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Saving a rusty R100

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  • Right now I'm up to test fitting everything in the car, before i pull it apart and paint it.





    Ive bought new Rx7 master and slave cylinders for the clutch, the brake master cylinder is away getting rebuilt, will get the clutch line done through the week hopefully.








    Working through the harness aswell. i want to get all the electrics working, even single thing, while the cars not painted.

    I have no idea why, but its been chopped and melted here and there. i spent a lot of today fixing it up, and I'm not even half way through it.







    My overflow bottle is the original R100 type, but i noticed today the pipe is split, and somebody has fixed a hole by braising a 2 or one cent coin over the hole. not sure what i will do with this yet.











    Im also thinking of side mounting the alternator. I'm going to see if the bracket still fits now that its side mounted from the front plate. i may have to modify the kit.





    I have the brake lines to attend to now .
    My videos https://vid.me/restoremaz

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    • Wiring was one of the biggest headaches in my old 2. Amazing how butchered a loom can become over 30 years !

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      • nice progress Dave and getting closer to paint and final parts restoration. Yeah electrical loom can be a real headache to fix correctly- just so time consuming . Keep up all the good work

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        • The webber manifold in the previous photos , was made for the series 1 R100 engine, and not mine, that is running the Rx7 series 3 tall port plates.

          anyway the guy that was doing this for me, has failed, and not completed mine, so I've had to start again and make it myself.


          i started by buying an off cut of a chunk of aluminium plate.







          I sprayed part of it flat black, then traced the top section of a 13b webber manifold onto it, and spent a bit of time cutting it out, all by hand.














          Next i made a cardboard gasket off the engine, and traced this on to the aluminium aswell











          After cutting out the ports by hand using a drill press and a die grinder, i made a jig, so the two parts are in position while i built the runners, at the right angle they need to be at on the engine.








          some of the pipe bends






          after many hours of cutting and shaping the pipes, (which i forgot to take pics of) i took it down the road to mr enforcer engineering.



          What took the previous guy 9 months to do absolutely nothing, took me and enforcer probably less than a day all up.










          Now i can get on with setting up the brake lines and exhaust.
          Last edited by restoremaz; 09-19-2017, 11:21 AM.
          My videos https://vid.me/restoremaz

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          • Looks good bro!

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            • No major updates this week, some next week for sure.

              Went out for a drive with some of the mazda club this arvo.

































              Last edited by restoremaz; 10-08-2017, 10:37 AM.
              My videos https://vid.me/restoremaz

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              • double post

























                My videos https://vid.me/restoremaz

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                • Good work Dave. I like the inlet manifold a lot. I really dig that R100 with the flares.
                  occasional blog: http://ewokracing.tumblr.com

                  Brought to you by me as I search Alta Vista for Geocities webpages using Netscape Navigator while listening to Jam & Spoon.

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                  • Ill get some more pics for you soon. it an original GS from japan, still running the 10a. the flares were done in japan.
                    My videos https://vid.me/restoremaz

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                    • back into the R100 after spending a few weekends on my brothers capella, and another mates car, getting them ready for rotary revival in a couple of weeks.


                      Currently trying to side mount the alternator, but i needed the crank pulley to be in the right spot, so i pulled the motor back out.


                      I thought, why not build it for a test start, once the electrics are done. so i put it together, with no porting or detail work, and no water kit. just a few o rings in the necessary spots, so i can fire it and run it for a minute or two, to sort everything out.



                      New apex seals, bearings, side seals, i always measure the apex seals now, as I've had a few sets from mazda that were too long.





















                      Next i needed a sump. i don't have an R100 sump so i cut and welded an Rx3 sump that came with some parts i bought. Its not perfect, ill clean up the welds and smooth it all out later when i start painting and detailing parts.

                      I got it fitting in the car, and clearing the crossmember, but when i went to fit the oil pick up, there was no room. So i made a little channel to clear it.


















                      Not the best welds, only doing with a mig. i want to learn to tig weld soon, and start doing aluminium and nice neat welds on mild steel.










                      Anyway lowered back into the car and onto the alternator bracket.











                      I could not use the off the shelf alternator side mount brackets that are for sale online, because I've side mounted my engine, and used the bolt holes they bolt up to, so Im fabricating my own.

                      i started with some scrap steel and bought a new alternator. I used the two top holes in the engine front plate, and two holes that the air con bolts to on the timing cover.












                      I will get some countersunk hex head type bolts for these to gain more room ...












                      This isn't the final mount, just tacked into place to work things out.

                      i need to come in closer to the engine, and lower, so the belt clears the dizzy once the belt is on the water pump. few more parts to make, and a lot more trial fitting.































                      Last edited by restoremaz; 11-12-2017, 11:33 AM.
                      My videos https://vid.me/restoremaz

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                      • Looks good. I havent welded in a long time but I always found TIG to be easy once you got your settings right. MIG I found required a lot more stuffing around etc.
                        occasional blog: http://ewokracing.tumblr.com

                        Brought to you by me as I search Alta Vista for Geocities webpages using Netscape Navigator while listening to Jam & Spoon.

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