Wednesday 16 May 2012

Throttle Cable Outer Stop

To stop the throttle cable outer wandering about at the pedal box end I  got a bicycle brake cable adjuster...


...and stuck it in the pedal box:


Job done!

ECU Location

After moving the battery out of the passenger footwell I decided to fill the freed up space with the ECU.
I used two of the existing ECU brackets (one of which was chopped down a bit) to bolt the ECU to the bulkhead.
It's not exactly heavy, so two M8 bolts and nylocs should be ample!
I also stuck some self adhesive foam to the back of the ECU before I bolted it on.  It'll do bugger all vibration wise, but it made it 'sit' better.

 
The loom to the ECU is the original MX5 one, albeit heavily stripped and modified.
The bulk of the loom goes to the engine bay via a hole in the side of the tranny tunnel panel using one of the MX5 engine loom grommets to protect it.
The rest of the loom goes up into the scuttle where it will eventually connect to the fusebox, clocks, and pedal box.


Monday 14 May 2012

Head Re-build

Way back when I bought the donor the previous owner warned me that one of the spark plugs was 'slightly rounded off'...
When I tried to get the plugs out it was clear it wasn't slightly rounded off, but completely and utterly rounded off.
As my attempts to get it out failed I ended up buying a spare head off ebay.
I got it several months ago and it's been sat under my desk at work.  Every now and then I've been getting it out during a spare lunch hour and slowly rebuilding it:




It's now finished with new stem seals and re-ground valves and seats (done the old skool way with grinding paste and a sucker on a stick) and ready to go on the engine.

Wiring - Fusebox and Relays

I can't remember if I've covered this already or not, but here's a pic of my fusebox and relays:


I made this up some time ago and fitted it to the scuttle bulkhead.
It might not be pretty, but at least it will be tucked away under the dash where no-one can see it.  Just hope I never need to change a fuse!

Battery - New Home

Well I was going to put the battery out of sight in the passenger footwell, but after buying a nice shiny ali bracket for it I decided to stick it on the engine bay bulkheadfor all to see.
To be fair it was a bit tight in the footwell and my bracket wouldn't fit.. :)
I've also stuck the main fuse next to it so I don't have un-fused battery going through ali panels.



I've held the bracket in place using rivnuts.  It was positioned so that 3 of them went into the chassis rails, and only one goes into the ali bulkhead alone.

Wiring - Pedal Box

Here's a couple of pics of the pedal box wiring:



Again, I junked this part of the MX5 loom and made a new one, and again it ends up behind the scuttle.

Wiring - Tunnel Loom

Here's some pics of the loom running down the tranny tunnel:





I junked the original tunnel loom and made this one from scratch.
It's covered in heat-shrink to protect it, and clipped into place with nylon p-clips and pop rivets.
At the rear it goes to the lights, fuel pump, and fuel sender (or will do when I wire the rear end up!).
In the tunnel it goes to the handbrake and gearbox (reverse/neutral/speed).
The front end of it goes up into the scuttle where eventually all the wiring will come together.

Clutch Switch

As the MX5 ECU needs a clutch switch I had to find a way to add one.
The OEM switch is an electrical one driven directly by he clutch pedal.  Because the pedals in the roadster are 'upside down', the only way I could realistically use the OEM switch would be to have it bolting into the floor from underneath the car.
As that would last the length of the trip to my first speed bump I needed a different approach...
So I decided to use the same pressure switch I used for the brakes and stick it the clutch line using another 3-way T-piece:

As an added bonus it put my flexi-line to the clutch slave in a better place.
There is some debate as to whether there will be enough pressure in the line to switch it, but time will tell!