Rusted Custard - VVT Turbo NA6

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DriveFast
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Rusted Custard - VVT Turbo NA6

Postby DriveFast » Sun Jan 19, 2025 5:40 pm

Hello,

I know the forums aren't that active anymore but I'm a sucker for a proper build thread and it's nice to have everything in one spot so here we go!

I've been around MX5's for awhile now, purchasing my first MX5 back in 2013 or so when I was in my early 20's. I ended up selling it a few years later because I was, and still am a little stupid. I maintain this was the nicest mx5 I've ever owned. It was a tastefully modified NA8 that I just enjoyed with regular maintenance.

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A few years later in 2018 I acquired a suitable replacement, another na8, but this time a little rougher but still in presentable condition.

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I had a mazda 3 MPS at the time, and it blew its motor. Whilst I was busy replacing it this na8 was my daily driver. A few weeks into daily driving duties it also blew up :oops:

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I maintain I'm not hard on vehicles, the mps's are known to spontaneously combust and the mx5 was just getting a little old and wasn't up to daily driving duties. I was driving up a hill in 3rd gear at 70km/h when the engine just let go. I've never opened the motor to see what went wrong but it sounded like a spun bearing in the bottom end. I still have the engine if anybody is looking for a 1.8 block!

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I ended up swapping in a VVT motor from an NB8B, a long with a custom intake and full exhaust system. I also installed a custom engine loom for the new link monsoon g4x ecu, did a complete egr delete and had the car tuned. It made 95rwkw on the dyno and was simply fantastic to drive. I did a few fantastic road trips in this car including two weeks camping around Tasmania in an MX5!

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A trip to Sydney and Bathurst (from Melbourne, the fun way)!

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And a trip around the Victorian high country.

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Sadly, 6 years into my ownership of this car, I came around a sweeping bend only to find a large log that had ended up on the road. The car hit the log, went up on two wheels, came down and bent the front control arms, destroyed one of the wheels and I was unable to steer the car becoming a passenger at 70kmh. The car eventually came to a stop, after hitting a tree.

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I was devastated, as I was just getting ready to complete the car by turbocharging it, it was meant to be my forever car but fate had other plans. I bought the car back from the insurance company and completely stripped it bare.

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I could have taken the money and run and moved onto another chassis, but I already made the mistake of moving away from mx5's once before, so the hunt was on for a suitable replacement. Shortly after receiving the wreck back from insurance, I embarked on another road trip. One that started off in a plane! I flew interstate to pick up a tired old na6 with 400,000km on the dash. Not just any na6 though, a mythical Malibu gold edition. It was pretty rough, pretty tired, I paid way too much for it, but I had to have it. I jumped into it and drove it all the way home without too many issues.

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It's good from far, but far from good. I think every panel has at least one dent, it's about 4 different shades of malibu gold/sunburst yellow and has small amounts of surface rust in a few locations, but I think it's worth saving.

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It will also be a fantastic place for my na8's VVT drivetrain, engine computer, brakes, and other such assorted things (like a turbocharger).

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I don't feel bad about not keeping it original, even though they're rare, there isn't that much special about them other than the colour, and this particular example has done 400,000km so it won't ever be valued by a collector. It's better if I just look after it as best as I can, fix the things that need fixing, give it a second lease on life and ultimately enjoy the car for a long time to come. Purists be damned!

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The first step in this journey will be to get it registered in my home state of Victoria. To do that it needs to pass a roadworthy, which it absolutely will not do without some elbow grease as there a few things that need to be addressed.

    The horn doesn't work at all.
    The pedals covers need to be replaced.
    the windscreen has a deep scratch on it and is slightly pitted.
    the rear brakes don't seem to work at all and appear to be seized.
    there's rust underneath the brake master cylinder as it appears to be leaking.
    all of the bushes under the car need to be replaced, along with the shock absorbers.
    it's slow to start and will run on 2-3 cylinders for 15-20 seconds after it starts.
    (This problem doesn't exist if you let the fuel pump prime for 30 seconds or so prior to kicking it over, so it's hopefully just an aging fuel pump or a blocked fuel filter.)

That's all of the immediately obvious things I'll need to address, but I'm still looking over the car and learning it's secrets, so who knows what I'll discover over the next few weeks. Hopefully not too much more rust! If you happen to read this nonsense please say hi! It'll be nice to know it's not just web crawlers and google robots keeping up with my poor decisions.

Thanks for stopping by!

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Re: Rusted Custard - VVT Turbo NA6

Postby Nevyn72 » Sun Jan 19, 2025 7:05 pm

Hello Yellow! :mrgreen:

I look forward to following your journey. :wink: :beer:
"A Convertible has a top you can put down when the weather's nice...... A Roadster has a top you can put up when the weather's bad."

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Re: Rusted Custard - VVT Turbo NA6

Postby greenMachine » Mon Jan 20, 2025 7:45 am

Good to see you back, and yes, nice to have a new build thread!!

Looks good in the photos, good luck getting it back on the road! My first thought was whether it had the SNC, which seems more pre-disposed to the key problem. But putting in the BP makes that irrelevant.

Are you going to get it regoed before doing the swap? That would no doubt speed up the rego step, but you might be doing some things twice. I guess having done the swap once, doing it a second time will be faster/easier - whenever it is done.

Looking forward to seeing how this progresses!

:mrgreen:
I never met a horsepower I didn't like (thanks bwob)

Build thread

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Re: Rusted Custard - VVT Turbo NA6

Postby ManiacLachy » Mon Jan 20, 2025 8:48 am

So happy to have a new build thread here, we need more MX-5 content in our MX-5 forum :mrgreen:

I applaud you for giving this old girl a second lease of life, those Sunburst Yellows are so beautiful. Add a 1.8 VVT and eventual turbo and it's quite a package. I'm looking forward to the updates.

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Re: Rusted Custard - VVT Turbo NA6

Postby 93_Clubman » Mon Jan 20, 2025 9:17 am

Welcome back - good read, especially for NA followers. As GM says, looks better in the pics than the description.

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Re: Rusted Custard - VVT Turbo NA6

Postby PaulF » Mon Jan 20, 2025 9:28 am

Good stuff! I also love a good build thread, though I've never been much good at maintaining one myself. NA + VVT + turbo is a hard combo to beat. Did you make the engine harness yourself? I've been weighing up a custom harness vs. a G4x PnP, mostly because all my factory wiring is 35 years old now.

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bruce
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Re: Rusted Custard - VVT Turbo NA6

Postby bruce » Mon Jan 20, 2025 9:51 am

Definite H plate for you.

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bruce
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Re: Rusted Custard - VVT Turbo NA6

Postby bruce » Mon Jan 20, 2025 3:29 pm

Hardtops seem to follow you around.

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DriveFast
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Re: Rusted Custard - VVT Turbo NA6

Postby DriveFast » Mon Jan 20, 2025 7:21 pm

Nevyn72 wrote:Hello Yellow!

Hello! Glad i'm not just shouting into the ether and people still traverse these parts.

greenMachine wrote:Are you going to get it regoed before doing the swap? That would no doubt speed up the rego step, but you might be doing some things twice. I guess having done the swap once, doing it a second time will be faster/easier - whenever it is done.

Yeah that's the plan, but plans change. The engine in the car and the gearbox for that matter look to be absolutely caked in oil. Not sure if it's just 30 years of grime or if we have some serious leaks going on. I don't want to spend money on this engine and gearbox combination, so finding out whether or not I just need to give it a good clean to remove the grime, or if it has some significant leaks will ultimately be the deciding factor.

ManiacLachy wrote:So happy to have a new build thread here, we need more MX-5 content in our MX-5 forum :mrgreen:
I applaud you for giving this old girl a second lease of life, those Sunburst Yellows are so beautiful. Add a 1.8 VVT and eventual turbo and it's quite a package. I'm looking forward to the updates.

I've always wanted a malibu/sunburst yellow, this has been the first one I've seen become available so I ignored all common sense and purchased it, despite it being a little rough around the edges.

93_Clubman wrote:Welcome back - good read, especially for NA followers. As GM says, looks better in the pics than the description.

It does have a habit of looking great in photos, must be the colour! Up close it's nowhere near as nice, but all of that can and will be fixed.

PaulF wrote:Good stuff! I also love a good build thread, though I've never been much good at maintaining one myself. NA + VVT + turbo is a hard combo to beat. Did you make the engine harness yourself? I've been weighing up a custom harness vs. a G4x PnP, mostly because all my factory wiring is 35 years old now.

I tried to modify the factory harness, ran into some issues and with the help of my tuner we made a new one. He did most of the fiddly stuff. I modified the original harness and deleted all of the engine bay side of things to make way for the new engine loom.

bruce wrote:Definite H plate for you.

I'm not sure what direction I will go. I'm contemplating club registering it, but due to the plans to put my VVT motor into it, it will most likely need to be M plates. I should speak to somebody at the club I guess. Yes, hardtops do seem to follow me around, more coincidence than anything else. Much prefer to be topless :lol:

Time for some progress

Thanks for the welcome! When I purchased the car I didn't notice the rust under the brake booster, it's in an awkward spot that's hard to see completely so I really wanted to tackle this first as I have no idea how long it's been there. I was having nightmares of crumbling metal, so whilst it's not strictly required for the roadworthy, it was something I had to do (I worry too much, I get it from my dad :lol:).

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I started by removing the old brake fluid in the reservoir with specialist tools.

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Once the fluid was drained, I removed the steering wheel and with help from a friend managed to remove the booster without taking the dash out, something I didn't want to do as everybody with an NA/NB will tell you, the second you pull the dash all the rattles become much worse.

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As you can see, it actually didn't look that bad and looked fairly fresh. After reading through the service history I discovered the last mechanic who worked on the car mentioned that the master cylinder was leaking, this leads me to believe this is all fairly recent which is great news.

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I gave it a quick wirewheel and was happy with what was underneath, this was hard work though as my wire wheel had seen better days, I also didn't have any extensions for my drill which made getting in there hard work as theres pretty limited access even with the booster and master removed. After a quick trip to the big green shed to purchase some new wire wheels, wire brushes, and drill extensions I was in business!

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The metal was ever so slightly pitted, but nothing to worry about, After tidying it up a little more I was ready to spray it with some CRC rust converter, as it's better to be safe than sorry with these things.

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You can see it beginning to work, this is a few minutes after spraying the bare metal.

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Two hours later I was left with a nice black primer.

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I gave the surrounding area a bit of a scuff and clean with prepsol and applied some etch primer.

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I originally planned to spray filler primer over the top, but the pitting wasn't bad enough to warrant the extra work sanding thick primer, so I opted for another coat of etch primer and then I called it a day. After it had dried I removed the tension from the brake lines so hopefully they're not too deformed once I go to put it all back.

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I will do a better job of prepping the surrounding area before I spray it yellow next Saturday, I just wanted to quickly get some primer on the metal so it wouldn't instantly turn to rust again, overall I'm fairly happy with the repair thus far. It won't be perfect but when I pull the motor in a couple of months I'll respray the entire engine bay with my spray gun anyway so the topcoat will be temporary.

As I opted to remove the steering wheel, naturally I had a play around with the busted horn. The problem seems to lie with the button, or the weird extension piece that was between the wheel and the steering column, grounding the horn pin instantly gave me the 'Bweep Bweep!' noises I was missing, so that should be a relatively easy job to tick off the list as the relay and the wiring all seem to be fine. :mrgreen:


Bonus image just because it's cute, my nieces absolutely nailed my Christmas present this year. Mini Custard! 8)
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Jeo
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Re: Rusted Custard - VVT Turbo NA6

Postby Jeo » Tue Jan 21, 2025 9:50 pm

DriveFast wrote:I know the forums aren't that active anymore but I'm a sucker for a proper build thread and it's nice to have everything in one spot so here we go!


True facts. All three of them!

Keen to see it progress though.

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DriveFast
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Re: Rusted Custard - VVT Turbo NA6

Postby DriveFast » Sat Jan 25, 2025 5:04 pm

Finished the rust repair off today, I ended up applying the filler primer, knocking it back with 240, 400, and 600 gritt sandpaper, before applying seam sealer to replace all the factory sealant I knocked back with the wire wheel.
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It took a few coats of sunburst yellow to get decent coverage, the paint is basically transparent, I see why mazda painted the bodies white before applying it.
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I then went over it with some 2k clear to give it some form of protection.
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I'm happy with the repair for now, it will most likely get re-done when I pull the motor as the entire engine bay really needs a freshen up, and with the motor out of the way I'll be able to do a better job using my spray guns, this was just a quick rattle can job as I didn't want to give the rust a chance to take hold. Rust never sleeps as they say.

Tomorrow I'll hopefully take the rear calipers off and apart, the rear brakes don't seem to work at all, I'm hoping my na8 calipers will fit on the na6 rotors/bracket as that will be an easy thing to fix if so. I've read for the rears it's only the bracket that's different between na6 and na8 rear brakes to accommodate the larger rotor. I'll eventually buy slightly larger wheels so I can run my na8 brakes and rotors, or some nb8b 'big' brakes in the future.

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bruce
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Re: Rusted Custard - VVT Turbo NA6

Postby bruce » Sat Jan 25, 2025 6:10 pm

I've got an M plate but I've got an sr20det engine swap.
Makes no difference, you just tick whichever box you like on the application form. Putting in a 1.8 or even turboing it is kind of trivial.

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bruce
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Re: Rusted Custard - VVT Turbo NA6

Postby bruce » Sat Jan 25, 2025 6:36 pm

Yes, Mazda had to put the yellow cars thru the paint line twice. Yellow Kia Stingers got recalled and repainted.

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DriveFast
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Re: Rusted Custard - VVT Turbo NA6

Postby DriveFast » Tue Feb 04, 2025 1:40 pm

bruce wrote:I've got an M plate but I've got an sr20det engine swap.
Makes no difference, you just tick whichever box you like on the application form. Putting in a 1.8 or even turboing it is kind of trivial.


Haha I was more worried about the club specific rules. M plates might be the go. Not much progress this week, everything is at a standstill whilst I work out what i'm doing for suspension bushes. I'm considering giving the I.L Motorsport rubber bushings a go, at 40% stiffer than OEM but still rubber as i'm not a fan of Polyurethane bushes. Has anybody used these before?

Once I make up my mind and the bushes arrive I can continue to take a part the corners of the car before reassembling everything including the NA8 brakes, new ball joints, and wheel bearings. and car will hopefully be ready for a roadworthy. I still need to arrange a windscreen but that will hopefully be trivial. I have some old standard NA shocks and springs i'll swap in for the purposes of passing the roadworthy.

Once it has plates on it, it can come apart again for all the fun go fast stuff.

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Re: Rusted Custard - VVT Turbo NA6

Postby bruce » Tue Feb 04, 2025 3:11 pm

Easy. Join club, get RWC, fill in form, take it to VicRoads.


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