Project Rexy (Car content - 56k warning)

B3rni3

New member
Hey guys there wasn't any section relating to cars and bikes and such so I put this here so if it's wrong I apologize.

Ok then I said I would post this here as some people may find it interesting.

When I started driving I had an old VW polo. I wanted to make it special for me and mod it just the way I would like it, I even researched loads of parts when i was bored at night. After about a year of saving a different car caught my eye, naturally one I couldn't afford but had to have. I saved up for over another year and bought my current car that I have 5 years. I have been slowly doing work on it with some minor set backs but mostly gains so here is a little project log of it so far hope you enjoy.

A few pics to start this thing off, when i first got the car.

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Shortly after i got the car it sprung a coolant leak. So had the car gone for a few days while the offending pipe had to be found and replaced. Soon after that i got the car back. A few months after that the clutch slave cylinder sprung a leak. Fixed that and back on the road.

About a month after that the clutch fork snapped leaving me stuck in town late at night, not the most pleasurable experience.

Anyway I got that fixed and was saving to get all the bits i wanted for a good single turbo conversion when the engine wiring loom decided to go caput. I put the car into a reputable garage who shall remain nameless, they said they had a very good auto electrician and could sort it. So 3 months later and me raging at this point I got the car back with minor issues with the car. I was just happy to have the car back so put up with the minor things. In hinde sight not the best idea.

My savings took a dent but soon were back in the right direction.

Xmas 2008 comes and the worst thing has to happen. Engine went in the car. Seriously depressed at this stage and considered selling it numerous times over the next month.

Handed the car out to a guy from irishrotary who is now a friend for an inspection and he confirmed that the engine had thrown a tip. So I took a few days to see if i could afford a rebuild and if I would even do it or just sell as is or do a cheap rebuild and then sell. I finially made my decision and decided I liked the car too much and I'd keep it and rebuild it properly. So I gave Fiachra the green light for the rebuild.

A few weeks later the engine was out and stripped and inspected. The engine had been rebuilt when I bought it but the parts used were not what I wouldd call of rebuild standard. They can be used but to do it right meant replacing or the very least re-lapping them. The cause of the failure was due to the engine using too much oil to lube the tips and the low oil level sensor being broken so the engine went a little low on oil and one sharp corner on hard acceleration meant no oil went to the tips causing them to stick, break and the bearings to break also.

So I got my list of parts which was long and placed my orders. I decided that this would be the right time to change a few bits for better parts ie cooling system and ecu etc. Also as I had so many problems with the car in the past I decided to replace as much of the aux bits and pieces I could afford and source. Things like sensors, intake piping and water pipes etc.

Here is a quick list of all the parts that I got.

New rotor housings x2

New rotor x1

Replaced eccentric shaft

Front side housing

Center side housing

Rear side housing

Full o-ring kit

Full gasket kit

full rebuild kit

New oil pump

New water pump

All vacuum pipes replaced with silicone ones

Check valves replaced with newer better ones from a guy in the states

Engine wiring loom replaced

Dash wiring loom replaced

Engine mounts replaced

Replaced all offending sensors

Replaced sump

Replaced the twin turbos for lower millage ones I got at a bargain

So many other small bits which I will post pics up and show a picture of the mazda invoice too. That makes me sad looking at the total everytime.

Aftermarket bits

Power fc ecu and commander

Koyo rad

V-mount intercooler

Samco intake hoses

Samco radiator hoses

Hks downpipe

Magnaflow resonated midpipe

Apexi n1 cat back

Sard 850 cc injectors x4

Denso upgraded fuel pump

Intake street ported 3mm enlarged

Exceedy single plate clutch not sure which one

Battery relocated to booth

Defi water and boost gauges

Drilled and grooved discs

Hawk hp+ pads front and rear

Stainless steel clutch line

Stainless steel brake lines

New sealed battery for booth

Upgraded brake fluid

Greedy intake elbow

Removed during rebuild

Air pump

Catalytic converter - This car is exempt from emissions testing over here.

Air conditioning

Removed double throttle butterflies

I got the rebuild kit but the water seals had split slightly,they could have been used but better safe then sorry. So had to get new ones off mazda.
 
Heres two pics of the invoices.

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Right after a few weeks of sourcing and buying parts work could really begin.

Pic of the engine in but no aux parts fitted.

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After a very long time I finally got the car back be it still with a small snag list of issues but it was back. Over the next few weeks I was running the car in I got the small snag list fixed in Fiachras free time.

The next step was the long running in period of being limited to light throttle and 3k revs.

I quickly raked the millage and oil changes up and soon was ready for mapping. I booked the ferry to england in oct 08 and before I went I changed the oil, filter, plugs, fuel filter, gearbox and diff oil. So the car was now ready for its trip to London and to get mapped.

I must say being stuck to 3k revs on english motorways in a sports car is hell. The car got there with no hassle at all, I am so glad I changed alot of small things. Stayed in my sisters house and a few days later I got the car mapped (not going to mention by whom as you will find out later why not). First drive was unreal. Shit my pants unreal. Boost was upped to 1bar on second turbo and .85 on first. the drive home was done very quickly.

Since then the only problem I have had with the car mechanically and electrically is a failing tachometer (common rx7 problem and a bracket holding the rad not being up to the job but nothing major).

Since then I have been a little busy but nothing too major. I bought a 99 spec rx7 front bumper of Joe on irish rotary and a carbon fiber splitter and a set of tein flex coilovers. Got them fitted and was well pleased with the result

Last thing i did was got the wheels reconditioned by wheel doctor winter 2009 as part of the group buy on another car site.
 
Since that there was some trouble however. Summer time 2010 my engine decided to pack up again. This time we believed it was due to a poor map causing detonation which broke the rotor tip. It could not have happened at a worse time because I was saving up for a few cosmetic bits and when I had purchased them a few days later the engine went. The parts in question arrived fairly quick and here is a few pictures of them.

diffuser

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diffuser with center diverter

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vortex generators

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side steps

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These were bought to compliment the carbon fibre front splitter and the colour of the wheels.

Shortly after I bought my second rebuild kit as per the pic below.

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In the mean time I had fitted the above parts.

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I had to modify the diffuser slightly to fit with the exhaust.

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While I was waiting on getting the car out to Fiachra again I bought some more goodies.

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A two stroke oil injection converter for the engine to run two stroke injection to help lubricate the engine better.

And a water injection system for the intake to cool the intake temps and help stop detonation on full boost.

Some pics of the side skirts fitted.

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Next I got the car out to Fiachra and we stripped it. I got lucky as the damaged tip did not cause too much damage on its way out of the engine.

I got a replacement second hand rotor which matched my other one weight wise and a new clutch plate. I also got a new intake temperature sensor which reacts faster than the stock one.

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Engine after disassembly

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Main engine block

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Rotor after a bit of carbon removed

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While waiting on some parts to arrive I got the intake pipes and brought them home. I did some filling down of the welds and prepped them for paint.

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Some more parts painted including the intercooler and throttle body. I ran out of paint and when I went back the next lot of paint was not quite the same colour which annoyed me but when fitted you would not notice it.

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intercooler in different light

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with samco piping

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Did a test fit in my spare room.

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While waiting for the various parts to arrive no work had been done on the car and it was sitting for a few weeks. Some mess ups with bad parts and having to send them back cost me a lot of time. When I next went out to the car to paint the engine bay it looked like this.

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At this stage I was almost in tears seeing my pride and joy in such a bad state. The paint did not last well over the winter break we took because the roads were too dodgey to travel. The first few jobs I did was remove the rear lights to do a 99 spec rx7 conversion to them and mask up the engine bay and also remove what I could which was not much.

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After doing that I had not much time because of the weather so I went home and proceeded to do the light conversion.

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And finished. Took me about an hour in total to do both lights.

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