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RX7 6L Wannabe Sports Sedan

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    RX7 6L Wannabe Sports Sedan

    This is the story to date of my RX7 build to compete in local level sprints and short circuit racing at Oakey, Pittsworth, Gatton, QR, Norwell, Morgan Park and Carnell. I'll run in Sports Sedan class but it'll just be a 'budget' build, not with the extreme mods and aero of a national class car.

    Quick backstory:
    I had an SR20 S14 that I gradually built over 2 or 3 years, competing in sprints at Oakey, Pittsworth, Norwell, Carnell (Stanthorpe) and Morgan Park. Was street registered and mildly modded with CAMS cage, forged SR with 250rwkw, PFC, Ohlins coilovers, 1.5 way, etc. It was driven to all events until I got a car trailer and deregistered it early 2014, but a few months later I blew the SR in practice at Morgan Park, June 2014 .



    Looking back 2 years now I should have just slotted in another SR but I already had a disassembled L76 6L put aside so decided it was time to put that in as I'd dreamed for a few years. Not really having the money for the full conversion I mistakenly said to my mechanic "no hurry" and 9 months later SFA had been done besides engine machining and long block assembly. About the same time that I was giving him a boot up the ass, TT linked an RX7 shell on the PF Facebook page. Like most car enthusiasts I'd dreamed of having an FD3S, so decided it'd be a great chassis for the LS and in August 2015 went on a 36 hour road trip with a mate down to Canberra to pick up the shell, which came with

    CAMS cage
    Samberg LS crossmember (early version)
    T56 box with Ripshift
    Surge tank & external pump
    FEED widebody guards
    Stripped & a bit hacked up
    OMP seat
    Tein HA coilovers



    The Meisters looked fucking porn on the car, but unfortunately weren't going to suit the tyres I wanted so they were sold off along with my S14 shell to fund the new build. They were replaced with Weds TC105N 18x10.5+12 with 295/30/18 Hankook Z221s on all corners (still going to need some work to fit up front) and I've got some 18x9.5s Rotas that I'll put some NT01s or similar on for practice. I've also upgraded the brakes with 330mm K-Sport front calipers and 314mm RZ rears.



    The L76 engine was rebuilt to L98 with forged rods and pistons, 237/250 cam, dual valve springs, tie-bar lifters, etc. Added Moroso electric water pump, Milodon winged sump, McLeod RST twin plate clutch and Fidanza 12.5lb aluminium flywheel. I won't be running power steering so the only belt-driven accessory on the engine will be the alternator.

    We dropped the engine in with the recommended mounts and came across a stack of problems. The front of the sump didn't clear the steering rack by quite a margin with the Samberg bumpsteer rack spacers, so we had to ditch those and the rack now clears by a few mm. The original transmission tunnel was already hacked to pieces so we didn't have much choice but to cut the whole thing out. The back of the manifold is extremely close to the engine bay lip, so I'll cut this out soon. I bought a set or Sureflo headers that are meant to be for this conversion but 3 out of the 4 driver's side pipes were miles off fitting.



    Fast forward a few months and my mechanic had put it in the too hard basket and not touched it, so I took it to another motorsport fabricator who welded in a new tunnel, floor & seat supports, dropped the floor for an underfoot pedal box, and reworked all the pipes to fit. Unfortunately the steering shaft seems to just clip the pipes so I'll need to space the engine up a few mm, which will help with a bit more rack clearance anyway.



    Along the way I ditched my POS Michael Spencer built trailer for a Tilta and picked up a 4 post hoist for home. Most recently I've stripped the car right back as much as practical and I'm waiting for a clear weekend of weather so it can be soda blasted and primed. I'll then paint the interior and engine bay before everything starts to go together.



    I've got a pile of parts waiting to be fitted which I'll post more about when they go on. My main expenses remaining are the fuel system, tailshaft, exhaust and respray, and then there's a whole lot of assembly to do!
    LS Powered FD3S RX7

    #2
    So much awesome...

    Sent from my HTC_0P6B using Tapatalk
    RIP Carly - a smile to light the world.
    06/07/2011

    http://www.performanceforums.com/for...#post842594902 - making little toys for the big boys

    Comment


      #3
      Tough motor build- I went pussy cam.

      Didn't we talk about the Sureflo header kit recently? They are made long on the tubes so you can trim and weld depending on how tight the package is. Walt Kowalski on here said they fit in his ok. Haven't got mine in yet so can't comment further.

      What is the difference between the early and late Samberg crossmembers? Mine fit great but less than a year old

      What diff are you running?

      Comment


        #4
        Yeah there was no way the Sureflo headers could fit at the angles they came, even with ends trimmed to length. I had 3 separately people try every combination with the motor in and out of the car. Some pipes had to be bend to different angles and extended in the mid-sections. I'm not sure why mine is different but it's sorted now.

        At the moment I'm just running the standard diff with Samberg mount.

        Do you need a pedal mount adaptor? I've got 2 types of Samberg adaptors that came with the car and I don't need.
        LS Powered FD3S RX7

        Comment


          #5
          The header situation sounds crap. I hope mine is different. Don't want to pay the money then back them up. I'll find out soon enough.

          I have the Samberg 8.8 subframe. Fit quite well and only needed a little die grinding because his bolt holes are so tight. I prefer to do that anyway than have massive bolt hole clearances.

          I have a pedal adaptor already thanks

          Comment


            #6
            Will have the shell back from bead blasting this week

            LS Powered FD3S RX7

            Comment


              #7
              Ok so I was wrong. The Sureflo kit comes nowhere near fitting. The collectors wouldn't accept pipes without serious manipulation and the tube bends are miles off. I take back what I said and now hope I can take back what I bought. Fingers crossed.

              Comment


                #8
                Damn, I was hoping it was just mine that had been bent up wrong. I was just lucky to get mine modified at mates rates while getting my tunnel and driver's floor replaced. Their $120 'Patented Merge Collector" is rubbish too, just a big oval pipe hammered roughly in the middle at each end.

                I've been working on the car slowly but business, USA trip in a few months and wedding at the end of the year are eating up my time. Engine bay and interior have been painted, engine, gearbox and headers are mounted but the steering knuckle just touches on a pipe and two of the pipes on the passenger side touch each other. It takes a bit of effort to get the merge collector on each side and I'm worried that'll put stress on the welds or cause a leak at the flange.

                Trying to get the brake lines and pedal box sorted now. I keep coming across little pieces I need to find that then hold up everything else, like grommets for the braided lines.


                Blasted & primed
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                That explains the overfenders
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                Satin black engine bay
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                Machinery grey interior
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                LS Powered FD3S RX7

                Comment


                  #9
                  Looking good.

                  The extractors appeared to be a generic bought in Chinese kit. The stainless tube looked like Chinese stuff but the giveaway is always the plastic bubble wrap and China dust. The Collectors I got were decent looking- individual tubes and all that- but they were welded too close together and warped all the tubes so no pipes would slip in without a lot of tweaking.

                  Comment


                    #10
                    Here's the engine mounted. Even with 5mm spacers under the engine mounts there's barely 1-2mm clearance to the steering knuckle (and without gaskets on the header flanges) so they'll need a bit more modifying.



                    Braking system mostly completed this week. I've mounted the OBP pedal box, reverse swing hydro handbrake, Wilwood master cylinders and Earls braided lines. Now just need to make a bracket to hold the reservoirs, clamps for the lines, and bend up a heel plate.



                    Still trying to figure out a location, size and mounting for a custom fuel cell. Today I started by trimming out the spare wheel well, nek minnit, entire boot floor is gone.

                    LS Powered FD3S RX7

                    Comment


                      #11
                      Hasn't been much happening on the car while I've been working long hours but I do have a massive pile of parts on the shelf and on their way. My aluminium driveshaft arrived today, just 6 days turnaround for a custom shaft including shipping from Shaftmasters.

                      LS Powered FD3S RX7

                      Comment


                        #12
                        I've been on a US holiday for a while and now back into it, really pushing to have it running by the end of the year. I've found a good mechanic who can take the car in the next week or 2 and should be able to carry on with everything I can't. I had another fabricator organised to do the exhaust while I was away and I had to give him a kick up the arse to get going on it this week.

                        Side pipes!



                        Spent the weekend machining some aluminium items

                        Custom fuel cell with baffles and trapdoors, ready to drop off for welding



                        Brackets to bolt remote oil filter & thermostat to front of heads



                        Racepak dash mount


                        Brake & clutch reservoir mount
                        LS Powered FD3S RX7

                        Comment


                          #13
                          Very nice work.
                          Rust is lighter than carbon fibre.

                          My Italian 510

                          Comment


                            #14
                            Lovin the speed holes man :D

                            Login all of it really. Dream build man

                            Sent from my HTC_0P6B using Tapatalk
                            RIP Carly - a smile to light the world.
                            06/07/2011

                            http://www.performanceforums.com/for...#post842594902 - making little toys for the big boys

                            Comment


                              #15
                              Cheers, it was very satisfying when it all worked out. I did miscalculate my notches in the side baffles meaning the front compartment was slightly smaller than expected and almost too tight to change the pre-filter, but I just flipped them around to make the front compartment larger before dropping for welding yesterday.

                              My exhaust and gearbox mount were finished today too. Just a single X-muffler so hopefully not too loud. I did make a conscious decision to aim the side pipes away from the noise testing equipment at all the clock-wise Queensland tracks :D


                              LS Powered FD3S RX7

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