Revamping the Rx7

Well since the engine in the rx7 has shed its moral coil, and i still need to get my rally on, I figured i'd waste some bandwidth on the project at hand. Right now, i have a short amount of time before a deployment, which will help me fund everything while at the same time limit my time to work on the car. My goal is to make the Idaho Rally 2012, about two months after i return home.

At this point i have two main things to accomplish: engine and suspension

The engine replacing the rotary will not be rotary. I am going to remain with a mazda engine as to be compliant with rally america and also to remove any possible contest from Maxattack! rules (since they follow whatever sanctioning body). I am pulling the engine tomorrow in fact so ill continue with that later.

The other thing is the suspension. After getting under the car and poking around i can see i need to give it a good once over and i might as well use the "good" rx7 spares i have for it anyway. The biggest is the 2nd generation rx7 front subframe. A very easy swap and yields better steering, stronger suspension, a normal lug pattern and improved braking. All good things. To make the lug pattern in the front, i will have to change the rear axles out to the GSLSE model axles. These had the 4x114.3 pattern. All of this is temporary because in time i do plan on going with a different rear axle all together but again, time is my problem. Anyway, the axle in the car was a older rx7 axle and had a smaller spline and smaller bearings. The later GSLSE axles would not just go into the housing proper. Had to change out the whole deal. Wasnt too big a problem since i had 4.78 kia sportage 3rd member with an rx7 lsd already in my GSLSE housing.

I have also been looking at strengthening, and rust removal. Woven into this was clearing for the 15" wheels. (lug pattern change...). The car has had some previous rust repair and has made making the rear fender wheels flared and clearanced difficult. Was easy on two previous cars i have done, but this one is less than optimal. That said im making progress.

A few pics to tide over. Will be making updates frequently until i deploy. Also one of shop bunny. Somewhat like a shop cat. Just better tasting.

HAHA! That's funny as hell! My mom helps run the Posion Center (Where Mr. Yuk is from [the green face] )

Nice choice!

I'm starting to see a trend here...

I'll have to start putting pix of my pet spider at the end of picture posts.

Alex - What's your plan for flares?

Quote
Pete
Alex - What's your plan for flares?

it will look exactly like the picture below! Wheels too actually... since i parted that project out to get the rally up to par. (no title shell...) Further progress was made today but the pictures are on my phone so maybe ill get them on here in a few.

Also i have noticed that the bilstein shocks seem to limit how much travel the rear has but a few inches.. they just max out too soon.






Edited 1 time(s). Last edit at 07/30/2011 10:55PM by Gravity Fed.

The remaining portions of the steering was removed today including the steering box and column. The stud that will hit the new subframe were removed and the frame pinch rails notched for clearances. The new steering column was pulled from the parts car as well. Was some progress. Hot as hell today too. Welding tank is getting refilled tomorrow so i can start the finishing the rear flares and the rear subframe studs.

Welded in the rear bolts tonight. Got the axles in the rear end. I also started welding the rear flares back up! I spent most of the day dismounting 34 rally tires. Ill finish up more tomorrow and get pictures.

so now comes the question of "how do i mount this stupid engine." Its seems that frame rail mounts would only work on the passenger side. The Driver's side has the steering in the perfect place to not work. Pics of that are below. I am using the 2" sleeved bushing tube mount (is there a simple word for this??) A friend of mine savvy with machining made me some aluminum inserts to use will mocking the engine and welding. This is so the poly doesn't melt, obviously. Im probably going to build off the sub-frame.

Also, the cam sensor hits the firewall before the front of the oil is clear of the steering rack, to my preference. If i can move the sensor into cutaway into the firewall, then the engine's front can come down since the pan would clear. This would allow me an easy closing hood.

Anyway, here is what im working with...















Edited 1 time(s). Last edit at 08/14/2011 01:25AM by Gravity Fed.

Looking great. I thought about putting a turbo BP into an RX-7 chassis too. My other thought was using the Miata subframes and a-arm suspension too. But keeping a strong rear axle is smart.

-Jon

i think ive put together just about the best combination of mazda parts for a rear wheel drive rally car. The axle may end up getting swaped for the volvo 5 lug dana so i can run the bigger brakes up front without issues and alter the rear geometry. We shall see. thats for another year. Right now she needs to run for 2012.

flares are done! Lots of cutting and welding for clearancing. And battling old rust repairs on the driver's side.

those are awesome!

and functional! lots of clearance. And i already had them so why not.

more progress!

Engine bay was stitch welded as was most layers of metal touching it. Painted over that with tractor paint so i could get the fenders on. Seems as though some of the attachment points have been...rusted and had bolts broken off. Reminds me of home (ohio) anyway.... ill have put some screws into it to hold. But they are mostly on.

Also finished the rear structure welding and coated it all with truck bed liner. I just need two more weldable inserts and the rear mudflaps will be on as well. Engine will be going in soon i supposed. 13b engine i had laying around is the game plan. will be cheaper and i can reuse a lot of parts. Also better for me to learn on!