Stredrotor's RX4 Coupe * Project 20B *

[Stredrotor]

Thought I'd start a thread on my 1974 RX4 hardtop.

I bought around 2 years ago after previously having a 13b turbo 1973 RX4 hardtop and an '86 Series 4 RX7 turbo over the last 15 years.
The car had a carby 13b and first gen RX7 5 speed, it ran well but I needed more power. I think of the RX4 as mazdas "muscle car" so it needed a engine with the muscle, hence a 20b :reddevil:

The RX4 as I bought it....

http://img511.imageshack.us/img511/5421/coupefrontmg4.jpg (http://imageshack.us)
http://img140.imageshack.us/img140/1798/coupeseatsjw6.jpg (http://imageshack.us)
http://img116.imageshack.us/img116/3637/coupereardr6.jpg (http://imageshack.us)

Striped and painted the crossmember and replaced tie rods, sway bar and bushes.
http://img364.imageshack.us/img364/32/crossmemberyh9.jpg (http://imageshack.us)

All installed!
http://img171.imageshack.us/img171/2213/installedcrossmemberku0.jpg (http://imageshack.us)

[Stredrotor]

The next acquisition for the 20b project, a series 5 gearbox :D .

http://img205.imageshack.us/img205/7682/series5gearboxas8.jpg (http://imageshack.us)
I got a awesome bargain the other day, a bloke at work tipped me off to some 16 inch F90 Simmons at a second hand shop. A bit of bargaining and these were mine for $140. :D

http://i28.tinypic.com/2s6lymd.jpg
All 8 inches wide.

Picked up a Microtech LTX12, coils, loom and Eboost
http://i30.tinypic.com/2zi901g.jpg

Just got the engine in place to work out the engine and gearbox mounts
http://i30.tinypic.com/28mnss4.jpg
http://i29.tinypic.com/25rcrqs.jpg

[Stredrotor]

For Fathers Day I asked for some kid free time to work on the Mazda, so I got around to doing the old shorten shifter housing mod......
http://i227.photobucket.com/albums/dd173/Stredda/Shortenedshifter.jpg

Modified the gearbox cross member to suit the old RX4 one.....
http://i227.photobucket.com/albums/dd173/Stredda/Gearboxmount.jpg

Made some plates to mount the engine off and exhaust manifold flange :D ......
http://i227.photobucket.com/albums/dd173/Stredda/RHenginemount.jpg
http://i227.photobucket.com/albums/dd173/Stredda/LHenginemount.jpg


Now I just have to install the engine and box and fab the mounts off the suspension crossmember.

[Stredrotor]

Here's the prototype mounts:)
The engine and gearbox is mounted 50mm further back than the 13b to help with clearance at the front of the engine bay.

http://i227.photobucket.com/albums/dd173/Stredda/FabRHenginemount.jpg
http://i227.photobucket.com/albums/dd173/Stredda/FabLHenginemount-1.jpg

RH engine mount now finished
http://i227.photobucket.com/albums/dd173/Stredda/RHenginemount1.jpg
http://i227.photobucket.com/albums/dd173/Stredda/RHenginemount2.jpg

And test fitted.
http://i227.photobucket.com/albums/dd173/Stredda/RHmountfitted.jpg

Left hand mount completed, sits quite nice .


http://img42.imageshack.us/img42/5561/lhmount.jpg (http://img42.imageshack.us/i/lhmount.jpg/)

Should be strong enough :!: :D

[Stredrotor]

R/H side mount installed.....

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0943.jpg

...and L/H

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0942.jpg

Getting there

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0941.jpg

My latest purchase 60mm Tial waste gate and a GT42, ball bearing, water cooled A/R 1.06 exhaust. Now have to get in and make the exhaust manifold.:)

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0940.jpg

[Madaz]

WOW! What a project you have there. :icon_tup: Looking forward to updates.

[Modified Dave]

Very nice fab work on the engine mounts, but how come you didn't throw a gusset or two on the inside of the L shape on them? Looks like there's plenty of space for a few gussets, though maybe that'd be overkill given the thickness of material used?

And a GT42?! Wowzers, how much power are you planning to make? :)

[Rogue_Wulff]

Trans mount really needs some rubber thrown in somewhere, or it's liable to have massive vibration issues.
Otherwise, awesome project.

[Stredrotor]

Yea, it's now got a 10mm thick piece of rubber between the mount and gearbox bracket plus the crossmember is rubber mounted as well.:)

[Stredrotor]

A bit more forward progress.....

Got the pipe layout sorted, think it will flow ok :D

http://i227.photobucket.com/albums/dd173/Stredda/Manifoldfab.jpg
http://i227.photobucket.com/albums/dd173/Stredda/Manifoldfab3.jpg
http://i227.photobucket.com/albums/dd173/Stredda/Manifoldfab2.jpg

Just got to sort out the transition piece on top

Couldn't help myself and did a test fit in the engine bay

http://i227.photobucket.com/albums/dd173/Stredda/Turbotestfit.jpg
http://i227.photobucket.com/albums/dd173/Stredda/turbotestfit2.jpg
http://i227.photobucket.com/albums/dd173/Stredda/Turbotestfit3.jpg

Now have to have a think on how I'll plumb the wastegate.

[85rx-7gsl-se]

This is a great build you have going here.

[estevan62274]

Nice!!! keep up the good work!!
Cant wait for more updates!

[13bpower]

Great build i like whene people put new tec on old school car,hay ma keep up the great work nice looking rx4....

[Stredrotor]

Finally got a few days to make this manifold

Tacked manifold to 25mm plate to help stop distortion......
http://i227.photobucket.com/albums/dd173/Stredda/Manifoldtackeddown.jpg

Welded and turbo bolted on.....
http://i227.photobucket.com/albums/dd173/Stredda/weldedwithturbo.jpg

Fitted to engine to see how it fits.
http://i227.photobucket.com/albums/dd173/Stredda/enginefitup.jpg

Now to fit the wastegate pipe! .

[Stredrotor]

After a lot of thought decided to plumb the waste gate straight off the collector under the turbo.
I know it's probably not the best location for flow but there was really not enough room to run three separate runners.

Here's the pipe tacked up.......

http://i227.photobucket.com/albums/dd173/Stredda/wastegatefitup.jpg

...and test fitted in engine bay.

http://i227.photobucket.com/albums/dd173/Stredda/testfit.jpg

Pipe welded on and wastegate fitted :D

http://i227.photobucket.com/albums/dd173/Stredda/20bmanifoldGarrettGT42andtialwasteg.jpg
http://i227.photobucket.com/albums/dd173/Stredda/ohyea.jpg

And bolted onto engine :drool5:

http://i227.photobucket.com/albums/dd173/Stredda/fittedtoengine.jpg


Next is step is to send it off to get the mounting faces machined flat.

[Stredrotor]

I got the exhaust manifold back from having the sealing faces machined flat so I have been able to make the 3 1/2 inch dump pipe, a tight fit but it clears :D . Just have to make the flanges to bolt the exhaust system to it. (When I make the exhaust system.)

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0037.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0034.jpg

After I weld the flanges on, the turbo exhaust housing, manifold and dump pipe will be sent off to be ceramic coated. Should help keep the heat down and looking good.

.....also mounted the coils

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0038.jpg

[pdxhak]

Awesome build!

[pineapplesoymilk]

good luck get some videos up when its finished!!!

[Gregory Casimir]

damn dude, that is gonna be sick!

[Proxy One]

Damn nice build, ive always had a soft spot for Rx4's and this one is sure to be the nicest ive seen.

[vincentrx7]

A bit off subject, but will a RX4 bellhousing fit a 20b? And what does a series 5 trans come out of? Nice build by the way.

[Stredrotor]

A bit off subject, but will a RX4 bellhousing fit a 20b? And what does a series 5 trans come out of? Nice build by the way.

An RX4 bell housing would fit a 20b but the later FC Turbo models onwards gearboxes run a larger flywheel so have more friction surface the clutch to grip.

Sorry, you guys know the series 5 RX7 as the second version of the FC RX7 model. It is often related to in Australia as First Gen RX7 as Series 1,2 and 3 Second Gen (FC) Series 4 and 5 and Third Gen (FD) as 6,7 and 8.

[vincentrx7]

thanks for the info. I looking for options on transmissions to hold a 20b's power.

[My5ABaby]

Sorry, you guys know the series 5 RX7 as the second version of the FC RX7 model. It is often related to in Australia as First Gen RX7 as Series 1,2 and 3 Second Gen (FC) Series 4 and 5 and Third Gen (FD) as 6,7 and 8.
We use that to. We usually just say "S5" though.

[need RX7]

Amazing. Updates? :)

[Stredrotor]

Haven't had much time to work on it lately:(. I have decided to remake the dump pipe it came a bit too close to the brake lines.

I am chasing a throttle body so I can make a start on the water to air intercooler setup.

Plus I said yes to make a 20b turbo manifold for a guy in Melbourne :banghead: but it's extra cash and I learned a few things from making mine.

[Breckboarder55]

Excellent work man! I look forward to seeing some updates.

[kbken62]

What are you going to do for brakes and rear end?

[Stredrotor]

What are you going to do for brakes and rear end?

Not sure yet, like to have a good disk brake setup.




Here's a bit of an update not much but it's one step at a time :) .

Lashed out on a Westside Exhaust and Custom radiator and oil cooler combo.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0100.jpg

Also a PWR barrel cooler, heat exchanger, filler spout and water pump I scored for a good price off ebay.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0099.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0101.jpg

Now have to make some mounts for the radiator and heat exchanger and plumb up the barrel cooler.

Getting there ever so slowly.

[Stredrotor]

Found a bit of time this arvo, so with the mounts welded on I mounted the radiator and made some trial mounts for the heat exchanger radiator.

Also had a bend welded onto the end of the barrel cooler to bring it in line with the radiator.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0107.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0108.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0109.jpg

Waiting on a 135 degree bend from plasmaman to go up to the throttle body to finish it off the intake side.

.

[Stredrotor]

Shaping the end of the tube to match the chopped off snout.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0128.jpg

Trial fit up.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0126.jpg

Spent a few hours sanding out the casting marks on the snout and the hammer marks on the tube.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0130.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0131.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0132.jpg

Now just have to get my mate Troy to weld the pipe and snout together. (Don't have an AC tig to do Aluminium)

[Stredrotor]

Hey guys, today I moved the wastegate outlet which fouled on my new radiator :blush5: .

Cut it off and shortened it........

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0158.jpg

Then welded it up!

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0170.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0171.jpg

The pipe from the barrel cooler to throttle body now welded.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0162.jpg

I made a mount for the coils. I think they should work there :confused: .

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0159-1.jpg

Here's a pic of the dump pipe, just tacked up at the moment. When I get the lower flange cut and tacked I can see if the flange will fit past the engine and steering box :dunno: .
Then I can weld that up as well. :D

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0160.jpg

[rotarycrazy]

the only problem you might experience with the coils so low is if you ever run into rain or a larger puddle getting them wet. I would make sure to make some sort of shield or something along those lines to keep them dry. Nice project so far cant wait until i can dig into my rx2 more.

[To_Slow]

Nice looking project... will be nice to see a vid of it runing ...:)

[Stredrotor]

the only problem you might experience with the coils so low is if you ever run into rain or a larger puddle getting them wet. I would make sure to make some sort of shield or something along those lines to keep them dry. Nice project so far cant wait until i can dig into my rx2 more.

I plan not to drive it in the rain as much as possible. A sunny day driver.:)
Nice looking project... will be nice to see a vid of it runing ...:)

Don't worry I'll post up a vid of it running:biggthumpup:

[rotarycrazy]

I am a worst case scenario kind of guy :D

[chrisa]

Awesome car. I can't wait to see it completed.

[Stredrotor]

Just a quick update guys, with a few jobs around home keeping me busy I haven't had a lot of time on the old girl. So while I am waiting to get a bit of cash together for the stud kit and the rotors to be machined I have managed to sneak out to the shed a few times. Wore my fingers a few centimeters shorted by sanding and polishing the intake manifold and throttle body snout.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0413.jpg

Still needs another sand I think to get a few more scratch marks out. It's not going to be any show car but I always wanted a car with an engine bay I was proud of. :D

[dr50376272]

awesome

[Stredrotor]

Just a quick update. Didn't get much done over the break, had a lot of stuff to do around the house.

But I did acquire some coil over struts and S4/5 calipers and slotted disks. :D
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0557.jpg

[dr50376272]

did you have no rust in your scuttle box area?

[dr50376272]

R/H side mount installed.....

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0943.jpg

...and L/H

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0942.jpg

Getting there

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0941.jpg

My latest purchase 60mm Tial waste gate and a GT42, ball bearing, water cooled A/R 1.06 exhaust. Now have to get in and make the exhaust manifold.:)

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0940.jpg


boy.. that whisky and cola must have set you back a bob or two !:-)

[Stredrotor]

Yea I was quite pricey but I got a free turbo and wastegate:302:

Anyway while I was waiting to get my TIG fixed I decided to make a start on removing the dash. I have a crack free replacement to go in and I need to remove the dodgy chopped loom. A mate of mine thinks he might have a unmolested one.

Dash gone.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0602.jpg

One loom with some dodgy chops
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0614.jpg

The connections that plug into the fuse box. Been getting a bit hot me thinks.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0613.jpg

Loom removed.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0617.jpg

Cracked old dash.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0603.jpg

Crack free replacement! :D
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0604.jpg

[Stredrotor]

New update :D . Purchased a Xtreme Rotaries side mount alternator kit and alternator with twin pulley.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0618.jpg

On the down side now have to modify my coil mount as there is slight fouling on the front coil. :ugh2: Oh well that's what ya get when you buy your parts one at a time.

[prrex4ever]

Luv your build, looking great!

[Stredrotor]

Bit of an update, I cleaned up the dash, rust converted and primed the dash frame. Also stripped and repainted the steel cover panel.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0633.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0629.jpg

Also after finally after getting my TIG back (well they replaced it :D ) I got around to welding the exhaust probe bung in and shaping the dump pipe to give a bit more clearance for the steering box.

http://i227.photobucket.com/albums/dd173/Stredda/007.jpg
http://i227.photobucket.com/albums/dd173/Stredda/008.jpg

Should be able to send it off to get ceramic coated now!

[Stredrotor]

Hey Guys, got my exhaust manifold, dump pipe and turbo exhaust housing back from getting ceramic coated.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0750.jpg


The finish is not as smooth as I thought it would be but it looks allright. As long as it holds on an keeps a lot of the heat in.

About half way through fabricating the front crossmember so after Monday I will have a break from my studies for 3 weeks so might be able to get a bit more done. :D

[Stredrotor]

Fabricated the front engine mount crossmember...

http://i227.photobucket.com/albums/dd173/Stredda/Front_crossmember.jpg
http://i227.photobucket.com/albums/dd173/Stredda/Front_crossmemberinstalled.jpg
http://i227.photobucket.com/albums/dd173/Stredda/Crossmember_mount.jpg
http://i227.photobucket.com/albums/dd173/Stredda/Newmounts.jpg

Should be able to pull the engine out now and throw a whole lot of money at it :eek: .

Then start paint stripping the engine bay. The fun begins!

[85rx-7gsl-se]

Wow this this is going to be incredible.

[Stredrotor]

Pulled the engine out ready to strip the engine bay.

Couldn't help myself and made up and engine stand with some scrap steel I had laying about.:coolgleamA:

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0773.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0772.jpg

[prrex4ever]

Very nice!

[Stredrotor]

Well as my holiday in Sydney was ruined before it even started by the bastard ash cloud, I did get a bit done on the Mazda.

Removed everything from the engine bay.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0774-1.jpg

Looked a bit nasty down here. :eek:
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0776-1.jpg

After a coat of paint stripper came to this.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0824.jpg

Note how this side was a different colour. Must have taken a hit once upon a time and replaced.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0823.jpg

Then got stuck into it with a assortment of wire wheels and finished of with this little beauty.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0825.jpg

And came up like this.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0826.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0827.jpg

A bit of damage on the chassis rail probably when the inner guard was replaced.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0828.jpg

Now will throw a bit of rust converted around and finish the front panel. Also when I removed the front guards found this :icon_tdown: but I will leave this for another time.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0829.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0830.jpg

[Buggy]

Those front corners are a common spot for rust. I had to replace mine as well. They actually aren't hard to replace. Just takes some time, a welder, and a BFH. :)

[Gregory Casimir]

pretty

[mazpower]

Very nice!

[DriFD3S]

keep up the awesome work! Looks amazing!!

[mattallac]

well to start the build is awesome so far , i have a 73 rx2 2 door with a turbo and i have a couple questions ,1 i have an s5 trans also, how do you do the shortened shifter housing mod and 2 how do those pwr heat exchangers work compaired to a normal intercooler ?and how good are they for street use (daily driving) ?

[Stredrotor]

well to start the build is awesome so far , i have a 73 rx2 2 door with a turbo and i have a couple questions ,1 i have an s5 trans also, how do you do the shortened shifter housing mod and 2 how do those pwr heat exchangers work compaired to a normal intercooler ?and how good are they for street use (daily driving) ?

This is a quote from Bumpstart from Ausrotary....

remove the gearstick
take the cover off the side of the extension housing, and withdraw the grub screw that holds the shifter cup socket to the inner selection rod
remove the shifter assembly from the back of the box
( undo the bolts holding it to the rear of the box )
remove the outer tube..
( it should pull out with rubber seal on the end )
the shifter assembly will have several sets of bolt holes which attach it to the box
the idea is to cut away from this extension housing the entire front set of holes
and move the entire shifter assembly forwards onto the next set of holes
( everything moves forward one set of holes as the front pair are cut off just forward of the next set of holes )

now, the outer tube need shortening this same amount.
( cant recall the dimensions, its been a while , but its easily measured )
hacksaw will do...

now, the inner rod ( that's normally inside the outer tube )
requires this same length removed
and a new hole drilled and tapped for the grub screw
( to hold the cup socket which is the bottom of the shifter )

re - assemble.....
the shifter should now be over the top of the rear of the box
( and not behind it )
pretty easy to do, not easy to picture without some pics...
( and buggered if i am dragging mine out to take pics )

measure twice, cut once

The distance you cut it will be the distance the housing is moved foward, which is in this case the distance between the front and rear hole centers.

Hope this helps.

[Stredrotor]

Holy Shit! Nearly 12 months since last update. :eek:
Well I've had a bit on the go with a few home projects, work, family and serious case of CBF at times.

In the meantime I purchased a Toyota Hilux diff with the mounts already at the correct width for my RX4 with the axles machined and drilled for 4 x 110 studs and SV RX7 disks.

I removed the old diff and as you can see it was painted purple. Only on the rear side and over dirt, grease and grime. :gay:
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1504_zps0ae2d0a1.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1505_zps96824177.jpg

I went to test fit the Hilux housing and found the holes used to locate the housing on the spring spigots was too small. :wallbash:
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1496_zps87a7867f.jpg

So off to the local tool supplier and bought a 29mm hole saw. I cut a hole in a scrap bit of flat bar and then tack welded centrally around the hole on the housing.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1498_zpsc2653605.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1499_zpsa5d4e77a.jpg

I took the center drill out of the hole saw arbour and drilled a larger hole in the spring mount.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1501_zps96af45d4.jpg

I cleaned the spring saddles and repainted them.

Did the same to the otherside then test fitted the housing. Even got to see what my Simmons look like on for the first time.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1507_zpsaf7d615d.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1512_zps28bba287.jpg

Now I am planning to duplicate the factory diff torque rods and mounts fitted factory to some rare RX4s but with some adjustability.
http://i227.photobucket.com/albums/dd173/Stredda/DiffLinks2_zps04f16997.jpg

[Stredrotor]

A bit more progress!

I have made my rear caliper brackets to adapt the RX7 calipers to fit the Toyota Hilux diff housing.

First I created a CAD model of the diffhousing, axles, bearing and housing, disk rotor and a rough model of the RX7 caliper.
http://i227.photobucket.com/albums/dd173/Stredda/CAD%20stuff/HiluxRX4DiffHousing.jpg

Then I printed a 1 to 1 drawing of the profile an cut it out of MDF.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1513.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1514.jpg

Then ground out the step down.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_1515.jpg

When I was happy with the fit I created a DXF file and had them laser cut and had a mate mill the step into them.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0006.jpg

And here is one fitted! :D
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0009.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0012.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0013.jpg

I also bought some new rubbers that go top and bottom of the leaf springs. Bought almost the last lot that Mazda had left.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0008.jpg

[Stredrotor]

I got the laser cut parts back this week so I started work on the 2 link mounts.....

This is the CAD model.
http://i227.photobucket.com/albums/dd173/Stredda/CADdiff2link.jpg

This is the mount for the chassis.
http://i227.photobucket.com/albums/dd173/Stredda/chassismount.jpg

These are the mounts to go on the diff housing.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0041.jpg

And here are they all are with a bit of a mockup.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0042.jpg

[Red Baron]

Can't wait to see the end product.

[speedjunkie]

^Me too. Should be badass.

[Stredrotor]

I found a bit of time to get some welding done this morning.

Welded up the two link diff mounts.

http://i227.photobucket.com/albums/dd173/Stredda/2linkmount_zps2cb50525.jpg
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0110_zpsc47f4404.jpg

...and the links themselves.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0114_zps44347915.jpg


Painted and fitted.:D

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0115_zps969f6a21.jpg

When I am happy that I have finished with the diff I'm getting it powercoated.

[Stredrotor]

Ok a bit of an update!

Here's my latest investment...
http://i227.photobucket.com/albums/dd173/Stredda/NewTKO600GreenBroBellhousingandTwinplate_zpsd26afa 86.jpg (http://s227.photobucket.com/user/Stredda/media/NewTKO600GreenBroBellhousingandTwinplate_zpsd26afa 86.jpg.html)

Tremec TKO 600 5 speed with Carbon Syncros, Brass fork pads and with an Ultimate Street short throw shifter, Quarter Master Hydraulic bearing, slip yoke for the tailshaft, a Direct Clutch twin plate, and a Green Brothers steel bell housing. :coolgleamA:

I have to do a little mod to the box to suit the RX7 turbo starter and fabricate a gearbox cross member, I will detail this later.

[RedR1]

im glad to see the project is still going strong. lovin it!!

[Stredrotor]

Had to make a mod to the TKO to clear the starter for Green Brothers bellhousing.

Some of this area has to be removed and a new hole drilled.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0370_zpsb6bd0479.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0370_zpsb6bd0479.jpg.html)

Marked out the material to be removed and drilled new hole.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0373_zpsc2305ab2.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0373_zpsc2305ab2.jpg.html)

Chopped! A bit un-nerving on a brand new gearbox:eek:
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0375_zps3142b10e.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0375_zps3142b10e.jpg.html)

Bellhousing back on.:icon_tup: Just need to get hold of a turbo RX7 starter to double check fit up.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0376_zpsdd569ae3.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0376_zpsdd569ae3.jpg.html)

[Stredrotor]

Just for interest, this is the difference between my old SV RX7 box and the TKO.

670mm Vs 730mm from belhousing face to shifter position. The RX7 box I had already done the shortened shifter housing mod.
http://i227.photobucket.com/albums/dd173/Stredda/SVRX7VsTKO_zpsc62648cb.jpg (http://s227.photobucket.com/user/Stredda/media/SVRX7VsTKO_zpsc62648cb.jpg.html)

[Stredrotor]

I put the TKO on the back of the 20B today and dropped them into the engine bay to measure up the gearbox cross member.
Sorry I don't have any pics at the moment as the missus is away and she took the camera and my phone is no better than a potato.

The TKO fits the RX4 transmission tunnel very well and shouldn't need any "clearancing".

I have measured up and modeled the gearbox cross member.
http://i227.photobucket.com/albums/dd173/Stredda/TKOcrossmember_zps1a91e617.jpg (http://s227.photobucket.com/user/Stredda/media/TKOcrossmember_zps1a91e617.jpg.html)

Turns out to only need a very simple design :) .

[Stredrotor]

Here's the photos of the fit up...

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0406_zpsbc315c2f.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0406_zpsbc315c2f.jpg.html)
The shifter comes out pretty close to the factory hole. (Already butchered for the early RX7 box when I bought it :ack2: ) The engine is 50mm further back than factory so normally would be spot on.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0407_zps1a7a0500.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0407_zps1a7a0500.jpg.html)
Good clearance around the firewall.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0408_zpsa457fee0.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0408_zpsa457fee0.jpg.html)
Not bad around the trans tunnel either.

As soon as I get the laser cut parts back I'll fab up the cross member.

[Monkman33]

Wow. This build is great! I really like how much fabrication you are doing on your own. And your rubber isolated transmission crossmember is great!

[Stredrotor]

I added some gussets to my CAD model just to stiffen things up.
http://i227.photobucket.com/albums/dd173/Stredda/TKOX-MemberCAD_zps5ccae91d.jpg (http://s227.photobucket.com/user/Stredda/media/TKOX-MemberCAD_zps5ccae91d.jpg.html)

Got my laser cut parts back so welded it all together.
http://i227.photobucket.com/albums/dd173/Stredda/TKOX-Memberwelded2_zps3b64b78a.jpg (http://s227.photobucket.com/user/Stredda/media/TKOX-Memberwelded2_zps3b64b78a.jpg.html)
http://i227.photobucket.com/albums/dd173/Stredda/TKOX-Memberwelded1_zps03b2447a.jpg (http://s227.photobucket.com/user/Stredda/media/TKOX-Memberwelded1_zps03b2447a.jpg.html)

Bolted in place.:cheers2:
http://i227.photobucket.com/albums/dd173/Stredda/TKOX-Memberfitted_zps1e42518a.jpg (http://s227.photobucket.com/user/Stredda/media/TKOX-Memberfitted_zps1e42518a.jpg.html)

Checked the dump pipe for clearance as well. All looks sweet!:icon_tup:
http://i227.photobucket.com/albums/dd173/Stredda/TKOdumpclearance_zps39c53257.jpg (http://s227.photobucket.com/user/Stredda/media/TKOdumpclearance_zps39c53257.jpg.html)

[Whizbang]

who are you using for laser cutting?

also, this bell housing is new to me. Is it a one off or a produced item?

[Stredrotor]

who are you using for laser cutting?

also, this bell housing is new to me. Is it a one off or a produced item?

I use a local Tasmanian sheet metal company, SERS. They do a lot of work for the Caterpillar factory I work at.

The bell housing is made by Green Brothers Racing in New Zealand, www.greenbrothers.co.nz. They build in batches as they get orders. They make a Supra to Rotary steel bell housing as well as the TKO and some adaptor plates to use the Mazda cast bell housing.

[Whizbang]

this might sound silly, but the TKO does not share the same pattern as a T-5 tremec correct?

[Stredrotor]

this might sound silly, but the TKO does not share the same pattern as a T-5 tremec correct?

Not sure:dunno: Whizbang

[Whizbang]

Not sure:dunno: Whizbang

I have T-5s laying around I would love to stick to a rotary.

[Stredrotor]

Just a small update.

Got the tail shaft done by the guys at Jayben. 3 inch, one piece.:)


http://i227.photobucket.com/albums/dd173/Stredda/IMG_0503_zps5a32959b.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0503_zps5a32959b.jpg.html)
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0505_zpsc18a2be2.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0505_zpsc18a2be2.jpg.html)

[RedR1]

i am loving this project

[Stredrotor]

Started work on the sump as the custom one that come with the motor won't fit.:cuss: I had the flange cut then started working on how much room I have.

I removed the old front engine mount cross member as I need a bit more clearance.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0513_zpsc1094705.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0513_zpsc1094705.jpg.html)
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0521_zps47ad6fcd.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0521_zps47ad6fcd.jpg.html)

Then I mocked up the lower half in cardboard.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0518_zps0e9c15e6.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0518_zps0e9c15e6.jpg.html)
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0517_zpscf3707b6.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0517_zpscf3707b6.jpg.html)
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0516_zpsb328ba42.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0516_zpsb328ba42.jpg.html)

Next to the old custom sump.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0519_zpsc260fe14.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0519_zpsc260fe14.jpg.html)

After that I modelled it up in Inventor.
http://i227.photobucket.com/albums/dd173/Stredda/Cadsump1_zps610189fd.jpg (http://s227.photobucket.com/user/Stredda/media/Cadsump1_zps610189fd.jpg.html)
http://i227.photobucket.com/albums/dd173/Stredda/Cadsump2_zps1b4ad7bb.jpg (http://s227.photobucket.com/user/Stredda/media/Cadsump2_zps1b4ad7bb.jpg.html)

Even welded it!
http://i227.photobucket.com/albums/dd173/Stredda/Cadsumpwelded_zpsecc52ac2.jpg (http://s227.photobucket.com/user/Stredda/media/Cadsumpwelded_zpsecc52ac2.jpg.html)

Should give me a bit over 5 litres capacity.

Now I just need get the lower half cut.

[Stredrotor]

Spent a bit of time in the shed last night an made a tail-shaft loop.

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0528_zps2c0c07da.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0528_zps2c0c07da.jpg.html)

http://i227.photobucket.com/albums/dd173/Stredda/IMG_0529_zpsff5a045f.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0529_zpsff5a045f.jpg.html)

I used the factory studs for the old two piece tail-shaft.

[Stredrotor]

Had a little bit more progress.

I got back the laser cut parts for the sump and tack them together for a trial fit up.


http://i227.photobucket.com/albums/dd173/Stredda/SumpTrialFit_zps36e46731.jpg (http://s227.photobucket.com/user/Stredda/media/SumpTrialFit_zps36e46731.jpg.html)

Good clearance on the crossmember.
http://i227.photobucket.com/albums/dd173/Stredda/SumpClearance_zps48e38da3.jpg (http://s227.photobucket.com/user/Stredda/media/SumpClearance_zps48e38da3.jpg.html)

But after checking clearance on the oil pickup I knew I had a problem.:banghead:
http://i227.photobucket.com/albums/dd173/Stredda/SumpPickupclearance_zps041baca6.jpg (http://s227.photobucket.com/user/Stredda/media/SumpPickupclearance_zps041baca6.jpg.html)

This is a 13B turbo pickup.
http://i227.photobucket.com/albums/dd173/Stredda/13BTurbopickup_zpsb611bc21.jpg (http://s227.photobucket.com/user/Stredda/media/13BTurbopickup_zpsb611bc21.jpg.html)

Started to design a lower profile pickup.
http://i227.photobucket.com/albums/dd173/Stredda/20BSumpPickup_zps10aa57b8.jpg (http://s227.photobucket.com/user/Stredda/media/20BSumpPickup_zps10aa57b8.jpg.html)
http://i227.photobucket.com/albums/dd173/Stredda/SumpPickup_zpsd284beca.jpg (http://s227.photobucket.com/user/Stredda/media/SumpPickup_zpsd284beca.jpg.html)

The sump will have to be modified.
http://i227.photobucket.com/albums/dd173/Stredda/20BSumpMod_zps1b89008b.jpg (http://s227.photobucket.com/user/Stredda/media/20BSumpMod_zps1b89008b.jpg.html)

And even then I will have to lower the swaybar. Might have a look at some of those anti-dive spacers.
http://i227.photobucket.com/albums/dd173/Stredda/20BSumpSwayBar_zpse32ee102.jpg (http://s227.photobucket.com/user/Stredda/media/20BSumpSwayBar_zpse32ee102.jpg.html)

[Stredrotor]

Made the sump pickup today! :D
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0581_zps9bc94da7.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0581_zps9bc94da7.jpg.html)
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0582_zpsce0f7735.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0582_zpsce0f7735.jpg.html)

[bacteria]

Awsome project!

[banzaitoyota]

Looks good

[Stredrotor]

Parts for my sump are made ready for welding! :biggthumpup:

The flange is screwed to a piece of 8mm steel plate to help with distortion, here with the sump pickup in place.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0588_zps422051c0.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0588_zps422051c0.jpg.html)

Here with the sump base and pickup cover plates.
http://i227.photobucket.com/albums/dd173/Stredda/IMG_0586_zps405d4a97.jpg (http://s227.photobucket.com/user/Stredda/media/IMG_0586_zps405d4a97.jpg.html)

Hopefully organising the welding next week as I don't have an AC TIG to weld alloy. :(