need beer.

[WE3RX7]

I think this may be a first "resto rx8 project" lol. I plan to restore mine in about another 5 to 10 years, lol...

On the BHR, build your own kit. I thought about going that way too, but then priced everything out and you can save yourself $100 or more if you do it yourself. BHR builds a great product, but its really all OTS stuff... the only "hard part" is the bracket which really isn't that difficult.

Also, REW is a good swap. After seeing the cars at Dave's (especially that white MS RX8) the swap is CLEAN and definitely a good way to go.



Good buy, and we'll be glad to have any rotary at DGRR... luckily, more and more guys are buying outside their generation so the love is spreading :)

[FC3S Murray]

$5000


You sneaky son-of-a-bitch! :) THAT IS A STEAL!! Congrats man. I really wanted to see the SSR's on the FC though....

BTW; love the interior on the 8. I have become a big fan on the tan/black combo over the last few years.

[project86]

i hate you for buying that for 5k. but good find thats awesome. i want an 8 so bad.. but i would never lose my fc for one. it was my first love ....

[djmtsu]

i hate you for buying that for 5k. but good find thats awesome. i want an 8 so bad.. but i would never lose my fc for one. it was my first love ....

Trust me, I love me FC too. So easy and CHEAP to work on. Lends well to homebrewed parts! My mom couldn't believe I'm selling it either!

Murry, I will have some pics of the FC with the SSR's soon. Last part to fix it is sitting at the dealer, have to pick it up today.

Hell, depending on how things go, I might still bring the FC to DGRRX. If it doesn't sell before then, or the 8 is screwed up, I'll bring it out one last time!!

WE3RX7- Do you think you could get me a parts list?

[TitaniumTT]

I think you should bring the FC to Deals one last time if you still have her. You'll have the 8 for a while and no definate timeframe on the FC

[05rex8]

keep the renesis; boosted or not--it's a great engine, its just not a dyno queen motor like the rew

if you do boost it, do your homework ;)

[prican]

nice find

[djmtsu]

Some parts should be here today:

-new clutch pedal assembly
-new steering wheel
-new shift knob
-radiator comb

*Big thanks to Tom at partsgroup.com!!!!

[djmtsu]

Parts are here!

jfaplanet is doing some strengthening welds to the new clutch pedal assembly, should be able to pick it up today. Sadly, the 8 is outside, so I couldn't do anything last night. It has been super cold out, and the FC is in the garage almost done.

Woot!

[Gregory Casimir]

nice find dude.

[FC Zach]

Sweet! Great find, sad to see the 2nd go

[nuke0907]

nice upgrade. :)

[djmtsu]

Getting there.

Received my flip key today. When I get the chance I am taking it to the dealer to get it cut and programmed. I only have the Valet key, so I can't do it myself.

[WE3RX7]

Ah man - that sucks... programming the key yourself is no big deal. I have done a few so far, but I'd like to get a flip key for my '04 as well. Def need the actual key though.. hope they dont screw you on the cost, last time I had a dealership do it it was around $180 to program the key, not even cut it!

[djmtsu]

I have the hook up.

The husband of a lady I work with is a tech at Nelson Mazda. They are cutting the key for $18, and he is programming it on the DL.

Once that is done I can do more myself.

Win!

[nuke0907]

sweet deal. i've wanted one of those for a while now.

[djmtsu]

sweet deal. i've wanted one of those for a while now.

You can pick them up cheap on eBay. I paid like $40 shipped for the remote with blank key. I think the store is Midwest Keyless. As soon as it arrived, we tested it on Fero313's Mazda6, and it programmed perfectly.

[pineapplesoymilk]

dude i am so gelous haha

[djmtsu]

Put in the new clutch pedal assembly today, and programmed the flip key remote. Both work perfect.

The car is takes a while to start. I don't know if it is bad plugs, bad coils, or a combination of the two. The dealer said it has new plugs, but I doubt it. The coils...who knows how old they are, and they are know to be crap.

On the road though....it is sweet! She pulls hard and handles great! Has a little alignment issue, pull left a little. Trans shifts great and it really feels like it pulls great all the way to redline.

SO, I am hoping that new plugs and coils will cure the slow start.

[reddozen]

keep the renesis; boosted or not--it's a great engine, its just not a dyno queen motor like the rew

if you do boost it, do your homework ;)

I agree 100%... Renesis is a better motor overall, or I should say, I think it has more potential.

[Dazed and Rotarded]

dj , beware of the switch and poppin the trunk.. leading 8 battery killer!! lol

[djmtsu]

Small update yesterday.
New coils installed
New plugs installed
New filters
Changed oil
New steering wheel
new lug nuts ( :p )

Installed the Axxess iPod adapter.....and I am pretty sure it blew up my Head Unit. The display above the stereo lights up, but does not display anything. No sound from the stereo, it won't even power up.

:(

[WE3RX7]

S did the plugs and coils solve your problem? You may have a bad starter too... did you go with stock coils?

[djmtsu]

Starter has been replaced per the TSB. I did go with stock coils, since I got them for cost. I do need wires still, found that out when changing everything out. No big deal, ordering the RB wires today.

The car starts alot faster cold, and starts better hot, but not as quick as I would like. The car feels much more powerful, that is for sure.

Now if I can just figure out why the stereo is acting up, and why I have a CEL now.

Ugh, typical rotary, I should have switched to BMW's :leaving:

[Whizbang]

5000!! damn man

[sbrian2]

Ugh, typical rotary, I should have switched to BMW's :leaving:

Not any better, trust me. My 325Ci has had more problems in the past 15 months than my CRX has had in 15 years.

[My5ABaby]

Now if I can just figure out why the stereo is acting up, and why I have a CEL now.
It's probably code 49, "Driver is a tool". Autozone, Advance, or Death will clear it for you.

[djmtsu]

It's probably code 49, "Driver is a tool". Autozone, Advance, or Death will clear it for you.

All your parts are belong to me.

[djmtsu]

Progress!

The stereo issue is fixed. Part of the faceplate detached from the stereo unit. Pushed it back in and resecured the screws, all is good. iPod adapter works perfect, and I am quite happy.

The CEL was for Secondary Air Solenoid Circuit. I wiggled the wires, and made sure the connections were good, and reset the light. Drove around at lunch, and home from work, and it has not come back on. The idle is smoother now as well.

I ordered some RB wires, hopefully they will be here Friday (and not Monday like UPS says).

Now it just needs tint, and a GOOD cleaning/polishing before DGRRX!!!!

[My5ABaby]

The CEL was for Secondary Air Solenoid Circuit.
Hmmm, I guess I was wrong. :rofl:

[djmtsu]

Just got my Racing Beat wires in from Atkins Rotary.

Hopefully I can get these on this week, if the rain and cold would just go away!

A friend that does PDR is at the house fixing the dents today, crossing my fingers that it turns out good.

[djmtsu]

Well, I have been driving it alot in the last few weeks, and I think I have a major problem.

Replaced all the ignition components, and now she fires up alot faster, and runs great......

But on initial start up after sitting overnight, she chugs for about 30 seconds, and I swear I smelled coolant this morning.

Yay. So now I am on the hunt for a Renesis short block.

Pretty sure it is either a coolant seal, or cracks in the housing.

PS- Less than a month to DGRR, so if I don't get a hook up cheap and fast, I will be there in the Volvo. :(

[project86]

well at least youre makin progress. nothing come easy with these damned things. sounds like youre gettin alot figured out fast. keep it up

[djmtsu]

Aight slight update.

I cleaned the MAF, and TB. De-greased the engine. Polished the yellowed passenger headlight. And ran some Seafoam through it.

It starts hard cold still, running STUPID rich when it finally fires up. We are talking mosquito killing smokescreen for around 30 seconds. Nobody can figure it out, so fuck it.

Also, this is today's fun.

Thought I popped it today.

I had to drive about 30 miles to the Volvo dealer to pick up a part for the S80. Then it was a gingerly drive about 25 miles down a 2 lane. As I was jumping on the highway for a quick 5 mile jaunt to my exit, a problem occurred.

I was merging with traffic, had in 3rd, and punched it. RPM's climbed to about 5.5K, then it fell FLAT on its face, WTF???? I tried again, and the same thing. So I back down and just accelerate like a normal human.

Everything seemed fine. I look down, and the fuel light had come on. I tried to push it again, and it stumbled again and fell flat around 6K.

Hmm. So I get off my exit, and stop for gas. Fill it up with Premium. As I pull out I say, fuck it.

Completely disable DSC and TCS, drop the clutch and hammer down. She put down patch, got sideways and pulled all the way to the beep beep.

I guess my fuel pump doesn't like low fuel.

PS- It barely started after work, but fired right up at the Volvo dealer. POS.

[WE3RX7]

Cheap cars come with a price :)

Have you run a compression test on it lately? The smoke screen could be a number of things... is it black/fuel, blue/oil or white/coolant?

Is it up to date on all PCM flashes?

[djmtsu]

It is up to date on PCM flashes.

It is a whitish gray. It doesn't smell like coolant, just straight up fuel.

I know that it is going to need an engine soon, which is why I don't care to compression test it. I guess I could, Charles has a Rotary Diagnostics unit.

This summer is going to be new engine time, already planned.

[TitaniumTT]

I would have a serious look at the injectors and fuel pump fuel sock fuel filter wiring etc etc. It sounds like all your starting problems, pig rich running, stumbling @ 6k etc etc can all be attributed to fuel issues.

Personally, with my experience with those things, I'd send the injectors out, pull the fuel pump, replace the sock and filter, voltage test the pump while running under load, and go from there.

[djmtsu]

That is the plan right now. I am just waiting on a price from my guy at the Mazda dealer, then I will send off the injectors to Injector Rehab.

I need to get this damn FC shell out of my garage so I can tear this apart.

[WE3RX7]

If it had interior - I'd tow it away for ya :)

[djmtsu]

This morning, she fired right up like it was a damn Honda.

This thing really is friggin' possessed!

Drove to work with no issues other than the random low coolant light, which really isn't an issue.

[djmtsu]

Today was FUN coming home from work.

I jumped on the highway, and was immediately halted by a traffic jam. So I sat for about 40 minutes, inching forward. Finally cleared the wreck, and then I start getting fuel pump issues. Anything past about 5K rpm's made it fall flat.

Then it got worse.

Stopped at the gas station real fast, and let it run while I ran in. Came out, turned out of the gas station and it sputtered out....dead.

Pulled off the shoulder, and tried to crank it. Nothing, when I floored the pedal to do the fuel cut, it didn't sound any different from when the car was cranking normal.

No fuel.....at all.

Luckily, I was close to home, so if I had to tow it, a friend with a chain could have helped me. Instead, I sat for 20 minutes, and prayed to the rotary gods. Luckily, it fired up, and made it home.

If I can't get my hands on a pump within a week, I am bringing the Volvo to DGRR. What sucks, is I will be out of town for the next few days.

Dammit........again.

[FerociousP]

Commute FAIL.

[mazdadude7]

Bummer man :( I had similar issues with mine. It ran better with the maf sensor unplugged? I wouldnt recomend doing it for a long distance but next time it acts up see if it works better unplugged

[MazdaMike]

Moar pics dude! That is awesome a total steal for 5k..but sounds like an FC the way its treatin you lol.

[djmtsu]

Sorry guys, been out of town for the last couple days.

Going to pick up a used pump with 30K on it after work. I'll throw it in this weekend and see how things go next week. If it keeps acting up, I am going to have to take the Volvo to DGRRX, which makes me a little sad, but it is friggin' fast, so it should still be fun.

[djmtsu]

New fuel pump is in. What a PITA. Seriously. If it wasn't for the damn plastic 'lock ring' that holds the pump in, it would be so much easier. Instead, I had to buy a $20 tool that I most likely will never use again. Lame.

Anyway, it fired right up, and drove fine. I took it up through 3rd redlining every gear, and it seemed to keep up. Tomorrow, I am taking it to work, which will get the pump alot hotter, and then we will see if it has issues still.

Still crossing my fingers that I can take her to DGRRX.

[djmtsu]

This morning I go out, and had every intention of doing the normal 'deflood' when I started the RX-8. Except I was tired, and forgot.

To my surprise, it fired right up, in fact, I don't think it has EVER started so quickly!!!

Hopefully this was the answer to all my fueling issues.

[project86]

so as far as the flooding issues go with these damn things can you get that valve from mazda trix that bleeds the pressure back to the tank for the rx8? or is it only good for the fcs?

[FerociousP]

that would be considered treating the symptom and not the problem. And the Rx-8 is "returnless" with only 1 line going up to the rail.

[djmtsu]

Yep, what Paul said.

Hopefully the rich startup is gone. It fired up perfect this morning, the engine turned over maybe twice and it fired, with no misfire light afterwards.

Stay tuned, lunch break is in 15 minutes.

[IH8DSM]

good luck dj haha im hopin my starter fixed my problem so far it starts a lot easier

[djmtsu]

Well, it started super rich and I had to 'deflood' before it would start. I am going to beat the shit outta it on the way home from work today. If the pump hold up, and I don't get power loss issues, I will take it to DGRRX. If it continues to be fussy, I'm rocking the Volvo.

[djmtsu]

Ok, last night after work, it fired right up. This morning it fired right up.

I hope the ECU is 'learning' since the pump was replaced. We will see.

Right now, it looks like the 8 might make it to the Dragon.

[My5ABaby]

Ok, last night after work, it fired right up. This morning it fired right up.

I hope the ECU is 'learning' since the pump was replaced. We will see.

Right now, it looks like the 8 might make it to the Dragon.
You're like a latin soap opera...

:toetap05:

[FerociousP]

Ggggoooooaaaalllllll!!!

[djmtsu]

You're like a latin soap opera...

:toetap05:

God I wish my life was like a Latin soap opera. The women in those shows are stacked!

[IH8DSM]

Tellemundo

[djmtsu]

The RX-8 has two chances for redemption at this point. As long as she behaves the rest of today.

Stay tuned for the after lunch update!

[My5ABaby]

The RX-8 has two chances for redemption at this point. As long as she behaves the rest of today.

Stay tuned for the after lunch update!
Now an infomercial...

[djmtsu]

It started up fairly quick at lunch, but threw a misfire code and had a rough idle for about 10 seconds. We will see what happens after work.

I am fairly certain I will be bringing the Volvo to DGRRX. I just don't want to pop it right now. A rebuild/new engine will come soon, but I don't want it to be right now.

[djmtsu]

Update

Pulled the plugs yesterday, after maybe 800 miles. The front housing, Leading position plug had a brownish liquid on it. Looks like I have a small coolant seal leak. Yippie!!

Being that I don't really give a shit, since I will replace the entire engine, and upgrade the radiator at the same time, I am going to block the heater core, and use some Bars Ceramic Head Gasket repair 'magic bottle'. I know people hate that shit in a rotary, but I have friends that have run it for over 2 years in their rotaries before developing any recurring issues.

Pics of the plugs (3rd from the left is the L1 plug)
http://lh6.ggpht.com/_OFjbTkyhkOs/S9jNLPwJZwI/AAAAAAAACJ4/j0MK0HWcA-s/s800/IMAG0038.jpg

http://lh5.ggpht.com/_OFjbTkyhkOs/S9jNLS23xDI/AAAAAAAACJ8/IKQtkQBqGIw/s800/IMAG0039.jpg

[djmtsu]

Car is still running good. Just got my best fuel mileage out of a tank ever. 260 miles, 12.5 gallons.

Not too bad, the locals I ask average between 220-250 per tank, so I got a little better, since I wasn't beating it too hard.

[project86]

Being that I don't really give a shit


:icon_tup::rofl:

[Max777]

Car is still running good. Just got my best fuel mileage out of a tank ever. 260 miles, 12.5 gallons.

Not too bad, the locals I ask average between 220-250 per tank, so I got a little better, since I wasn't beating it too hard.

Is that local milage? It seems like my turbo II gets around 16-17 as well... but it's turbo????:o11:

[djmtsu]

It is mostly highway miles, about 15 to work and then 15 back, with maybe 4 miles in town to pick up my son.

My TII used to average 28mpg on the highway, and about 15-16 in the city. I could leave here and make it all the way to DGRR without filling back up until I go there.

[djmtsu]

Might be selling the RX-8. Don't worry though, will be staying in the rotary gang. Just need to recover some cash from the baby expenses, and am saving for the next rotary ride Mazda releases.

I am looking at a few FC's to hold me over....

If someone wants it, let me know, I am letting it go CHEAP.

[My5ABaby]

You are so ADD with your cars... :rofl:

[djmtsu]

I didn't say I was for sure selling it, but if someone wants to buy it, then let it be.

[rx7 vinnie]

Man I haven't turned a wrench on my 8 in months.

[djmtsu]

Man I haven't turned a wrench on my 8 in months.

Neither have I, just been driving it almost everyday!