Back From the Dead Build Thread
 

Several months ago, I decided I wanted an NB turbo project. I bought an NC new several years ago, and have had lots of fun cars that I've added a few bolt ons to, but I figured I was ready to take on a bigger project. I set up some craigslist alerts covering everywhere within a few hundred miles of San Francisco, and then I ultimately decided on this 2002 SE.

It was a write-off, sold at auction to a m.net member who was planning to use it for an exocet build. He decided he wanted to go with an MSM instead, and I managed to grab this for $2500. At the time, I thought it was a steal. Replace a few parts, do a bit of paint and body work, and then TURBO POWAH!

This is what it looked like when I started:

https://www.miataturbo.net/attachmen...ine=1419885979
https://www.miataturbo.net/attachmen...ine=1419885979

And in my ignorance I figured this wasn't too big of a deal :loser:

https://www.miataturbo.net/attachmen...ine=1419885979
http://nige.nl/Z6yf/Image%202014-12-...44.28%20PM.png

So I bought it!

That was in September, so I've got a couple initial updates, then I'll just post here as I progress through the build.

Here is a walk around video of the car as it sat when I bought it:
The known issues were:
- busted bumper cover and trunk
- cracked diff carrier case
- shot tires, one which barely held air
- flat battery (although I figured it just needed to be recharged)
- minor body and paint work

Because of the cracked diff carrier, I decided to drive it home on a uhaul trailer. It cost about $200 to cover the 150 or so miles.

https://www.miataturbo.net/attachmen...ine=1419889737

Once I started pulling the car apart, it became apparent that I had bit off a little more than I was prepared to chew.

https://www.miataturbo.net/attachmen...ine=1419890959

https://www.miataturbo.net/attachmen...ine=1419890959

Hm, I wonder why the trunk won't close...

https://www.miataturbo.net/attachmen...ine=1419890959

https://www.miataturbo.net/attachmen...ine=1419890959

Ah, that's why

https://www.miataturbo.net/attachmen...ine=1419890959

Once I started pulling the car apart, it became apparent that I had bit off a little more than I was prepared to chew.

https://www.miataturbo.net/attachmen...ine=1419890975

https://www.miataturbo.net/attachmen...ine=1419890975

Hm, I wonder why the trunk won't close...

https://www.miataturbo.net/attachmen...ine=1419890975

https://www.miataturbo.net/attachmen...ine=1419890975

Ah, that's why

https://www.miataturbo.net/attachmen...ine=1419890975

Time to get to work.

I started by painting the replacement bumper cover. I found a nice lot by the water where I used to keep my boat, and set up my compressor. Sand, primer, base, clear. I just used paint and a $100 air gun set from TCP Global - Quality & Service Since 1974
It took longer than expected, so I did the last couple coats of clear in the dark. It came out looking pretty good though. (sorry, no pics of the process).

I also replaced the battery, because after sitting for a couple months with the trunk open, the one that came with the car was fucked. I had it tested and after 15 minutes the machine still couldn't come up with an estimate of how long it would take to get tested. The new one was promptly stolen out of my trunk when I parked outside, so I got another one from Amazon.

I rented a storage unit and got to work bending everything straightish. For this process I used a 10 ton portapower I got on Amazon. It is cheap chinese crap, but it did the job. I did my best to isolate each bend and strap or brace everything else. In the end, the most successful bends were done by pushing off of the good frame rail to bend the bad one.

http://nige.nl/Z83N/Image%202014-12-...34.51%20PM.png



After a few hours of this, I was able to get the new bumper support on

http://nige.nl/Z7lN/Image%202014-12-...36.28%20PM.png

Then after a bit more bending, the trunk closed!


And finally after more bending and some bondo and epoxy, I got the bumper cover and lights on (that bumper cover used to be green)

http://nige.nl/Z80x/Image%202014-12-...38.52%20PM.png

Then I swapped the diff carrier case (damn wrecker sent me one from a 1.6, so that set me back another day) and I was driving!

With all that done, I still needed tires to pass the inspection to get retitled. I decided while I was at it I would get some light 17x7s, and opted for the new TR Motorsports FF10s from Tire Rack. I also went with a slightly bigger side wall - 205-45/17 which should give a little better gearing on the 6 speed. I think they will look pretty good as soon as I can lower it a little, and I can lower enough to let the wheels will the wheel wells without being stupid low to the ground. Still waiting on those Tecnas...

https://www.miataturbo.net/attachmen...ine=1419893625

I also found that the driver side tie rod was bent. I adjusted it until the wheel was straight and the car handled okay while I wait for the new one to come in. I'm not going to bother getting an alignment until I install the tecnas.

That's all for now. Lots more to come over the next few months.

I'd love your input on my plans. My goal is for a 220-250hp daily driver. I also want to try doing e85 with a flex sensor.

Here is what I've done so far:
- ghetto trunk frame straightening
- battery
- first round of painting
- diff carrier case
- mazda competition diff bushings
- FM sways
- Wheels/tires (yeah, y'all don't like 17s, but at <15lbs they should do fine)
- replaced various busted parts (tail light, bumper, trunk)

Here is what I have either waiting to go on the car, or have ordered and am waiting for:
- AEM wideband
- Brainpowered MS3x
- MK Turbo kit
- Tecna shocks/springs

Here is what I still need:
- clutch and flywheel (949 if it's ready by then, otherwise FM happy meal)
- ebay IC/BOV/piping
- GT500 injectors

I'm planning to do MS, then injectors, then clutch, then turbo.

I've also got a bunch of little things to fix, mostly body work. I'm taking a night school class at a community college for body work and welding.

Lol looks like turbofans trunk.

Ha, in some ways that looks worse than my trunk! Not folded down like mine though.

Fun to watch those straightening videos. Wow.

Yeah, 10 tons is a lot of force. For a few of the higher load pushes we half closed the shipping container doors and hid behind it like a blast shield. We also broke a couple of the portapower ends. It takes a lot of force to straighten a frame rail!

https://www.miataturbo.net/attachmen...ine=1420062773

I tried to replace the bent tie rod last night, but the guy at Napa gave me one for a '92 not an '02. Funny, they look identical, and where the inner tie rod threads into the steering rack, the thread pitch is the same, but on the newer cars it is imperceptibly wider. I couldn't be sure by eyeballing it so I had to use a caliper. Looks like I'm taking wifey's car to work today while I wait for the proper part to come in :facepalm:

I got the right tie rod in last night. For anyone else doing this job, after I got it in and was close-ish based on measuring the other side, I would drive, adjust, drive, adjust until the wheel was straight while driving in a straight line. You can access the tie rod to adjust it just by turning the wheel all the way to one side.

Bits and pieces are starting to roll in. Here we have:

Knockoff BOV direct from the People's Republic, branded as HKS
$15 used boost gauge
$free.99 clutch disc(k)
Replacement soft top latches
Gently used wideband

https://www.miataturbo.net/attachmen...ine=1420915824

Yesterday I also put an order in at flyinmiata: a roll bar (Hard Core Sport with leather cover and no diagonal), and a set of V-Maxx Xxtreme coilovers.

I was really looking forward to the Tecna's but the latest update doesn't look good for getting them any time soon, so I got a refund. My car desperately needs an alignment before it goes out on the track, and I'd rather not do it twice. Also, my front shocks are totally hooped so the car handles like crap.

More goodies arrived today :party:
In the middle - :brain: MS3x to make my car go fast. On the right is SA2010 helmet I got for $130 in Amazon, which is even comfortable! Should help protect me when I'm driving so fast. On the bottom left, a roll bar go pro mount so I can feel awesome watching myself drive around a track after. Sweet.

https://www.miataturbo.net/attachmen...ine=1421284889

I picked this Hard Dog Deuce up for $150 on Craigslist, brand new #win. It was missing some bits, which I got from the good folks at Bethania Garage for $100. The biggest win of all is that I have it now, so I can install it this weekend, so I can race next weekend. Yay!

https://www.miataturbo.net/attachmen...ine=1421284889

Proof for my wife that the miata actually does make a great family car! :giggle:
https://www.miataturbo.net/attachmen...ine=1421284889

Made some more progress on the weekend.


Attachment 131654

Red, obviously better than black. Plus they can go up and down and harder and softer. #win



Attachment 131655

Stripped down for the roll bar install



Attachment 131656

Air chisel makes this fast, and fun!

I'll have it all together in time for buttonwillow :party;

Posts like the one above make me realize how terrible my megasquirt harness is. Maybe I should fix that.

Slow progress the last couple weeks. I'm taking a body work class at a local community college, and am waiting to get this car on the frame rack. I don't want to do anything major first, as things like dent repair, alignment, and paint would all have to be redone after. Hoping to finish straightening the body next week.

In the mean time, I've adjusted the clutch pedal to give myself more space for my long gangly legs. Gas pedal mod and foamectomy are next. I've also adjusted the ride height tirelessly to get it to the point where I don't bottom out and all sides are equal height. I removed the front fender liners for a bit more clearance.

Another project I've got on the go is a bosectomy. I'm ridding the car of the crappy bose unit in favor of a super simple amp and phone mount. It will have 2 functions - run sound like Pandora, directions, and audio books from my phone; and function as a decent hands free phone system. I'm using a tiny power amp and a bluetooth connector with mic, and mounting it to textured ABS.

https://www.miataturbo.net/attachmen...ine=1423454477

https://www.miataturbo.net/attachmen...ine=1423454477

https://www.miataturbo.net/attachmen...ine=1423454477

To be continued :party:

Great stereo idea! I am interested in seeing the results.

I finished the stereo install and am quite happy with the results. I think it gives a much cleaner appearance, and is stipped down the the functionality I need, which is 100% iPhone based. Not that it matters much for my car, but it also shaved 10+ lbs.

https://www.miataturbo.net/attachmen...ine=1423768648

https://www.miataturbo.net/attachmen...ine=1423768648

https://www.miataturbo.net/attachmen...ine=1423768648

I also did a foamectomy, and it made a huge difference. My hat doesn't try to fly off on the highway anymore, and I generally just fit better.

https://www.miataturbo.net/attachmen...ine=1423768648

Nice work, I really like that radio idea. Props.

Look what arrived today!! Attachment 134363

becausericecar

I've also picked up a pair of Elise seats in beige, and I'm going to dye them BMW burgundy, along with the other accents. They should give me a lot more head room, and be comfy and look sweet. What else can you ask for?

I got 'er on the frame rack today, and was advised to replace the rear panel (the one that goes between the tail lights). After some grumbling, I acquiesced and took it off the rack without making any pulls. I'll take another crack at it in a couple weeks when the part gets in.

I've got to commit a couple weeks on the frame rack to fix the damage properly, so while I'm twiddling my thumbs over that, I've made a couple more changes.

I re-oriented the iPhone mount since the iPhone sucks in landscape, which also made room for the wideband gauge, and eventually a boost gauge.

https://www.miataturbo.net/attachmen...ine=1426825020

I also changed out the cigarette lighter for a double USB charger.

https://www.miataturbo.net/attachmen...ine=1426825020

And I t-ed off the vacuum line from the cruise control and ran it to the foot well, ready for MS glory.

Got my MS3x all hooked up today. WB, AIT, and the works. Plugged it in to my computer and set up the settings for all the sensors. Cranked it over, and nothing. :sad2:
At that point I was out of time, so I went back to stock and I'll have to read some threads and stuff to figure out what I might have missed.

I have some progress, and some non-progress to report.

First, the non-progress. I've basically run out of time for my build, due to increasing family obligations. Also, I took a class at my local community college so I could have access to a frame rack and painting booth. I didn't get the time I needed on the frame rack, and now the semester is over. Basically, I had to say fuck it. No turbo for me. No properly repaired car for me. So here is the progress I did make:

1. Alignment to FM specs. Hey, if all my wheels are pointing the right way, that's good enough right?

2. Paint. By the time I was certain that I wouldn't get the time I needed on the San Francisco City College frame rack, the painting booth was also booked up for the rest of the semester. Boo. But hey, who needs a painting booth anyway? I just converted my carport into a painting booth.

https://www.miataturbo.net/attachmen...ine=1430865645
https://www.miataturbo.net/attachmen...ine=1430865645
https://www.miataturbo.net/attachmen...ine=1430865645

I think it came out okay!

https://www.miataturbo.net/attachmen...ine=1430865645

Not perfect though. I may fix this properly one day, or it might just be a beater daily/track car until I buy something else.

https://www.miataturbo.net/attachmen...ine=1430865645

This dent looks like you should just be able to pull it out, but it is related to some compression from the accident. It really should be gently removed by pulling the back of the unibody on a frame rack. I would have liked to just remove the dent, but I'll have to save it for the bigger frame-straightening project if I ever get to it.

https://www.miataturbo.net/attachmen...ine=1430865645

Now I just have to buff it up and slap a MSM spoiler on it.

PS. Yeah, those altezzas are kinda ugly. I got both for the price I can sell my one good tail light for. I'll hit them with a couple coats of light tint to lessen their impact. The important part is that this car is super fun to drive, and it is all basically the same color. Woot!

accidental double post. Er, bonus post!

muffler is bent too?
if you need one I got one for you. free

It was bent. Now it's slightly unbent. Also the visible hole in it has been welded closed. I thought the loud growl was from the upsized diameter cat back and roadster sport muffler. With the hole plugged it's pretty normal!

Thanks for the offer! Let me see if I'm heading out to Sacramento any time soon.

Seam welding. :party:

I went with the caterpillar-style, and figured I'd just grind away where I was going to weld. Seemed to work okay except that the paint kept catching on fire. Next time I'd probably just grind it all down, and then also I'd probably do more welds of the same length for better coverage. But meh, it's way better than the shitty factory spot welds.

https://www.miataturbo.net/attachmen...ine=1430919938
https://www.miataturbo.net/attachmen...ine=1430919938
https://www.miataturbo.net/attachmen...ine=1430919938
https://www.miataturbo.net/attachmen...ine=1430919938

I am a bit sad that a MKTurbo setup won't be going on this thing.

I'm extremely sad. When I slowly accelerate with my foot to the floor, I just have to imagine a wailing turbo, a whoosh from a BOV and third gear tire spin.

MORE RED!!

Yup, I made my interior redder, becausericecar. Mostly though because I really don't like the brown interior on the metalic grey exterior. I went with "BMW Burgundy"

https://www.miataturbo.net/attachmen...ine=1431839357

Before:
https://www.miataturbo.net/attachmen...ine=1431839357

Before/After:
https://www.miataturbo.net/attachmen...ine=1431839357

After:
https://www.miataturbo.net/attachmen...ine=1431839357

I think it came out pretty good! I'm quite surprised actually. I read some good reviews, but I still felt like I was rolling the dice.

Update time!

With the seam welding and a good alignment, this car now handles exceptionally well. The dyed interior is holding up shockingly well.

I put some better brake pads in and cleaned the air filter and took it to Sonoma raceway and had a blast. The biggest problem is that I don't come close to passing the broomstick test, even with a low mounted race seat. I guess I'll need a bigger car to get my tall ass to the track.

I've also decided that I'm going to do this whole turbo thing with the goal of ending up with a kick ass street machine, so we'll see how that goes...

MS3 went in today. This one was Reverant built and included a solid base map. So easy - I just followed the instructions, started the car, and drove away.
Next up: Flow Force Injectors and MK Turbo!

Also... just in case anyone thought the above was a good idea - I saved $100 on only having to do an alignment once, but I just had to spend $250 replacing my two front tires after crazy wear after only 5000 miles. False economy.

How tall are you? I'm 6'1" and mostly torso and I pass broomstick by an inch or 2.

Aluminum seat mounted to the floor.

I'm 6'2" and when I sit upright on the floor without a seat I'm over, slightly reclined I pass. Problem is I drive to work every day in this car, and drive to LA about once every 3 months. An aluminum seat bolted to the floor with the rear humps cut out would work for the broomstick test, but would be a major PITA on the street. I'd love to find a solution that allows me to go back to stock seats when I'm not on the track.

Marrad seat for you. Designed for miatas, includes brackets, has slider. Works with 6pt harness. FTW. I have one, it is *much more comfortable* than my stock 01 foamectomied seat with the cushions in, and works well for track/autocross. It is somewhat expensive, but it is comfortable, it works, and it is designed specifically to fit into NB miatas.

For reference, I am 6'2, 34" inseam, 32" waist. I pass the broomstick test with a helmet with my Hard Dog M2 Hardcore Hardtop rollbar.

Marrad miata seat at Goodwin Racing.

Edit: it is not the least expensive option out there. But it works - it's comfortable, gets you as low as you can get, accepts harnesses, works with 3pt stock belts.

Richard and I are the Marrad tag team. Perhaps we have convinced E02K, but I will back up Mobi here too. Get a Marrad! The new version with the side belt holes is rad.

$1000 for a seat? Crazy. Did you buy 2, or use something cheaper for the passenger side?

It is on sliders and uses the stock mounting points?

http://www.arizenracingsports.com/pr....asp?prod=MLX1 - $750 - Black Cloth

Thanks for the seat suggest! I'm going to try that out. I tried again with no seat and my back slightly reclined, and it looks like if I add >1 inch of height via the LX1 seat I could clear.

https://www.miataturbo.net/attachmen...ine=1445450403

In other news, I've got my MS3 running well. Flow Force Injectors shall be installed this weekend!

Whoa- where does the crotch strap go on the Marrad seat???

I might end up getting one for my drivers' side and then moving the crappy sparco sprint V over to the passenger side.

$1000 (or $750 at the other link) for the seat, mounts, and sliders ready to bolt in. You'll spend that for any other seat of comparable quality (I did).

Or you can do what I did and pay less than that for something that isn't of comparable quality :bang:

I did that too. Then I realized I'd made a horrible mistake and wasted $130 (depreciation on the $180 piece of shit I bought the first time around).

You need a taller roll bar.

A taller roll bar would be good, yes. However taller roll bars are also ~3 inches farther forward, and as it stands now my head is uncomfortably close the the roll bar in the event of a rear ender (look at the passenger seat position, that's how I drive with my stock seats).

Smaller steering wheel and sit closer. I'm 6'1 with a ~31" inseam and I had to get a hard dog hardcore m2 non rollbar to fit under. I have an ultrashield bolted to the floor.

Richard is leggy compared to me.

Why did the lotus seats not work? They get pretty low I thought.

I think they get about as low as the Sparco Sprint V, which I have now. It seems that the Marrad seat gets the lowest you can get while keeping the stock humps, a key feature for a non-racecar IMO.

Marrad's are rad. I've had one for years. I have the old version with no side harness holes. The new ones with side harness holes are freaking awesome. They also have a center hole for a crotch strap for the person who asked earlier. The lower cushion is in two pieces and you can run the crotch strap with or without the cushions in.

fine.


I broke down and bought one. It's probably going to turn out to be an excellent decision. Coming soon to a for sale section near you: Sparco Sprint V + PCI bracket

^I think I'm sold on the Marrad as well...:burncash::burncash::burncash::burncash::bu rncash::burncash:

Are you in California? Gesso is looking for a Sprint V.

I am in California. Gesso should buy my sprint v!

I just got the last all black one, but he has a couple with red stitching or there is always the back order.

I think you'll find the Marrad seat very comfortable. When using the harness I take out all three cushions. On the street with the stock 3point belt I leave all three cushions in and it's very comfy.

If you find you need a little something with the pads out these work well, and won't really add to your seat height any: Memory foam pads. That's the real stuff, dense and comfortable.

When I Google Marrad seats I get this site; http://www.arizenracingsports.com/default.asp. is this legit? 'cause the price seems way cheap ($499 vs $999 from Goodwin).