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Discussion Starter #21
A small assortment of things have happened this week...

Bonnet repair/strengthening
So I had a bit of flex in the carbon bonnet where it extended out from the molded mounting section that the hinges bolt to.
I'd long been meaning to fix it. So i finally got around to sorting this out.
Removed the bonnet, gave the areas that need repair a quick sand to scuff them up, then laid down a few layers of some scrap carbon I had.


After the resin in the repair patch had set, I cleaned it up with a grinder, sanded and painted to blend it in.


The flex that used to exist here is now long gone, really happy with the bonnet now


Clutch
In preparation for more of the powers, new clutch has been swapped in. Exedy button ceramic should do the job. These things are actually made just 15mins down the road.


Battery
Thinking about a better spot the put the battery, this might do. Moves the weight to the middle of the car, and the cables are much shorter.
Not 100% convinced this is the best spot to put it. I guess we'll see.


That sound deadener stuff
I was doing something else and got distracted, and suddenly had an impromptu desire to start hacking the sound deadener out of the car with a chisel.





I'll just need to hit it with some paint and it'll be good as new.
 

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Discussion Starter #22
I know what you were thinking.
This thread is getting boring, just another bloke with a slow MX5.

Well thankfully, Turbo bits are coming in the mail very soon.


More progress on things that are actually on the car...
Have made myself some duct work to direct radiator air out the bonnet.
Used good old painters tape to mark out the openings and give me something to work to.
Mocked up the shape with cardboard.


Then, cut out with aluminium sheet. Held together with rivets.
It bolts to the radiator with 8x M4 bolts, and is fixed to the radiator and the pair are installed into the car as a unit.
This now all needs to be installed before the intake hoses are installed.


The left side is shallower to accommodate the intake manifold. The right side doesn't have these sorts of limitations so i could curve it in a more 'open' shape.
Not immediatly obvious from the photos, but the central section actually tapers in a V shape.
You can see the holes for the intake hose and radiator hose on the left side of the duct.


Here it is installed with the coolant hose mocked up.
All the edges match up to the existing bonnet louvers so very little air will (should) bleed out.



Put the Cusco Diff together and bolted that in the car. Need to remember it still needs oil.....



I often found my heel would burn a hole in the paint below the accelerator/brake pedal. This would even result in the bare steel going rusty.
So, made myself this little foot panel. Scrap Aluminium plate cost me about $3. Marked and drilled some holes for style points and gave it a brushed look with some sand paper.



Oh and I drove an ND


Thanks to a fellow forum member and mx5er, I had the opportunity to take a demo car for a private, no obligation hoon around my local streets.
Even had the thing delivered to my door.


This particular model was the 2litre and certainly had more oomph than I expected. Although, it's smaller than I had anticipated, and with the roof up my head was hitting the soft top.
 

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Awesome work! I would love to know how the radiator venting works out. Ive often wanted to do the same type of thing, just never got around to it.
 

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Discussion Starter #27
Hello!
So update on, well, it's mostly just purchases. I've bought myself an OMP seat, now i need to try shoehorn it into the car. wish me luck as goddamn i hate the lack of space in an MX5. Being over 6ft makes fitting my stupid head under the roof far too difficult.
Also, I have purchased some LS2 coil packs. Once I get the car up and running I will sort out getting them wired up and plugged in. While I don't expect any immediate issues with the stock NB VVT coil on plugs, I am trying to do things properly and do them once. Plus the coils are really pretty cheap as every second Holden Commodore runs them here in Australia.
And have spent some cash on some silicone stuff and aluminium things to make intake/intercooler pipework. It will take a little masterchef-ery to fit around the radiator ductwork when I get around to it.

Things that I have actually been doing.....

Diff Bushes
So to go with the diff update from my last post, here's some GarageStar diff bushes to stiffen things up.
Little did I know, I could get them from OMGpham, almost made the mistake or ordering direct from GarageStar instead of helping out a fellow aussie.
Pretty easy to swap in. The hardest part is certainly getting out the old ones. I lubed them up with some WD40 and then went at it with the drill to loosen up the rubber center, then taught them a lesson with a chisel and hammer to knock the things into submission (and knock them out of the diff).


Turbo Is Here
NitroDann has very graciously delivered some nice birthday goodies to me. A manifold and downpipe to go with my S14 turbo.
He helped me out and of course knows how to make a turbo MX-5 go fast without qualms of reliability so I am pleased to run his work on my car.
The downside is, now I have no excuses for not having the car running other than my lack of time.
I do like the subtlety of the low mounted turbo, and the efficiency in the downpipe design is a nice benefit also.



Wing
Lastly, a sneak peak of the new wing designed and CAD drawn by myself and lightyear. Water jet cut 12mm alloy is not cheap. If you know someone who can do it for a reasonable price, please let me know.
There is a foam core to go with this, that should hopefully appear next week. Then we will need to put it all together.
 

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A lot of good stuff is happening here. I'm too curious how that rad duct works out. i was planning on doing something similar since the reroute frees up a good amount of space.
 

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Discussion Starter #33
Went to a Sunday morning car meet a few weeks ago which was down the road from home.
Was impressed with how 'lamborghini-like' this Lotus was with the wild wing and the huge tyres.... the colour was pretty awesome also.


This thing was also very impressive, a mostly home built GT40 replica. Everything was very neat and meticulously built.


Bought a new (proper) seat for the track car. It's not easy finding a seat that will fit properly in an MX-5, particularly given I'm over 6ft.
This OMP showed promise with dimensions not too much larger than the old Sparco.


Making the seat fit, with half decent headroom, I decided to cut the floor.... sooo it doesn't look so neat, but trust me on this.


Seat goes in nice and snug. I haven't yet finished mounting it up, but its pleasing to finally have a seat thats actually got some comfort


I've now mocked up the pipe work to the intercooler. (please excuse the horrid photo)
I'm running 2" tubing from the turbo the the cooler. And 2.5" from the cooler to the throttle body.
For the hoses on the exhaust side of the motor, I've purposefully gone around the radiator duct as much as I could. The the hose to the throttle body however will run a directly through the duct.



We picked up a new car....


So, despite what I mentioned in a previous post about the no obligation test drive of the ND, here's our new White 2.0l ND for my number 1 lady to daily drive.
I promise it's for her and not me.


Oh and them feels when you come back to your car to find an SP parked next to it.



......so yeah, 3 white MX-5's in the garage now.
 

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Discussion Starter #35
So we had our first trial with making the new wing.

The alloy plate is used for mounting the wing to the car, and for the wing endplates to attach to. However for this first test we decided to use some plywood as the plates cost about $50.


Weighing the foam core, it was under 290grams. (0.6pounds). We also used about 1.5kg of resin. The wing was cut to 1.4m span to match the car it will bolt to.


For this test piece, we opted for a few layers of fibreglass, a layer of plain weave carbon fibre and some strategically placed carbon offcuts for strengthening.
You can see our plywood end pieces in place


After layup, the wing was wrapped in plastic and returned to its original block to help with holding shape.


The whole block was placed in a bag. Vacuum pump hooked up. Start sucking.


After a few hours, we went to check the progress only to discover that the heat of the curing epoxy had exceeded the limits of the polystyerene. The end result was a very warped part.


So we need to find an alternative foam, or change the choice of resin, or change the process to reduce the heating effects... or some other alternatives which we have not pondered up yet.
We trialed the strength of the wing even in its deformed state. With near 200kg static weight in the centre of the wing, it did not flex, however any more than that and the wing started to fail.

Nonetheless, it was a good test.
 

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Discussion Starter #36
Just a small update on things that aren't my car.

Had a visit from a 300+hp NB recently to help make an airbox and bracket for the COPs.
It was certainly interesting to get up close to a car running a turbo setup not too dissimilar to what I plan on using. Albeit this car is a little more beefy in the engine department.


Also visited Sandown raceway with the lightyear for a weekend of the state championships to enjoy the smell of fuel and rubber in the air and for an opportunity to get some inspiration and ideas on how to change/improve my own car.



With aero always on the mind, I really liked the many details of the Audi R8's. The design of the front end was awesome. One of these was for sale for only $150,000aud.


This sports sedan with its body removed offered a close up view of some sexy details not normally seen.

 

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This thread is proper keep it going. How are you liking that supercharger? I think I'll eventually go with a turbo but I have always been a fan of how it just feels like a bigger stock motor rather than having a little lag but the turbo route is cheaper so I'm leaning that way.
 

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Discussion Starter #38
This thread is proper keep it going. How are you liking that supercharger? I think I'll eventually go with a turbo but I have always been a fan of how it just feels like a bigger stock motor rather than having a little lag but the turbo route is cheaper so I'm leaning that way.
Thanks for the kind words.

Supercharger is going really quite well. The power level is certainly suitable for a street car, and there seems to be no effect on drivability. Good linear power.

For the sort of driving this car does, it's great. The fact that I can reverse the install back to 'stock' if I ever need to is also advantageous.
 

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Discussion Starter #39
I forgot to post up the video i made of the wing.


So needless to say, attempt 2 was much better than attempt 1.
This wing is strong, weighs about 2.7kg (~6lbs) and works well on the silver NB.
The gurney flap was cut down to about 4 or 5mm.

We will hopefully make another wing soon, however there is a good chance we may try a different method again.... and make a wider wing.
 

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I'm at work right now so I can't see your youtube video.
but what material did you end up using? (and what material did you start with as foam material?)

Love this project man, the diy is great!
 
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