My first Eunos! build Number 5

[Mazda Mender]

I had a jass dial cluster plate, but was not 100% happy with the LED's, so i ordered some fresh led's and updated it to look more in keeping with Daryls interior with it being a MK 2 dash in a MK 1 so wanted more modern/retro look, it worked out really well we feel....

Before...

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After....

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[Mazda Mender]

We changed the seats to some MK 2.5 ones for comfort , but on the understanding that there would be no headrest speakers that he was use to , so we extended the speakers to the rear back panel,with plans to update the HU to a full touch screen and relocate the aftermarket gauges to the drivers windscreen pillar( we are making one up).
Also upgraded the engine pulley's, to the 1.8 mk1 multi ribbed alternator belt as apossed to the 1.6 V belt which we find wears out fast and produces a lot of dust , the only real issue we hit was the alternator 1.8 pulley sits more foreword on the shaft, which sets the belt all out of c**k , which was putting pressure on the water pump pulley and crank pulley causing the bolts and pulleys to work loose, grinding the spacer off the back of the alternator pulley solved the issue to pull it in more to sit straight.

Also changed his throttle cable because of stretch for age..

[Mazda Mender]

Extra pics once lined up....

[Mazda Mender]

We are getting close to getting her run in to have a full respray , so with that being the case ,we finally found time to fit the bonnet vents we got some years back, we wanted something subtle and not over the top in your face, anyway after a template was made up and a lot of measuring and measuring again and again ...... i was happy with where they would go for the cuts to happen, S/S mesh was found for the vents, and after a quick rub down and flash over with paint, they are being repainted so no need to go mad.
After the paint was dry it was time to cut and bond the mash in, this took the most time than any of the rest, time consuming and fiddly, but once all cut and bonding into place time to cut, grinder and dremmel, wet and dry, and added paint to the fresh alloy, the frame had to be fettled also for the louvers to sit correct, so kept as much of the frame as possible and over bonded it back to the skin before fitting the vents, any way pics....

[Mazda Mender]

Something else i am in the process of finishing for his roadster...

[ian_c]

Just caught up with this - what a great build! Silver ones are the best ones

[Mazda Mender]

Service ,New CAS seal, Rocker seal, engine flushed ,fresh oil and filter, brake discs, pads changed and bled off, all done with Daryls young jedi watching....

[Mazda Mender]

Pillar pod made, gauges moved and touch screen fitted, new gear knob and drift button.....

[Mazda Mender]

With the on going process with a really annoying fault on Daryls Roadster and the process of elimination swapping parts because the ECU says " nothing is wrong, everything is good ,nothing to see here" it is not the case, but on testing I noticed that the O2 sensor was not giving a peak signal and running dead flat, so needed to be changed , Saturday was the day , nice dry day, so daryl could crack on while i hit the welding...
Well it turned into a major fight, with every time full on, i kept pulling away to help and we were hanging of a scaffolding pole it was the bad, and i left Daryl to it popping back and forth everytime i heard " this f*cking car, i am going to burn it" are spanners being thrown in anger.
He finally got what was left of the sensor out at 8.30pm and i called time on the welding at 8pm, we had to recut the thread before even thinking about the newer one going in, she is wearing a S/S down pipe and even with getting the pipe glowing red it still did not help, and i am sure the sensor as been in for at least 25 years or so and was fussed in there good style, not the worst i have dealt with, Chris holdens after cat was by far the worst, so newer one went back in with a bit of Grrrrr, extended the wire, and everything away down on the ground for 9.30, showering at 10 all good.
Long day, and i did let him stay with it ,rather than Dad doing it, and credit to him he did ,although he had no chose as the old sensor was destroyed, i hope he felt that sense of achievement, we'll find out today if that as cured the fault, i don't think it will ,as it feels like an electrical issue, that intermittent which is frustrating , as i would rather it fail and tow him home and find whats dead to fix it, but hey the joys of cars...

[Mazda Mender]

Now with Daryls being a Mk 1 with a mk2 interior, we see her like a retro modern look, so when we put the cluster together we went with that idea, the hazard switch we got from Jass performance , but never happy with it with it being a toddle switch and a huge brushed S/S disk , it just looked out of place and just did not look right , we always refereed to it as the small willy on the dash,so after some searching and trial and errors and fabrication, i found something that finally worked ,look correct and retro modern that fitted in with the cluster,happy with and also illuminated, electric window switches next...

[Mazda Mender]

We also fitted the missing air deflector from underneath the bonnet....

[Mazda Mender]

Well it was time for a bit of surgery after her 31 years on the planet ,not bad really and the so called carbon foot print of her far at ways the new electric throw away cars...

On raising her for some maintenance work ,it became apparent that when bringing her to rest on a axle stand on the passenger rear jacking point and the cringing sound like cornflakes breaking ,plus the fact that the axle stands head started to slowly disappear into the sill ,that it was time to arrange some time to cut her open, I had spoken a while back about upgrading the jacking points to far thicker steel in the future anyway as a personal curse of action as i have always felt that they are a weak point on these roadster as it is the main area used as them become older requiring work to keep them going and they take a lot of abuse thats not thought about until they pop, they are only body panel steel on the underside that is corrugated, so not really the strongest of points..

So a plan was made, some panels bought etc, Daryl added to my insurance to use black blur number 1 to use for work, while i attacked her...
First thing was to get her up high enough to work on and safe, remove the side skirt, and before its said...the side skirt did not cause the issue as we thought about it while first fitting them ,apply a thick layer of under seal and leaving drainage sections all the way along, assessed what was needed including fresh metal the the rear arch also while at it which meant bumper off..

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I started with cutting the sill sections to good metal and then the rear arch, and once opened up it soon became clear it was blowing both ways , so out it all came to fresh good metal....

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All cleaned and sprayed with zinc weld through primer and started the weld up the rear arch, repair panel was ok but not the best out there ,started with the inner part of the arch and onto the outside,,,

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[Mazda Mender]

So then it is on to the sill...

Started by rebuilding and upgrading the jaking point to thicker metal ans spreading the load more and building up the rear lip,So there is something to guide to and weld to ( yes the welds were flattened and treated before boxed up for good)

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And then making up the end panel section ready and all the other sections....

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The next pics are from in the inner section that i cut open to show just how bad that inner section is bad for drainage with the very tight castle section, so i have changed the design to composite it , it will make more sense when you compere these with the repair thats been done...

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and it in...

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Inner sill repaired...

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Danny popped around and skimmed and painted the rear arch for Daryl, hairdryers were used in this process Massive thanks Danny.

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Outer panel welded in and sill end, ,i went over the top with the stone chip for protection behind the skirt and the exposed panels , i did killed all the inner sections with cavity wax etc...

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Once the stone chip had finally gone off ,the underseal was added to all the corner( underseal is added as a protection seal as stone chip acts like a carpet under lay/cushion-er and is porous)....

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Once that had cured, it was time the bond the skirt back on...

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And then i issued Number one son with a must ,finish undersealing the back end , it was needing a refresh....

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[blackyb]

[Mazda Mender]

So daryl nursed her home on Thursday, just as i had put everything away from removing and fitting a newer power steering rack and bled off on Carls, with what seemed to a suspected slave cylinder on the clutch giving jip , so torches and tools back out and swapped out for a brand new one, bleed off and still the same, so a phone call to super Andrew at Autolinkmx5 for a clutch master and two service kits to refurb Daryls old one coming off and another i found to also refurb for that "next time", it arrived early Saturday and swapped out after sorting out Carls brake master.
Removed the clutch master and all the pipes etc on Daryls and fitted a braided hose straight from the new master to slave and bled off, lovely strong clutch engagement again and after a test run of Carls and Daryls , it was all good again on both.

Stripped down the two old masters, cleaned,painted, and fitted the new inners and two like new again safely stored and labeled ( there is a walk through guide on here on refurbing them).
Pics to follow...
M-m