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Fat 4 RE Rx4 coupe

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  • Fat 4 RE Rx4 coupe

    So i have been on here a while but been watching some thread some feed back but not put one up of my own car, checking out a few. Now i am start one up from when i got it to now

    Back story
    Well i have owned a few Rx4 over the years now! Got my first one we i was 17 and had one ever since. So 15 years on 6 later this is my latest car

    I got this Rx4 as my old car got defected and had lots of modification done to it and lots of little bits and pieces missing. and the first replacement shell was not as good as first thought

    This was a good example to start my fresh rebuild with and out of 6 or more car which i checked out this was the best with no major damage (most of the other had major chassis damage and smoky motors) and was running but had a defect on it but it did have the s3 rear end on it but i just wanted a car to drive so it come home with me

    here are some photos of how it was the day i got it, it was drivable but i wanted to get it looking sweet

    It was the cleanest body Rx4 for sale at the time, straight body and chassis, had a 13b bridge port Rx4 motor, weber, vinyl roof and was complete but the car was in some need of some some TLC to get it where i wanted it

    i also did like the look of the vinal roof lining

    Now the rebuild started the day i got it home and started to stripper her down to change the colour of the interior from brown to Black.
    Changing the suspension over to my already rebuilt and new stuff i was using in another project and getting it ready to clear Regency ( which the as the same as a road worthy in other states ) as the car had a defect on it when i bought it

    So in my small shed space i pulled a few off and started repairing and paint things

    Not long after this we got our first new home so i had to pack up ever thing up so i could move into this beauty of a shed

    Which i filled filled up very quickly with both my Rx4's

    the old bridge port motor only had about 6000km or so on it when i got it and i only put a few 100 more on it before i ripped it out
    and sold it to a guy in Newcastle with the ported manifold and lightened flywheel

    then i peeped my Fully rebuilt 13Bt series 4 block which was rebuilt about 1999 (got to put about 10,000km on it) before it sat around for 3-4 years while i was getting a body sorted out for it

    New Engine specs
    Rx7 s4 turbo motor
    Large extent ported
    race modified gears and installed window bearings bearings
    2mm Mazda seals
    12a turbo front cover
    12a turbo water pump housing
    brand new oil lines
    Weber S4 manifold which is port match the the inlet ports
    (old spec: 48mm weber with bigger jets)
    K&N air filter
    series 4 alternator which was fully polished by me then had it rebuilt
    installed the gilmer belt drive
    lightened flywheel which a heavy duty clutch pressure plate (balanced together) and a standard type clutch plate)
    and a few more chrome bits that i could not polish

    This is the engine bay almost finished but i decided that i had been waiting too long to drive the car i didn't paint the engine bay (5 year and 3 cars)

    This is the only pic i got the the original interior, had brown dash, door trims, back seat, had so old bucket seat which were stuffed

    Black dash in with My Recaro's bucket seats, black door trims, black centre console, Rx7 s2 steering wheel

    Black Recaros seats
    Black re-trimmed dash
    New black carpet
    New seat belts
    Black head lining
    Good condition black center consol
    Re-trimed sun visors and front pillar trims
    New front seat belts

    The gearbox
    was changed over from a rx4 4 speed to a supra 5 speed which was been fully rebuilt with[/quote]

    Supra 5 speed Specs
    New sincros
    New shifter bushes
    Bead blasted housing
    New rubber gearbox cross member mounts from Mazda
    I Polished the dellor gearbox bell housing
    Chromed the clutch fork
    Brand new starter motor
    Custom gearbox mount with new supra rubber mount

    Installed the rebuilt 2 piece tail shaft which was balanced up to 4000 RPM

    This was the rebuilt suspension which has been all powder coated it Black of red and had a few small things ( brackets and some bolts) chromed and got stuck in to polishing what i could from my other project
    Lowered Front springs powder coated red
    Koni Red front shocks
    K-Mac adjustable strut tops
    New super Pro bushes through out
    New ball joints
    New Tie rod outer (inner were ok at the time)
    New pitman arm
    2in new lower rear leafs with extra leaf and anti tramp half springs

    Brakes Upgrade and sway bar
    Twin sway bar kit powdered coated red
    Rebuilt brake booster and master cylinder
    R31 skyline brake calipers (polished) and rebuilt on custom mounting brackets
    626 vented disks bolted to standard hubs
    Braided brake lines front (ADR approved)

    the front end stuff

    Polished front calipers (R31 calipers with 626 rotors) and braided brake lines , black powdered struts, red powdered springs and sway bars

    The Diff, rear suspension and brakes
    Standard diff with drum brakes
    kyb rear shocks
    16mm rear sway bar add to the rear powder coated red

    twin system with extended primary's, 2 resies one in each twin pipe collecting just before the diff
    Turbo rota flow rear muffler

    Cooling system
    new 4 core radiator
    twin thermo fans

    This was it ! took about 6 months to get all done and took the car to get the defect cleared (a road worthy). It was a good day as it passed the first time and got comments for the inspectors and keep the noise level down just @ 97db ( that was with a restrictor plate in the rear section before the rota flow muffler) but a pass is a pass

  • #2
    Re: Fat 4 RE Rx4 coupe

    So after the car was registered i puts some k's on it and then went and took some photos

    gave the car a good detail inside and out


    • #3
      Re: Fat 4 RE Rx4 coupe

      Good to see the old girl on here Matt! I didn't know it was a brown trim car! Did you get through regency with the 48IDA?


      • #4
        Re: Fat 4 RE Rx4 coupe

        one of the best colours on a 4 imo 8)


        • #5
          Re: Fat 4 RE Rx4 coupe

          Originally posted by Garant
          one of the best colours on a 4 imo 8)
          "Life can only be understood backwards. Unfortunately, it must be lived forward." ... Kierkegaard


          • #6
            Re: Fat 4 RE Rx4 coupe

            Originally posted by jdmrx2
            Good to see the old girl on here Matt! I didn't know it was a brown trim car! Did you get through regency with the 48IDA?
            Yeah i finally got a thread up---- now time for the real updates :P

            Yep brown interior, it was the only colour trim choice with the colour D8 (Olive Metallic or Jewel Green depending on which colour chart you look at. which is factory colour code) from my knowledge. also with the colour D9 Alexandrite gold metallic (same as my original coupe colour) was brown . white was a mix between black and brown

            It went through as the pics in second post :twisted: weber was not a issue as its a 1/74 car = pre emissions and they could not do any thing about it

            Originally posted by Oracles
            Originally posted by Garant
            one of the best colours on a 4 imo 8)
            Cheers guys i do really love the colour and with the white vinyl roof it just sets it off


            • #7
              Re: Fat 4 RE Rx4 coupe

              Then after about 1 year i decided to put my fuel injection on just before a Big cruse (100+ rotary's and other cars) which ment i had to pull my finger out!! i only gave my self 2 months to do it

              Which is

              Injection perfection 50mm manifold which was polished by me and then had some new seal and bearings
              custom adapter plate for the K&N air filter
              4x s4 550cc injectors
              Ram pods
              Fuel rail
              Malpassie rising rate reg with 1 1/2 in Autometre pressure gauge
              Carter 7psi pre pump
              2 Lt surge tank
              Bosch 044 high pressure pump
              Microtech MTX-8 computer
              Quad coils on custom bracket
              Polished CAS

              it looking a bit messy while installing it

              A shot or the custom K&N adaptor and coil bracket

              A finished shot of the injection

              Get it all done and tuned in time for the cruise. Ended up with 121-126kw at the rear wheels

              some pics from the cruise and meet spot... Man these were the good old days in the rotary scene in Little old Adelaide


              • #8
                Re: Fat 4 RE Rx4 coupe

                Simply stunning...!! 8)
                Awesome colour and even better with that off-white vinyl roof. :tu:
                Great stance too...
                It's not what you drive - it's how you drive it...

                Best Regards,

                JDM '77 Toyota Trueno 1600GT Sprinter (TE61)
                + a handful of classic BMW's from the 60's and 70's.


                • #9
                  Re: Fat 4 RE Rx4 coupe

                  so i have forgotten about this thread and not finished my updates so i will continue where i left off

                  I decided that after our wedding in 2008 and our honeymoon to Europe i had 1 week before i went back to work so i went and got a price to clean up my old rims that were powered coated white originally.

                  Them on my original Rx4 when they were white

                  16in performance FX5 rims
                  Goodyear Eagle F1 G3 front
                  Goodyear Eagle F1 rear

                  They had been paint stripped (alkalined stripped) but one was found to be pouris and i had let them sit for 4 years thinking
                  that it would cost a shit load to fix.

                  This is them installed on one side only paint stripped

                  So i took them back to the Performance rims and they repaired them on the spot (at no charge) and quoted me $60 a rim for powder coating and to machine the lip so they all got dropped off and in 3 days they returned looking like this but only cost me $50 a rim 8)

                  Installed with new tires Goodyear Eagle F1 G3 on front and old Goodyear Eagle F1 on rear as they were in my shed with only 500km on them

                  Getting them installed

                  The finished product


                  • #10
                    Re: Fat 4 RE Rx4 coupe

                    so then started the upgrades with all the parts i had accumulated over the years, starting with the drive line from the motor back

                    Now some more upgrades are going in

                    New lighten billet flywheel
                    Excedy heavy duty pressure plate
                    4 puk sprung center clutch plate
                    New clutch master cylinder
                    New clutch slave cylinder
                    And already has a braided line
                    Front 24mm race swaybar (new) getting paint stripped and powdered coated red

                    new flywheel all bolted up

                    clutch braided line

                    A rebuilt rx4 diff with all casting marks removed and brake line cover then all powdered coated black

                    Rx7 s3 rear brake conversion fully rebuilt

                    Rear Brakes
                    Rx7 s3 rebuilt calipers
                    Rx7 s3 rear vented disks re-drilled to 4x110
                    Custom alloy mount brackets
                    Modified Rx4 hand brake cables

                    Got my braided line for the rear back

                    just got to install and bleed them

                    a pic of the hard line on the diff

                    I also got new spring saddle rubbers coming for it to so its all nice and fresh back their

                    And i also found out that my steering box is shagged (which is the only thing in the front end that was not rebuilt)
                    So rebuilding or buying a change over one

                    Old steering box as it looked before rebuilding it

                    Rebuilt steering box with new steering joint, new bearing, gaskets and painted the pitman arm again as it was looking a bit average

                    My Brake booster Painted up, new stainless steel sleeved master cylinder and modified for rear disks

                    And brake booster/master back in the car just have to do a final bleed


                    • #11
                      Re: Fat 4 RE Rx4 coupe

                      How as some might have noticed the my s2 coupe has the s3 ass end on her which was the only down fall of the car as it had mixed identities which i was told it had been changed in the early 80's [why i don't know :roll: ]
                      so with the help of some good people i have been getting the bits together to be able to change it over

                      so is is whats in on it ATM

                      So i have been picking parts up
                      2 to choose from 8)

                      and with a good clean set of tail light, an ok bumper, a re-chromed rear number plate light and one of the back dress panels

                      and a mate had this sitting at his house

                      so i cut it off so i can get it stripped and unpicked so it can be installed

                      this is all the parts installed to check for alignment and all looks good 8)

                      now its the fun bit of unpicking and making the decision to take it off the road for a longer period to do this change over and maybe the vinyl roof as well as the cancer is most likely at work under their

                      Got a couple of new/ re-chromed parts parts for the rear s2 conversion

                      Update on back panel--after unpicking it i dropped it off to get paint stripped and de-rusted and come back looking like this
                      with the corner section all cleaned up and in a water base sealer

                      Front stone guard all paint stripped and will need a little more repair still


                      • #12
                        Re: Fat 4 RE Rx4 coupe

                        So getting the car ready for a well needed tune and giving the car a full service

                        a sump that was sitting around for a long time unsealed and was also paint stripped and de-rusted, has a water base sealer on it also

                        Painted the sump i had cleaned the same color as the motor

                        I had some sump stiffening plates and bolts zinc plated years ago, a new sump gasket, Oil filter and Motul oil for it

                        Gasket installed and about to fit the sump

                        i Had to drop the cross member to get the sump out which was a bit of a pain but gave me a chance to clean some stray oil for the steering box and old sump that was around

                        Serviced the K&N air filter and oiled it up (man it was dirty) and come up good, new fuel filters going in too, Just need to install the new spark plugs and get the thing Dyno tuned

                        Also trying to complete some of the engine bay wiring upgrade with a modified left hand bay loom with upgraded alternator wiring and charge light relay so it is all plug in just need a 10amp diode for it and can install the loom

                        So spent some time on the dyno with some good resaults :thrust: :thrust:
                        even with the minor fucking around with the Vac problem and fixing it i am so happy with the tune and its like a new car to drive now =P~ [/size]

                        So smooth through the rev range and no shuddering when the staging kick in now

                        So after 3 hours on the dyno we got 123.1kw atw before the final tune
                        Dyno max - dynodynamtics

                        then on the final power run it made 125.8kw at the wheels with air cleaner off and 122.6kw atw with the air cleaner on

                        before and after read out (well the before one was after the first clean up of the map and before fixing the Vac problem


                        • #13
                          Re: Fat 4 RE Rx4 coupe

                          So with the decision to turbo the car in late 2008/ early 2009 (which was the intention to so when i built the motor in 1998/99)

                          Started by spending some cash on the turbo setup over a bit of time and collecting parts for the install

                          So got a turbo manifold with 48mm turbosmart waste gate and screamer pipe, stainless steel dump suit 4 bolt T3 rear housing, oil and water feeds, plenum to suit injection perfection setup, 2 x 850cc semiens injectors and 2 x bosch 1600cc white tops

                          a closer look at it with some other goodies :twisted:

                          So still working out turbo options at the moment but think it will be a GT35R (GT3540 with 1.06 rear )

                          still more money to spend before it is ready to be installed like dump back exhaust, intercooler and piping, pod filter, BOV (if running one), and some other small mods that need to be done/fixed before it is all a goer

                          So the intention to do a turbo install lead to the need of suspension and brake upgrades!!!!!!

                          after accumulating more parts i got back in the shed and start the install of some of the new parts that have been brought in the last few months

                          So Rear adjustable koni got installed to day and st on almost hardest setting (still got to go for a drive to find out if too still)
                          shock waiting to be installed

                          Removed the KYB (almost new) shocks and put these in

                          i still have to remove the K-mac rear sway bar and get it powder coated red like the rest of the Bars and front springs

                          Then started getting all the new BIG brake conversion ready

                          The list goes like this:
                          New bearings
                          Standard hubs with studs put in them
                          Custom Garage custom Rx7 s4/s5 caliper mounts
                          275-280mm vented and slotted disks (R33 skyline) which bolt up to the original hubs and cause no change in offset
                          S4 Turbo calipers fully rebuild (new seals etc) zinked all bolts, paint red with detailed (white) MAZDA logo
                          DS2500 pads (i think that's what they are)
                          Car already has braided brake line all round

                          Well the kit is brought from Custom garage and it is not re-drilled to 4x110 rather that they have been drilled so that they bolt up behind the hub as the standard disks would (see pic below) and it does not change the track of the car or the need to change off set of rims.
                          I am not sure if their is any extra to be modified to the disk it self as i have never seen a r33 disk unmodified before

                          Standard hubs

                          as they would be sitting on the car

                          where the caliper would mount to the strut

                          THEN THE UPGRADE INSTALL HAS STARTED (was around March 2010)

                          the front of the car is up in the air and the twin sway bars are out and the brakes are coming off \/

                          So the new 24mm sway bar got stripped back and powder coated

                          And the finish on it

                          And the old brake setup before it was removed and is for sale

                          More pics of the brake conversion, New bearings installed and backed with grease, new wheel nuts, disks bolted to hubs

                          trial fitting the setup

                          More pics to come once it is all done :twisted:.......

                          So brakes are all in just have to refill and bleed them

                          A comparison shot for all

                          and a few more finished ones

                          just not sure if the braided line are going to be ok as they are the ones i had done for the old setup and i hope they are not to short [-o<, when i turned the wheel to full lock all seemed ok

                          Just have to get out and install the 24mm bar but i have to modify the lower control arm rubber retaining plate as the outer one centre hole is just to small (by 1mm all round) as the new bar has a larger diameter thread ](*,)

                          back down on all 4's
                          OK so install is all done and may just need a final bleed of the brakes and a re-nip of the suspension, pedal feels good and need to take it for a drive to test it all


                          Had the wheel alignment done today and i got to say that i am more than happy with the overall change to the hole car with turn in response and positive corner feel

                          Also the brakes are bed in and just feel wicked and does it pull the car up so dam well. No signs of lockup at all and pedal has a nice travel but quite firm

                          Rx4's Cruise here we come :twisted:


                          • #14
                            Re: Fat 4 RE Rx4 coupe

                            Just took some new pics of the car on the weekend (April 2010) after a wash with the new brake upgrade, suspension upgrade and new number plates

                            i really like this pic


                            • #15
                              Re: Fat 4 RE Rx4 coupe

                              The brakes that i had on it was not to bad (but disks were 40mm smaller and only single pot calipers) + and the fact i have the S3 rear conversion on it, but due to the next stage of the project this was a must :twisted:

                              So very soon the Gt35R - GT3540 is getting brought and then that will be installed and a front mount cooler. I have every thing but the cooler, dump back exhaust piping and the turbo ........ So i cant wait 200+Kw here we come \/

                              :twisted: GT35R 8-[ here we come

                              So deciding on the inter cooler was a bit of debating around a front mount (air to air) or barrel type water to air cooler.

                              I am thinking of getting a top outlet medium to large cooler, one with both the pipes coming out above the radiator (drop the height of radiator slightly) , short runners from cooler to the Plenum, plus the car is not getting cut up in any way and i really don't want big pipes running around the front stone guard and through to the bay

                              So this arrived today (late April 2010) :twisted: :twisted: :twisted: :twisted: :twisted: New GT35/40 1.06 rear

                              Time to start setting things up

                              Still need a front mount cooler, piping, dump back exhaust to the rear rotaflow and some small things to get it all on 8-[ 8-[ :thrust: :thrust:

                              Then I got out in the shed and started playing with the collection of parts i got for the install and mocked it up to see how it all sat

                              So the NEW parts list
                              Garrett GT3540 1.06 rear
                              Turbosmart 48mm waste gate
                              Custom stem pipe turbo manifold
                              Custom dump Suit Gt3540 in Rx4
                              Braided oil feed
                              Stainless oil drain
                              Water lines
                              New turbo gasket set
                              Injection perfection 3in Plemium
                              Bosch 1600cc white top injectors
                              Semans 850cc injectors
                              Autometre Phantom Boost/Vac gauge
                              12a turbo water pump housing

                              To come
                              Front mount intercooler (custom)
                              Piping to suit
                              Air filter
                              Blow off valve????
                              Boost controller (maybe e boost 2 or a duel port manual type)
                              Exhausting piping between dump to rota flow

                              More pic up when more happens :twisted: :twisted:

                              *June 2010*
                              Tezzer shots

                              Turbo and manifold mocked up on the spare block

                              Sitting in position in the car

                              not real happy with the manifold as the guy i got it off must of modded the engine cross member as it is sitting only 2-4mm off the chassis rail and i can't get the waste gate on.........

                              so looks like a small mod to make it all good ](*,) :-k unch: \/

                              Took the front cover off the turbo and polished the shit out of it

                              back on the the car trial fit

                              July 2010
                              So got out in the shed today and played with the turbo manifold

                              Started by re fitting the turbo to the manifold to check the positions before modifying it

                              Then took to it with a grinder and cut the flange off the runners :twisted:

                              This is the clearance i got once removing the above pieces 22mm off the front runner length and 16-18mm off the rear

                              Turbo back on manifold (the white stuff is foam just to support the manifold as it has not been welded yet), dump pipe fitted

                              Also fitted the screamer pipe to the gate, but i am going to get a plumb back pipe done when it is at the exhaust and keep the screamer for track day and for when i feel like running a muck at letting every one else know about it

                              With not modifying of the dump pipe this is the clearance now

                              Not sure if i will mod it slightly just to gain some more room ???

                              just need to clean (machine) the face of the flange now and then weld it all back together
                              before cutting


                              Now Checking out intercooler options and getting prices :twisted: :-"