Another RX7 in the mix Time to start my own build thread. :up: I'm starting to build my 1983 Mazda RX7 GSL into a rally car! I'm at the stage where all I have left is... everything. My story: I fell in love with rallying when I was 15. Well that's not quite true: I fell in love with the WRC when I was 15. Spent my high school career reading about the cars, watching youtube videos, playing loads of Rallysport Challenge 2 on my Xbox, and refurbishing a '83 Subaru GL 3-door we got for free, which, after we got it running, raised to have 11" of ground clearance, named "The Beast," and scared ourselves numerous times with very unstable 35mph drifts. [img]https://www.facebook.com/photo.php?fbid=1006753700577&set=t.773575082&type=3&theater[/img] When I was 18, I bought a 1985 Mazda RX7 GSL and, thanks to that and Initial D, got distracted from rallying with the idea of street racing. I then decided that street racing wasn't very cool after I discovered that when you mess up, you can crush your car on the passenger side up to the transmission tunnel with a guardrail, and then the state makes you pay for all damages you caused to their property... and guardrail isn't cheap! :( (I don't have any photos of that anymore. It was a sad time in my life). Luckily, I had a 1983 RX7 with a motor with blown apex seals, so before insurance came and totaled my car out, I did a quick bolt-in motor swap so I could keep my good engine (only 109k on the ticker). I left that shell with the bolted-in motor (which I ended up oiling pretty regularly) sitting in front of my parents house for the next 3 years, much to my moms dismay. I was scared of the wiring (which as far as I'm concerned, is magic blue smoke trapped in the wires, and you know you did something wrong when it starts escaping), and was so busy with full-time school, the Formula SAE team, and a job, I spent most of that time trying to decide whether I wanted to turn the car into a rally car, or just scrap it. I'm now studying Vehicle Engineering Technology-Plastics Engineering Technology major and am very involved in my Formula SAE team (feel free to check us out at our [url=https://www.facebook.com/pages/WWU-Formula-SAE/161101373930495]Facebook[/url] page). [img]https://www.facebook.com/photo.php?fbid=293668794007085&set=pu.161101373930495&type=1&theater[/img] This last September, I decided I wanted to keep the shell and turn the Mazda into a rally car. I towed it from my parents house to where I'm living and started to tear into it. Removed all the emissions, started to teach myself wiring, stripped the interior, and fixed a bunch of issues that arose from letting the car sit for 3 years. I drove it for the first time 2 nights ago. There are still a few issues I need to fix before I would call it reliable, but it was a fantastic feeling to tear up the caul-de-sac and I couldn't stop laughing with excitement after I pulled it back in the driveway. I have an independent study this quarter based around reverse-engineering a RA regulation roll cage for the car and then building it. I'll be boxing in the suspension and seam-welding a few things (that won't require jigging) during that time as well. Should be a fun project, though I am a little worried about finishing it in time before the quarter is over. I have 9 weeks to go and am analyzing the rules currently to decide on the best elements to include in the cage for the cabin. So here is how it stands now: It has a carbureted 12a. And is all stock other than what follows. Current Modifications: -Stripped interior -- removed tar sound deadening -Stripped Nikki carb -Racing beat headers -AFCO aluminum radiator - custom mounts (still need to shroud) -Stripped emissions -Gutted dashboard -Working on de-looming and gutting all unneeded wiring -Removed headlight motors -POR-15 on the front end Planned modifications (so far): -FIA/RA roll cage/boxed strut towers -Bucket seats (either purchase, or I know how to make carbon fiber parts so I might make my own if I can) -Electric radiator fan -2nd gen Direct Fire Ignition -Skid plates -Suspension (not sure what yet) -GSL-SE subframe/axels -1.5:1 Steering quickener -Hydraulic e-brake -Adjustable prop valve -Prevent Watts link from binding (oil lite bushings maybe) -Possibly a wideband for making for simpler rejetting of the carburetor -Wheels and tires.... a lot -A tiny battery (I'm using a dead battery with only 10.85 volts left and it starts the car just fine) -Possibly Z31 300ZX brakes (if I can make them fit) - or I'm an intern at Girodisc Racing Brakes, so I may see about making floating 2-piece rotors with custom CNC aluminum top-hats and the rear rings for a WRX or an Elise or something along those lines We will see how far I get on this or if I can finish it. I am hoping to go to grad school and my top choice is on the other side of the pond. If I'm lucky, there will probably be a caged and moderately modded FB for sale in about a year and a half. ;) Photos: https://www.rallyanarchy.com/phorum/read.php?5,60038,60038#msg-60038 Wed, 01 Jul 2026 20:44:58 -0500 Phorum 5.2.15a https://www.rallyanarchy.com/phorum/read.php?5,60038,105469#msg-105469 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105469#msg-105469
Quote
zack13277
I actually thought it handled ok for stock struts and shocks. I'm still going to build it, RX7's are part of rally history and it shouldn't be that much work or handle that bad. We'll see I guess.

Do the stuff we've been talking and it'll be Soooper Bitchin enough..]]> john vanlandingham Construction Zone Tue, 31 Mar 2015 14:52:39 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105467#msg-105467 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105467#msg-105467 zack13277 Construction Zone Tue, 31 Mar 2015 14:42:23 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105444#msg-105444 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105444#msg-105444
Quote
Gravity Fed
ill give you everything but overweight. how is it overweight???

For the size of car it is, it's pretty damn heavy since practically everything on it is massively overbuilt. On the plus side, you can use that to your advantage and pull out a ton of weight. For example, last week we pulled nearly 20lbs out of the rear bumper alone on our Chumpcar.


Quote
mekilljoydammit
I have to kind of object to the "not at all in any racing setting" bit, and just have to say that compared to what for those? Most production cars are crappy for racing purposes without work.

I'm not disputing that most production cars don't make good race cars out of the box. Though some cars are more capable in any form of preparation than others. In terms of the FB suspension/steering, it's a glorified pick-up truck, though with maybe even worse geometry. Or look at the front rotors - tiny, hardly any venting, and integral to the wheel hubs. Trust me, they dump a ton of heat into the bearings.

Quote
john vanlandingham
Gotta agree. A stock POS road car Escort is nothing to write home about..

EVERYTHING got work, and nearly always the same stuff as Group 4 Escort if they were in Group 4 and the MFG had the foresight to homologate the parts.
Or in National classes where rules were sensible...not always the case...

Millen's RX7 was Mazda shell and motor...Everything else was Group 4 Escort.

And it was a thing of beauty to watch him dance with that car..

Bingo. But to get an FB there is heaps of work. If you're going to put that much work into something, why not start out with a decent chassis to begin with, and then that level of work puts you ahead of the playing field, rather than trying to pull even with them?

Don't get me wrong guys. I still love the 1st gen RX7. I'm glad I'm racing in one currently. I'm even more glad of how damn simple the things are to work on. But it has its inherent flaws, and some of them are pretty major. I was only suggesting to zack13277 that he look into using a different car as a stage rally car.]]> MeCalledEvan Construction Zone Tue, 31 Mar 2015 07:32:45 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105435#msg-105435 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105435#msg-105435
Quote
mekilljoydammit
I have to kind of object to the "not at all in any racing setting" bit, and just have to say that compared to what for those? Most production cars are crappy for racing purposes without work.
Gotta agree. A stock POS road car Escort is nothing to write home about..

EVERYTHING got work, and nearly always the same stuff as Group 4 Escort if they were in Group 4 and the MFG had the foresight to homologate the parts.
Or in National classes where rules were sensible...not always the case...

Millen's RX7 was Mazda shell and motor...Everything else was Group 4 Escort.

And it was a thing of beauty to watch him dance with that car..]]> john vanlandingham Construction Zone Mon, 30 Mar 2015 20:46:16 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105433#msg-105433 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105433#msg-105433 mekilljoydammit Construction Zone Mon, 30 Mar 2015 20:37:44 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105432#msg-105432 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105432#msg-105432 Gravity Fed Construction Zone Mon, 30 Mar 2015 20:04:12 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105383#msg-105383 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105383#msg-105383






A bit more:








2013 and 2014 Champin in the hardest 2wd series in the world:




Seems more and more are thinking that this simple, available, basically good car is a sensible choice...
Nothing fancy, just good...]]> john vanlandingham Construction Zone Sun, 29 Mar 2015 23:48:22 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105377#msg-105377 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105377#msg-105377 zack13277 Construction Zone Sun, 29 Mar 2015 21:41:19 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105376#msg-105376 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105376#msg-105376 Now I'm kinda regretting doing that with the FB even. It's not much of a capable chassis at all in any racing setting - overweight, underpowered, terrible suspension geometry, terrible steering geometry, tons of steering play, shitty brakes, awful cabin space. You'll notice that many of the members here were telling me that and I was disregarding their suggestions - that was a mistake.]]> MeCalledEvan Construction Zone Sun, 29 Mar 2015 21:07:24 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,105374#msg-105374 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,105374#msg-105374 zack13277 Construction Zone Sun, 29 Mar 2015 19:46:25 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68898#msg-68898 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68898#msg-68898 I am a student at Western in the Vehicle Design Program. I also have interned at a machine shop all last year and am proficient in both manual and CNC machining (both in operation and programming in CAM and/or G and M code).

Dave asked me to type up what I learned is being done. That's what I did. This is what people do for the Toyota Tacoma. All I wanted to know was if I could do it with that axle, and that the drums weren't integrated into the drive system. I found out that they aren't and I can knock that system off and put a disc on there. So here I was looking at the 'what' and the 'how'.
I hadn't put much thought into the 'why' yet. Thank you for bringing that to my attention.
Calipers: once again, what I typed up is only what I've read is being done. Any caliper? Sure you can use any caliper. Is it a good idea and will it work well? No. I'm well aware of that. But thanks again for questioning me on it and making me think.

As for the 'why'. I hear ya man.
Here's my plan and my 'why'?
1) Measure caliper piston area/swept radius/etc and calculate effective stopping power for the front axle.
2) Measure CG height and roughly calculate dynamic axle forces.
3) Roughly calculate out needed stopping power for rear brakes
3.5) Look at the rotors that are friggen huge and measure diameter, top hat offset, etc and look for an appropriately-sized alternative.
4) Do the same for calipers.
5) Figger out how to my mount calipers.

Good for 'why' and thinking? Would you do anything different? I know you have a ton of experience in reverse engineering shtufsh like this.

And no, they aren't really teaching us too much. I'm mostly self-taught. Kinda lame for a college education. I'm just trying get that piece of paper that says I'm smart now. One year to go and have tuition covered with scholarships so I won't waste any moolahs.

Those are pretty, but almost definitely out of my current budget.]]> MeCalledEvan Construction Zone Wed, 25 Jul 2012 11:26:41 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68892#msg-68892 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68892#msg-68892
Quote
MeCalledEvan
It's pretty easy to do the swap.

Then what's the question?



Quote

There are full kits for around $450, but those are for people who really are afraid of DIY work.
The DIY is almost as easy at a fraction of the cost:
You need a caliper mounting bracket (found them on eBay for $24, or I'm a machinist so whoop-de-shit),

You are?
I thought you were a student at Western in the Auto design program.





Quote

rotor, caliper. Rotors to use are '86-'89 Chevy light pickup 4x4 vented rotors, measuring 1 inch thick.

Wait.
Stop.
You are saying on a little weenie RX7 you are suggesting putting a 1" thick rear rotor on the BACK AXLE?


Quote

You have to modify the hub and bore it out more for axle clearance. Caliper can be whatever you want to use (if you make your own mounts), but if you want to use the purchase caliper mounts, use 79-85 Cadillac El Dorado rear calipers w/ e-brake.

And what pray tell are you worried about "with ebrake".
What is the piston size?
If you say any caliper, that is the "what".
Dude, I'm helping you here, learn to say the "why".

The 'what' is a useless assertion without a stated "why".

What the fawk, aren't they Ttrying to teach you anything up there?

You still have that absurd and nonsensical quote in your signature...seems you believe it.
.

Well you can make assumptions, but they are useless to share without "why" and "why" is size, diameter, costs, ..precedent...

How do people Google search images?
Search this:
]]> john vanlandingham Construction Zone Wed, 25 Jul 2012 10:19:17 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68884#msg-68884 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68884#msg-68884 The DIY is almost as easy at a fraction of the cost:
You need a caliper mounting bracket (found them on eBay for $24, or I'm a machinist so whoop-de-shit), rotor, caliper. Rotors to use are '86-'89 Chevy light pickup 4x4 vented rotors, measuring 1 inch thick. You have to modify the hub and bore it out more for axle clearance. Caliper can be whatever you want to use (if you make your own mounts), but if you want to use the purchase caliper mounts, use 79-85 Cadillac El Dorado rear calipers w/ e-brake.

That's all I've got so far.]]> MeCalledEvan Construction Zone Wed, 25 Jul 2012 02:04:12 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68864#msg-68864 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68864#msg-68864
-Dave]]> eyesoreracing Construction Zone Tue, 24 Jul 2012 17:27:52 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68863#msg-68863 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68863#msg-68863
Quote
john vanlandingham
Quote
MeCalledEvan
I found a Toyota rear end, but it's got drum brakes. Before I go and buy it, does anyone know how hard it is to convert it to rear discs?

Yes somebody knows how hard it is to convert to discs.

Shirley you should be able where to search (who pushes the idea?)

Yeah yeah. I had looked on this forum and couldn't find nuthin, which is why I asked. Then I had the bright idea to look on that magical place called Google. Took me to a bunch of Toyota forums with a ton of the info I needed. Funny how that works isn't it?]]> MeCalledEvan Construction Zone Tue, 24 Jul 2012 15:17:53 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68822#msg-68822 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68822#msg-68822
Quote
MeCalledEvan
I found a Toyota rear end, but it's got drum brakes. Before I go and buy it, does anyone know how hard it is to convert it to rear discs?

Yes somebody knows how hard it is to convert to discs.

Shirley you should be able where to search (who pushes the idea?)]]> john vanlandingham Construction Zone Mon, 23 Jul 2012 11:29:36 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68819#msg-68819 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68819#msg-68819 MeCalledEvan Construction Zone Mon, 23 Jul 2012 10:52:17 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68444#msg-68444 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68444#msg-68444 Pete Construction Zone Sun, 15 Jul 2012 09:22:39 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,68430#msg-68430 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,68430#msg-68430
I got the wipers working and my buddy explained why I was so confused about the wiring. Everything that has an intermediate setting (turn signals, windshield wipers, clock, door dinger, etc) in the RX7 is not run thought relays like normal. Instead, it is run through a microcomputer titled "the flasher unit."

He also got me started on stripping a lot of wires. So I have been systematically going through and clipping out my harness. I've removed about 3/4 of the wires in the car and last night I started to re-loom everything back together.

In addition, I've been shopping. I found a 2nd get subframe, powersteering rack, front calipers, and oil cooler. So now its time to find more parts cars to get the uprights, hubs, struts and rotors! I'll probably wait to put this all in until after I get the main spider of my cage complete. I'm looking for access to a welder currently. As soon as I'm done with all this wiring, I will be ready to start. Originally the plan was to use the welder at school, but access is very limited over the summer. I'll be able to use it in the mornings on weekdays, I hope.

I do have a question. Rear axle with 5X114 lug pattern that fits the RX7. What options do I have? Volvo? Toyota pickup? Any recommendations?]]> MeCalledEvan Construction Zone Sat, 14 Jul 2012 11:00:15 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67594#msg-67594 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67594#msg-67594
Quote
eyesoreracing
I had similar wiring issues on my 510 rally beater and finally plopped down the $250 for an EZ Wiring harness and just re-did the whole thing. Working with a pre-made generic harness like that is pretty damn simple. Takes a while, but its simple, brainless, meticulous work. The car is hilariously reliable now. Looks like it got stuck between Godzilla's toes, but starts every time and everything works.

That's a really good idea Dave! Thanks. Before I do that though, I have one last defense: an Electronics Engineering student. My buddy has been in charge of designing and building the wiring harness on the Formula SAE car for the past 2 years now. Within the next couple weekends, I promised him beer for help with my cars wiring. We will see how much success we can have, but the guy is an absolute wizard with wiring so I have high hopes.]]> MeCalledEvan Construction Zone Wed, 27 Jun 2012 10:18:38 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67409#msg-67409 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67409#msg-67409 eyesoreracing Construction Zone Mon, 25 Jun 2012 00:43:13 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67408#msg-67408 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67408#msg-67408 I keep rediscovering is that the wiring for pretty much everything in this shell I have is super duper fucked. Almost to the point of me toying with the idea of tearing the whole harness out and making my own for just powering the essentials. I don't think I will just yet, because that's a steep learning curve and I don't have the time or money for an undertaking like that right now.
The wiring I discovered for powering the wiper motor in this chassis almost made me laugh (or cry): it has wires leading to the fusebox, but nothing on the other side of the fuse. Time to start chasing little blue wires around under my dash! :.(]]> MeCalledEvan Construction Zone Mon, 25 Jun 2012 00:38:40 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67274#msg-67274 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67274#msg-67274 alkun Construction Zone Thu, 21 Jun 2012 17:01:59 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67269#msg-67269 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67269#msg-67269 Pete Construction Zone Thu, 21 Jun 2012 07:09:57 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67260#msg-67260 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67260#msg-67260 MeCalledEvan Construction Zone Wed, 20 Jun 2012 20:27:08 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67145#msg-67145 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67145#msg-67145
I've been playing with these silly things since 1998, every one needed to have the pivots cleaned up. One was a Texas car and another was a summer-only Wisconsin car. The first time I encountered it, I didn't do anything about it until the wipers stopped mid-stroke.

Needless to say, use a GOOD grease. I'm fond of the black synthetic brake grease, seems to stick around a long time.]]> Pete Construction Zone Mon, 18 Jun 2012 18:22:15 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67139#msg-67139 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67139#msg-67139
I'm assuming nothing really needs to be done to the plastic pivots in the linkages, just the 2 threaded brass ones? Getting them off just looks like careful work with some small snap-ring pliers, correct?]]> MeCalledEvan Construction Zone Mon, 18 Jun 2012 17:57:55 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67133#msg-67133 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67133#msg-67133
Quote
MeCalledEvan
When my car ran last with the windshield wipers, they were slow. Like really rrrrrreeeeeeeeaaaaalllllllllllyyyyyy slow. To the point where they would die mid-swipe half the time. I'm not a huge fan of that.

It's probably not the motor YET, it's probably the wiper pivots.

Take them apart NOW and clean them and grease them, which costs nothing but time, or you WILL burn the motor out, which costs money.

The wiper transmissions are long since NLA, so cleaning and greasing is the Only Option. Be careful not to crush the brass sleeve that the pivot rides in while trying to wrestle it apart.]]> Pete Construction Zone Mon, 18 Jun 2012 17:17:17 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67067#msg-67067 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67067#msg-67067 MeCalledEvan Construction Zone Sun, 17 Jun 2012 15:31:30 -0500 https://www.rallyanarchy.com/phorum/read.php?5,60038,67066#msg-67066 Re: Another RX7 in the mix https://www.rallyanarchy.com/phorum/read.php?5,60038,67066#msg-67066 pdxphil42 Construction Zone Sun, 17 Jun 2012 15:19:17 -0500