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Thread: RX7 6L Wannabe Sports Sedan

  1. #1
    Registered User neil_se's Avatar
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    RX7 6L Wannabe Sports Sedan

    This is the story to date of my RX7 build to compete in local level sprints and short circuit racing at Oakey, Pittsworth, Gatton, QR, Norwell, Morgan Park and Carnell. I'll run in Sports Sedan class but it'll just be a 'budget' build, not with the extreme mods and aero of a national class car.

    Quick backstory:
    I had an SR20 S14 that I gradually built over 2 or 3 years, competing in sprints at Oakey, Pittsworth, Norwell, Carnell (Stanthorpe) and Morgan Park. Was street registered and mildly modded with CAMS cage, forged SR with 250rwkw, PFC, Ohlins coilovers, 1.5 way, etc. It was driven to all events until I got a car trailer and deregistered it early 2014, but a few months later I blew the SR in practice at Morgan Park, June 2014 .



    Looking back 2 years now I should have just slotted in another SR but I already had a disassembled L76 6L put aside so decided it was time to put that in as I'd dreamed for a few years. Not really having the money for the full conversion I mistakenly said to my mechanic "no hurry" and 9 months later SFA had been done besides engine machining and long block assembly. About the same time that I was giving him a boot up the ass, TT linked an RX7 shell on the PF Facebook page. Like most car enthusiasts I'd dreamed of having an FD3S, so decided it'd be a great chassis for the LS and in August 2015 went on a 36 hour road trip with a mate down to Canberra to pick up the shell, which came with

    CAMS cage
    Samberg LS crossmember (early version)
    T56 box with Ripshift
    Surge tank & external pump
    FEED widebody guards
    Stripped & a bit hacked up
    OMP seat
    Tein HA coilovers



    The Meisters looked fucking porn on the car, but unfortunately weren't going to suit the tyres I wanted so they were sold off along with my S14 shell to fund the new build. They were replaced with Weds TC105N 18x10.5+12 with 295/30/18 Hankook Z221s on all corners (still going to need some work to fit up front) and I've got some 18x9.5s Rotas that I'll put some NT01s or similar on for practice. I've also upgraded the brakes with 330mm K-Sport front calipers and 314mm RZ rears.



    The L76 engine was rebuilt to L98 with forged rods and pistons, 237/250 cam, dual valve springs, tie-bar lifters, etc. Added Moroso electric water pump, Milodon winged sump, McLeod RST twin plate clutch and Fidanza 12.5lb aluminium flywheel. I won't be running power steering so the only belt-driven accessory on the engine will be the alternator.

    We dropped the engine in with the recommended mounts and came across a stack of problems. The front of the sump didn't clear the steering rack by quite a margin with the Samberg bumpsteer rack spacers, so we had to ditch those and the rack now clears by a few mm. The original transmission tunnel was already hacked to pieces so we didn't have much choice but to cut the whole thing out. The back of the manifold is extremely close to the engine bay lip, so I'll cut this out soon. I bought a set or Sureflo headers that are meant to be for this conversion but 3 out of the 4 driver's side pipes were miles off fitting.



    Fast forward a few months and my mechanic had put it in the too hard basket and not touched it, so I took it to another motorsport fabricator who welded in a new tunnel, floor & seat supports, dropped the floor for an underfoot pedal box, and reworked all the pipes to fit. Unfortunately the steering shaft seems to just clip the pipes so I'll need to space the engine up a few mm, which will help with a bit more rack clearance anyway.



    Along the way I ditched my POS Michael Spencer built trailer for a Tilta and picked up a 4 post hoist for home. Most recently I've stripped the car right back as much as practical and I'm waiting for a clear weekend of weather so it can be soda blasted and primed. I'll then paint the interior and engine bay before everything starts to go together.



    I've got a pile of parts waiting to be fitted which I'll post more about when they go on. My main expenses remaining are the fuel system, tailshaft, exhaust and respray, and then there's a whole lot of assembly to do!
    Last edited by neil_se; 05-06-16 at 09:00 PM.

  2. #2
    Registered User fantapants's Avatar
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    So much awesome...

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    06/07/2011

    http://www.performanceforums.com/for...#post842594902 - making little toys for the big boys

  3. #3
    Registered User lukevl's Avatar
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    Tough motor build- I went pussy cam.

    Didn't we talk about the Sureflo header kit recently? They are made long on the tubes so you can trim and weld depending on how tight the package is. Walt Kowalski on here said they fit in his ok. Haven't got mine in yet so can't comment further.

    What is the difference between the early and late Samberg crossmembers? Mine fit great but less than a year old

    What diff are you running?

  4. #4
    Registered User neil_se's Avatar
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    Yeah there was no way the Sureflo headers could fit at the angles they came, even with ends trimmed to length. I had 3 separately people try every combination with the motor in and out of the car. Some pipes had to be bend to different angles and extended in the mid-sections. I'm not sure why mine is different but it's sorted now.

    At the moment I'm just running the standard diff with Samberg mount.

    Do you need a pedal mount adaptor? I've got 2 types of Samberg adaptors that came with the car and I don't need.

  5. #5
    Registered User lukevl's Avatar
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    The header situation sounds crap. I hope mine is different. Don't want to pay the money then back them up. I'll find out soon enough.

    I have the Samberg 8.8 subframe. Fit quite well and only needed a little die grinding because his bolt holes are so tight. I prefer to do that anyway than have massive bolt hole clearances.

    I have a pedal adaptor already thanks

  6. #6
    Registered User neil_se's Avatar
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    Will have the shell back from bead blasting this week


  7. #7
    Registered User lukevl's Avatar
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    Ok so I was wrong. The Sureflo kit comes nowhere near fitting. The collectors wouldn't accept pipes without serious manipulation and the tube bends are miles off. I take back what I said and now hope I can take back what I bought. Fingers crossed.

  8. #8
    Registered User neil_se's Avatar
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    Damn, I was hoping it was just mine that had been bent up wrong. I was just lucky to get mine modified at mates rates while getting my tunnel and driver's floor replaced. Their $120 'Patented Merge Collector" is rubbish too, just a big oval pipe hammered roughly in the middle at each end.

    I've been working on the car slowly but business, USA trip in a few months and wedding at the end of the year are eating up my time. Engine bay and interior have been painted, engine, gearbox and headers are mounted but the steering knuckle just touches on a pipe and two of the pipes on the passenger side touch each other. It takes a bit of effort to get the merge collector on each side and I'm worried that'll put stress on the welds or cause a leak at the flange.

    Trying to get the brake lines and pedal box sorted now. I keep coming across little pieces I need to find that then hold up everything else, like grommets for the braided lines.


    Blasted & primed
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    That explains the overfenders
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    Satin black engine bay
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    Machinery grey interior
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  9. #9
    Registered User lukevl's Avatar
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    Looking good.

    The extractors appeared to be a generic bought in Chinese kit. The stainless tube looked like Chinese stuff but the giveaway is always the plastic bubble wrap and China dust. The Collectors I got were decent looking- individual tubes and all that- but they were welded too close together and warped all the tubes so no pipes would slip in without a lot of tweaking.

  10. #10
    Registered User neil_se's Avatar
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    Here's the engine mounted. Even with 5mm spacers under the engine mounts there's barely 1-2mm clearance to the steering knuckle (and without gaskets on the header flanges) so they'll need a bit more modifying.



    Braking system mostly completed this week. I've mounted the OBP pedal box, reverse swing hydro handbrake, Wilwood master cylinders and Earls braided lines. Now just need to make a bracket to hold the reservoirs, clamps for the lines, and bend up a heel plate.



    Still trying to figure out a location, size and mounting for a custom fuel cell. Today I started by trimming out the spare wheel well, nek minnit, entire boot floor is gone.

    Last edited by neil_se; 14-08-16 at 11:49 PM.

  11. #11
    Registered User neil_se's Avatar
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    Hasn't been much happening on the car while I've been working long hours but I do have a massive pile of parts on the shelf and on their way. My aluminium driveshaft arrived today, just 6 days turnaround for a custom shaft including shipping from Shaftmasters.


  12. #12
    Registered User neil_se's Avatar
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    I've been on a US holiday for a while and now back into it, really pushing to have it running by the end of the year. I've found a good mechanic who can take the car in the next week or 2 and should be able to carry on with everything I can't. I had another fabricator organised to do the exhaust while I was away and I had to give him a kick up the arse to get going on it this week.

    Side pipes!



    Spent the weekend machining some aluminium items

    Custom fuel cell with baffles and trapdoors, ready to drop off for welding



    Brackets to bolt remote oil filter & thermostat to front of heads



    Racepak dash mount


    Brake & clutch reservoir mount

  13. #13
    Opens Guido's Avatar
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    Very nice work.
    Rust is lighter than carbon fibre.

    My Sports Sedan

  14. #14
    Registered User fantapants's Avatar
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    Lovin the speed holes man

    Login all of it really. Dream build man

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    RIP Carly - a smile to light the world.
    06/07/2011

    http://www.performanceforums.com/for...#post842594902 - making little toys for the big boys

  15. #15
    Registered User neil_se's Avatar
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    Cheers, it was very satisfying when it all worked out. I did miscalculate my notches in the side baffles meaning the front compartment was slightly smaller than expected and almost too tight to change the pre-filter, but I just flipped them around to make the front compartment larger before dropping for welding yesterday.

    My exhaust and gearbox mount were finished today too. Just a single X-muffler so hopefully not too loud. I did make a conscious decision to aim the side pipes away from the noise testing equipment at all the clock-wise Queensland tracks


    Last edited by neil_se; 23-11-16 at 09:26 PM.

  16. #16
    Opens Guido's Avatar
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    Thought noise testing was in field at Lakeside?
    Rust is lighter than carbon fibre.

    My Sports Sedan

  17. #17
    Registered User neil_se's Avatar
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    Oh really? I haven't actually raced there, just done brekky laps. It's only really Carnell Raceway that I'll be at regularly where they're stringent. The comparison tests I saw for this muffler showed pretty good noise suppression, there's probably just enough room after the 90 degree bend for additional small mufflers if I have a problem.

  18. #18
    Registered User PXL265's Avatar
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    Yup, gunna fire straight into the meter at lakeside....

    But being at Toowoomba would suspect that lakeside isn't on the agenda every weekend.

  19. #19
    Registered User neil_se's Avatar
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    Nah, there's enough tracks and events closer to home. It's hard to predict exactly what the noise will be like.

  20. #20
    Registered User neil_se's Avatar
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    Not getting much done lately with heavy work schedule but I did make my remote oil filter & thermostat lines today and a pedal box heel plate.






    I think I'll need to space this up a bit to put more of the ball of my foot on the pedal rather than my toes.
    Last edited by neil_se; 11-12-16 at 11:08 PM.

  21. #21
    Registered User neil_se's Avatar
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    Trying to get a few more fiddly bits done before Christmas and my wedding.

    Radiator shroud & Maradyne 14" thermo




    Alternator bracket for the Tuff Stuff single-wire alternator. Haven't decided on mounting yet, will either get a turnbuckle tension rod to use the first bracket or spacer tubes to position the second bracket up front.



    Pushlock oil and water lines (Fragola fittings with Aeroquip hose)

    Last edited by neil_se; 18-12-16 at 08:14 PM.

  22. #22
    Registered User mx_paul's Avatar
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    Well done! I like everything about this car ,it is relevant to my interests.
    Quote Originally Posted by bigmuz View Post
    Really who cares- you go to the pub and come home with no money smashed. The price of beer is kinda irrelevant.
    Quote Originally Posted by JZK25 View Post
    I bet it thong slaps like a boss with that exhaust on it. 253 yo!

  23. #23
    Registered User fantapants's Avatar
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    Fucking cool...

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    RIP Carly - a smile to light the world.
    06/07/2011

    http://www.performanceforums.com/for...#post842594902 - making little toys for the big boys

  24. #24
    Registered User neil_se's Avatar
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    Cheers fellas. It's nice to have the tools to make neat pieces at no cost, wish I'd learnt to use my TIG before now though.

  25. #25
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    Are you going to add some flaps to that shroud?

  26. #26
    Registered User neil_se's Avatar
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    I considered it but couldn't find much info for or against them. The same area in front of the radiator will also feed the air intake and maybe brake ducts.

  27. #27
    Registered User neil_se's Avatar
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    After further thought, I picked up some 75x1.5mm rubber today so I'll cut in some flapper holes something like this


  28. #28
    Registered User neil_se's Avatar
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    I had Kristian from Goleby's Parts spend a few hours on the car over Christmas/New Years.

    Radiator mounted, top radiator hose sorted


    Enough space up front for the filter and intake over the top


    Fuel cell welded and mounted


    Tonight I sorted out more of my custom alternator mount, tensioner & belt
    Last edited by neil_se; 03-01-17 at 09:33 PM.

  29. #29
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    Fuck this thing is turning out porn!

  30. #30
    Registered User neil_se's Avatar
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    Last week I had a Kaaz 1.5way LSD and Driveshaft Shop chromoly axles installed, then I dropped it off to my auto elec yesterday for engine and body wiring.


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