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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.





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





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.





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 11: Power Windows Installation - My 76 Mazda RX-5 Cosmo Restoration
I now present episode 11 of my '76 Mazda RX-5 Cosmo restoration. This episode deals with the task of installing the AutoLoc PW4650 universal power window kit. This kit includes motorized actuators which rotate the existing manual window cranks, driving the manual regulator and thus converting it to power without the need to fit an entirely new window regulator. Additionally it includes all wiring and switches (not installed yet), and mounting brackets. As it is a universal kit, it is universally wrong for every application and must be customized to fit. The installation was straightforward though time consuming. I have to admit, this episode is a monstrosity and quite a bit longer than normal. But for good reason, because I didn't want to do a "To be continued" as the next episode will be quite special. Included in this part: custom fitting AutoLoc universal power window actuators, making cutting channels into the inner door for space, patching and finishing off the channels with welding and sheet metal, cutting sheet metal from templates, media blasting before painting, making brackets for actuators, a surprise at the end.





Basic tuning of MegaSquirt - (watch in HD) Data recording and analysis - MX5 Unleashed episode 004
My MS PNP installation http://www.mx5unleashed.com/tech/megasquirt-pnp.html Episode 004 - Basic tuning of MegaSquirt PNP, data logging and Data analysis. Thanks to http://www.diyautotune.com/





Part 33: Turbine Heat Shield Fab & Intake Manifold Cleaning - My 76 Mazda RX-5 Cosmo Restoration
Part 33 of my '76 Mazda Cosmo restoration deals with what I would consider to be two important, though miscellaneous, tasks. While waiting for the Intercooler parts to arrive I tackled what I thought would be a quick and easy job; building a turbine heat shield. I won't admit how long it took but suffice it to say that the Intercooler supplies not only did arrive during the heat shield build, but were also packed away under the car and began to grow shop dust. Regardless of the time it took I must say I'm quite happy with the heat shield as I've seen very few like it. So many of the turbine heat shields on the market are nothing but a bit of bent sheet metal and a mounting bracket. At that point I decided I may as well deal with another small job so I took the time to remove excess OEM equipment from the throttle body and eliminate all the unnecessary vacuum nipples on the upper intake manifold. Included in this episode: turbo turbine heat shield fabrication, turbo assembly/disassembly, template making, stainless steel sheet metal cutting/drilling/grinding/bending, TIG welding stainless, OEM intake manifold extra nipple removal, TIG welding aluminium, FD throttle body simplification





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.





"My Classic Car" Episode feature on Jay Leno's Mazda Cosmo. (www.msmazda.com)
The Mazda Cosmo was the first rotary sports car. A great and interesting presentation of a unique and rare classic. www.MapleShadeMazda.com





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.





Rotary Engine Breakthrough?
The Wankel engine always held out a lot of promise, but never was able to fully deliver on those promises. It was never very fuel efficient, and the Exhaust temperatures were very high. But now an independent car tech thinks he has stumbled onto what held that engine back. Get more video everyday at http://autoline.tv





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.





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 10: My 76 Mazda RX-5 Cosmo Restoration - Shaved Door Sheet Metal
In part 10 of my 1976 Mazda Cosmo restoration, I continue the surprisingly long task of shaving the door handles. Last episode I left off after cutting the patch panel to fill the hole in the passenger door. This time I weld the panel in, fix the huge amount of warpage my improper welding technique caused, then do the same on the passenger side. Shaving the door handles took a lot more time than I thought it would and it feels nice to have it all finally done. Included in this episode: patching door handle holes, welding sheet metal, grinding down welds, hammering out warp caused by welding, learning how to not screw it up next time.





6 Peoples Reactions to the CRAZY 900hp 3Dx Evo
We had a blast giving people rides in the Evo, even had a guest driver when we gave Miss Thai Thai a ride after her photo shoot! See what people thought about the car, caught a lot of people off guard. TEXAS STREETS & TX2K13 Release now and shipping! http://www.1320video.com




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