Yup I think that is the cleaner solution. Just need to get some more 4001 diodes once radioshack opens.

:brain: :party:

So the good and the bad news.

Good:
My wiring wasn't the cause of my engine suddenly not turning over. After reviewing all of my wiring several times, I couldn't find the issue.

Bad:
So, seeing that there were no issues with the wiring, I started pouring over the rest of the engine bay to see if something had broke, I had knocked a connection loose, or something to indicate the problem.

So while I was looking at my alternator, I noticed that the alternator post wire seemed loose, so I went to tighten it and the hole thing snapped off the alternator. Unfortunately including the terminal/post. I was using a 1/4" socket wrench and to ensure I didn't over-torque, I was holding it by the head of the wrench. The post must have already been damaged at some point.

Hopefully I can find a shop to weld a new post on tomorrow and get the engine started after. I must have damaged it while I was removing the oil pressure sensor from the engine. My own fault, but at least I now know why the engine wouldn't turn over, which is comforting.

Picture of said sadness

https://www.miataturbo.net/attachmen...ine=1397641446

Make sure to take the internals out for them, they might not weld it otherwise. Or buy new. Would be sad to turn in such a pretty alternator for a core.

Yeah I already removed it. Wish I could just get a new core and keep the housing.

Shouldn't be too hard for them to weld it so I can re-thread it for M6x1.0.

Jeff that's going to be a tough one. There are a couple of things that might be troublesome...

1. There is a nylon isolator around that post so it doesn't ground out to the housing and that's absolutely going to melt unless it's removable.
2. In order to weld that they'll need to clamp the ground cable to something of the same polarity on that alternator and there isn't much to work with.

This sounds strange but if you're really trying to keep that alternator and that post is not a serviceable part - your best bet might be to drill and tap it. Then use a bolt and a washer to keep your lead in place. I'd use your judgement on weather or not you have enough material to do so.

Second possible solution - locally we have a place that rebuilds alternators and I'm sure they would be able to re-use the housing. Maybe you have something similar near you?

This sucks considering you recently put a new expensive bearing in it...

Dibs on the new bearing if you replace the alternator though :wavey:

Idea:
1. buy a new alternator and pay the core charge, take it home.
2. swap the housings
3. return your old guts in the new housing and get your core charge refunded.

+1. Just don't return it as new/unused. Not that I think you would do this, but I got an alternator for my truck from a FLAPS where someone did this. I was not a happy camper.

Right, definitely. You're retuning old guts/new housing to get your CORE charge refunded, not the whole purchase price.

The fun part is where they accused ME of doing that when I tried to return it. It had a "Lifetime Warranty" so I just made them test it, listen to the crunchy bearings and give me a new one anyway. :jerkit:

His guts aren't bad, the housing is.

The stud actually comes off the internals sadly.

Any way to solder a new stud in there?
I can't quite remember how it physically connects.

for something you are torquing a 10mm nut onto, it would be to weak of a connection to use solder.

I actually got really lucky on this one. There isn't an alternator rebuild shop here in town but one of the shops down here whom I'm good friends with, recommended me this guy who had just retired and had been doing it for 20+ years.

Called him up and he said he'll have a new stud on for me tomorrow and rethread it to m6x1.0 for me as well. When I brought it by he said he'd resolder all the copper joints on the internals and replace the brushes for free as well. Very nice older gentleman, pretty much had an entire alternator repair shop in his garage.

This is yet another reason why I try to make friends with people rather than meaningless financial transactions. They will go above and beyond for yah when you are nice!

Here is the original stud for those who are trying to remember how it connects to the internals.

https://www.miataturbo.net/attachmen...ine=1397689793

Obviously... I assume the stud threads/presses/fits mechanically and electrically connects through metal junction.

Good to hear you found a simple solution :)

Decided to distract myself a little until my alternator gets done. I was always less than happy with the lighting inside the Miata. Seeing anything is a laugh, let alone trying to find something on the floor.

So instead of making a visor blank I decided to hack it up and install an LED. I had some spare plastic from an old side marker on my Jetta laying around, so I cut a circle out of it, and then cut a matching hole. Then spent way way way to long getting the plastic to be flush with the visor plate. A little epoxy to seal the plastic so no light bleeds through the edges and a ghetto mount for the light later, and we have brilliance! Everything is easily visible inside the car.

It isn't perfect looking even after polishing the plastic for 15-20 minutes, but it works, it's bright, and unless it was pointed out to you, you probably wouldn't notice. Far cheaper than anything aftermarket out there. $5 for the LED, scavenged light socket from the old car, $2 for an inline fuse, and soldered to the contact points on the passenger footwell lights.

https://www.miataturbo.net/attachmen...ine=1397736351

Also put the Rennenmetal hardtop bracket on in preparation of the hard top being done today. Decided to use the stock bolts rather than the ones provided with the brackets. I like the gold zinc rather than silver hex bolts. I'll probably trim the plastic around the bracket OR cut up a spare trim piece and make a cover that will velcro on for easy removal to really hide the bracket.

https://www.miataturbo.net/attachmen...ine=1397736351

Also put a new LED inside the footwell light. Talk about a powerful LED! I may have ordered an unnecessarily strong one, but no complaints.

https://www.miataturbo.net/attachmen...ine=1397736351

Light difference between stock and new is very apparent.

https://www.miataturbo.net/attachmen...ine=1397736351

So much light it even lights up the drivers side!

https://www.miataturbo.net/attachmen...ine=1397736351

That was a fun little mod, and much more useful than a blanking plate. If I did it again, I have some thoughts on making it look really clean, but for now, it ain't too shabby.

Where's my coupler?!?

:rofl:
Lovingly making both coolant pipes Polar Bear Brothers. The fit was absolutely perfect and it is obviously going to do a better job than my busted ass, probably-going-to-rust, coupler.

https://www.miataturbo.net/attachmen...ine=1397739683

I totally forgot I installed it, luckily I got a picture before I did!

So it looks as though I may have been a little lucky that I damaged my alternator. The repair guy called and asked if I knew my main bearing was toast...apparently the main bearing which goes just below the brushes(and the one I was to scared to remove) sounded terrible. Luckily he said he had a couple new 800 series bearing sitting on his desk, so he will replace it.

Plus he will completely reassemble it for me as well as resolder all the copper wires, seeing as several were loose. I'm glad he is reassembling the unit, that way I know it was done right!

Nice! Sounds like you dodged a bullet there!

Did you ask him what kind of beer he drinks? This guy is worthy.

Cool.

If the guy won't take cash payment, find some other way to compensate him. A lot of older people just want some human interaction, so maybe take over a sub and have lunch with him. Anything to show your appreciation.

Yup, blessing in disguise for my rampant stupidity!

Seriously. Next time I head down to St. George I'm bringing him a ton of bread and some quality beer.

Maybe he prefers Utah beer...obviously not the 3%abv crap you find in the grocery stores here in this blessed state.:facepalm:

https://www.miataturbo.net/attachmen...ine=1397752295

How about a ride in the country's finest NA? I let my aunt's new husband drive the Silver car (he's in his 90s). He's still talking about that.

I really love finding these kinds of guys that have these skills and tools, its seriously becoming a lost art. I feel like a lot of these skills are dieing out in what is becoming a more and more disposable society where "No User Serviceable Parts Inside" stickers dominate and the threat of litigation prevents people from exploring how things work

</rant>

Nice job on the LED's. I did something similar to the gauge cluster on my '74 pickup. Now I can finally see how fast I'm going in the dark :rofl:

Well looks like the silver lining has a corroded core...

Just got a call back and said once he started to tear into it he noticed it had been rebuilt once before, and not very well. He said after rebuilding it, and testing it on his bench, the regulator and rectifier are shot.

He asked how the hell was I even driving with this, since it was barely producing any charge at all, and that is after almost completely rebuilding it as well.

Sigh....well looks like a new core in needed after all! Luckily he said he won't charge me, but I offered to bring him some bread for recompense.

Normally I'd be suspicious that he caused the damage, but the shop owner who recommended him is not one to associate or do business with people who do poor work. Who knows if I damaged it when I removed it from the housing or not. I'm not going to point fingers, just fix the underlying problem and move on with my life.

This sounds like act of gratitude from the early-middle-ages.. I like it.:rolleyes:

He wouldn't take my money!

When cutting my re-route chevy hose i used a sink pipe. It was very difficult to get it to fit in the hose but with some strength and a little lube it is snuggly in place. Looks purdy too. It's no custom curly fitting and it's diameter is a little too big but I was having difficulty finding anything I liked in the right size. Also it's brass so no rusty poo poo.

https://www.miataturbo.net/attachmen...ine=1397760692

Am I the only one that keeps their visor anymore? lol When the top is down and I dont have a hat it works great at blocking the sun from burning my head/face.

Mine are still there, mostly because I'm short and they don't bother me that much. Taking then out without plugging the holes would drive me crazy, though.

First 24hr period without a jeffbucc post? Anyone call emrg3ncy response?

He's probably on a sleeping binge...

I still don't understand why you went through all this effort over a second hand alternator. Is it just because you had the housing powdercoated or whatever?

Imo, just buy a new OEM one, or a just a used OEM one and clean it up. Used ones (that work) can be had on this forum for like $30-45. Then just wire wheel the shit out of it until it looks nice, spray rattlecan clear over it, and it should look pretty damn nice.

:2cents:

I'm only 5' 11", but for some reason they were always in my line of sight. I honestly always forget to use them unless I happen to be driving right as the sun is setting, which I usually try to avoid due to my eyes being sensitive to light after I had Lasik done.
A combination of several long naps, taxes, new employees, and bills made me take a little hiatus!:crx:

At the time I didn't know the alternator was already rebuilt, so I saw no point in replacing it with a new one. I thought it was worth the shot of rebuilding it before ponying up a lot more money on a newer unit.

I'm currently waiting on a new alternator to ship to the shop, hopefully next Monday it will come in.

===

Trying to finish up the rear mud flaps and finish little bits and bobs until the alternator gets here. This took a long time to get right.

After I cut it I had to find some way to pull the flap up to the body otherwise there would be a 1/2" gap between the top of the curve and the bumper. So I took a heat gun to it and slowly applied heat until it was pliable enough to bend into place, and hold it in place till it cooled enough to retain its shape. Then, I put a few skims of bondo on some of the deeper scratches, sanded out the smaller bumps, and painted it with this awesome awesome rubber bumper paint. Much more durable than just paint, it is very flexible so it won't chip, AND best of all, no plastic adhesion promoter needed.

I have only done one side because I want to make sure I'm happy with the result before I put that much effort into the other side. Bondo, as some may know, takes a long time to sand if you want it to look nice.

Going to let it cure in the sun for a couple hours before I try mounting it up. Going to use a little 3M trim double sided tape to make sure it stays flush with the bumper.

https://www.miataturbo.net/attachmen...ine=1397928464

https://www.miataturbo.net/attachmen...ine=1397928464

:rofl:Also I made a duck shadow with the first picture!

:bowrofl:

It's a sign from the gods that you should replace your MS with a dual powercard setup.

I thought MS was the end all be all? I don't even know what the hell a dual powercard setup is!

===

Mounted up the flap. As you can tell from the picture I trimmed the top of it(by the lip) just a wee bit too much. If/when I do it again, ill probably fix that and make it even more flush by tucking the edge under the lip eliminating the need for 3m tape.

Not too shabby though, I can live with it.

https://www.miataturbo.net/attachmen...ine=1397962916

https://www.miataturbo.net/attachmen...ine=1397962916

Did you convert your long mud flaps to short ones? If you did, wow that looks good. Do you have any side shots?

I think the rear lip gives the illusion of it being shorter, I honestly don't know if it is a short/long flap.

Here are some side shots for yah.

https://www.miataturbo.net/attachmen...ine=1397966248

https://www.miataturbo.net/attachmen...ine=1397966248

Flap #2 all finished up

https://www.miataturbo.net/attachmen...ine=1397985384

Also used some proper 2k heat wrap sheeting on the air box since I didn't have much faith in the aluminum tape, and to help block as much of the heat inferno 12" behind it. Looks much better too.

https://www.miataturbo.net/attachmen...ine=1397985384

All finished up, looks great!

https://www.miataturbo.net/attachmen...ine=1397988776

https://www.miataturbo.net/attachmen...ine=1397988776

https://www.miataturbo.net/attachmen...ine=1397988776

Just needs plates now :) looking really good better than new!

So gr8. Do you wish you sprayed the rear lip to match because Jeffbucc?

I think there are some mold flaws in the plastic(because ebay) that are a little annoying, but for now I'm selectively ignoring it. It is a small enough difference that I don't really care.

This choice is probably best for your health lol

Well this took longer than I expected. Very hard to cut and not mangle everything with the seat and roll bar in. Put a little rubber tubing around the edges to clean it up a bit.

Going to grab my hard top on Tuesday. My parents are coming down this week and hopefully their Touareg will have enough space to put it inside the car. I don't want to risk scratching fresh paint by strapping it down to the rack on my Jetta. Plus it'll be nice to have another pair of hands to help put it on.

It ain't perfect, but with the top on you can't even see it so....who the hell cares.

https://www.miataturbo.net/attachmen...ine=1398030190

Who are you, and what have you done with Jeff?

A very, ready-to-be-done, car restoration project owner.

I'm a lurker but I've loved reading your entire process. If you wanted to know, those are short mudflaps.

https://www.miataturbo.net/attachmen...ine=1398100458Long v Short NA Mud Guard by Sploinkin, on Flickr

Back to lurking I go!

Hey Jeff:

Interior Lighting Upgrade kit for second generation Mazda Miata

I think either they or someone else have a kit to put LEDs in the visor block off plates too.

so, is this thing boostin 2 barz yet?

They shipped them the wrong alternator for a totally different car. Shop owner is furious. So another day or two if I'm lucky.

I tried searching salvage yards for millenia/miata or other alternators that are known to work, but being Southern Utah, no dice.

I'd buy one outright online but the shop friend is giving me a 3 year warranty on the alternator, plus, since I have a good customer relationship with him, I'd rather get it through him rather than cut him out on the money he has earned by tracking it down for me.

And yes, I'm weird about supporting local businesses rather than some unknown source.

Hoping to be boosting as much of it as possible.

Something I did notice was my e-clip on the wastegate popped off. It doesn't seem very reliable. Do you guys recommend drilling through the actuator rod and safety wiring it together for a bombproof connection?

I just used a tiny loop of bailing wire twisted to itself around the groove for the c-clip. It's held on great so far, and you'd never notice it unless i pointed it out to you.

No you're not.

That's a very good thing and you should keep doing it :)

Hell, yes. If you don't support the one who do things like this, they don't stick around for long.

I do the same, paying more for HW at the local mom & pop place, rather than going to the big box stores. Simply because when I go in to ask a question, they actually know what I'm asking, and can usually give an informed answer. That's worth a few bucks more easily.

Lowes has some good E Clips that Ive used that stay on pretty good. Be sure your actuator is flat on the waste gate lever. It could have tension on it pulling up causing the clip to break.

This can also cause resistant and give bad boost readings.(probable)