Nice work on the Car and the yard, shed and fences mate a credit to you

Great build thread, love the yard i have to say.
Can not wait to see updates on the wagon.

This will no dout be my favorite wagon in Aus, did you have the rx3 trims for the boot? And will you woodgrain the read panel?

Ha ha cheers mate, they say dont count ya chickens.. my car could turn out crap! hahaha well I hope not.

Yes I have the trims for the rear and badges etc its all away getting polished painted blah blah. The fake wood grain sticker is a funny one I have definately considered it, I sent an email to a mate and mentioned putting it on my car and he replied with a picture of Cletus from the Simpsons. If your getting the joke!!!!
Its one thing I'll wait until last thing to apply it if I do. However I do plan to have a copy of the rx3 wagon style side stripes front to rear.

I'm trying to get cracking on the wags but its all go at my place at this point in time. more on that next update! Currently hunting a set of the lower rocker panel sill strips for rx3 808 sedan and wagons. hard to find and even harder to get shipped!

Thanks for the kind words from those above. I do try not to get all back yard and no car but unfortunately I need the yard and sheds done asap! back in a couple days with a decent update.

Any new updates on the low flying blue weapon?

_________________
Rockin' the 7 in a street near you.....

Ok so, here we go...

The wagon is sitting there patiently waiting my attention. I've put it up on jack stands and removed the front guards wrapped them in bubble wrap and hung them high out of harms way. The garage has become acces for works again so the car is covered up. Although behind the scenes when weather restricts play, I have been finalising some things for it. sending stainless strips off to be polished locally, a few odd parts over to Restoremaz. Then a couple down to the powder coaters. Here is my 24mm sway bar back from the coaters

By beans161 at 2012-08-05
Whiteline provide a 24mm bush set for the front to match the bar but its yellow! so I had to order whiteline end bushes in yellow to match and remove my red Nolathane ones ( nolathane dont make a bush for 24mm sway bars) so I've swithed to yellow bushes for the sway bar as I dont want multicolored shit everywhere.
I'm hoping to get cracking on it in the next few weeks I've just been a bit distracted as I've had a heap of works going on out back. I had a birthday recently which landed me with this cool present pictured below from my very understanding girlfriend. Funny part is she had no idea what the fuss was about!

By beans161 at 2012-08-05
Stoked as it will add to the old school streeter flavour that I'm after.

The yard is now fully taking some shape. Its been a hard slog in the last few months but the recent works has made it all seem like I'm getting there. Last time I updated I had just replaced the fence with my neighbour.

By beans161 at 2012-07-18
The next works I did call on the professionals for. I wanted to turn more of my dreams into reality so we called an builder and got them to design the pergola as I had planned in my head, suprisingly it was all ok and got approved first go! It was time to add some cover out back in prep for finally doing the concrete. roll out the pics.
The facia we replaced and the area pre construction. notice the brackets added on day one of the build in the latter pics then into carpentry.

By beans161 at 2012-08-05

By beans161 at 2012-08-05

By beans161 at 2012-08-05

By beans161 at 2012-08-05

By beans161 at 2012-08-05

By beans161 at 2012-08-05

By beans161 at 2012-08-05

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By beans161 at 2012-08-05

So finally my yard design has its grand masterpiece in place time to add the Merbau stain to match the decking. The texture coated columns are a light shale grey, the house will be done to match that eventually.


By beans161 at 2012-08-05

By beans161 at 2012-08-05

By beans161 at 2012-08-05

By beans161 at 2012-08-05

By beans161 at 2012-08-05

Still allot more work but this is the first time we've had cover out the back since we moved in so this is a momentus occasion for us in our little home. I'm very happy with the progress and really want to focus on conctrete and the shed next. That require some small side jobs out back but hey all part of the fun! So thats all from me for now.

Update:
Recently I Have been researching raditators and oil coolers. The task of finding a good quality setup that will look fairly factory when finshed well.

The plan is to have a new PWR alloy type as they offer performance but do a neat complete setup with fan and come in black, but I want it to look somewhat factory by mounting in the standard laocation. Alloy radiators these days are made to sit back to allow for front mount intercoolers the other issuewas the oil cooler mounts if the stickout and foul on the chassis. I contacted PWR asked a few questions and the guy was quite helpful and confirmed they supply it powdercoated black, also understood my query on mounting location and got the dimensions emailed through on pdf promtly. I wont post them here.

After a bright idea from a mate I went down and grabbed some 70mm polystyrene foam and cut out a template matching the dimensions they sent on the plans

By beans161 at 2012-08-12

This is how it would mount if you rang and said give me a radiator for rx3. Great if you want a front mount cooler etc, but not here in this garage.

By beans161 at 2012-08-12

I want it to hide under the cowl and sit forward like the standard fitment. Thankfully the size they supply will fit under the cowl however will require the mounts located on the reverse side to where they normally put them.

By beans161 at 2012-08-12

By beans161 at 2012-08-12

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By beans161 at 2012-08-12

Oil cooler mount tabs location will be ok also.
My issues are small but basically come down to around 50mm of clearance.

Well I had a day on the car, so I got cracking and went and got some new bolts and put the swaybar, crossmember and few other bits in ready for the motors fitment.

By beans161 at 2012-08-12

By beans161 at 2012-08-12

By beans161 at 2012-08-12

By beans161 at 2012-08-12

By beans161 at 2012-08-12
Made some progress up front with the engine crossmember and sway bar etc

So then I gave the gearbox a once over with a wire wheel.
Before

By beans161 at 2012-08-12
After

By beans161 at 2012-08-12

By beans161 at 2012-08-12
Not sure if I should leave it brushed finished or paint it, if I did paint then what... silver, black arrrggghh. Next is give the motor a tidy up and by tidy up I mean clean and paint. The motor is a runner so only removing a few parts to paint and clean it. I'm going to tape it up and paint the plates flat black only, maybe the gearbox could be going black if I get trigger happy with paint in my hands.... Thats all for this weekends progress. Cheers for reading

Update: running around town getting things happening!

The past week I have done some more research and found the direction I want to go with my Diff and running gear yes I have changed a couple things again. I've always had a plan however as many of you know nothing is a sealed deal until its installed and functioning.

I have contacted a local Differential specialist to ensure its top quality and able to be engineered and approved at a later date. They suggested a couple different options and I have decided to trust the professionals rather than get them to make a set up of bits and pieces that other mazda owners have said is good and works, like a hilux with skyline discs which is the current trend locally.

Fuel system modifications is also on my to do list, I have started accumulating some parts to get it happening. Looking at what will work in the wags and how to hide everything so I dont have a hatch area full of fuel systems and battery, nothing worse in my view!

I mentioned the radiator in the last update, should have it delivered in the next couple weeks. Also sent my gearbox off to have the gear shifter relocated forward so when I install the 12a rx7 style box the lever will sit closer to the original rx3 position.

When I have spare time I have ventured out into the garage, installing some more of the removed parts like wiper motors and mechanisms, headlight mounts and buckets and the rear door handle. Nearly all of my chrome and stainless strips are in being polished as I do not have the equipment or skills to do it myself. Restoremaz has my last couple badges, tailgate trims and vents etc. When they all get back I can install a few more things and start making it look like a car again. Its fun to attach parts for the final time in most cases.

I also sprayed the motor with bright shine and left it soak in then cleaned it up, added some masking tape and then hit it with a couple solid coats of flat black engine enamel. Its now looking much neater, once the box is back from having the gear shifter mods done I'll be attaching it to the motor and lifting it in.

Next on the list is to hit the online workshop manuals as I will need an 808 wagon wiring diagram to assist me with making my own new looms for the engine bay. Planning on rewiring the engine bay with hidden wiring looms under the front quater panels with new cables to avoid problems, also repairing old looms to accomodate the changes and adding a new fuse box system to control the new gauges, controls, fuel and engine management systems...

Once the motor is sitting in I can start connecting it up and getting ready to run, I will also be able to sort the gearbox crossmember and mounts. Then do the dash swap to the rx3 setup. Once the dash is in I will start my wiring for the new bits and pieces. It will also allow the windscreen to be installed!

More pics next update.

Excellent read I love this thread

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REgards, Mo Melville

Cheers Mo! Any recent updates on your many projects?

loving your thread.. looking forward to finished product
just wondering about your diff comment tho, i cant really see any downsides to running a hilux other than the extra weight.. theres a massive selection of ratios and lsd centres are readily available at great prices.
what does the diff specialist recommend?

Cheers mate! Thanks for your positive feedback.

Just to be clear I have no issues with other diff options or brake setups for that matter. Also I know there are plenty of workshops who can do good diff upgrades and whilst I'm sure they are great I feel more comfortable going to a company that solely work on diffs and transmissions. It all personal choice and piece of mind really I guess. My original plan was to build a Mazda using modified parts but I'm trying to avoid a set up made of bits and pieces from multiple different cars.

The reccomendation was to go for a shortened skyline/pintara Borg Warner disc brake 4:11 lsd with custom moser axles.

Love the powder coated black radiator idea. Very stealth.

What bushes are you running through the car?

Good to see you are going old school with the monster tach. I have one to go in the coupe and I am sure I will cop some flak for that. I reckon they suit the old school look of the car.

Starting to get exciting, really coming together now!!

_________________
Rockin' the 7 in a street near you.....

Thanks again for kind supportive words guys, it is definitly motivating to say the least!

Update: I have recently had a week away, a 2000+km road trip. It was good to get out on the highways and enjoy some quality twisty bitumen. I'm such a fan of the Alpine switch-back roads, we did the high country to the snow and then "The great ocean road" home. A good drive when not stuck behind grey nomads! definately want to take the mazda on some tours when its running. I was in a mazda this time, however it was my chicks 323 sp20 getting a good workout not a rotary... ok back to the build.

Last time I mentioned the gear lever mechanism moved forward on my gearbox to hopefully enable it to be located somewhat closer to the original position, that way my centre console will fit nicely. Fingers crossed I guess until its actually in! I'm very close to putting the motor and box together and fitting. Borrowed an engine crane from a buddy so there no excuses now... except finding the time!
BEFORE:

By beans161 at 2012-08-12

AFTER:

By beans161 at 2012-09-03

On a side note to that, I have held off on swapping the dash until the motor and box is in. I was all keen to get it in but the gear lever and gearbox mounts has me cautious as I may still need to make some further modifications.

Got a call from the metal finishers that my stainless strips are polished and ready to collect, I will be heading down later today, pumped as this should allow me to attach the tailgate chrome!
I managed to chase down some plastic clips for the tailgate chrome strips. One good thing about having an older generation panel beater he knew what I was after and the parts I'll be using are actually from a VW beetle . Its a small press in clip that basically provides a mounting for the chromes. seen here:


By beans161 at 2012-09-03


By beans161 at 2012-09-03

Picked up the diff ready to be sent down to be shortened and refreshed. Doesnt look like much now but after a clean and removal of a few bits it will be sweet!


By beans161 at 2012-09-03

Lastly - The radiator/oil cooler could only be a few days away they said 2 weeks, so waiting on a call or email from PWR is kind of exciting.
Picked up a couple bits like crank angle sensor, an original black plastic oil cap and oil dip stick.. small things but key to making it look like a factory fit.

Nice work, be careful powder coating some stuff. I asked my powder coater about doing my fuel tank. Lucky he knows what he's doing and said he can't do it. The one time he did one the heat from oven melted all the solder in the tank joints and the tank became useless, well would no longer hold fuel.

The radiator you bought must be TIG welded together if they are powder coating it for you. I know most factory radiators are held together with solder which means they'd suffer the problem as the fuel tank I mentioned.

If anyone here knows the answer to this it's got to be you. I'm trying to find some rear wagon quarter glass rubbers for a guy restoring a Rx3 Wagon in the USA. I've asked my Mazda guy (waiting on reply), if that avenue fails any idea who would have the right ones ? I'm not making anything on them just helping some guy out finish his car. If they are the style that holds chrome that would be a double bonus.

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Ebay reproduction parts for sale here

Hey John,

The radiator is coming from PWR. I'm confident they know their stuff as they primarily supply race type products. But any tip like that is always appreciated as I enjoy furthering my skills and knowledge.

Ok window rubbers.. Both rear sides and rear hatch? Oh anyway, I'm no real help to be honest. So I had a night pondering, but have really not looked for apart from an googl/eBay search here n there. I noticed on mine (exactly as you pointed out) a very small feature. It was the groove for the chrome strip. Now because we didn't get the chrome strips no one cares... But say your a guy like me, building a replica of a car we never actually got.. I then start to question, how close to perfect do I want to be and more to the point, what parts can I get quickly at what price and how close are they to original. At the time when I needed to get my windows in I couldnt justify the price for the set from a place like phils, at the risk of it not being correct. So I used my original ones with the groove. My advice would be find a decent set of originals just in case.

Now that I am further into building the car I have changed my mind and I am actually going to purchase one of the rx3/808 wagon rubber sets from phils just to see for myself A:quality and fit B: if they have any rubbers I may have missed or needed, also the grooves for rear window chrome etc. I do think they do the rear and side windows too but could be wrong and could not say if it had the groove for the strips. I did call but didn't ask for them specifically? But I still need those strips for the side windows too.. So if you maybe know of any?

I have a question, the door window chrome strips that run on top of the door panel, are they supposed to have a thin black rubber like seal/gasket or double sided tape between it an the paint? It seems like it should to me, chrome straight onto paint just doesn't seem right. Everything has a little seal to protect the paint even the rear reflectors so why not these? other Mazda's of the same era did but I have no idea with these. Thanks in adavance.

Ben, I think the guy restoring his wagon from the USA has already tried Phils. From what I can gather no one makes the side rear quarter rubber for wagons. I have looked around the globe, all over Australia, New Zealand, Japan, USA, parts of Europe... nothing ! The last remaining hope for this guy is to put him in contact with one of the guys that would have more local knowledge in Japan. Actually I have one other avenue that's worth a try

The problem with the old ones is they go rock hard and crack as 40yo old rubber does.

Last of all Mazda still sell a few of the extra items that are in those kits... ie door cushion switch rubbers, clutch fork cover rubber boot, door lock gaskets, pedal rubbers, strut top rubber mount, strut top shock nut covers etc etc and more... and they are all CHEAP (except the strut top mounts ~ $70). Just need to order them. Each to their own I suppose. Nice progress, look forward to the next update.

Cheers John, Sorry the side windows are a difficult one. If you happen to locate them let me know. I'm hunting the chrome strips for the side windows too..

I will try mazda for the parts you mentioned, I have only hesitated because our local dealers really are not very helpful with parts. you mention rx 234/ or even early rx7 and they basically say no before they even look for a part number. Its quite frustrating to say the least. I should go in with a list of part numbers not mention what they are for and just say can you get these for me then see how I go! but knowing they have them now I persist..

ok so I've been busy... made some GOOD progress, but with that comes some more difficulties and work to do and parts to source. When installing aftermarket engines and parts its never a case of whack it in! Here is the chrome strips mentioned last update


By beans161 at 2012-09-06

By beans161 at 2012-09-06

SO.. my new pitman arm from the steering box to connect the steering is a bitch to get on, I gave up! and then I began fitting the motor but have clearance issues due to the motor choice. nothing is ever too easy with these cars!


By beans161 at 2012-09-06

By beans161 at 2012-09-06

Introducing the car to its new life source!


By beans161 at 2012-09-06

By beans161 at 2012-09-06

AND ITS IN!!! da daaaaaaa... ( YES the plenum is just an old one while I work on the car)


By beans161 at 2012-09-06

By beans161 at 2012-09-06

By beans161 at 2012-09-06

I havent gone into details regarding my motor before now. Its an original 12a turbo with a matching 12a turbo 5 speed. A rare and uncommon motor in its standard form, just what I like - rare mazda goodies! No porting mods no rebuild. (why touch something that was running in the previous car) as they say - If it aint broke dont FARK with it! I know of one 12at in particular that has never been rebuilt and has quite along rest in between outings - that gives me a quiet confidence in these motors. So for now its going in as is!

Ok so heres my next little problem: Actuator hits the chassis rail.. DOH!


By beans161 at 2012-09-06

By beans161 at 2012-09-06

By beans161 at 2012-09-06
I think my issues relate to this crossmember and engine mount set.


By beans161 at 2012-09-06

By beans161 at 2012-09-06
Gear lever in the cab, still no mounts just held up with a jack and block of wood.

By beans161 at 2012-09-06

But never the less the motor is in the car!!! so stoked to tick that box finally, and the gear lever popped out of the cabin hole first go! (please note the dirty plenum is just a dummy one until i'm finished tinkering) I have allot more work finalising the fitment of the motor and getting the clearance correct. so after 7+ years my car has a rotary in the engine bay. HEEEEELLLLL YEah!! Ok thats all from me. time to get dirty!

loving the progress mate, 12at should go alright

you going to hi-mount the turbs to clear steering box? that should sort your actuator issue..

Cheers frenchy.

Nah no manifold changes. That would lead to plenum changes etc etc. i want the standard motor I like it looking nice a stock with the old school turbo writing and all! Will mean a little fiddly work but I'm confident it will go together nicely if I take my time. Thanks for reading!

Oh if anyone has a tip on how to get the control/pitman arm back onto the spline of my steering box, please school me. much appreciated!!!