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51  General / Autos and Autosport / Re: Hit a deer in the Miata at 50-60mph on: September 26, 2015, 03:49:26 PM
Yeah, I'm glad it wasn't worse and I wasn't hurt.  I'll pull the bumper and hood from one of my parts cars and then cut the front frame horns off to get the whole radiator and hood support assembly in one piece, then graft that onto this car.  I think I'm going to end up stripping the car down and painting the whole thing instead of driving a multi-colored Miata or just spraying the front end.  Should be good practice for the Cobra.
52  General / Autos and Autosport / Hit a deer in the Miata at 50-60mph on: September 26, 2015, 03:06:07 PM
So last Sunday a little before 10pm, I was driving through Amelia back to my house in the Miata.  A truck was coming the other direction, so I was looking down at the road so as to not be blinded by its lights.  All of a sudden, I see a deer in front of me...and I hit it before even having a chance to brake.  Pulled the car off to the side of the road expecting the radiator to be destroyed, but thankfully it wasn't.  I couldn't find the deer on the side of the road and didn't feel like walking through some farmer's soybean fields to try to find it, but it must have been pretty small.

It beat up the front bumper, buckled the hood, tore the headlight cover off the passenger side and bent the hell out of the fancy dual headlight setup that's on there.






Opened the hood and found that the support was bent up.  It was touching the radiator in the middle and got twisted to a weird angle.




Oh well, time to start pulling everything apart.  Danielle helped me drill out a bunch of spot welds and we pulled the front radiator and hood support off the car.  I'll pick through my Miata boneyard tomorrow and figure out which of the cars I want to chop up for a replacement.









53  General / Autos and Autosport / Re: Factory Five Cobra Build on: September 26, 2015, 02:51:21 PM
Well, it's time for another update.  I've made some progress on plumbing the cooling system.  Unfortunately, I hit a deer in the Miata last weekend, so the Cobra will have to wait until I fix that car.  Here's where it's at now though.

After painting the radiator mounting brackets, I laid everything out on my workbench.  Instead of using the corrugated flexible pipe that Factory Five supplies for the radiator hoses, I got some 1.5" aluminum tube, mandrel bends, and some radiator hoses with a bunch of bends in them that I could hack up.




Jeff came over to give me a hand and we started mocking stuff up.  The upper radiator hose/tube was basically perfect just using two 45 degree bends.  I didn't even have to cut them.




The lower is more complicated, we cut a 180 degree bend in half to get a 90, then a section of straight pipe, then another 45.  Taped it together and then took it out of the car for Paul to weld.  Note that the blue masking tape leaves much less residue than the regular.  Should have used that on the lower, too.






Paul welded everything up and I bought a real coolant expansion tank rather than the one Factory Five provides with the kit, which some people claim is too small and results in air being sucked into the cooling system on a regular basis.  Now I just needed some way to bead the ends of the tubes, that's what the Vise Grips are for.




I don't have the best picture, but I copied some other folks on the internet and welded a washer onto one jaw of the Vise Grips and ground a notch in the other jaw.  Running around the soft aluminum tube, it's pretty easy to create a raised bead so the hose doesn't slip off once clamped on.








The plumbing looks good in the car.  I may have to lower the radiator cap fitting some, we'll find out when I put the body on.



54  General / Classifieds / Re: 3.4L Boxster for sale on: September 18, 2015, 06:36:01 PM
Well, Summer is over and I've put another 2k miles on the car without any new issues.  I've contemplated just putting a standalone ECU in it or swapping in all the wiring and ECU from the 996, but don't have the time.  Now that I don't need a car with A/C anymore, it's time to get rid of this so I can put heat in my garage.  New price of $10k.
55  General / Autos and Autosport / Re: Factory Five Cobra Build on: September 11, 2015, 02:59:16 AM
Yup - still not sure what to do with it.  I'll likely just part it out after selling the Boxster.
56  General / Open Forum / Re: My Garage Build - The Airboxer Garage on: September 10, 2015, 05:51:47 PM
I like the rotisserie.  How much you think the shell weighs?
57  General / Autos and Autosport / Re: Factory Five Cobra Build on: September 07, 2015, 03:38:25 PM
Well, I made some progress on the Cobra this weekend.  Got a bunch of small stuff done to finish up the brake lines and mounted the radiator.  The radiator sits at a 51 degree angle and the Factory Five-recommended radiator mounting method is to just bolt the top of the radiator to a 3/4" square tube and leave the bottom unsupported.  That's pretty sketchy, so we bought a kit someone sells to support the bottom.  Now to take it all apart and paint it, then figure out how to route the hoses.  Paul and Jeff were over, so I've got some ideas.



We also made progress on Jeff's F500 car this weekend, though as we were rebuilding one of the carbs we found that the pilot jet was clogged AND stuck so we couldn't get it out.  Even after heating the thing with MAPP gas and soaking it in Kroil, it was stuck.  We ended up breaking the tip of a screwdriver off in it trying to get it out.  Time for new carbs.

We also used some time to move some cars out of the yard and back to the garage.  Now we've just got two left in the backyard.  One Miata missing a front-end and the donor Mustang missing the rear end.  Will have to figure out a good way to move them.



58  General / Autos and Autosport / Re: Factory Five Cobra Build on: August 16, 2015, 04:28:35 PM
Well, it was a productive weekend, though most of the progress was on the garage rather than the car.  Since I moved all my tools down, many have been taking up space on my workbenches while I figured out where to put them.  Since nothing had a real "home", I kept putting stuff down wherever I last used it, which meant I kept losing things and spending 5 minutes just finding them again.

I decided that I wanted most of my hand tools up on the wall where I could see them clearly, so I ordered a bunch of Ernst socket rails and wrench organizers that I could hang.  In addition to those, I made some wooden holders for my ratchets and extensions.

I laid out a pattern in a piece of scrap wood and drilled a bunch of holes



Holds my extensions well



I drilled some more holes in a piece of scrap to hold my ratchets



Mounted them on the wall with metric sockets on the left, SAE on the right



And then mounted the rest of my tools.  Having all of this wall space is nice.



I also made a shelf to hold my screwdrivers and managed to re-use a piece of scrap 3/8" fuel line to make a rack for my pliers




On the car, I got the braided stainless lines in, so I made some brackets out of 2" aluminum bar so I could mount them to the chassis.  Paul came over and gave me a hand running the hard brake line to the rear.  It's all bent into shape now, but I need to mount it to the frame and flare the ends still.  It was so much easier working with two people - the line is 12' long and has to be maneuvered around all the various frame tubes to get into place.  I'll have to take some pictures when I do some more work next weekend.  The only one I have right now is one of the rear braided line and mount.

59  General / Autos and Autosport / Re: Optima Charlotte 2015 on: August 12, 2015, 06:08:04 PM
pictures look good to me.  that sounds like a pretty awesome event and a great experience.  how did you get into it?

your car sounds good in the video, too - do you have a remote microphone?  all of my gopro videos just sound like wind noise Smiley
60  General / Autos and Autosport / Re: Factory Five Cobra Build on: August 10, 2015, 03:45:30 AM
Well, I made some more progress in the last couple weeks.  Paul and I had been talking about wanting to be able to roll cars around our garages, so we built a couple sets of wheel dollies.  I can move the car around the garage alone without having to make a lot of turns, which is nice.






Looking at the factory position of the rear brake calipers, I didn't like the options I had for running the brake lines, so I decided to swap the calipers to the front side of the axle, which required pulling the rear end apart for like the third time.



I had to grind a notch into the opposite end of the mounting flange on the axle to accommodate the ABS sensors.



I mounted the passenger caliper on the driver side and vice-versa so the bleeders are in the correct position.




Lastly, I spent yesterday starting to run the hard brake lines.  The lines from the master cylinders the to ABS pump are at least parallel to each other, though I need to figure out how to brace them.






I need to run a hard brake line to the rear of the car, install the soft lines and mount the fluid reservoir.  Once that's in place, the brakes should work, though I'll need to wire up the ABS.
61  General / Autos and Autosport / Re: Factory Five Cobra Build on: July 27, 2015, 08:04:00 PM
Justin,
     I just gotta say that this is freaking awesome, what an experience for you and your Dad to literally build a car from the ground up! I love reading up on the post.

Thanks!  We're having a lot of fun.  Hopefully now that that garage is together and the car and all my tools are down there I'll be able to make some quicker progress.  Would love to have it running (sans body) by the end of the season and then tackle the bodywork over the winter/spring.
62  General / Autos and Autosport / Re: Factory Five Cobra Build on: July 23, 2015, 06:26:19 PM
Well, it's been a busy few months, so I haven't made a ton of progress on the Cobra.  My Dad and I did manage to roll it down to the big garage a few weeks ago and I just started work on the brakes.

Here it is sitting in the new garage





I'm installing the ABS from the Mustang into the Cobra, which is going to complicate things quite a bit, but hopefully be worth it.

Here is the pump, I need to find a place to mount it


The factory mount isolates the unit from vibration.  I want to use as much of it as possible




I cut off the horizontal mounting points and welded on a tab to get three bolt holes on roughly the same plane




I decided to mount the unit in the front passenger side of the engine bay.  I made a brace to bolt the mount to.  I will paint the brace and mount gloss black to match the chassis




63  General / Open Forum / Re: Interested in eventually getting into HPDE on: July 21, 2015, 12:02:59 PM
For most clubs, you should just need the rollbar because it's a convertible.  Depending on the club, you may need some arm restraints if you don't have a hardtop.  You'll want to change all your fluids, including a brake fluid flush (as stated above, DOT4 is the way to go), and make sure the caliper slides are well lubricated.  You could run coolant in your car at all the HPDEs I've ever been to, but everyone has slightly different rules.  When you find a club, just shoot them an email.

Thankfully, Miatas are pretty easy on consumables.  On our LeMons car, we were running the cheapest rear pads with the cheapest rotors all around, only spending some money on front pads - and the brakes tended to last around 50hrs of track time.  At Miata speeds, you really don't need a lot of braking power Smiley  We were running whatever decent decent brake fluid we could get our hands on easily for not too much money (ATE Super Blue/Type 200, Amsoil DOT4, Wilwood EXP600).  We also ran good motor oil (Amsoil Dominator).
64  General / Classifieds / Re: Take off tires on: June 12, 2015, 04:11:16 AM
This gets me thinking.... I finally decided to spend some money on autocross this year on tires. So I purchased the BFG Rivals, this season so far I estimate I have 30 runs on them. When should I consider shifting them from front to back etc... RWD FRS...

I don't believe the Rivals are directional, right?  If that's the case, I would do like James said and cross rotate them (front left to back right, front right to back left, rear left to front left, rear right to front right) every event.  If you want to do it less frequently, just do it when they start to wear differently.

I'm used to driving a car that only wears the front tires though, so the difference in tire wear after every event is noticeable.
65  General / Classifieds / Re: WTB - NA Miata drivers side fender and/or door - red on: May 18, 2015, 04:33:40 PM
...Know there are a few folks here who may horde some cars...

Pretty sure this is me.  I have a red Miata parts car.  The fender and door are straight, but with faded paint (and a missing mirror).  Come to my house, swap me with your crappy parts and some cash or other item(s) of interest and they can be yours!
66  General / Open Forum / Re: Looking for your next autox car?? on: May 18, 2015, 04:29:42 PM
This is awesome! Looks like those old CRX's were too cheap. All sold out!


There's one under a tarp in someone's back yard on Huguenot Rd......



I've got one under a trap too if anyone wants a project real cheap like

Even though I know you meant "tarp", "trap" is definitely more appropriate.  This is the kind of trap I always fall for.
67  General / Classifieds / Re: Toyo RR's on: May 18, 2015, 10:57:50 AM
where are you located?  i am interested, though not sure i really need a dedicated set of summer tires for my non-autocross car.
68  General / Classifieds / 3.4L Boxster for sale on: May 10, 2015, 06:23:03 PM
Car: 1999 Porsche Boxster w/3.4L and Boxster S parts
Mileage: 75k (body) 87k (motor)
Asking price: $10,000
Contact name: Justin
Email: justin dot loehlein at gmail dot com

Hi all - I'm selling my '99 Boxster that I swapped the 3.4L from a 996 into.  I built the car for my wife after her 996 got totaled last summer, using the motor from that car.  It runs and drives fine around town, but runs lean over 4k rpm at WOT according to my wideband O2 sensor.  The previous owner of the Boxster had it setup for a 3.4, but sold it to me after blowing up two motors.  After much troubleshooting, I suspect the computer does not have the correct tune on it.  I had a local European shop (Perception Motor Werks) look at it and they agreed it's likely the ECU.  Unfortunately, nobody around here tunes these things and I lost all motivation to work on the car since my wife decided she didn't want it.  Anyways, I've got way too many other projects (finishing my garage, Factory Five Cobra, prepping my track day car, restoring my truck, maintaining about 8 more cars), so this one's gotta go.  Details below.

Details of shell
1999 Porsche Boxster
75k miles
Boxster S brakes
Boxster S suspension
Boxster S 3rd radiator
5 speed - shifts great
987 Cayman S exhaust

Donor motor
3.4L from 2000 911
~87k miles
LNE IMS bearing
Motul 8100 X-cess oil since we've had it (~30k miles)
Many new parts while motor was out - AOS, dual mass flywheel, clutch, spark plug tubes, cam seals, water pump, all hoses, belt, power steering lines, etc

I've put ~2k miles on it since completing the swap.  It's fun to drive, but I don't have the time for it.  There are a bunch of door dings, some minor scratches on it, and the passenger corner of the rear bumper is wavy from a small hit in a parking lot.  It'd make an excellent track car once the tune was sorted and wouldn't be too difficult to make it pretty, too!

Here are some photos of the donor motor






And the Boxster (pics from 5/10/15)










You can see the waviness in the rear bumper










You can see a bunch of the door dings and scratches here






The top works great




Interior is clean.  I have the full interior, though the rear carpeting is not in the car to speed up getting to the engine bay








Shoot me an email if you are interested.  I'm happy to answer any questions.
69  General / Autos and Autosport / Re: Factory Five Cobra Build on: April 26, 2015, 05:23:48 PM
So, I had the last week off of work and my Dad came down to help out on the garage and the car.

We wrapped up the power steering cooler



We also started on the wiring



There is a ton of extra wire that I'll have to clean up



I bent up some pipe to get water to the heater core



It's coming along!



We also put up plywood panels in the workshop portion of the garage and the electrician was able to wrap up his work.  We started moving some stuff down there for storage.  Hopefully this week the aprons get poured and then we can finish spreading stone around the building.



Jeff came over Saturday and gave me a hand welding up this awesome workbench/toolbox using some parts bins that I picked up from a Radio Shack that was closing.  I'm happy with the way that it came out and am making a couple more.
70  General / Autos and Autosport / Re: Factory Five Cobra Build on: March 29, 2015, 05:21:28 PM
Made some more progress.  I pulled the rear end out to get it narrowed 1.5" so that we can keep the ABS.  I also got the motor back in, made the fuel lines, and mounted up a power steering cooler.

PS cooler mounted to some 1" square tube.




The FFR kit comes with an in-tank fuel pickup for an external fuel pump.  I wanted to run an in-tank pump, so I picked up a 320lph pump that came in a pickup with AN fittings welded on.




The fuel supply line is 1/2" and the return is 3/8".  I'm using stainless steel hardline which comes in coils, so I had to straighten them out.




Tube straighteners are ~$300 and basically just some wheels in an adjustable frame.  Folks online have made them, and I had some scrap angle iron laying around, so I ordered some concave wheels and got to work.








The finished product in action.  It works pretty well.  The final result isn't perfectly straight, but I can work with this.






I spent probably a whole day measuring, bending, test-fitting, measuring, removing, bending, test-fitting, etc. over and over again.  I must have removed and installed the lines about 50 times.  I got the 1/2" line finished up first since the 3/8" is a bit easier to work with in case I needed to tweak it to fit next to the 1/2" line.  The end result looks pretty good to me.  I still need to make a few braided hoses to connect the lines to the fuel pump and the pressure regulator, but that should be pretty quick.

The hard lines start at the back of the car.  AN hose will connect them to the fuel pump, running under the panhard rod mount.  I was originally going to run the hard line under the panhard rod mount, but realized that I needed to be able to remove it to get the rear end out.



I used some fancy-pants aluminum clamps to mount the lines to frame.





The lines come through the engine bay on the passenger side footwell.  I mounted the filter there, where it seems like it will be easy to access.  I wish the filter opened up from the other end because then it would have been easier to mount at the rear of the car near the fuel tank where there is plenty of room.




I'll probably wrap up the power steering system next.  Then onto the brakes, which I'll use my tube straightener and bender for again.
71  General / Autos and Autosport / Re: Factory Five Cobra Build on: March 08, 2015, 02:52:02 PM
And I'm in Mechanicsville, about 10 miles east of RIC airport. I'd be happy to drive the car over there if it ever dries out :-)

Nice, I'll shoot you an email.  Would be good to take a look at your car before I start drilling holes in my Dad's Smiley

Over the past couple weekends, I tackled a couple other projects.  I did manage to run some mig wire along where I'm planning to run the fuel lines.  I tried a couple routes: 1) on the outside of the passenger frame rail and 2) inside the trans tunnel (as recommended by the engine builder!?!?).  I'm definitely going to run the lines on the frame rail, it seems a bunch safer and is not any more complicated.








Once I got that laid out, I pulled the motor back out to put the the steel bellhousing on and attached the transmission, which was way more of a hassle than it should have been because I didn't notice that the clutch alignment tool had a smaller diameter pilot surface than the transmission.  Once I realized why it wasn't lining up, I just used the transmission to line up the clutch.  I also cut some mounting points off the rear of the transmission that interfere with the frame.





72  General / Technical Help / Re: Car scales and corner weight? on: March 05, 2015, 07:41:11 PM
The scale pads are ~2 5/8" tall with a 15"x15" footprint.  I have a set of wood roll-offs for it, but you still need to get the car in place, jack it up, put the roll-offs under the wheels, and position the scales before you can use it.  I like the idea of ramps a lot.  I guess if it was possible to drive over the rear set of ramps and onto the front set, we could crank out a bunch of cars pretty quickly.
73  General / Technical Help / Re: Car scales and corner weight? on: March 04, 2015, 09:12:43 PM
Seems like it would go faster if we just had ramps. Drive your car on, get the weights, get off and go make your adjustments and come back while others are getting their weights. Unless someone has the ability to adjust as it sits, too much time would be spent tweaking and going up and down.

This is a good point.  Maybe someone will build me some ramps Smiley  Hopefully it dries out and warms up soon so I can get the garage wrapped up.
74  General / Autos and Autosport / Re: FSR Summer 2015 Drivers Ed at VIR on: March 04, 2015, 10:15:20 AM
I really want to go, but we're having a family reunion for my Grandmother's birthday that weekend.  I'll have to find another event to go to with you guys!
75  General / Autos and Autosport / Re: Factory Five Cobra Build on: February 27, 2015, 06:00:39 PM
Sweet project. Where you located ?
Ron

I'm out in Powhatan.  You?  I'm actually looking for a point of reference to figure out if I can mount my fuel filter on the firewall.  I think it will depend on how much the body overhangs it, which will determine if the element can be removed from the top when the car is assembled.
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