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Hi Inkafone, Not quite ready for the IVA test yet, work and life get in the way! Car now has body fitted and painted and other than a couple of gripes is all but done. Alternator light refuses to go out but the alternator is charging and the air con of the mazda still refuses to switch on the lexus compressor. The power hardtop still refuses to operate but on the whole i’m getting there. I am hoping to go to the Thoresby car show at the end of May in my classic mini, just out of a two year hibernation and then get to as many shows as possible.
Excellent news Andrew, there’s nothing quite like a V8 without exhausts!!! I will be there Friday, Saturday and Sunday. See you then.
Quick update. with the rolling chassis now actually rolling I find myself requiring some bodywork. Having looked at putting it on myself and realising that the electric roof needs to fit correctly to work and I am missing several brackets the decision was made to get Ivers fit it for me thereby ensuring precision. I took the chassis over to Martins and then promptly went to Switzerland for a couple of weeks and left them to it. Upon my return it now looks convincingly like a car! Once back at home I need to finish things off under the bonnet and remove the dashboard for trimming so off with the doors and front panel again. My nice induction system now fouls the bodywork so back to the drawing board and redesign using 3D printed ends to do from round to rectangular and back again with a rectangular tube in the middle. This then allows me to mount the MAF unit and cone filter in the right place. I have also extended all the wiring for the headlamps etc and as I wasn’t happy with the position of the battery I have re sited it to the boot along with a box for the jack. This meant having a positive terminal in the engine bay and I found a suitable one off an Audi that all my wires can connect to. I don’t fancy the idea of not having a spare wheel so I found a suitable space saver and then made an aluminium box to sling under the boot floor using an opening flap in the rear bumper to access it. Now I can work out what space I have left for the exhaust back boxes before getting a custom exhaust made.
Hi Andrew, progress indeed. I contacted a man in New Zealand who is an expert in these engines, (Cartune NZ on youtube) lots of very informative videos, and he sent me wiring diagrams to make up my own relay box and identified all wires. You will have a FP wire and a FPR wire which run the Lexus pump. FP works the pump and FPR is a resisted feed to give a 2 speed pump depending on requirements of the engine. When running the Mazda pump both these wires are connected due to being a single speed pump. Also the Lexus doesn’t prime the system but just works when cranking and running. The standard Mazda wiring primes first but won’t run without the Mazda engine telling it to so I wired direct from the Lexus to the Mazda pump and it all works fine. I will be down at the NEC at the classic and Restoration show at the end of March with my part finished car along with Martin and Mick with two complete cars. It would be nice to catch up there.
I finally got round to the job I have been putting off i.e getting the engine to start. Having taken advice from various people it would seem that getting the two ecu’s to talk to each other even though they are both Japanese is much more difficult than first imagined. I discovered a man on youtube (best source of reference) and learned more about the Lexus engine in a week than any manual can tell me and so got in touch. He is in New Zealand and he provided me with all the information needed to build my own relay and fuse setup to get the engine running. After carefully following this I coupled it up and bingo, the engine runs – incredibly loudly with no exhaust on! Surgery needed to wipe grin off my face. I only need to identify the correct wires coming from the Mazda ignition switch to give power to the ignition circuit and the start circuit and it will now run off the Mazda key complete with immobiliser. Now on to the auto transmission interlocks to make it safe in start and we are cooking!
Hi Geoff, welcome to the club and good luck with your build.
I am in the process of building a V8 version which is throwing up some interesting problems but none insurmountable. If you want to text me your email address or mobile number I will send you a photo of how the wiper mechanism fits. Roy has just finished his 2ltr one so he would be a good contact for you along with Martin and Malcolm for detailed information.
Speak to you soon,
As I wanted to retain as much of the Mazda wiring as possible I tried to fit the fuse box. Alas there is little room behind the radiator but having spoken to Andrew he has made his own enclosure and it fits so rather than relocate and extend 98 wires I have done the same. I fits very tightly but it fits. This enables the Mazda loom to follow its original path so few things need extending. With this in place I can now locate the radiator and condenser in place. My Lexus engine came with a large viscous fan so this had to go and I managed to get the Mazda rad fan to fit the Lexus radiator so the wiring lines up. Result! With the little space left I can make a small header tank and other than extending the bottom hose slightly that should see the cooling sorted. On to induction. There is no space for the original Lexus air ducting so a large silicone elbow on the plenum and another one for the MAF sensor joined together with an alloy tube with ports in for the various hoses in between is going to have to be made. A lump of aluminium and some serious turning later and job done. It fits nicely and is anchored to the chassis rail. All it needs is a cone filter to top it off.
Thanks Andrew, that has just saved me the cost of a bespoke radiator, well done for thinking outside the box!
With the steering column modified it can now be fitted permanently as tight to the chassis as possible, there is 3mm clearance from the manifold heat shield! I now have a pretty powder coated front subframe so back on it goes. The engine would be put in from underneath in the factory but that isn’t practical from my perspective so I have removed the radiator frame from the front of the chassis so the engine will go in from the front. The exhaust manifolds now foul the chassis so off they come to have the flanges removed and re-welded back on 10 degrees further round. This has resulted in the engine is in !!! Now in the process of lining up the gearbox and diff flanges ready for a bespoke propshaft to be made.
Hi Andrew, any progress made? Can you send me your details and I will give you a call, I have some information that may be relevant. Cheers.
Dammit! whilst lowering the chassis off the rotisserie I had a spot of bother resulting in the chassis dropping and hitting my hand on the way down – broken hand ensues!! Four weeks later I can now get back to it so with the engine and transmission on the crane I find that it’s mighty tight and that the rear lifting hook on the engine fouls the chassis crossmember. Out again to remove said hook and while it’s out the subframe can now go for blasting and powder coating. Whilst away it gives me chance to fit the bulkhead wiring loom and a bit of bulkhead soundproofing. That done the dashboard follows so that I can fit the steering column and work out the extension needed before putting the engine back in. Must keep going!
Well, slow progress at the moment, work getting in the way, however chassis was collected from Martin on Easter sunday and placed on the rotisserie so that I can fit the fuel lines and the brake lines without crawling around on my back. The petrol tank had to be modified so I removed 5 inches from one end and plated it back up. This will lose me half a gallon capacity but thats life! Having done that the subframes have been loosely fitted, the front one being modified for the V8 so now on its wheels its time to drop in the engine for the first trial fit and see what clearances we have for the steering column etc.
Hi Roy, Just wondering how you are getting on with your build. Is it ready for paint yet? Mine is still at a very early stage, too much work getting in the way of progress.
Hi Andrew, just picked up my chassis on Easter Sunday so it’s now in my garage on the rotisserie ready to start. Problem is I’m going to Italy this weekend so nothing will happen for a couple of weeks. Good luck with the engine.
Hi Andrew, have you managed to persuade the engine into life? My kit is due next weekend so fingers crossed. I will be at the classic car show next friday so maybe will see you there. Keep busy!