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 23: Middle Intake Manifold Fabrication - My 76 Mazda RX-5 Cosmo Restoration
After part 22.5 was posted, it took the remainder of November and December to finish the driver side sheet metal. I worked my butt off to get it done before January 1st, and indeed, accomplished that task so I was able to start the new year sheet metal free! So I am happy to say that episode 23 is sheet metal free! In this episode I fabricate the parts necessary for my unique combination of intake manifolds, combining an FD RX-7 upper intake with an GSL-SE RX-7 lower intake. Doing so requires the fabrication of a custom middle intake manifold out of aluminium, complete with provisions for secondary fuel injectors. You'll see me build flanges from scratch (using my new drill press), measure and cut intake runners, TIG weld it all together, port match the flanges to the gaskets and runners, install injector bungs, curse at the difficult welding I caused, add -6 AN bungs to a stock RX-7 primary fuel rail, and build a fuel rail for the newly fabricated manifold. I'd like to thank DIYAutoTune ( http://www.diyautotune.com ) for supporting this project and providing some of the parts used in this episode.
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.
Part 41: LED Tail Light Conversion, Part 1 - My 76 Mazda RX-5 Cosmo Restoration
Surprise! Part 41 of my 76 Mazda Cosmo restoration is here! Part 41 is the first in a two part episode covering the conversion of the unique Cosmo tail lights from outdated incandescent light bulbs to modern LEDs. I decided to pattern my tail lights after those of the 2012 Dodge Charger, creating an outline of large LEDs, and filling the rest of the lights with small LEDs. I know it's been a while since my last episode, mainly because I've been sharing my Cosmo time with the time spent working on my new house, setting up the new shop, getting my RX-7 back on the road, oh and those little things like job, food and sleep. So I chose the tail light project because it was something I could work an hour here and there on, without requiring a fully functional shop. So here, I cover deciding on the LEDs, designing the control circuit based on an Arduino ATTINY85, and then beginning the actual LED'ding of the tail lights starting with the reverse lights. Circuit boards are designed, etched and assembled, then the new LED illumination added to the reverse lights. In the 2nd half of this episode, we'll cover the brake and turn signal lights, building the controller and integrating it all together into a spectacular assembly. Circuit schematics, source code and PCB designs in this episode can be found at: http://www.aaroncake.net/76cosmo/taillights/