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51  General / Autos and Autosport / Re: Factory Five Cobra Build on: June 04, 2016, 03:55:39 PM
Well, after getting Paul's VW running for Hyperfest, I'm back to working on the Cobra.  I told myself I was going to just hack the wiring together quick and dirty to get the car running, and then clean it up over the winter, but I can't help myself.  I pulled apart the harness that came with the motor and have started to re-route it and clean it up.

There was a bunch of extra wiring because the engine harness is generic.  There was an extra 10 feet of wiring on the fuel pressure sensor!  You can see it curled up on the ground in this pic.  The engine harness is the one with the grommet and all the loom on it.




Loom pulled off and everything spread out




One thing I didn't like was that there were adapter connectors between the harness and some components - MAP sensor, IAC valve, TPS (not shown).  That makes it difficult to bundle everything up, so I cut the adapter connectors out and re-terminated the ends.






Then I started bundling things together, looming the individual connectors, and looming the bundles.  It looks real clean.










Unfortunately, I forgot to run a few wires for the gauge senders, so I'm pulling everything back apart to run them.  Also, I noticed the connector on the distributor pickup was messed up.  Here is a picture of an assembled connector.



One of the terminals on the pickup connector was pushed in.  If anyone knows where I can get one of these terminals, let me know.  It's the one on the top in the picture below.  Compared to the Weather Pack terminal on the bottom, it's almost the same size - the length of the tip to the retaining tangs is only 10mm vs the Weather Pack's 15mm though.

52  General / Autos and Autosport / Re: Civic engine swap on: May 28, 2016, 03:30:06 AM
You could talk to J-Spec Auto for a motor and trans (you'll need a trans, too).  I assume you're looking for a B18C out of a GS-R?  The B18Bs only make like 140hp, so I'd skip them.

This swap is pretty simple and there is a ton of info/support online (like this guide).  I'd consider doing it yourself if you have somewhere to work on it.  If not, there may be a coupe folks at the autocrosses you could talk to.
53  General / Technical Help / Re: Car scales and corner weight? on: May 10, 2016, 11:15:31 AM
I'll try to find some time - the scales don't fit in my Miata, so it needs to be some time I'm driving someone else's car or towing my junk there.  I'd really like to have my Dad's Cobra running for the practice day in July, which might work out well for me to bring the scales.
54  General / Autos and Autosport / Re: Street Touring brake cooling? on: May 09, 2016, 06:56:02 AM
Miata with a v8 swap it is

I've got some Miatas I'll sell you.  Conveniently, I also have a 331 and T5.  You're basically half way there!

Smiley
55  General / Technical Help / Re: Car scales and corner weight? on: May 03, 2016, 07:18:39 PM
So, my plan is still to bring the scales out on Saturday, unless it's raining.  If it rains, I'll bring them Sunday if it is dry out then.
56  General / Autos and Autosport / Re: Street Touring brake cooling? on: May 02, 2016, 05:00:47 PM
I'm interested in knowing the answer to this as well.

You could always come to one of the prepared/modified classes Smiley
57  Pictures and Media / Pictures and Media from Events / Re: VMP 4/24/2016 Media on: April 27, 2016, 03:57:27 PM

I get an error when trying to open the link.
58  General / Autos and Autosport / Re: Factory Five Cobra Build on: April 24, 2016, 06:08:03 PM
Well, I've been doing a bunch of piddly things over the past few weeks, so I don't have a ton of pics.  I do keep finding things that the "professional" engine builder did wrong.  Makes me worry about the rest of the motor.  Anyways, I think I've got the cooling system and power steering almost buttoned up.

I mounted the coolant overflow next to the brake reservoirs.




I was worried I might have to lower the height of the radiator cap, but after laying the hood on, we've got plenty of room.






So, with everything buttoned up, I pulled a vacuum on the cooling system to see if it had any leaks.  There was a leak somewhere - large enough that you could hear air being sucked in from somewhere around the upper radiator hose and thermostat housing.  I checked the hose clamps on the hoses and checked the heater hose fitting in the intake manifold - no leaks.  I poked around a bit and found that the thermostat housing was leaking.  Not normally a big deal, but the reason why it was leaking certainly is - it's the wrong housing!

You can see here the blue lines outline where the bypass hose is on the housing.  That tube should be ~5mm further inside of the mating surface on the intake manifold.  I'm sticking a pick in the back of it and I could get the tip of the pick inside the housing.



Here you can see there is ~82mm between the outside of the bypass hole on the manifold and the lower mounting bolt.  On the housing that was installed, there is ~88mm.  Thankfully, we had the stock housing off my dad's old 302, which fits correctly.





Anyways, we threw it back together.  There are some extremely slow leaks (loses 1psi of vacuum after about 15 seconds) that I pinpointed to the paper gaskets on the thermostat housing and water pump.  I think it's just because they're dry.  Once there is water in the system, it should be fine.  Before I do that, I think I'm going to pull the valve covers though and see if I see anything else "off" about the motor.  I'm debating whether or not to pull the whole motor apart.  On the one hand, it would probably mean an extra month before getting the car running - and if it blew up, it would be my fault.  On the other hand, I'm fairly skeptical about the quality based on the number of small issues we've seen.  I've got some time to think about it while we try to get Paul's car ready for Hyperfest.
59  General / Autos and Autosport / Re: 1st Gen Ram Rebuild on: April 24, 2016, 05:35:06 PM
Well, we finally got the cab off the parts truck last weekend and were able to roll the frame out of the garage so it's no longer taking up room.



I also didn't want the cab to take up and floor space since it'll be a while before I start any real work on the car, so we rolled some scaffolding under it while it was on the lift, screwed some supports to it, and let the truck down.  Now it's tucked up neatly in the corner.



I did also find a pretty bad coolant leak in the actual truck.  All the hoses had been replaced, but there are two rubber caps that appeared to be original...and extremely dry rotted.  Even with the engine off, I could touch the cap and a small stream of coolant would shoot out.  I replaced those as well as the thermostat at the same time.



Hopefully this is it until I wrap up the Cobra.
60  Results / Autocross / Re: April 2016 Results on: April 24, 2016, 05:02:00 PM
Thanks for posting quickly.  I like the formatting!
61  Results / Autocross / Re: Run by class on: April 23, 2016, 04:15:09 AM
I heard talk of rotating around, though some of the classes that have a small number of people may move around differently in order to balance out the numbers.
62  General / Open Forum / Re: Street Freaks on: April 11, 2016, 05:08:23 PM
I enjoyed the show.  Looking forward to more.
63  General / Technical Help / Re: Car scales and corner weight? on: April 02, 2016, 04:04:27 AM
I could bring the scales to the Practice Autocross in May.  It would give you total weight and rough balance.  Highly dependent on how flat and level an area there is to set them up.
64  General / Autos and Autosport / Re: Factory Five Cobra Build on: March 27, 2016, 03:54:53 PM
We're trying to find a nice shade of maroon.  Maybe something like this, with no stripes.

65  General Category / Announcements / Re: Autocross Point series on: March 27, 2016, 03:53:00 PM
Also, I raced yesterday, but not as a member, if i choose to become a member, can I get my points for that race added to the championship series?

If you join this year, your points from this race will count.  Joining is easy and gets you your permanent number, plus the $5 discount each event.  Here's the link Smiley
66  General / Autos and Autosport / Re: Factory Five Cobra Build on: March 20, 2016, 03:16:46 AM
Thanks, Engelbert.  The 3D printing is pretty interesting.  I've wanted one for a few years and this seemed like a good excuse to buy one.  If you need anything done, let me know.  It's really good for small parts and brackets.
67  General / Autos and Autosport / Re: Factory Five Cobra Build on: March 19, 2016, 04:07:52 PM
Well, I finally buttoned up the brake hydraulics.  I got to use the 3d printer to print out a grommet where the soft brake lines, hard brake lines, and wiring harness come through the firewall.  I printed it in two pieces to sandwich the firewall.  I also left opposite-facing slots in it where the wiring harness comes through so that I could slip it over the harness, instead of trying to pull the harness through.

Here is the hole in the firewall that I've gotta put the 4 brake lines and wiring harness through




And the grommet




I installed it around the wiring harness and then pulled the soft brake lines from the reservoirs to the master cylinders




Once that was in, I pushed the hardline through, bent up and flared the portion inside the car that connects to the master cylinders






I filled the master cylinders and pressure bled the system.  I found some leaks, but thankfully after tightening the fittings down some more, everything seems to be fine.  The stainless steel lines need a lot of torque.  I think I'm gonna try and button up the cooling system next.
68  General / Autos and Autosport / 1st Gen Ram Rebuild on: March 13, 2016, 03:56:00 PM
So, most of you know I use my Caprice as my tow vehicle.  I love that car, but given the likelihood of open-top track day cars in my future, I'd like to get an enclosed trailer and there is no way I can pull that with the Caprice.  The T56 is already well beyond its design limits moving 10k lbs of car and trailer.  And even the club's small enclosed trailer acts like a giant air brake behind the Caprice at highway speeds.

I've always loved 1st gen Cummins trucks.  I've regularly scoured Craigslist and eBay for them.  I made a deal to buy one about 5 years ago, but it was a Sunday and the bank wasn't open, and someone offered the seller more money later in the day.  Anyways, about 18 months ago, I found a fully loaded extended cab, 4x4, 5 speed truck on eBay.  I made a deal with the seller, drove the Insight up to Long Island, and drove the truck home with the Insight behind it on a trailer.  The good news - the truck was mechanically overhauled a couple years before I bought it.  The bad news - it spent its whole life in NY, so it's a little bit rusty.

Here are some pics from the seller's original ad










Here are some shots of the floorboards.  You can put your hand through them!






I've driven the truck a little.  Hauled Paul's car to VIR last year.  There's a lot more room for sleeping in the bed compared to the wagon Smiley






I also started looking for a clean cab once I got the truck home.  Last summer, I found the perfect donor - a rust-free extended cab shell.  It was a gas truck without a motor.  I went and picked it up with the wagon.  I wish I had taken pictures because it was super sketchy.  The truck is longer than my trailer.  The interior is pretty nasty after having sat outside with the windows down for potentially the last 8 years, but the sheet metal is clean!








Jeff's been giving me a hand with a bunch of stuff in the garage recently, including starting to pull the truck apart.  He got the whole front end off this weekend.  4 bolts and we should be able to pull off the cab.  Then I can get the heap out of the garage!




I don't expect to start making much progress until I'm done with the Cobra later this year, but I'm looking forward to it.
69  General / Autos and Autosport / Re: Factory Five Cobra Build on: March 13, 2016, 03:28:56 PM
Got a couple small items done this weekend.  I don't have pictures of everything.  I re-made the fuel line that connects the two fuel rails.  The engine builder cut it too short and also only installed it half way onto the fittings.  He also only installed 3 of the 4 fuel rail mounts, so I ordered and installed another.  Not a big deal, but disappointing.

I made a couple of tweaks to the 3d printed master cylinder reservoir bracket and re-printed it in black




I also re-bent the power steering return line and mounted the lower radiator tube Paul welded up.  I raised the cooler up to make more clearance for the radiator hose.  If you compare the shot of the lower radiator hose to the one a couple posts up, it is much better.






Jeff also helped me frame a 42"x56" poster of the LeMons car that I had made like a year ago.  I made the frame out of a 2x4 and box jointed the ends.  Now I need to figure out where to hang it.



70  General / Classifieds / FS: 7qts Amsoil 5w40 European Car oil on: March 13, 2016, 02:46:38 PM
Since we got rid of Danielle's R56 base Mini Cooper last year, I've got the remainder of a case of Amsoil 5w40 Euro Car Full SAPS motor oil.  7 full quarts.  Figured I'd see if anyone could use it.  $40 for all 7 quarts.  I can bring them to the first autocross.

71  General / Open Forum / Re: My Garage Build - The Airboxer Garage on: March 10, 2016, 05:48:05 PM
Can't wait to see how the paint turns out!
72  General / Autos and Autosport / Re: Street-touring Pony build on: March 05, 2016, 07:38:56 AM
That looks pretty sweet. So much tire!
73  General / Autos and Autosport / Re: Factory Five Cobra Build on: February 14, 2016, 07:00:13 PM
Alright, I'm back at it after getting the Miata mostly squared away.  There are a few things left that I need to take care of before I can run and drive the car:

Brakes
- install master cylinder reservoir
- bleed brake system

Cooling System
- install overflow tank
- install lower radiator tube, ensure fit
- install heater hoses and heater valve
- fill, bleed system

Fuel System
- remake fuel rail crossover hose (engine builder did poorly)
- add missing brace to fuel rail (engine builder only installed 3 of 4)

Misc
- re-make PS return line
- oil, transmission fluids
- clutch line
- throttle cable
- install headers, exhaust

Wiring
- all of it Sad

I started knocking out some of the easier stuff this weekend.  Of course the brake and coolant reservoirs Factory Five supplies are garbage.  The brake fluid reservoir may hold 4oz of fluid...and it's not vented.  People report issues sucking the reservoirs dry or creating a vacuum because they are not vented.  Great.  So, I ordered some nice reservoirs, but now I need to find a place to mount them.  It looks like the driver's side frame tube at the top of the engine bay will be the best spot, but the hard brake lines I made are in the way.  Jeff helped me start to remake them so that they snug up under the tube.

At the same time, I need to make some brackets to mount the lines and the reservoirs.  I got a 3D printer last month, so I decided to mess around and print some test brackets for the brake lines and the brake reservoir.  The brake line clamp is simple, it spaces the lines about an inch out from an existing mount and has two holes for the lines.  I printed these out of cheap HIPS plastic, which I bought in red.  I'll remake them out of black ABS or maybe some polycarbonate, if needed.








I printed the block 80% hollow, with a 1mm shell.  I wanted to see how strong it was, so I decided to try and jack up the Miata with it.



That's the back wheel off the ground.



The block survived fine, you can see where it made an impression in the wood.



Here, I cut the block open.  You can see how it's supported internally.  Seems to be plenty strong.




Jeff helped me mock up the brake reservoir bracket.  I need to make some adjustments to the size, but that's easy to do since it only takes like 5 minutes in SketchUp, then I can re-print overnight.










I'll start knocking stuff off the list and hopefully have this thing running in a couple months.
74  General / Autos and Autosport / Re: Hit a deer in the Miata at 50-60mph on: February 02, 2016, 08:35:12 AM
Looks great, glad to see it back on the road!

Heard you may have some luck using a heat gun to pop those front dents out.

Good call.  I may try that out.  Now I'm worried about the car being too nice, considering this was my winter beater Smiley
75  General / Open Forum / Re: Dyno Day on: February 01, 2016, 11:59:17 AM
Just trying to get some baseline pulls.

Guess your baseline numbers!

I may actually bring the Miata, since it runs now. I'll guess 101hp, 108ft-lbs.
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