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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.


 


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Part 13: Clearing The Engine Bay - My 76 Mazda RX-5 Cosmo Restoration
With the engine built, it seemed logical to focus a bit on where that engine is to live: under the hood. Episode 13 has me stripping all the remaining mechanical components out of the engine bay in preparation for it to be blasted, repaired and painted. This is dirty grunt work, not particularly stimulating but at least it isn't sheet metal. It's been a while since my last update and rest assured, what you see here is only a small fraction of what has been done. I have plenty more footage ready to edit. Included in this episode: removing all engine bay mechanical components, removing brake lines and cylinders, labelling and removing wiring harnesses, removal of the steering gear, orderly disassembly of an engine bay.





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.





The Mazda Rotary Engine Part 1
Educational film by Toyo Kogyo about the Mazda Rotary Engine. Shows how the Rotary engine works with comparisons to the Piston Engine. Also shows the Mazda RX500 test vehicle on a banked circuit and the Mazda Cosmo Sport (or 110S). Originates from the late 60's.





Part 34: Water To Air Intercooler Installation, Part 1 - My 76 Mazda RX-5 Cosmo Restoration
It's time for part 34 of my '76 Mazda RX-5 Cosmo restoration. This time, I'm installing the water to air Intercooler. I've installed and fabricated plenty of air to air Intercoolers in my time but never a water to air unit. I chose to use water to air on the Cosmo because it meant that I could keep the piping as short as possible for the best Boost response and because of the limited amount of room to run charge piping out to the front of the car due to the large rad and A/C condenser. It was definitely a learning experience for me as I underestimated the amount of time needed to fabricate all of the components. Thus, I have split the episode into two parts. In part 1 of the installation, I fabricate a throttle inlet adapter to fit the FD throttle body, position and mount the Intercooler, build charge piping, weld on a BOV flange and IAT bung, fabricate an aluminium water tank with inlet/outlet/fill bungs and mount the heat front heat exchanger.





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.





*13B DOO* 13B ROTARY-POWERED SEADOO JETSKI
A dream project fifteen months in the making. Stay tuned for launch... coming 2011...





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 4: My 76 Mazda RX-5 Cosmo Restoration - Engine Cleaning Continued
In part 4 of my Cosmo restoration, I continue cleaning the engine components, a task which was started in the last video. It is actually quite involved to clean and inspect the internal engine parts and it can easily take more time then it does to disassemble and build the engine. While I did clean all the parts from the 4 port Cosmo 13B, I will only be using the housings, oil pan and a few other components. The rest of the engine will be the irons and rotating assembly from a GSL-SE 13B.





Montaje del Motor Renesis - Mazda RX-8 - NO REBUILD
Proceso de remontaje del motor Renesis de un Mazda RX-8. NO ES UN REBUILD de Motor puesto que no se han cambiado ninguna junta de estanqueidad, sellos de aceite o sellos de motor. Se ha limpiado todas las piezas y se han reutilizado, con el propósito de practicar el montaje del motor y almacenarlo de una manera mas compacta para en un futuro rehacerlo con piezas destinadas a su uso en competición. Manual de Taller: http://foxed.ca/rx7manual/2003mazdarx8/





Wankel engine and Quasiturbine
motory s rotačními písty





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





Best Of Rotary Sounds
Please Check Out My Facebook Pages https://www.facebook.com/LifeOfDrifting?ref=hl https://www.facebook.com/pages/Hellaflush-JDM/300484093402979?ref=hl





Piston vs Rotary Team P.R. vs USA
http://Import2race.com Racewaypark New Jersey http://stage2race.com





Part 8: My 76 Mazda RX-5 Cosmo Restoration - Engine Hole Tapping and Painting
It's a Festivus miracle that I now present Episode 8 of my Cosmo restoration. Now that the engine is fully ported, episode 8 deals with the final prep of those engine parts before engine assembly. In this episode the rear iron and water pump housing are tapped for sensors and fittings, and then all the engine parts are glass bead blasted and then painted with POR-15's engine enamel. Also included: adapting S4 water pump housing to older 13B, tapping rear iron for turbo coolant feed, masking the parts for blasting and painting, final soap and water wash, watching paint dry.





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Which car is faster? Which Car is Faster?





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