1996 Uk spec Rebuild (we hope)

[John&Luke]

There is a good guide on here buddy.
M-m

Job all done. Went with EBC Ultimax pads and discs from Autolink

Very useful guide. My only comment would be the guide doesn't mention using threadlock on the carrier bolts when refitting.

I also used a laser tools wheel hub grinder attachment that fits over the wheel stubs and allows you to clean the surface of the hub free from corrosion so the disc runs true. Good bit of kit in my mind.

[Mazda Mender]

Glad the guide was of use, but.....

My only comment would be.....

You don't need thread lock, that's why it's not in the guide, where or who has told you that?,what are you reading? we know are stuff and been doing it a long time, if thread lock is required plus the strength of thread lock for the job in hand as there are many, it will be stated in the guides etc for what we are doing, so you all do the jobs correct.
M-m

[John&Luke]

Glad the guide was of use, but.....

My only comment would be.....

You don't need thread lock, that's why it's not in the guide, where or who has told you that?,what are you reading? we know are stuff and been doing it a long time, if thread lock is required plus the strength of thread lock for the job in hand as there are many, it will be stated in the guides etc for what we are doing, so you all do the jobs correct.
M-m

Always used thread lock on the carrier bolts in the past. Cant see it doing any harm?

[John&Luke]

Good day today, made some good progress.

First job was fitting our new exhaust


Went with a stainless steel IL Motorsport exhaust. Very pleased not to loud. :)

Finished job.


Need a new heat shield so made a template so I can make one up from either stainless or ali.


Then, MOT at local garage. Pass. no advisories :)

[Mazda Mender]

Need a new heat shield so made a template so I can make one up from either stainless or ali.

Normal thing to see rotten rear heat shields, we have a ally one from Jass performance and a S/steel one i made on two of ours,make sure you fit some spacer washers between the shield and tub.
M-m

[John&Luke]

Need a new heat shield so made a template so I can make one up from either stainless or ali.

Normal thing to see rotten rear heat shields, we have a ally one from Jass performance and a S/steel one i made on two of ours,make sure you fit some spacer washers between the shield and tub.
M-m

Yes agree was planning on some 6mm rubber washers between the heat shield and tub to cut down on vibration.

[John&Luke]

Been suffering with this steering wheel since day one. I guess you either love it or hate it.



Eventually found a decent condition and priced original steering wheel. Fitted this afternoon. Wow what a difference, both visually and from a driving point of view! Very pleased :)



Need to review my to-do list and take a stock check on what to do next>

[John&Luke]

So decided that a carbon slam panel would be a nice addition. I had some carbon fibre sheet left over from a previous project. So first job was the template.


Used thin card for this and then transferred this to my carbon sheet. Once transferred, cut out the various holes and opening for the bonnet catch.



Then fitting with 3 self tapping screws. Overall a nice little project. Couple of photos of the finished panel. Just needs a Mazda Menders sticker to finish it.
If there was a demand happy to manufacture some more.

[Mazda Mender]

Just needs a Mazda Menders sticker to finish it.

Hint hint i'll sort some out they are in the process of new ones being made buddy.
M-m

[John&Luke]

So got around to replacing my rear exhaust box heat shield. Old one was a bit rusted up.

Old shield with my card pattern.


And new one cut out of some stainless sheet and bent to follow the original pattern. Used 4 thick rubber washers between the shield and underside to limit heat transfer and any chance of vibration noise.



Nice little job for Saturday pm.

[John&Luke]

Ok so time to start my winter project.

Full respray!!!!.

So job No.1 not for the faint hearted. Rear arch and sill replacement. Nice new panel from the guys at Autolink

The sill had a previous pack repair. Whilst the repair looked structurally ok the finish was poor. This suggested to me that it had be a patch instead of a prober restoration. Also three rust bubbles around the arch meant a full replacement was the best option. Good point was all the spot welds on the arch lip could still be seen so the likelihood was that his hadn't been attacked before.


Started by pealing back the bottom sill section.


No real surprises the tin worm had been to work and suggested my plan of action was justified.

Bit more cutting and grinding left me this (sharpie lines are my next cut marks.


Getting quite involved now. I'm NO EXPERT, so any tips advice would be VERY WELCOME.

I plan on replacing the inner side with a home fabricated section as £100 for a new inner sill that I will cut up to be just 8" long seems a bit steep! Thanks, look forward to the advice.

[fujikun]

have a look at this guys, might help ya out.viewtopic.php?f=35&t=4888&p=49632&hilit=california#p49632
its currently in a council lock up waiting for my new garage to be built .

[John&Luke]

have a look at this guys, might help ya out.viewtopic.php?f=35&t=4888&p=49632&hilit=california#p49632
its currently in a council lock up waiting for my new garage to be built .

Cheers Fujikun!, gives me confidence that I can tackle this job. Useful pictures as a reference to.

So by way of an update, had to replace a small section on the floor and return lip which I did over the weekend.


Treated the surfaces to weld through primer. Then tonight had a go at replacing the inner box section that I had cut out. managed to get the new section tacked into position before calling it a night. Nice having soiled new metal going back in.



In between cutting and bending the new steel, priming it, and waiting for it to dry. Remove my side reflectors and drilled the back plate so that I could then mount a 5w bulb holder. Wired this to the side lights and hey pressto side marker lights.


Very please with myself.

[John&Luke]

Couple more hours has resulted in the inner sill being finished off. All welded up and primed.


Then started removing the arch by drilling the spot welds and cutting the rotten section out following the contour of the wheel arch.


The leading edge of the inner arch is in good condition as shown below.


But the back edge is going to need some more work. I will need to fabricate a new inner arch lip for this area.

[John&Luke]

Sorry meant to ask. Don't suppose any member has a a sheet metal shrinking machine I cant hire/borrow for a small fee???