I braced my PPF by using a second PPF for added strength. It doesn't extend the full length, but it could. I didn't want to reinvent it, just strengthen it.

 

O/k with the Bimmer E36 diff.
Quite a few guys have done this, but what are the preferred associated bits such as half shafts and hubs, etc...

 

Gentlemen, do you think I would be able to use this single component urethane to cast custom diff bushings?

Here is all the data:



I am trying to design captive bushings which will be mounted vertically, just like the stock diff bushings in the Miata.
With a large enough diameter (80 or 100 mm) Shore 60 - 65 should hopefully be able to absorb most of the vibration/buzz/drone of the BMW diff.
There will be no front mount to the subframe, I will use the PPF.

 

Can confirm. 6 speed with 3.636 here also. Not boring.

 

Getrag 6 speed gearbox has arrived...



I also received a "dummy" diff for measuring purposes.

Time to get this project in gear...

 

I finally started turning wrenches on the car!

And, definitely keeping my promise to make this project as complicated as possible...

Here's the fruit of 4 afternoons so far:





The drivetrain swap idea evolved into a full blown restoration project. ( I decided on a 3.15 diff with clutch type, 1.5 way LSD)
The shell will go to a body/paint shop to get stripped down to bare metal and repainted.
It will be ceramic coated and wrapped in clear protective film after that.

I ordered and received a metric ton of parts (mostly trim pieces, clips and fasteners) from Mazda.
Also, an oil cooler with a 92C thermostat, electric actuators to replace vacuum cans (for the turbos), an embiggened large turbo, new hoses, brakes, ball joints, R8 coils, complete 3" custom exhaust and flat underbody panels with venturi tunnels will go in the car.

BASF is supplying all paint and paint related materials free of charge, a very prominent body/paint center is doing all the bodywork and paint, again, free of charge for promotional considerations, and ceramic coating + protective clear wrap will be applied, yup, at no charge by the leading brand over here for the same reason.
Also, I scored a 40% discount from Mazda for all the parts...

It will be a new car, no doubt.

Details to follow...

 

Wow! Eager to follow along, please keep the updates coming

 

Interesting development with the steering rack...

There was some annoying play in my steering wheel, and I decided to adjust it once the car was in 2 pieces. Much easier that way.
Long story short, I adjusted it per the factory shop manual, and steering effort increased considerably when I turned the wheels full lock. Almost impossible to move...

Readjusted the play with the wheels on full lock, and steering became way too sloppy when centered.
I guess the rack itself is worn in the center, where it spends most of its life.

Time to take it to the remanufacturers. There is a very reputable one not too far from me.

 

Aaand, it's dead.

Water damage. Rack teeth are all chewed up.

I need a new gear rack...

 

How many miles are on that rack?

 

About 150k miles.

 

I was wondering if you guys could help me with a very strange problem.

My steering rack is beyond repair. Both gears are shot, it is unsafe at any speed.
Mazda only sells new parts in Turkey, and the price is, um, prohibitive. (Around $3K)
I can order a reman unit from Rock Auto. They have one available from BBB, which, apparently is a good, reputable company located in the US.

Unfortunately, Turkish customs do not allow remanufactured, rebuilt, refurbished or reconditioned parts into the country.
Meaning, if I order the BBB steering rack it will either be sent back or destroyed at the customs.

So, I was thinking maybe I can order one and have them send it to a forum member.
That way all paperwork that contains such words can be removed, the box could be taped over to get rid of any such statement on the box itself, and it could be shipped to my address that way.
I would, of reimburse the cost of shipping to Turkey via Paypal.

Or, I will switch over to tiller steering.

What to you think?

 

Hey Hakan,
I can help you out with a used rack from Germany, if that helps? Or are even used parts a problem?

I'm on vacation till 20th Sept, but after that I'm all in. They can be had for like 80-150€ all day long with pump and everything. Send me a PM, if you can wait a few weeks, I'm happy to help.

 

^ same, but in Greece. BTW you are the first person I know of that actually has this issue (maybe water ingress through torn boots at some point?) so I would go to a used one.

 

I, via the company I work for, could ship you the rack. Let me know.

 

Seconding a used rack.

 

Tim, you have a PM.

 

Thank you very much for your kind offer to help guys.
Unfortunately, customs people open every package and reject the part if it looks used at all.
I would have to find someone who is driving from one of those locations to Turkey, and that is a pretty slim possibility at this time.

Believe me, I am exploring every angle.

 

I have a steering rack!

 

That was quick, given the circumstances