More tasks getting marked off the list - won't be long before I'll be able to wire it and start her up!

But in the mean time - Windshield frame starting to be layed out and sized - it's 1" angle stock with slots cut at the inside radius to achieve the bend - Getting this all figured out before ordering glass (decided not to do Lexan)

 

Trying to finish up the dash - I made kick-panel templates out of 1/4" ply - the panels are a 30/70 split so I can removed the larger, passenger side panel without bothering to remove the driver side piece.

[img]https://i.imgur.com/NQZdj7K.jpg[/img]


Then I re-created the shapes in metal

[img]https://i.imgur.com/KvxNAVH.jpg[/img]

[img]https://i.imgur.com/lqBxYKu.jpg[/img]

[img]https://i.imgur.com/M76UUwd.jpg[/img]



Also mounted the gauge pod and switch panel (Gauge pod isn't removable, the switch panel is)

[img]https://i.imgur.com/PXTHX1p.jpg[/img]

[img]https://i.imgur.com/53onoxp.jpg[/img]

 

More items knocked off the list:


Did some work on the cowl - needed a finish panel between the roll cage 'Dash Bar' and the firewall - this is 18ga hot-roll - I used plated M5 rivnuts w/ matching screws.

[img]https://i.imgur.com/BGIb1SU.jpg[/img]


Then worked on a cowl panel - some use rubber / mesh, I chose sheet metal

[img]https://i.imgur.com/YtQHw3g.jpg[/img]

[img]https://i.imgur.com/PdyIQv4.jpg[/img]

[img]https://i.imgur.com/dUzfhuR.jpg[/img]

[img]https://i.imgur.com/NQeOGOU.jpg[/img]


Installed the 'end caps' - same material

[img]https://i.imgur.com/q93LIGd.jpg[/img]

 

Next came finishing up the windshield frame - will be going with a glue-in piece of glass (Lexan previously was the plan - but it doesn't wear well in a DD application)

 

Completed the 'V' in between the Main Hoop back stays - regs require all intersections to be within 4" of each other - the 'bottom' ends of the tubes are 3-3/4" off the plate base

[img]https://i.imgur.com/sJZOuPK.jpg[/img]

[img]https://i.imgur.com/hfc3ZSN.jpg[/img]

[img]https://i.imgur.com/zClU8pm.jpg[/img]

 

I finished up the frame for the gun safe (See posts above - detailing the reason for adding this feature to the car) - I really, REALLY didn't like how it was looking when placed in from of the shifter - so this was the alternative location - I think I'm at peace with it.

The frame will be wrapped (similar to the dash 'kick panels') in sheet metal. The safe is secured to the frame via (3) bolts on the underside of the safe, bolt holes provided by the manufacturer.

Added below the frame work was a mounting point for the relocated cig outlet and (2) USB plugs - both behind waterproof coverings.


[img]https://i.imgur.com/wLVO4LN.jpg[/img]

[img]https://i.imgur.com/WiQamoo.jpg[/img]

[img]https://i.imgur.com/nTKStRI.jpg[/img]

 

Relocated the battery to the passenger footwell - there's plenty of space, and a planned rally 'foot plate' will be installed in front of the battery. Tacked in - the uprights and slide left / right if the form factor should change in the future - will wrap the top strap in some form of vinyl/rubber.

Not sexy - but should be effective.

[img]https://i.imgur.com/KxJyCVI.jpg[/img]

[img]https://i.imgur.com/KYhfniM.jpg[/img]

[img]https://i.imgur.com/5i4P7NN.jpg[/img]

 

The plan - drop the roller-skate off the 1999 silver tub, bolt-up the upgraded roller-skate from the red car (practically everything would transfer - minus ECU)

2002 Red Car Parts List (and the reason for all this work):

1.8L Engine w/ FM II turbo kit (Garret 2560r) - Forged rods, ported head, valve springs, head studs, comp bearings, Super Miata coolant re-route, 2.5" exhaust, Magniflow cat
6spd trans, Flying Miata 'Happy Meal' clutch kit, 14lb flywheel w/ braided lines, 'brass' shifter rebuild kit
3:90 Torsen
Piggyback ECU (sadly) w/ the 4 extra injectors
PPF stiffener Rear subframe stiffener, 'butterfly brace', Poly bushings
Big brake kit

NO RUST!! (See photos of the sub frames on the Silver car - surface rust EVERYWHERE!)


SO, the work begins:

99 Silver body up - Silver 'roller skate' ready to be rolled out! (see all the surface rust on the sub-frames? ick.)

[img]https://i.imgur.com/n6FbqK4.jpg[/img]

[img]https://i.imgur.com/TkNEVt1.jpg[/img]

[img]https://i.imgur.com/HT7hF9Z.jpg[/img]


The old and worn 'roller-skate' from the 99 - stock everything, surface rust on EVERYTHING

[img]https://i.imgur.com/pJs0OgX.jpg[/img]

[img]https://i.imgur.com/OkpJDG7.jpg[/img]

[img]https://i.imgur.com/RPUXHyS.jpg[/img]

The state of my driveway at this point in the project

[img]https://i.imgur.com/oWpUZwe.jpg[/img]

 

Next steps:

Pull the upgraded 'roller skate' off the 2002 Red Miata, then mount the 1999 Silver Miata 'roller skate' under the Red car.


Before the first cut:

[img]https://i.imgur.com/Oorozb5.jpg[/img]


Red body up, red roller skate off!

[img]https://i.imgur.com/LAjLcXE.jpg[/img]


Red roller skate out!

[img]https://i.imgur.com/5t1h05v.jpg[/img]


The driveway at this point in the project

[img]https://i.imgur.com/nbbJoWt.jpg[/img]


Then I split the silver roller skate, pulled the motor/trans (for resale)

[img]https://i.imgur.com/oyBcRxu.jpg[/img]

[img]https://i.imgur.com/UeqcudI.jpg[/img]

Next was mount the silver sub-frames to the red car (so it can be rolled under a tree, perfect part-out 'donor)

[img]https://i.imgur.com/4A7HC6r.jpg[/img]

 

Next steps - got the roller skates swapped and bolted in - on to the wiring!

Got the harness I removed from the 2002 layed across everything and hooked up - grounds held down with C-clamps, fuel tank propped up with a piece of wood - seems legit, right?

[img]https://i.imgur.com/FDaxJwx.jpg[/img]

[img]https://i.imgur.com/43utZw9.jpg[/img]

[img]https://i.imgur.com/L4BDJ2a.jpg[/img]

[img]https://i.imgur.com/2jrtWdB.jpg[/img]


Well, success! Started within the first 5 seconds.


So - with that verified, I moved on to splitting up the factory wiring harness - fingers are sticky and stained black - but got everything (pretty much) stripped off, just down to the wires.

 

Alrighty - updates!

Picked up wrecked 01 - VVT, 6spd, Torsen, Hardtop - Good deal



Also, picked up some 15x9's - I don't have coilovers yet, don't want to venture any wider until suspension is updated / adjusted:

 

Wrapped the gun-safe frame - used 16ga hot-roll - pretty happy with the result - still need to clean up some corners, but not bad:

[img]https://i.imgur.com/gQAMiRv.jpg[/img]

[img]https://i.imgur.com/GmZlrkG.jpg[/img]

[img]https://i.imgur.com/4dk3uBs.jpg[/img]

 

On to the radiator / intercooler.

If you remember - This car originally was a silver 1999, no turbo - so the front bumper / rad support was designed with that in mind. Fast forward a couple months, I got ahold of the red 2002 with the turbo (which I stole the roller-skate from) - so the kart needs an intercooler now - therefore requiring a bit of a re-design.

Picked up a good ebay unit - 'V-Mount' (over-radiator style) for piping simplicity, and I like the aesthetic. Messed with the arrangement a bit, then locked in both units with clamps and wood spacers above/below/between (to maintain clearances):

[img]https://i.imgur.com/LBKsrk6.jpg[/img]

Using some 1/8" plate, I created matching brackets:

[img]https://i.imgur.com/NtLTQkb.jpg[/img]

[img]https://i.imgur.com/nIWqmr6.jpg[/img]

Overall I was pleased with the strength of the system, but not the look. SO, pulled out the grinder and did a slight re-design.

[img]https://i.imgur.com/vCUKHET.jpg[/img]

 

Ended up cutting back the plate that secured the pegs on top of the radiator - then used some steel pipe (cut about 1/2" tall) that were sized to friction-fit over the rubber caps that fit over the radiator pegs - overall, the new brackets look much better (personal opinion) and still maintain the same strength:

[img]https://i.imgur.com/BQcK3WA.jpg[/img]

Adding the intercooler made all my clearances FAR tighter - this required the purchase of 'slim' fans - 1.5" thick - ended up with the style that zip tie through the radiator core

A radiator relocation to the rear of the car might happen down the road - at this point I wanted to keep all the plumbing simple.

[img]https://i.imgur.com/tvAld7t.jpg[/img]

 

Moved on to the aluminum piping and couplers next.

[img]https://i.imgur.com/Sm7YGWE.jpg[/img]

The odd thing I had to tackle was retaining the Flyin Miata Bypass Valve. This unit has a 1-3/8" inlet/outlet - but I was unable to turn up a 2.5" 'T' with a 1-3/8" off-shoot.

SO, I went with a 'Type-S' BOV style flange, then bought an adapter plate that mounts to the BOV flange, but has a 1-3/8" outlet. Goofy, but it works.

Not entirely sure if I like the location of the 'hump' couplers - but they're the only location that has (initially) made sense.

[img]https://i.imgur.com/vBwgEds.jpg[/img]

[img]https://i.imgur.com/khJb30g.jpg[/img]

[img]https://i.imgur.com/Csctu9w.jpg[/img]

 

I really like the over-the-radiator approach. I may have to steal your idea there.

 

Thanks man - steal away!

I had a MP62 setup, the intercooler piping worked the same way. I like the simplicity - and with everything exposed (no body work), I think it looks cleaner.

Some say there's a benefit of less cu ft. for the turbo to pressurize for boost - but honestly I think *any* gains are negligible (but it starts great fights on forums!!)

 

Have made lots of (small) progress - getting me MUCH closer to the first test-drive (it won't be 'street legal', but will help me verify that everything is working as it should)

Completed:
_Replaced exhaust gaskets
_Timing Belt / wp / idlers / etc, etc
_Reinstalled ALL the wiring harnesses, got the car idling well, verified that everything is up, running and working
_Re-Routed the lines for the battery relocation (up to the passenger footwell)
_Re-Wired in the Link ECU and O2 signal modifier
_Finished up the seat backets
_Mounted the 5pt. harnesses w/ new anchor points where required
_Reinstalled the fuel tank (properly) with all fuel lines / routing done
_Drilled / Mounted the driver seat
_Installed the quick disconnect hub and steering wheel

Blah Blah Blah.


Here's what I DON'T want

[img]https://i.imgur.com/UCebtfl.jpg[/img]

 

Looking good. Planning to add door bars?

 

Yes siiir!

I've been trying to complete as many things off my 'to do list' as I can BEFORE putting in the door bars - Once the door bars go in, the accessibility gets cut to nothin!

On that topic - been having a debate with myself - original plan was an 'X', but I've seen some neat Nascar-ish hybrid designs - along the lines of your Eliminator - not sure which to pursue. I'd like to keep it race sanctioned.

So yeah - not sure which way I'll go!



This is what my list looks like for 'after test drive' :

_ 3rd Brake LightBracket
_ Seat-back braces on roll cage
_ Final weld entire cage
_ Mount turn signal stalk, gauge pod, gauge hood
_ Door bars
_ InstallSide mirrors
_ Buy / Install Rear view mirror
_ Roll Bar Padding
_ Passenger Foot Rest / Battery Cover
_ Clean up at fenders / body frame rails / Holes in engine bay / defects around chassis / holes in body
_ Rear spoiler / wing- Mounting System
_ Panel insert mounting tabs
_ Buy / Install windshield
_ Install cup holders
_Create Hanging System for Muffler
_License Plate Mount
_ Strip Wire Harness (remove tape / coverings)

_ Wire-in switches @ center knee panel:
Hazard
Accessory
Start-Button
Turn Signal Switch
Horn Button

_ Wire-in tail lights
_ Wire-in head lights
_ Wire-in Third brake light
_ Wire-in license plate light

_ Wire-in all gauges
Boost
AFR
Oil Pressure

_ Temp. wrap wire harness (run for year)
_Door Bar panel inserts - Smoked Gray - Lexan
_Flock dash panels (?)
_Front bumper tube end caps
_Heat Insulation – firewall / transmission tunnel (?)
_Arm Rest
_Engine bay strut bar
_Diffuser at rear bumper
_Front / Rear fenders
_Relocate radiator to rear of car
_Panel / Covering at fuel tank
_Oil Catch-Can (?)
_Pedals w/ Grip Tape
_’Wire Tuck’ engine bay
_Engine bay – clean, paint, powder coat, bolt heads, etc
_Paint / Powder Coat
_Beauty Tray at radiator / intercooler (?)
_Beauty Cover at spark plugs