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Helpful ReplyKnightrous' House of AW11 (and SW20, and ZZW30)

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Tree
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RE: Knightrous' MZW11 & AW11 2012/12/31 01:33:47 (permalink)
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I like seeing DIY cold air intakes, especially on a mid engines and it would be pleasing if you squeezed just a bit more hp from the CAI. Also who doesn't enjoy the musical intake roar of a 4 banger hehe
Knightrous
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RE: Knightrous' MZW11 & AW11 2012/12/31 09:37:14 (permalink)
+1 (1)
B24: It's not progressing fast enough haha, I've spent 10hrs on the bonnet this weekend and it's not even in primer yet. There will be a couple of late nights this week and I'm starting annual leave on Friday, so progress should increase!
 
Tree: I really wanted to pipe the intake into the cabin so I can listen to the song of the ITB's, but alas I was worried about the boys in blue classifying it as a child killing device that will end the universe.
EssDub
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RE: Knightrous' MZW11 & AW11 2012/12/31 11:06:10 (permalink)
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I just found my new sig quote :D

B24
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RE: Knightrous' MZW11 & AW11 2013/01/01 22:47:44 (permalink)
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It's crazy the amount of time you can spend on the mods. The bonnets look great. Better mod than mine!
 
Knightrous
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RE: Knightrous' MZW11 & AW11 2013/01/05 01:12:55 (permalink)
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Cranking out the progress for the MR2 Challenge.


Fitted the first one, just need to pull the Koni shock out of the other side and fit it into the other coilover.


Ever since I bought the car, the battery clamp has been a piece of **** that keeps bending. So I fkn fixed it good this time, riveted some 20mm box section to it and gave it a lick of paint.
Knightrous
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RE: Knightrous' MZW11 & AW11 2013/01/05 20:41:51 (permalink)
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Another busy day in the driveway!

First up, the bonnet was given a coat of etch primer. This is the first time I've used an electric spray gun before and it's certainly causing a few difficulties. Despite what it says on the box about paint viscosity, I seem to get better results the thinner I make the paint and increase the spray power... Wierd machines, think I'll be able to make it useful with some hacked mods to it, but in stock form these things are **** :P

 
Next up I started making the ducting that forces the air flow from the radiator to the bonnet vent. This is a rough jig I use for making big bends across the sheet, its not perfect, but it's better then trying to do it by hand or over the edge of a table or concrete slab.

 
The first version ready to fit.

 
And it fits fairly well, just a few areas to modify. You can see where the cutouts allow the radiator hoses to pass through.





 
Quickly put the radiator back in to make sure the thermofan cleared the duct. Enough space to slide my hand down the back of the fan.




 
Now I decided to quickly add the final rough dimensions just for those that might be interested in doing this them selves. It's a very, very rough guide! YMMV!

 
Painted the duct stealth black. Maaaaaad!

 
Then gave the firewall cut out a lick of paint as well.

 
Then I mounted the duct with some rivets and gave the whole lot a quick spray to make it all uniform


 
The view through the front from the numberplate

 
It's getting dark now, so I might go get started on fitting the other coilover and refit the radiator back into the front end.

Knightrous
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RE: Knightrous' MZW11 & AW11 2013/01/08 00:46:13 (permalink)
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4 days to go!

Finally after two weeks of waiting, the silicon bend comes from JustJap, so I finished off the intake. I was making some brackets up to hold the pod enclosure, but it's really rigid just from the support of the silicone hose, so I'll leave it be.


Since I dropped the 20V into the TrackDub, the over flow bottle has just floated around on top of the gearbox and in between various hoses and looms, so to avoid it ending up somewhere else while out on track (like on the drive shaft like my old 16V one did...) I ended up making this bracket to hold it.



Will just put a ziptie around it to hold it into the bracket.

And to continue with the tidy up work on the car, I decided to restore the flaking paint on the trims.



Even the wipers that were slowly turning purple copped a rattle can job. Also found out that paint doesn't adhere to the rubber trims (not seals) around the doors. Ended up having to use wax and grease remove to take off the tacky wet paint, which still seemed to add a bit more life to the trims.


Just have the drivers side to finish off in the morning.

I would post up a pick of the bonnet in it's first coat of black paint, but the results are ****. I've officially resided to the fact everything spray paint related is against me currently. The regulator on my air compressor is fail, my compressor is too small, my gun sucks and splatters a bit too often, the wind picks up every time I mix up some paint and my clothes line makes a **** spray booth... I reprimand myself to $5 rattle cans from SuperTheif Auto!

Next up, deciding if I have enough time to sand the rims and give them a spray in sexy white.
5SGTE
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RE: Knightrous' MZW11 & AW11 2013/01/08 19:54:44 (permalink)
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Good prep is the key mate
Knightrous
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RE: Knightrous' MZW11 & AW11 2013/01/08 21:19:49 (permalink)
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Over the whole 80/180/400/800 grit prep work, washing, drying, wax n greasing removing then spraying.
Thing next time I'll just paint strip everything with the grinder and throw a clear coat over the bare metal :D
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RE: Knightrous' MZW11 & AW11 2013/01/09 00:03:17 (permalink)
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U gunna try polishing alli, urgh. Clear on bare metal could look awesome!
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RE: Knightrous' MZW11 & AW11 2013/01/09 01:09:24 (permalink)
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3 days to go! Rear brake upgrade time with a set of AW11 front rotors and SW20 turbo rear calipers. Also threw in a set of 75mm wheel studs since the 5mm spacer needed for this conversion leaves you with just a couple of threads to hold on with the stock studs.

Studs knocked into place. I didn't have to machine the knurl on them like the front hubs, so that was a bonus!


254X22 AW11 front rotor fitted with a 5mm waterjet cut spacer behind it. Leaves basically no hub left to center the rim, which is a real worry. I'm going to look at a couple of hub mods to fix though in the future (pending the wheels don't fall off between here and Wakefield >.>)



Brackets and calipers bolted on with some TRW pads.


And with a wheel back on, plenty of caliper to rim clearance (30-40mm) with my favourite little set of 15X7" ALT rims (If anyone knows where I can get more of these, LET ME KNOW!).

Tree
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RE: Knightrous' MZW11 & AW11 2013/01/09 11:08:28 (permalink)
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This car is basically gonna be all handling! Quite eager to see it in action :)
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RE: Knightrous' MZW11 & AW11 2013/01/09 14:54:30 (permalink)
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Tree
This car is basically gonna be all handling! Quite eager to see it in action :)

  With only ~83RWKW, I need to be able to brake later, get on the throttle sooner and take the corners as fast as possible or I'm just going to be out gunned by those with more horse power. At the end of the day, I want to push this car 10/10ths, if I don't have my foot flat to the floor, it better be hard on the brakes :)

And this is the main reason for stepping up to the big brakes.

Bitches love R888's :)
As much as the stock brakes work fairly well on the AW11, I believe they are not going to match the performance of the semi slicks, so I went to the cheap, easy bolt on options (ST185 twin pot fronts, SW20T rears).
Tree
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RE: Knightrous' MZW11 & AW11 2013/01/09 15:36:33 (permalink)
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There's something to be said for mild powered RWD with feet all the way to the floor
I think you'd give those guys a run for their money for sure with this dark horse, coupled with good driving everyone's gonna think it's got some monster engine hehe
 
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RE: Knightrous' MZW11 & AW11 2013/01/09 19:12:59 (permalink)
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I'm going to deploy some scare tactics...
https://www.youtube.com/watch?v=20tsugTUStM

Nice 35'c heat today, which I enjoy, however humidity is insane and makes me sad panda... But progress was made! Today I got into fitting the flush mount bonnet pins that I picked up off ebay.
 
Started by working out where they were to get fitted, traced the mount onto the bonnet then drilled some holes. Because I lack some tools in the garage right now, I drill heaps of small holes to cut circles out....

 
I run a couple of slots in it with the grinder

 
Then bend the cut outs up

 
Flex them a few times with the pliers and they snap out


 
File them a bit with a random rat tail file


 
Then started press fitting the fixture into the bonnet

 
Then drilled the holes into the bonnet using my 11 year old corded, cordless drill.

 
Put some rivets in the holes.


 
Tada, it's done...

Now to wait for the sun to go done so I can get around to flushing the brakes with Motul RBF 660 and bleed the system.
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