Fuel system, Diff, Panels, bit of everything really

So it's been a while since I managed to catch up with this. It has been reflected in the progress made over the month due to other commitments and struggling for parts from GBS/not planning enough to know what I need, but that is all part of the learning curve. However, the most was made from the weekend just gone as I managed to get available parts from an order sent ahead from GBS instead of waiting for the full order to be completed. That meant I was saved a weekend of looking a the car with no proper direction.

Anyway, a quick recap from the last blog post:

The diff was fitted...with cable ties...so not much good, just finding the right length bolts and the spacers to do so. This resulted in 3 M10 bolts with a handful of thick washers. I drilled down the pre-drilled holes in the chassis to ensure I got the right place, starting with my trusty 3.2mm bit working my way up to 5mm, 7mm then 10mm. Bit of a file and tidy up and job is a good-un.

The middle bolt was far too long and clashed, I could either cut it down or find a shorter bolt. The shorter bolt was the easier option and solved it nicely. The lower bolts, using the existing holes on the diff from the powerplant frame from the MX5 lined up well and bolted in.

A firm push and wiggle about to test the mounting, nothing moved, well the whole chassis moved so I'd say it's in tight. These were torqued to 50nm for the top bolts and 80nm on the side long bolts. ->These are estimated values based on the Mazda Owners Manual and other people's figures gained from other Manuals. These may or may not be the correct values, using them is at your own risk.

A little bit of safety/self preservation:

After jumping in and out, over and under, I soon found that the top of the aluminium panel to be rather rough/sharp. To save myself any injury, plus blood stains on the car, I used some chrome trim I had to cover the top. It looks ok, might swap it for black trim closer to finishing depending on my mood.

Other things I did over a couple evenings was finalising brake pipe flares/unions, tightening/torquing wishbone bolts & suspension bolts and trial fitting the steering wheel. Plus any various other little tasks that have slipped my mind currently...

On to the last weekend. I managed to get most of the fuel system things I needed which I had ordered the previous week. This included: Low pressure fuel pump, low pressure filter, mounting bracket for these, high pressure fuel pipe, high pressure pump and steering rack mounts. Also received was the gearbox and engine mounting kit, but that will be fitted to the engine and used when mouting the engine/gearbox.

To mount the low pressure pump (left) and filter (right) was straight forward in the end. The pump comes with it's own M6 mounting rubbers and nuts, I plan to use the rivnut mounting hole and drilled a new hole. The filter was a little more tricky. Using a 57mm exhaust clamp I drilled two holes and fitted this in. Upon trial fitting, it required a bit of editing moving the holes down slightly to avoid contact with the chassis rails. only 5mm approx, no problem.

 High pressure hose used between the components for ease of fitting. I have found that the high pressure pipe can be used for conenctions with the low pressure stuff going down the chassis as shown below.

 I have found that because the brake pipe is fitted with P-clips securely, plenty of cable ties will satisfy the IVA instead of fitting more and more P-Clips. On the plus side, it kind of hides my "dodgy" brake like and looks alright now.

High pressure fuel pump fitted on the drivers side footwell panel. Again, exhaust clamps were used, these are 54mm however, 51 may have been better, eitherway, its tight and secure so no problem. Missing the swirl pot so it has taken a stop for now.

Next was the steering rack. Just a simple case of fixing it in properly now I have the mountings.

Next, I spent a bit of time looking at the pedal box and preparing the scuttle/firewall. Take a look at the pictures below, see any problems?

This second one is fairly obvious, substantial panel gap? easy fix when fixed in properly I guess. Secondly on the right, the scuttle was bent at the factory and doesn't sit flat, slanting at a greater angle as you move from left to right. See it now?

Also, with relation to the pedal box. 1. it doesn't fit very well, will require a trim, both the sides and the lid. 2. the brake reservoir cap may be obstructed by the firewall/scuttle, making maintenance tough. IVA fail maybe?

And 3:  I had already spend a bit of time getting the pedal box to fit, increasing the hole to allow the accelerator pedal bolt/pivot to fit through, and filing the sides to get it to fit nicely with other panels. So in essence, the pedal box is not of suitable size, or the lid needs adapting to avoid squeezing it tight over the pedals/brake & clutch reservoirs. But nothing I can't handle! Just boringly time consuming.....

Not the best picture I've taken, was done the morning after before work due to the lack of light when I finished. Dedication to the point that only darkness will stop slow me down! It spent a night clamped thoroughly together so the scuttle looks a little more properly formed.