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Part 24: MegaSquirt MS3-Pro Installation - My 76 Mazda RX-5 Cosmo Restoration

Part 24 of my '76 Cosmo restoration is here! And I'm going to come right out and warn you; this is a long one. There is a lot of detail here, for you see, this episode covers in it's entirety the installation of the MegaSquirt MS3-Pro EFI system. Like the engine build in part 12, I decided to cover the entire process in a way that would help anyone performing a similar installation. And while this specifically covers the MS3-Pro, all the information is valid for any MegaSquirt installation and indeed, any other brand of standalone as well. In this episode you'll see from scratch the MS3-Pro installation from bare engine bay to fully wired and functional EFI system. Included is detailed coverage of making an ECU mounting panel, wiring in all the injectors and sensors, wiring up the 2nd gen RX-7 CAS and coils, Boost solenoid, e-fan relays and other EFI related accessories. So pour yourself a big drink, get comfortable, and enjoy. A huge thanks goes out to DIYAutoTune ( http://www.diyautotune.com ) for providing the MS3-Pro and other parts used in this installation. Rotary MegaSquirt Links: http://www.aaroncake.net/rx-7/megasquirt/ http://www.diyautotune.com/tech_articles/how_to_megasquirt_your_mazda_fc_rx7.htm


 


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Part 25: Turbo Manifold Fabrication - My 76 Mazda RX-5 Cosmo Restoration
Episode 25 of my '76 Mazda RX-5 Cosmo restoration is another long one, covering in its entirety the fabrication of the turbocharger manifold. Suddenly the engine bay started to look a little cramped when I began to position the GT3076R, so it took some plumbing to build the required manifold. Constructed out of 1.5" SCH40 304 stainless steel pipe, it was fully TIG welded with an argon back purge. Yes, this is another long episode because I wanted to show the manifold fabrication process in glorious detail so that this video would be a useful resource for anyone wanting to build a custom turbo manifold. So as I say, grab your favourite adult beverage, sit back, and enjoy. Included in this episode: fabricating a 13B Exhaust flange, fabbing a merge collector, positioning a turbo in the engine bay, measuring, cutting and fitting stainless pipe and els, tacking in position, setting up a back purge, final welding, port matching, custom heat shields. A huge thank you to ATP turbo ( http://www.atpturbo.com ) for helping out with some of the parts used in this episode.





Part 18: Floor, Frame, Firewall - My 76 Mazda RX-5 Cosmo Restoration
It's time finally for part 18 of my Mazda RX-5 Cosmo restoration. In episode 19 I continue repairing the rear floor pan, this time dealing with the drivers rear seat area as well as some of the bulkhead and frame below it. Once tired of messing about with floor pans, I move onto some easy sheet metal work involving filling some of the unnecessary holes in the firewall. Included in this episode: cutting out rusty sheet metal, cleaning up rust, prepping the areas for repair, fabricating patch panels, hand forming patch panels, welding in new metal patch panels, smoothing a firewall, fixing sheet metal weld distortion, a tornado.





Part 36: Fuel System and Fuel Lines - My 76 Mazda RX-5 Cosmo Restoration
With any rotary, a robust fuel system is a critical component in reliability. This is what will be covered in part 36 of my '76 Mazda Cosmo restoration. In this episode I set up the engine bay section of the fuel system. This includes the regulator, fuel Y block, and all the fuel hoses using braided line and AN fittings. I also bend up a set of stainless fuel lines for underneath the car. The fuel tank also needed some attention so I begin the process of getting it cleaned out and ready for modification to handle an in-tank EFI pump.





What its like owning a 3 Rotor 20B RX-7
I have one of the most amazing custom RX-7s in the world. I want to share my experience of owning and driving such a unique car. I explain where the engine came from, why its so special, and what it does to a Mazda RX-7





Part 26: Exhaust System Fabrication - My 76 Mazda RX-5 Cosmo Restoration
With the turbo manifold finished and the turbocharger installed, it seemed logical to continue on that route and finish the rest of the Exhaust. So in part 26 of my '76 Mazda Cosmo Restoration, I do just that. Starting with the downpipe, I build the full stainless steel Exhaust piece by piece to include a catalytic converter, resonator, middle muffler and rear muffler. It was a bit of challenge to fit all that equipment under a car never designed to contain it, however I believe I have achieved my goal of an above OEM quality, long lasting and quiet Exhaust system. In this episode you'll see me: build a downpipe, cut and fit tubing, weld to a v-band, build a midpipe with O2 sensor bung and flanges, position Exhaust components, cut tubing bends to fit resonator and mufflers, loads of TIG welding, set up Exhaust hangers.





How to Turbo - Part 1
After buying a Euro car last episode, Marty discovers he has not yet found his perfect vehicle... In this extended episode, we reveal what he got, and show how to make it faster. Wanna show the world that you fix your own shizzle? MCM stickers, ti shirts and other mad shizuoika available here: http://www.mightycarmods.com/collections/all Official Site: http://www.mightycarmods.com Forum: http://forums.mightycarmods.com Music from the episode is available here: http://www.mightycarmods.com/collections/music (Forced Induction by MOOG was featured in this episode) Also something to note around Mighty Car Mods: we are normal guys and are not trained mechanics. We like to make interesting car mods and show you how we've gone about it, but we can't promise that anything we show you will work for your particular car, or that you won't harm yourself, someone else, your car or your warranty doing it. Please be safe, be responsible and unless you know what you're doing, do not fool around with very serious machinery just because you've seen us make it look so easy. Talk to a qualified mechanic if you are in any doubt.





Part 32: Air Box and Coolant Recovery Tank Fabrication - My 76 Mazda RX-5 Cosmo Restoration
While I'm done with air conditioning, part 32 of my '76 Mazda Cosmo restoration still deals with moving air around, as I fabricate a cold airbox. After working so long on the Vintage Air system I wanted to do some simple fabrication, so the air box was a perfect choice. Made to accept a cone filter it is a true cold airbox that draws air from the inner fender. So not only will the box muffle the sound of the engine but it will also assure the turbo is drawing in the coolest air it can. Since I was in an aluminium fabbing mood after the airbox, I also continue on and build an aluminium coolant recovery bottle. Fitting perfectly in the little space between the radiator support and relay panel, made out of square aluminium tubing, it provides a hidden and elegant solution while not taking up any engine bay space. Included in this episode: making cardboard templates, cutting aluminium, bending/shaping aluminium, loads of TIG welding, nutserts, cutting tubing, fabbing a tank, welding bungs.





Part 22.5: Updates, Q and A, Misc - My 76 Mazda RX-5 Cosmo Restoration
June, July, August, September, October and November; Hey, I wasn't kidding when I said in episode 22 that it would be a bit of a wait for the next one! In that time I've been as hard at work on the Cosmo as I could manage, which unfortunately is not as much as I would have liked. It's been a busy summer with plenty taking me out of the shop. Even still, I've been working as much as I can and have picked up the pace over the last two months to the point where the driver side sheet metal is almost done. So what's in this episode, strangely titled as "Part 22.5"? Well, with the help of my special guest Rose Cora Perry, I answer some of the most common questions about the project. And along the way, there are a few tips and tricks thrown in, as well as a little bit of why the driver side repairs have taken so long. This episode is a little different, so I hope you enjoy...





Part 21: Front Sheet Metal Extravaganza 1 - My 76 Mazda RX-5 Cosmo Restoration
Part 21 is finally here! It's been quite a while since the last episode, and a lot has been accomplished. Not quite as much as I would have expected due to a busy time of year. After a trip to Jamaica at the beginning of February kept me out of the shop for two weeks, we entered auto show season with an auto show every weekend until mid March. Now that's over with, I've been able to get back down to the oh-so-fun sheet metal work. This episode focuses on the mass amount of front end sheet metal repairs in the fender and passenger foot well/sill area. Episode 21 is actually only the first part to this set of repairs, which we will finish off in part 22. And after that, no more sheet metal for a while! I promise! Included in this episode: cutting out rusted metal, drilling spot welds, loads of patch panel fabrication, welding it all together, weld through primer, POR-15, grinding.





Part 35: Water To Air Intercooler Installation, Part 2 - My 76 Mazda RX-5 Cosmo Restoration
In the last episode of my '76 Mazda Cosmo restoration, the basic components of the water to air Intercooler system were laid out along with the considerable amount of fabrication needed to build the throttle body inlet, Intercooler piping and water tank. As well as mount the heat exchanger and BOV. In part 35, we finish up the water to air Intercooler installation by taking care of mounting the pump, plumbing all the water lines and wiring up the system. Additionally support brackets are built to support the piping. Lack of space meant I had to get creative with pump position after accidentally creating a clearance issue with the water fittings. However once mounted I was very happy with pump position and the plumbing was straightforward. Included in this episode: Cutting/grinding/drilling aluminium, making aluminium brackets, assembling AN house and fittings, wiring relay to spare Megasquirt output, adding temperature sensor to Megasquirt analog input, plumbing air to water Intercooler with tank and pump, TIG welding brackets.





Part 12: 13B Rotary Engine Rebuild - My 76 Mazda RX-5 Cosmo Restoration
Just as I promised last episode, it is finally time to build the engine! Part 12 of my RX-5 Cosmo restoration covers the entire process of building the 6 port 13B Mazda rotary engine. While this engine is a hybrid of GSL-SE RX-7 and Cosmo parts, the process is the same for any rotary from a 12A to a 13B NA, 13B turbo, 13B-REW or any other variant of the 13B. This video shows the whole process of the engine build, starting from measuring the rotors and covering everything else including clearancing the side seals, assembling the rotors, complete assembly the short block, setting the eccentric shaft end play and installing the front cover and everything underneath it. It's probably the most complete engine build video outside of what you can buy from the vendors, and as such, is an hour long. After this one, I'm going back to videos under 20 minutes. But for now, grab a beverage of your choice, sit back, and enjoy.





Mazda Cosmo 110S - Jay Leno's Garage
Mazda Cosmo 110S. The first rotary-powered sports car. » Subscribe: http://bit.ly/JLGSubscribe » Visit the Official Site: http://bit.ly/JLGOfficialSite THE BEST OF JAY LENO'S GARAGE » Exclusive First Looks: http://bit.ly/JLGExclusives » Ultra Rare Supercars: http://bit.ly/JLGSupercars » Jay's Book Club: http://bit.ly/JLGBookClub JAY LENO'S GARAGE ON SOCIAL Follow Jay: http://Twitter.com/LenosGarage Like Jay: http://Facebook.com/JayLenosGarage ABOUT JAY LENO'S GARAGE A new video every Sunday! Visit Jay Leno's Garage, the Emmy-winning series where Jay Leno gives car reviews, motorcycle reviews, compares cars, and shares his passion and expertise on anything that rolls, explodes, and makes noise. Classic cars, restomods, super cars like the McLaren P1, sports cars like Porsche 918 Spyder and Camaro Z28, cafe racers, vintage cars, and much, much more. Subscribe for more: http://full.sc/JD4OF8 NBC ON SOCIAL: NBC YouTube: http://full.sc/MtLxIM NBC Facebook: http://facebook.com/NBC NBC Twitter: http://twitter.com/NBC NBC Google+: https://plus.google.com/+NBC/posts Mazda Cosmo 110S - Jay Leno's Garage http://youtu.be/0bUUzDKnPhc Jay Leno's Garage http://www.youtube.com/user/jaylenosgarage





Tuning EFI / Standalone Engine Management - Holset 1G Talon w/ Megasquirt2
I show a few tips and tricks while setting up my buddies eagle talon. Holset HX35 setup with MS2, the DIYPNP version. This video covers initial setup up until we turn up the Boost. Part 2 will be high Boost / high power. This car is going to be fun! Sorry this video was so long... http://www.doogielabs.com





Part 3: My 76 RX-5 Cosmo Restoration - Rotary Engine Disassembly And Cleaning
Part 3 of my Cosmo restoration shows disassembly of the 4 port 13B rotary engine and the beginning of the long process of cleaning the internal engine parts. At first I was quite worried about the condition of the engine after looking through the Exhaust ports, but as soon as I opened it up I was pleasantly surprised.





Mazda RX7 & JC (Eunos) Cosmo Junk Yard in Japan
This is an impressive, though very rough collection of sporty Mazdas. There are Efini, Infini & convertible RX7s and also 20B-powered JC Eunos Cosmos. Music Credit: Created by Dylan Benson, and used with permission and much appreciation. Dylan Benson on Youtube: https://www.youtube.com/DBProductionCompany Dylan Benson on the web: http://www.dbproductioncompany.webs.com/ See MORE videos: http://www.patreon.com/wasabicars Site: http://wasabicars.com Facebook: http://www.facebook.com/WasabiCars Shop: http://wasabicars.spreadshirt.com/





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