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robertf03
05-14-2008, 05:06 PM
engine tear down begins. Its off to the machine shop to see if its salvagable.

Sharpe
05-14-2008, 05:08 PM
Wtf is a sunbeam?

robertf03
05-14-2008, 05:11 PM
First sports car Bond ever drove.

Go watch Dr. No

http://www.sunbeam.org.au/models/alpine.jpg

jerryg79
05-14-2008, 05:18 PM
http://www.jamesbondmm.co.uk/vehicles/sunbeam-alpine.php?id=001

robertf03
05-14-2008, 06:00 PM
Engine from the blue one is going in the red one. Something fuel injected is going in the blue one. At this point probably a 1.6L Mazda 4 cylinder, maybe a 1.8 if it will fit.

http://tamor.org/forums/attachment.php?attachmentid=8913&stc=1&d=1157355889

uglyota
05-14-2008, 06:05 PM
you are gonna score so many dudes with that thing

robertf03
05-14-2008, 06:44 PM
I figured you of all people would support the 4 cylinder greenness

jerryg79
05-14-2008, 07:30 PM
so did you guys fence in your backyard or is that the neighbor's fence.

BMFScout
05-14-2008, 07:59 PM
they built a badass fence. Hey Flem answer your damn phone.

Eckert
05-14-2008, 08:17 PM
looks like a mini 55 t-bird

Fredo
05-14-2008, 09:46 PM
so this is why flem hasn't answered his phone.... Good luck with that engine..that first cylinder wall looks nasty.

uglyota
05-14-2008, 09:59 PM
I figured you of all people would support the 4 cylinder greenness
I support and validate it. I just think it's cute that's all :flipoff2:
Isn't the sunbeam tiger a v-8? Does it have more room in the engine compartment?

robertf03
05-14-2008, 10:44 PM
Tiger has different suspension and steering.



So it looks like the haynes book is full of **** on an engine weight of 240 pounds. Going to have to go to the storage unit tomorrow and get out the engine hoist.

Fredo
05-14-2008, 10:51 PM
Maybe you just need to eat your wheaties and hike up your skirt nancy.

You think that 2x4 is good for the tops of the fenders?

robertf03
05-14-2008, 10:51 PM
it's cool, its only a 3x2

(engine has been supported by floor jack)

Fredo
05-14-2008, 10:55 PM
Well, I can clearly see you have this completely under control then. :D

robertf03
05-15-2008, 12:13 AM
Fred, you know how we always joke about getting those ****ty adapters and the edelbrock intake putting a quadrajet on an ls1? now you can put 4 side draft carberators on an ecotec

http://quad4rod.accountsupport.com/index.php?page=shop.browse&category_id=4&option=com_virtuemart&Itemid=1

Fredo
05-15-2008, 11:10 AM
I think I've just found our new business plan flem. We need to start a company that does nothing but reverse engineer high tech motors to the most primative forms. Like converting an LT5 to 8 strombergs and magneto ignition. Or maybe just all systems in general. Let's make vacuum actuators for C5 vette pop up headlights...get rid of those fancy dancy electric motors they use. Or maybe even a finned drum brake conversion for Vipers. ****ing retarted stuff like that. Somebody will apparently buy the stuff.

robertf03
05-15-2008, 12:02 PM
If I'm reading this right, iron duke modified to take a small block head? So thats why they sell them individually

http://www.kansasracingproducts.com/About_the_Block.html

robertf03
05-18-2008, 07:52 PM
Blew it apart, taking it in tomorrow to the machinist then going to Mazda Heavan to find a 1.6 drivetrain for alpine #2

robertf03
05-20-2008, 10:24 PM
Zoom Zoom *****es :flipoff2:

bburris
05-20-2008, 11:03 PM
You get my PM?

robertf03
05-20-2008, 11:31 PM
did now, I found the socket at Northern

bburris
05-21-2008, 12:38 AM
Good deal.

DRAGOONRANCH
05-21-2008, 06:30 AM
Good deal.

??? (http://tamor.org/forums/showthread.php?t=7069) :flipoff2:

robertf03
05-21-2008, 02:13 PM
looks like it will fit

uglyota
05-21-2008, 02:23 PM
This project just got a lot cooler. Does Mazda have a nodata-like program for tuning/reprogramming?

BMFScout
05-21-2008, 02:26 PM
This thread is worthless without a turbo. :)

Doug Krebs
05-21-2008, 02:28 PM
thats why the exaust manifold is off!

robertf03
05-21-2008, 02:31 PM
This project just got a lot cooler. Does Mazda have a nodata-like program for tuning/reprogramming?

I haven't found anything like that. This engine had one of those flapper vane air flow meters so I'm not too interested in the factory stuff.

Most likely to least likely management systems are-

gm stuff that I found in my pants after leaving a junkyard :gigem:
megasquirt (ghetto, but for this application it actually supports everything I need)
Autronic EMS

uglyota
05-21-2008, 02:38 PM
always wondered how hard it would be to adapt a Honda harness to something else and run nodata. You should do that. No wait graduate first, then do that :D

agjohn02
05-21-2008, 02:47 PM
http://www.pe-ltd.com/

robertf03
05-21-2008, 03:47 PM
I need to learn up on turbos. It looks like t25s and t3s are the two that seem to be used the most on little cars.

This manifold looks like it would work, the downpipe is probably worthless but the flange could be reused


http://cgi.ebay.com/ebaymotors/90-94-miata-turbo-manifold-w-2-5-stainless-downpipe_W0QQcmdZViewItemQQcategoryZ33742QQihZ025Q QitemZ380027933257QQrdZ1QQsspagenameZWDVW

eight
05-21-2008, 05:43 PM
John has this book that's an interesting read on turbos.

agjohn02
05-21-2008, 05:47 PM
"Maximum Boost" by Corky Bell. he's an old ag with a company in san antonio that does turbo systems. Bell Engineering or something like that.

robertf03
05-21-2008, 06:43 PM
Didn't know he was an Ag. I've had his book for a while just never read it. Does it go over part #'s and stuff, or is it more generic?

agjohn02
05-21-2008, 06:52 PM
i saw an aggie ring in lots of the pics in the book and asked him when i spoke to him on the phone.

theres a whole chapter on how to install a turbo system on a miata

robertf03
05-21-2008, 07:20 PM
Sweet, it was one of those recommended books from Amazon. I need turbo housing dimensions. Thats going to be the deal breaker.

agjohn02
05-21-2008, 07:53 PM
http://www.turbobygarrett.com/

Seth
05-21-2008, 09:39 PM
So what kind of curb weight are you looking at? Also, what will the before and after power figures be?

tigweld
05-21-2008, 09:55 PM
gt2871rs "disco potato" they are expensive but worth it. ball bearing, internal wastegate I think they support about 325 pretty easily

My vote is to get a garrett, or maybe one of the newer extended tip bw's(don't know if they go that small yet though

robertf03
05-21-2008, 10:01 PM
stock Alpine 2100 pounds, 99 horsepower 103 ftlb torque probably at the flywheel
http://www.conceptcarz.com/vehicle/z12919/Sunbeam_Harrington_Le_Mans.aspx



I don't know what the weight will be after, I can't see how it'll grow more than 200 pounds.

Miata 1.6 is 116 HP 100ft lbs stock, so pretty close on paper. I don't know what a turbo will do to it. I don't plan on changing pistons so I expect it to be pretty mild to be happy with boost.

http://www.cargurus.com/Cars/Overview-c5725-1990-MX-5-Miata.html

From the 0-60 times I found online the Miata was something like 9 seconds faster, and almost 1000 lbs heavier. Probably more aerodynamic though.

agjohn02
05-22-2008, 02:26 AM
just stack a few head gaskets on it and tighten up the wastegate

Jackasic
05-22-2008, 07:34 AM
when you are back in town, I'll have youlook ar Rami's turbo miata.

robertf03
05-26-2008, 01:59 AM
Picked up a transmission from a 99+ MX5, it has an updated case with two possible shifter locations. I figured this would help get the shifter closer to the stock location. Unfortuneatly the redundant rear shifter housing does not clear the hole between transmission tunnel and the X shaped chassis.

robertf03
05-26-2008, 02:00 AM
New plan is to get a 97 or older transmission and mill the shifter down 1/4", weld a plate to the bottom and move the thing as close to the center of the transmission as possible.

I found one project online where they were able to get 4" out of modifying the shifter. I think I can get 8" my way, and it should line up close enough to the stock hole to require minimum floor pan modifying

robertf03
05-29-2008, 12:57 PM
Ordered a megasquirt kit. I feel so dirty

But it was cheap, and to my knowledge its the only drivetrain they offer this for http://www.diyautotune.com/catalog/megasquirtpnp-mm9093-199093-mazda-miata-manual-tranny-p-154.html

Thats almost AEM quality at 1/3rd the price (I bought the kit, even cheaper :gigem: )

One person running that system got 265 HP with 12 psi boost and had dyno sheets to prove it. I'll be very happy with anything over 200.

robertf03
06-02-2008, 11:09 PM
Went well until the optional stuff had to get installed (idle air control PWM valve, boost control, fan control.) Thats when the experimental nature of this efi system really shows. Lots of external "flying wires", but I think it will work fine. The plug and play version of this has a redesigned board to make it cleaner, but it uses surface mounted devices and isn't really sold as a kit.

That black crap is liquid electric tape. The bottom will be douched with it, and maybe the top, not sure yet.

Doug Krebs
06-03-2008, 01:05 AM
Should have taken it to the shack!

robertf03
06-04-2008, 12:03 AM
finished, now its back to solving the transmission problem.

BMFScout
06-04-2008, 12:05 AM
i hope the alligator clamps are permanent.

davido
06-05-2008, 01:20 AM
Rami @ Caffe Capri is a wealth of Miata knowledge to drop on you, on tap. He has a turbo and non.

robertf03
06-06-2008, 01:49 PM
Subway is givine one of these away.

Maybe the Get Smart movie will turn them into the next Elanor.

agjohn02
06-06-2008, 05:39 PM
...

robertf03
06-06-2008, 06:02 PM
Is that the yard where the guy won't sell anything? I might need a shortblock of that vintage.

agjohn02
06-06-2008, 06:14 PM
yup. i think this one is engineless but there was another in the distance that looked kinda like what you have. not sure though since i dont care about gay man cars.

robertf03
06-06-2008, 06:54 PM
yup. i think this one is engineless but there was another in the distance that looked kinda like what you have. not sure though since i dont care about gay man cars.

You got a record for racing the dumb and dumber bike, I don't think you have any room to talk.

jerryg79
06-06-2008, 07:35 PM
You got a record for racing the dumb and dumber bike, I don't think you have any room to talk.

nicely done

robertf03
06-08-2008, 03:01 PM
picked up an earlier transmission to fix the tunnel clearance problem, but the shifter is still in the wrong position and it doesnt look like it can be easily modified to work. Going the remote shifter path, probably using a t5 aftermarket chinese shifter since they are cheap and I'll be cutting one end of it off and modifiying.

colman
06-08-2008, 06:25 PM
is that scott's yard? off leonard

robertf03
06-08-2008, 09:53 PM
more better, less moving parts, cheaper and an unmodified t5 shifter.

Fredo
06-16-2008, 01:08 PM
Flem! **** that miata bull****! This is what you need....would definitely be unique!
http://dallas.craigslist.org/pts/721354538.html

BMFScout
06-16-2008, 01:18 PM
fawk yeah! I wonder if that is worth picking up just because. What should that motor go for.

robertf03
06-16-2008, 01:18 PM
30 cents a pound

BMFScout
06-16-2008, 01:35 PM
I'm just going to buy it for my imaginary belly tanker or rat rod whichever I build first. Only 3500 of those made. Wonder if he would take $500...hmmm...

uglyota
06-16-2008, 02:37 PM
I'm just going to buy it for my imaginary belly tanker or rat rod whichever I build first. Only 3500 of those made. Wonder if he would take $500...hmmm...

that's awesome...

tigweld
06-16-2008, 04:23 PM
Flem! **** that miata bull****! This is what you need....would definitely be unique!
http://dallas.craigslist.org/pts/721354538.html

haha fred that made me think of the midgets with the t bucket from back in the day

Fredo
06-16-2008, 04:39 PM
haha, I haven't thought of that couple in forever. I wish I still had my bolt pattern card that I got from them. I think it got destroyed when my wallet got soaked in the pool a few years back.

BMFScout
06-16-2008, 04:48 PM
http://www.jalopyjournal.com/forum/showthread.php?t=248260

robertf03
06-16-2008, 04:59 PM
I've had to do that a few times when a tape measure wasn't around.

Seth
06-16-2008, 08:48 PM
Everything I have ever heard about Cosworth is badass. My folks made friends with some Brits on vacation once, turns out he was a cop in the UK. Half his time doing drug busts, half on the queen's motorcade. His "patrol car" was a Ford cosworth that was apparently riduculously crazy for being a 2.0 liter or whatever it was. On a side note, he also has a son who was (is?) on Nigel Mansell's crew and had a kart that could do 120, he is an excellent magician, and he has a radio show. If you think I'm making it up, ask Jimmy about if I make things up!

Also, I think I saw a youtube (on here I'm sure) of a cosworth motor spinning like 20k rpm or something nuts like that.

So in conclusion, Flem you should do it, but since you won't, Jimmy you should and use on the ****pit that I see out in a field about once or twice a week.

BMFScout
07-31-2008, 12:39 PM
F'n Wankel?

http://dallas.craigslist.org/mdf/pts/777426045.html

robertf03
07-31-2008, 01:45 PM
I've already got plenty of tire chocks

BMFScout
07-31-2008, 01:49 PM
3 of 'em last I counted. The best chock X Chock X far!

Thought of a better zing: The Nova? Didn't work out so good last time!

Sorry, Flem.

robertf03
07-31-2008, 01:51 PM
they are included under the hood

robertf03
09-29-2008, 04:25 PM
DavidO's Miata and trophy makes me want to finish this

davido
09-29-2008, 04:27 PM
Oh yeah! It's fun.

robertf03
01-10-2009, 01:05 PM
engine is placed, drivetrain mount time

engine mounts - 91 XJ12
transmission mounts - 91 XJ6 left side

robertf03
01-10-2009, 01:15 PM
the crank pulley coincidentally lined up with the hand crank holes, so I figure its good.

KrazyKarl02
01-11-2009, 10:13 AM
the crank pulley coincidentally lined up with the hand crank holes, so I figure its good.

In that case, I'd leave the starter off.

robertf03
01-11-2009, 06:40 PM
something like this

robertf03
01-12-2009, 07:03 PM
engine side done

davido
01-12-2009, 07:13 PM
In that case, I'd leave the starter off.

Yep. Handcrank.... or you can suck start it. :flipoff2:

robertf03
01-13-2009, 08:29 PM
frame side done

85cj7
01-13-2009, 08:35 PM
look better than the cardboard ones did.

Flem-"F*cking tape, why won't you stick?"

robertf03
01-14-2009, 12:38 AM
stabbed

BMFScout
01-14-2009, 01:19 AM
sweet, let's go do donuts.

robertf03
01-16-2009, 02:46 PM
ugly trans mount. no pics of the crossmember, but its all in there.

Fredo
01-16-2009, 02:50 PM
You're still in Dallas?

robertf03
01-16-2009, 02:53 PM
no, those are from 2 days ago. Was up till 2 finishing the crossmember on wednesday.

Graystroke
01-16-2009, 04:38 PM
so does it move under it's own power?

85cj7
01-16-2009, 06:20 PM
I asked him that today, he said that he pushed it fast and made the mazda "zoom, zoom, zoom" noise, and that was close enough.

robertf03
02-10-2009, 03:41 AM
can't sleep, so I ordered exhaust parts. I think the kia manifold just won't cut it

from Great Plains Aircraft Supply
http://www.greatplainsas.com/exh4to104.jpeg

flange from jgs precision


now I just need some stuff to go in the middle. 1.375 tubing. Anyone know the cheapest place to get mandrel u bends? not as many 90's as in the gay ass model, but center dump style like that

tigweld
02-10-2009, 08:43 AM
u should put your inside 2 cylinders to the outside of the collector and your lenths would be closer

robertf03
02-10-2009, 12:45 PM
I agree, that design sucked

it'll probably be more like this, but I have to wait until I can take some measurements from the car again. I might switch the 3 to go over the 4 to make it longer, maybe do the same to #2. its pointless without measurements though.

Where do you buy your prebent mandrel pieces?

and how the hell do you weld the star in between the tubes? pull the gas line and purge it over the area with 4" of tungsten sticking out?

mudtoy67
02-10-2009, 12:51 PM
I think the star is welded in before welding the tubes in the collector.

robertf03
02-10-2009, 12:54 PM
that way doesn't sound any easier. at least 1 tube is going to be a mother****er to weld

uglyota
02-10-2009, 12:59 PM
maybe tri-y is passe but why do you want to do a 4-1 dump? Seems like it would be the ticket for the revs this thing will probably do and easier to weld too. Speaking of which are you talking about trying to weld only from the outside? I figured the collector would be welded from the inside with a pen-style torch.

robertf03
02-10-2009, 01:01 PM
I found some website where they did a dyno shootout on tri-y and 4:1 with different lengths on a miata and the 4:1 was more better

I'm also fighting steering arm clearances with the exhaust so my options are pretty limited, the stock manifold works if you never have to turn left.

uglyota
02-10-2009, 01:09 PM
as cool as it would be to build your own header, how hard would it be to convert to rack and pinion steering? And I think espearo has bought pre-mandrel bent joints before, maybe ask him where? Trick-tools' most recent email showcased some sweet header jigs

robertf03
02-10-2009, 01:14 PM
Other than drivetrain, I'm not changing the way the car handles. I want it to drive like an Alpine.

mudtoy67
02-10-2009, 01:30 PM
that way doesn't sound any easier. at least 1 tube is going to be a mother****er to weld

Weld it from the bottom:

http://image.carcraft.com/f/10415904/ccrp_0803_25_z+custom_exhaust_headers+tubes_weldin g.jpg


Then weld your collector.

RCcola55
02-10-2009, 01:33 PM
http://www.pirate4x4.com/forum/showthread.php?t=737811

robertf03
02-10-2009, 03:37 PM
I thought the tubing extended past the star in most apps. guess it doesn't matter

sasquatch
02-10-2009, 04:23 PM
http://collegestation.craigslist.org/pts/1029197240.html

Sharpe
02-10-2009, 05:18 PM
http://collegestation.craigslist.org/pts/1029197240.html

Hm if I could find 7 more of those think they'd work on Pigpen?

CheapJeep
02-10-2009, 07:26 PM
Jegs and Summit both sell pre-bent do it yourself kits.

robertf03
02-10-2009, 07:30 PM
I didn't see 1.375 in their catalogs

that airplane place has it pretty cheap. I think I'll wait until the flange and collector get here and maybe tack weld some shat on there to position them where they need to be so I can draw it up and figure out exactly what kind of bends I need

maybe some pvc pipe :D

CheapJeep
02-10-2009, 07:47 PM
toilet paper rolls and ductape.

Might have to do some research to see if you could make one of the applications fit but there are several with 1 3/8" primaries.
http://www.pacesetterexhaust.com/headers_detail.php

tigweld
02-10-2009, 08:27 PM
go here for all you header building questions www.turbomustangs.com

robertf03
02-11-2009, 02:03 AM
I'll check it out. I've got it setup so all I need is measurements and its ready to cut.

this place looks cheap. 4 ubends will cover the entire thing if it ends up being close to the model. http://www.magnumforceracing.com/ubend.asp

robertf03
02-16-2009, 10:38 PM
flange came in, got some measurements and its time to order tube

Graystroke
02-16-2009, 11:26 PM
shiny!

tigweld
02-17-2009, 08:36 AM
what are you planning on for a collector. can you use the comp to make your templates to cut a merge collector. if you do I would weld it for you if you give me the templates.

Jackasic
02-17-2009, 09:05 AM
http://www.icengineworks.com/

tigweld
02-17-2009, 09:42 AM
have u ever priced that stuff, I would have to fawk up a lot of tubing to justify the price(one the guys on turbomustangs was showing them off and he told the pricing breakdown). maybe if I was building headers every day , or if I knew a mandrel bending place that could make all the primaries one piece they would pay off

Jackasic
02-17-2009, 09:44 AM
friend of mine owens it, pretty cool stuff. I think it is close to a grand.

robertf03
02-17-2009, 10:05 AM
I bought the merge collector from great plains. Its sitting on my desk right now.

coneng.com has more sizes and larger selection. there tubing selection is better with a smaller radius, but more expensive.



I was going to cut a slot in a hose clamp for my tack clamp.

tigweld
02-17-2009, 10:31 AM
u sure its a merge and not just a pressed collector

http://www.stans-headers.com/parts.htm this is stamped collector

http://www.burnsstainless.com/MergeCollectors/4into1base/4into1base.html this is a merge

robertf03
02-17-2009, 10:37 AM
its stamped, starts with a 1.75 outlet, cut to length for whatever exhaust flange size you want.

All the miata fags say to run 2.5, I'm thinking 2.25. The primaries are only 1.375 16g. What do you think?

I could probably draw a template. How much of a difference is there in the way a merge collector functions vs a stampe? looks like mock up would be easier with a merge.


this gives me wood
http://www.burnsstainless.com/InconelTube/inconeltube.html

robertf03
02-17-2009, 12:06 PM
forgot the o2

Fredo
02-17-2009, 12:25 PM
Why wouldn't you just put the o2 in the pipe and run a heated sensor if need be?

Sharpe
02-17-2009, 02:03 PM
[Flem logic] o2 sensors cost $20 per wire. Thus, heated ones are not cost effective[/Flem logic]

Fredo
02-17-2009, 02:28 PM
I doubt you would even need a heated one. I just figure it would make more sense to put it in the downpipe incase you ever strip out the bung's threads or something.

Eckert
02-17-2009, 02:38 PM
this way cylinder #3 is most efficient.

tigweld
02-17-2009, 05:37 PM
its stamped, starts with a 1.75 outlet, cut to length for whatever exhaust flange size you want.

All the miata fags say to run 2.5, I'm thinking 2.25. The primaries are only 1.375 16g. What do you think?

I could probably draw a template. How much of a difference is there in the way a merge collector functions vs a stampe? looks like mock up would be easier with a merge.]


I think I would go about this two completely different ways depending on if it's gonna be turboed or n/a and possibly even another way depending on the the turbo size and how far its gonna be from the collector.

a merge I would think is better as there on every ultra high end motor ive seen, but I think there is much more tube length and turn in tuning involved to actually reap the benifits associated with it's design

robertf03
02-17-2009, 07:11 PM
I thought about building a spreadsheet to calculate primary lengths based on camshaft lift vs crankshaft angle and target RPM to keep it laminar flow but I realized I don't know what the hell I'm doing and said **** it, what would stacey david do?

KrazyKarl02
02-17-2009, 11:48 PM
what would stacey david do?

He'd make a custom PPG color or too!

Thats what Stacy David would do!!!

I think copperhead sunbeam butt love would be it's name:flipoff2:

robertf03
02-20-2009, 03:37 PM
St. John, check this place out
I talked to him and he said it sounds pretty easy

http://www.bradsfabinc.com/index.php

tigweld
02-20-2009, 05:30 PM
now that I know that place is there that ice system is more appealing. u get pricing?

Graystroke
02-20-2009, 10:26 PM
St. John, check this place out
I talked to him and he said it sounds pretty easy

http://www.bradsfabinc.com/index.php

i've been to their shop. they make all kinds of crap. when I was in there they were making headers for some kinda open wheel car. it's in Saginaw (use to be) by the big grain silos. they also did pipes for lots of bikes.

robertf03
02-20-2009, 10:40 PM
now that I know that place is there that ice system is more appealing. u get pricing?

not yet

I'm up here helping my brother move this weekend and I'm going to duck out for a few hours to bring him some drawings. He wouldn't give even a rough estimate without seeing the drawing.

DRAGOONRANCH
02-20-2009, 11:03 PM
it's in Saginaw (use to be) by the big grain silos.

we used to go to church up in them parts, back when we was baptists...

robertf03
02-21-2009, 11:48 PM
i've been to their shop. they make all kinds of crap. when I was in there they were making headers for some kinda open wheel car. it's in Saginaw (use to be) by the big grain silos. they also did pipes for lots of bikes.

worthless.

I couldn't have made easier directions for what I want and he just didn't get it. Also said he couldn't rotate the tubing after a bend and that it had to be removed and reloaded. I didn't actually see his mandrel bender, but it sounds like it sucks if thats the case.

Expensive too, said it would be $300 to $400

davido
02-22-2009, 11:14 AM
Post Pics! :)

robertf03
02-22-2009, 05:58 PM
don't laugh too hard at the gaps.

AggieTJ2007
02-22-2009, 06:19 PM
they look sweet, don't worry about the gaps, just gives better penetration

robertf03
02-23-2009, 12:18 AM
thats the problem, I'm shooting for nothing more than 100% since its fancy mandrel tubing.

Welding 18 gauge to the 1/2" flange sucks. I think this is the first time I've ever dealt with such a large difference in material thickness.

tigweld
02-23-2009, 08:20 AM
nice work flemy!!!!!! I'm impressed

robertf03
02-24-2009, 12:59 PM
ordered a 2 bolt flange

and some of this crap for the intake

robertf03
02-28-2009, 08:01 PM
Ran out of wire on the header, but got the cooling lines and intake are almost done

BMFScout
02-17-2010, 08:03 PM
you see this one?!

http://dallas.craigslist.org/mdf/cto/1561526056.html

robertf03
03-18-2010, 07:56 PM
this took way too long. I need a real mill

http://public.blu.livefilestore.com/y1pq0LStiViWktXdP2-cDgvbtH1x73YRymh56xtoq-13HbldRGsjiXnAqskJcUz2kblNj9YUsD6AtaZGXWPsBBpCA/img093.jpg


http://public.blu.livefilestore.com/y1pQz7PJlfAqpStcjEsZthXG2lbC4PXeFKtRORpHlQLaY_aRMi 19pnZnV4WVIn6dV88iQ1V1JsTVuhZSMmJ5KMHbA/img092.jpg

robertf03
03-18-2010, 09:27 PM
and the install. exciting ****, huh?

http://public.blu.livefilestore.com/y1p0EdO7yIhdArh7p8o1NRecaAPnXs3FeBGk9mdcYgXA2W2sN2 iXj-RzWDCX5ON-cfNKcbztng0yGNB3egqHHe9JA/img094.jpg

85cj7
05-31-2010, 09:51 PM
this might work for you. . . electric fans
http://www.texas4x4.org/showthread.php?t=33558

robertf03
06-15-2010, 11:39 PM
Well I can't find a miata ICM plug that isn't cracked and missing chunks so I think I'm going to throw out that ICM and bracket and go with a bosch.

http://apps.bosch.com.au/motorsport/downloads/ignitionmodules.pdf

BIM200 looks like a winner. Uses jpt connector instead of some ****ty tyco connector that looks like its been discontinued.

St. John, the 211 ICM would work great for v8 waste spark if you are still pondering that.

Need to take a few more measurements then its time to print a nailboard.

robertf03
06-17-2010, 04:09 PM
this harness is going to be sweet. I didn't want to reuse any connections since they are ****ty and 20 years old. Sourcing connectors has been a pain in the ass, but I think I've figured out who made each one. The Miata harness already used connectors from AMP/Tyco, Deutsch, Sumitomo, and Bosch. I've got to throw some Delphi junk in there to round it out.

Sharpe
06-17-2010, 04:15 PM
Did you find the ICM pigtail? Just solder wire leads to the tabs on the ICM and put a weatherpack connector on it. :gigem:

robertf03
06-17-2010, 05:39 PM
yes, motec sells them and after some more digging I found out sumitomo makes them.

robertf03
02-02-2011, 11:46 PM
http://www.flemcodesign.com/pics/header/h1.jpg

http://www.flemcodesign.com/pics/header/h2.jpg

davido
02-03-2011, 02:25 AM
Pretty piomp!

Sharpe
02-03-2011, 09:03 AM
Tite, gonna whack the flange flat on a mill?

robertf03
02-04-2011, 03:41 AM
no, I got the flange from some site that sold it and pipe fittings to make your own ghetto turbo manifold. Its probably twice as thick as it should be so I'll take my chances with warpage.

robertf03
02-15-2011, 11:35 PM
exciting **** going on

AggieTJ2007
02-16-2011, 05:16 AM
where did you get the parts for that?

robertf03
02-16-2011, 03:00 PM
most of it from mouser, but they had a stupid high minimum order for the relay terminals, they came from waytek

robertf03
02-26-2011, 10:49 PM
going to try some aluminum next week, but I think I've got the shifter figured out

http://www.flemcodesign.com/pics/alpine/milling.jpg

http://www.flemcodesign.com/pics/alpine/shifter2.jpg

http://www.flemcodesign.com/pics/alpine/shifter1.jpg

Sharpe
02-27-2011, 11:34 AM
Built a cabinet for it too?

davido
02-28-2011, 03:31 AM
You amaze me Flemboni. That's crazy stuff.

robertf03
03-16-2011, 07:10 PM
how to remove gudgeon pins

make jig on cnc router

http://www.flemcodesign.com/pics/pistonjig1.jpg




use press


http://www.flemcodesign.com/pics/pistonjig2.jpg

AggieTJ2007
03-16-2011, 07:21 PM
sweet

TdmayfieldIV
03-16-2011, 11:25 PM
That's what I did at cooks when I got bored. Except I could break the pistons so normally ended up breaking them off with a hammer and pressing the pins out of the rod. I would hate to do more than one with your rig, the rod would move down and make it press crooked and break the piston. You need a wall on the rear to support the rod.

robertf03
03-17-2011, 12:12 AM
pin presses into the piston, not the rod

KrazyKarl02
03-17-2011, 06:51 AM
pin presses into the piston, not the rod

Maybe that's why he does not work there anymore :flipoff2:

85cj7
04-07-2011, 01:45 AM
http://www.texas4x4.org/showthread.php?t=38030

robertf03
04-25-2011, 06:53 PM
getting there.

davido
04-27-2011, 03:51 PM
Reminded me of your project: http://home.earthlink.net/~roethler/engine.html

robertf03
05-09-2011, 05:43 PM
throw out bearing was almost worn down, glad I waited for the new one to show up.

http://www.flemcodesign.com/pics/alpinestuff/tobearing.jpg
http://www.flemcodesign.com/pics/alpinestuff/dirtyenginebay.jpg
http://www.flemcodesign.com/pics/alpinestuff/cleanenginebay.jpg

robertf03
05-10-2011, 04:21 PM
http://www.flemcodesign.com/pics/alpine/sunbeamengine.jpg

KrazyKarl02
05-10-2011, 04:57 PM
Sweet! Where is the Flemco Exhaust?

Seth
05-10-2011, 05:28 PM
Different car/engine I believe. This one is original motor, making it to a show in may hopefully.

robertf03
05-10-2011, 05:56 PM
correct

robertf03
05-15-2011, 08:41 PM
http://www.youtube.com/watch?v=D4DRA-weptE (http://www.youtube.com/watch?v=D4DRA-weptE)

robertf03
05-20-2011, 02:59 PM
its legal!

18591

robertf03
05-22-2011, 06:28 PM
Today was the All British and European Car Day at White Rock Lake in Dallas.
Yesterday I drove the Alpine for the first time since purchasing it, and the exhaust fell out about 1 mile into the run. I spent most of yesterday patching together leftover exhaust from other cars and got it running good enough to make the 10 mile back roads route to the lake. Ran pretty good at upper RPMs, but the Stromberg CD 150s need rebuilding.
my car
http://www.flemcodesign.com/pics/abcd/0.jpg
The Sunbeam group, minus one Alpine running late.
http://www.flemcodesign.com/pics/abcd/1.jpg

Rat Rod V8 MG
http://www.flemcodesign.com/pics/abcd/2.jpg

http://www.flemcodesign.com/pics/abcd/2.5.jpg
Yugo, Rover, Citroen
http://www.flemcodesign.com/pics/abcd/3.jpg
This thing was all kinds of awesome
http://www.flemcodesign.com/pics/abcd/4.jpg

Tank thing
http://www.flemcodesign.com/pics/abcd/5.jpg
Moke
http://www.flemcodesign.com/pics/abcd/6.jpg
French car
http://www.flemcodesign.com/pics/abcd/7.jpg

Sparling
05-22-2011, 06:46 PM
My grandpa has a red mgb in his garage, but it still has the 4 cyl, cool story I know

robertf03
06-06-2011, 11:37 PM
time to add some tunes. Picked up a chitty audiovox thats roughly period correct.

cracked it open and added an aux input.

robertf03
06-07-2011, 12:03 AM
added a limit switch that one of the preset buttons will hit. The switch will toggle between aux and AM

85cj7
06-07-2011, 12:06 AM
Pretty freakin slick!

TdmayfieldIV
06-07-2011, 01:14 AM
nice

KrazyKarl02
06-07-2011, 07:51 AM
Just so you know, you voided your warranty by breaking that seal.

How does this work? When you push the toggle, does it switch the speaker output so it is connected direct to your headphone jack? Does that mean the only thing powering the speakers is the phone? Or does the signal still go through the radios's amplifiers and you can control sound level by adjusting the radio?

robertf03
06-07-2011, 08:33 AM
It still goes through the amplifier and the trebel bass knob.

I'll post a picture once the circuit is done, the main part is a nte4066 chip that you can get at Frys and probably radio shack. Its basically an electronic relay that lets you select analog sources.

There was a blue wire in the radio that went to the volume knob. The volume knob is just a potentiometer so using a voltmeter I identified which one of the 3 legs was the low end of the carbon track, cut it, and the potentiometer side of the wire became the input line while the other half became the AM output line.

FJAggie07
06-07-2011, 09:49 AM
It still goes through the amplifier and the trebel bass knob.

I'll post a picture once the circuit is done, the main part is a nte4066 chip that you can get at Frys and probably radio shack. Its basically an electronic relay that lets you select analog sources.

There was a blue wire in the radio that went to the volume knob. The volume knob is just a potentiometer so using a voltmeter I identified which one of the 3 legs was the low end of the carbon track, cut it, and the potentiometer side of the wire became the input line while the other half became the AM output line.

:confused:

Sounds cool! :D

Hot Pocket
06-07-2011, 11:03 AM
Impressive Flem

robertf03
06-30-2011, 08:55 PM
rebuilt the tachometer with modern electronics, repainted needle with model car paint "flourescent red" from hobby lobby, obtained correct series 5 speedometer and cleaned it up.

http://www.flemcodesign.com/pics/gauges.jpg

Fredo
06-30-2011, 10:18 PM
Kickass Flem! You end up getting the carbs rebuilt yet?

robertf03
07-01-2011, 12:11 AM
yeah, got them on there tonight. I rebuilt them a week ago just haven't built up the patience until now to tackle those 2 bolts that require a crowsfoot. Big difference in the way it starts, the corrected timing helped too.

Fredo
07-01-2011, 10:32 AM
I told you to take the BMF-478G Sunbeam Mounting Bolt Tightening Tool with you.

AggieTJ2007
07-02-2011, 06:46 AM
I told you to take the BMF-478G Sunbeam Mounting Bolt Tightening Tool with you.

you keep a small child locked in the shop?

robertf03
07-12-2011, 11:40 PM
it almost has power brakes

http://www.flemcodesign.com/pics/booster1.jpg

http://www.flemcodesign.com/pics/booster.jpg

TdmayfieldIV
07-13-2011, 12:43 AM
who needs power brakes?

Sharpe
07-13-2011, 12:56 AM
Needs more soda!

robertf03
07-13-2011, 11:20 AM
needs more air filter. It was missing and the chamber was full of corn mash

robertf03
07-13-2011, 02:35 PM
http://www.flemcodesign.com/pics/booster2.jpg

TdmayfieldIV
08-16-2011, 11:40 PM
http://i736.photobucket.com/albums/xx6/TdmayfieldIV/IMAG0090.jpg

only $175, perfect finishing touch for the sunbeam.

robertf03
08-19-2011, 06:51 PM
187101871118712

85cj7
08-19-2011, 07:22 PM
Looks good man.

robertf03
06-23-2014, 10:09 PM
6 years later it fires up! Just needs another 6 and it'll be driveable

robertf03
06-26-2014, 11:04 PM
http://youtu.be/16eTBwFbdXY

davido
06-27-2014, 10:32 PM
Do you even time bro? :)

That engine is straight beast mode. They can take a beating, or so I've heard.

robertf03
06-30-2014, 09:59 PM
nope, haven't timed it yet :gigem:

It's not as straight forward doing the timing with the megasquirt, but it'll have to wait for exhaust and driveshaft. with no driveshaft it dumps fluid out faster than I can put it in.

Driveshaft is going to be kind of wierd too. I'm finding out the japanese copied then updated all kinds of stuff from british 60s roadsters. To upgrade the sunbeam to a 1310 ujoint I need a nissan Z driveshaft, same flange pattern and register. To go to dual circuit brakes a subaru GL wagon (which ironically would have been my first car if it hadn't been for the great Dallas Thanksgiving ice storm of 1995) brake cylinder bolts up with some plumbing.

robertf03
07-06-2014, 11:58 PM
sounds better with an exhaust, and the correct injector size in the ecu settings.

Magnaflow 2.25 round muffler, 2.25 exhaust, kustom header


https://www.youtube.com/watch?v=hAdpr6gyC6o

colman
07-07-2014, 12:36 PM
turbo on version 2.0?

robertf03
07-07-2014, 12:53 PM
I'd like to, but there is still plenty to do and possibly redo before turbo

robertf03
07-07-2014, 09:08 PM
so here is the ridiculously overkill downpipe with the muffler slid over it. It snakes it's way from the header through the exhaust hole in the X chassis portion of the unibody. It's tight, but I think with the right hangers and that flex section it should stay put and not bang around in the tunnel :confused2

http://www.flemcodesign.com/pics/miataexhaust.jpg

I still need to do the rear section that goes over the axle. But thats for later

robertf03
10-30-2014, 11:53 PM
Fuel lines and driveshaft done. It was a good feeling watching the wheels turn powered by the mazda engine

still have lots to so before it's burnout time

http://www.flemcodesign.com/pics/IMG_0620.JPG

http://www.flemcodesign.com/pics/IMG_0621.JPG

Sharpe
10-31-2014, 08:10 AM
Has is cost at least $6750 so far? If not, why bother?

robertf03
10-31-2014, 09:06 AM
Way more than 6750, I'm a car guy

robertf03
11-08-2014, 01:30 AM
Clutch and brakes plumbed.

Shifter completed, had to shorted the linkage 3/32. Modified alpine stick to bolt to t5 mount


So close. Picking up the modified radiator tomorrow

http://www.flemcodesign.com/pics/IMG_0691.JPG

Sharpe
11-08-2014, 12:27 PM
What's the HP difference between the two engines?

robertf03
11-08-2014, 12:34 PM
20 ish if you believe 60s power ratings and early 90s power ratings.

robertf03
11-09-2014, 11:26 PM
Loom and coolant lines almost done. I'm now running in to all the problems I said I'd deal with later like broken studs at the back of the engine that take 3 hours to remove


http://www.flemcodesign.com/pics/IMG_0710.JPG

http://www.flemcodesign.com/pics/IMG_0711.JPG

And for reference

http://www.flemcodesign.com/pics/IMG_0713.JPG

robertf03
11-10-2014, 09:59 PM
Played with some mig welding aluminum tonight. No spool gun, just a bottle of pure argon and a straight torch cable. Worked pretty good. My aluminum welding skills are bad, but my flap disc skills are great.

http://www.flemcodesign.com/pics/IMG_0735.JPG


http://www.flemcodesign.com/pics/IMG_0736.JPG

Sharpe
11-10-2014, 10:38 PM
So you managed to get the wire to feed through the liner? What thickness? Are you doing any other AL work?

robertf03
11-10-2014, 10:46 PM
.030 I had no problems. I was anticipating a birds nest and almost mail ordered a spool gun, I'm glad I didnt


i didn't touch the tensioner, I undid it to remove the steel, flipped it up and fed it through without tightening and it made consistent noise the whole time so I guess it was tight enough

i only have 1 more al welding project, and it's removing the Bosch crank sensor mount from my newest rover 4.6 and tack welding on the gems bracket. Sounds ethnic, but that's how it was done in the factory

the wire feed and heat are way different. Obviously I'm still figuring it out, but low amp and high feed compared to steel seemed to work. It makes a whooshing noise, not sizzling.

jerryg79
11-11-2014, 08:38 AM
Has is cost at least $6750 so far? If not, why bother?


;300745"]Way more than 6750, I'm a car guy

Well played!

KrazyKarl02
11-11-2014, 09:07 AM
That is impressive use of a flap disc! I am amazed you were able to get 0.030 aluminum wire to feed thru a liner. I've been attempting to do some Al welding with a spool gun and the wire is soft as ****. Similar experience with the noise and it is definately way more touchy to getting the wire feed and heat dialed in than steel.

robertf03
11-23-2014, 12:08 AM
Still finishing up all of the details. It's been running very rough, high idle, stumbling when the gas is hit. I suspected it was lack of throttle position input to the ecm since the 1.6 uses a throttle switch that tells the factory ecu idle and wot with nothing in between.

I went through every tps I could find at pick n pull and a Kia sephia was the winner. Same plug, same shaft diameter, just needs a spacer with a different bolt pattern

It's running much better with this setup

http://www.flemcodesign.com/pics/IMG_0842.JPG

http://www.flemcodesign.com/pics/IMG_0841.JPG

robertf03
11-23-2014, 09:22 PM
It moves! And then it gets towed home by a discovery

i overestimated the remaining fuel in the tank and the maiden voyage around the block was going well so I pushed it too far. Tried pushing it and found out the brakes are dragging. Burned up the starter and one of the linkage bolts loosened up

I think one more weekend of messing with it and it'll be good to go. It's got some balls compared to the stock one

robertf03
12-09-2014, 01:09 AM
So megasquirt has a neat "feature" where it fires the coils at power up. Not a big deal for a tuned vehicle, but for one with a rough fuel map on the rich side it can create enough of a bang to blow out the fuel pressure regulator like whiskey in a delorean.

I had to put together a rigged up daughter board of transistors to fix the problem.

I can't recommend these turds for anything. Way to crude and you have to have an electronics background and an oscilloscope just to get the ****ing car to start. The only one I'd consider using in the future is the ms3pro, but at $1000 bucks it's probably time to consider a real brand

robertf03
12-11-2014, 11:59 PM
So the ecm mods worked. No more random backfire.

E fan off a Kia something or other mocked up. It really shows the shoe horn it took to fit this thing. Less than 1" clearance between water pump and fan.

Cable x speedometer drive tested and moving the speedo 25% faster than expected. Easily fixed by changing some jumpers but the chart no longer applies.

I thought it would be a few more weekends, but realistically spring before I attempt to inspect and register.

http://www.flemcodesign.com/pics/IMG_0876.JPG

Fredo
12-12-2014, 01:42 AM
Sweet man. One inch is plenty of clearance at the fan. Lurch has just enough room to wrestle a vbelt past the pulley/fans.

Are you converting a vss signal to drive a cable speedo? If so, did you build the motor drive, or did you buy one?

KrazyKarl02
12-12-2014, 08:18 AM
It looks like his Cable/Speedo converter is that box in the lower right.

robertf03
12-12-2014, 08:31 AM
I bought one. It's called cable x. Dakota digital also makes one but they were back ordered for a few months

Fredo
12-12-2014, 11:26 AM
Cool. I've sold a couple of the Dakota Digital ones and they work pretty good. At least that is what the guys I sold them to told me. It's a neat niche product.

robertf03
12-12-2014, 11:54 AM
This thing seems noisy, but the engine was off and the cable had a 180 in it. Hopefully it's quieter than the fuel pump when it's moving