Mac#1 Motorsport Worx Build

[Red16]

jason61c said:

Keep up the good work, looks like a nice build

I wish I could keep my workspace that tidy!!

Thanks, I've suddenly got some motivation to crack on with the car, it's from a mate who's building a Mac Type 9R at the moment, his enthusiasm must be rubbing off!

You kind of have to keep it tidy if you havent got much space, lol.

MH said:

Tidy work there, it's looking good.

I like your vice mount too!

Cheers

I'm going to have to move the vice stand when the cars finished, as it will prevent the car going all the way in to the garage, doh!

[Red16]

Here's an update to cover the last few days worth of work on the car.

Cut out the transmission tunnel side panels







Purchase one ZX10R turbo engine



Engine spec is...

Dynajet Power commander 3 with hub
ECU and full loom
Adjustable cam sprockets
JE turbo pistons
Arrows con rods H beam
Cometic Head Gasket
APE billet manual cam chain tensioner
Muzzy lock up clutch
Modified stock sump pan
External oil filter relocation kit
GT30R Race roller bearing turbocharger
321 Stainless headers
2 inch up pipe
Billet plenum with internal bell mouths
44mm Tial waste gate
50mm Tial blow off valve
Bosch high horsepower competition fuel pump
Aeromotive billet fuel pressure regulator

It's making a healthy 225bhp/101lbft at 6psi and 303bhp/139lbft at 12psi



Tried to fit the engine into the car the other day and found that the mounts did not line up as expected, a call to Mac revealed that the 2004 engine I bought has different mounts to the rest of the ZX10r range (2005 onwards)... typical, lol.

So I set about fabrication a new engine cradle (mk1) and this is how it currently looks.



I'll be making another cradle (mk2) which will utilise the original rubber mounts to minimise vibration transferred to the chassis from the engine.

But for now this one will do until I modify the chassis engine mount, which is also not in the correct place for this engine. Not a lot in it, so it should be a relatively easy alteration.



At the close of play today, the engine is sitting nicely in the chassis and the sump is level and not too low.



The bonnet now just fits on over the top of the inlet manifold, I could lower the engine down a little bit further to gain a bit of extra clearance but I don't like the idea of the sump being any lower than it currently is, as it is sitting just about level with the base of the chassis.



The gt3071r turbo is quite a snug fit down the side of the engine bay



But there is still clearance between the turbo and chassis bracing, which I'm happy about as I don't want the turbo to be on show really, be nice to keep the car quite discreet.

Edited by Red16 on Tuesday 7th September 00:33

[bonesX]

OMG! You loon ;-) ZX10R's are mental enough without being breathed on... My MAC#1 ZX10R sprints 60 sub 4s blah balh... (read lots of green)

How are you going to contain yourself till it's built?!

[Red16]

Just making it a wee bit more interesting bonesX, lol, I'm struggling to contain myself at the moment, it's on my mind 24/7, when it's on the road I think i'll have my arse glue'd to the drivers seat!!!

The engine cradle (mk2) is progressing slowly, here's how it's looking at the moment.



I still need to weld in some spacers, to stop the cradle bending when the engine mount bolts are torque'd up.

[Red16]

Another piece of the engine cradle puzzle completed



Added the upper central mount to the engine cradle



Modified the lower engine mount on the chassis



The engine has now been removed allowing me to get into the engine bay to properly weld the lower engine mount on the chassis, it's only tack welded in position at the moment. While the engine is out i'll weld the underside of the central engine mount bar onto the engine cradle.

I've bought a few parts which arrived today, first off an intercooler



A larger radiator



Also have wheel nuts and a brake pedal saddle, so I can fit the pedals and when I have the brake hoses made up I can fit the brakes, bleed them, then fit wheels and have a rolling chassis

[Red16]

Chassis engine mount welded up



With a lick of paint



Fabricated and fitted a heat shield to the passenger side of the engine bay as the turbo sits close to the powder coated diagonal chassis brace bar, it should also help prevent the fibreglass side panel distorting with the heat.

[Red16]

I ordered a full set of custom braided brake hoses yesterday, but the fittings required to fit the Wilwood calipers needed to be ordered in, if all goes to plan the hoses will be made up tomorrow and i can get them fitted to the car.

I began to fit the radiator today, held it in position with green cable ties to allow the nose cone to be fitted to ensure it would fit inside the nose cone alright and leave adequate space for the intercooler to go infront.



Tried the nose cone on and it fit perfectly around the radiator



I then realised I didn't have any material in the garage to make brackets with, doh! So a quick trip to B&Q and I ended up with these zinc plated brackets which were just about perfect.



The holes in the brackets were opened out to accomodate the radiator mounting bolts and then the chassis was drilled so they could be bolted to the car.



The upper brackets have yet to be fitted. I'm leaving those until later to give me the option of making a little bit more space in the small part of the nose cone for the intercooler.

[singlecoil]

Red16 said:

That is a really creepy silhouette. Have you seen that early vampire film, Nosferatu?

Edited by singlecoil on Tuesday 5th October 21:13

[indy sean]

hi i did a mk with a zx10r turbo where will you be putting your intercooler then???

i ran a v one like you have still got it actually then chaged to a cossie one,

i ran mine at 8 psi and got 268 bhp, was lively, with a 314 diff they do run out of puff with the gearing on the zx10 engine as 5 - 6 is not much change in ratio, upto 120mph they are rapid,

cheers theres some video of mine on you tube,

[Red16]

singlecoil said:

That is a really creepy silhouette. Have you seen that early vampire film, Nosferatu?

I havent, but since googling it I know what you mean, lol.

indy sean said:

hi i did a mk with a zx10r turbo where will you be putting your intercooler then???

Intercooler will be fitted infront of the radiator, so it sits directly behind the opening in the nose cone, hoping to get the brackets made and the intercooler inlet/outlet modified to suit today.

indy sean said:

i ran a v one like you have still got it actually then chaged to a cossie one

What do you mean by a v one? Are you refering to the intercooler?

indy sean said:

i ran mine at 8 psi and got 268 bhp, was lively, with a 314 diff they do run out of puff with the gearing on the zx10 engine as 5 - 6 is not much change in ratio, upto 120mph they are rapid,

Thats a nice power figure I'm running a Freelander diff which is 3.21, so it'll be slightly slightly shorter gearing than yours, guess i'll just have to get the hang of changing gear quickly and regularly, lol.

What speed were you doing at the top end of 4th gear?

indy sean said:

cheers theres some video of mine on you tube,

Is that the white one with black chequer graphics?

[Red16]

Today I have mostly been playing about with an intercooler and radiator.

The intercooler inlet/outlet pipes have been cut off at an angle, rotated and then rewelded.
Then brackets were made and welded to hold the intercooler onto the radiator.







With the nose cone on you can see it's a tight fit but not fixing the upper radiator mounts to the chassis yesterday paid off, as it allowed the rad to be moved back slightly to gain enough space for the intercooler to clear the nose cone.



I think it'd probably look better and more subtle if the cooler was painted matt black.



Here you can see how the modified intercooler inlets/outlets now clear the radiator ready for boost pipework to be routed down either side of the engine bay.

[Red16]

Still no brake lines yet, rang the company who are making them this afternoon and they still hadn't received the fittings which were ordered on Monday

I couldn't wait any longer, so set about fitting the brakes to the front end of the car



Next step was to fit the wheels, but could only get 3 on as the bench was in the way for the last one.



Front brakes hiding behind the Pro Race 1.2 wheel



With the help of R6Franky and some of the neighbours the car was moved forward, the last wheel fitted and then finally lowered to the floor





End of play today I'm a very happy bunny

[jason61c]

Looks really nice, keep up the good work

We should have a meet for all the people planning to finish their cars for next summer!

[Red16]

Thanks Jason

A meet next summer sounds like a good plan to me, any excuse to take it out when it's finished will be taken advantage of!

Ph and here's another shot of it tucked away for the night

[bonesX]

Any updates, and (soz in advance for a uncomfortable question) have you a completion date, or is an as and when?

[Red16]

bonesX said:

Any updates, and (soz in advance for a uncomfortable question) have you a completion date, or is an as and when?

Don't worry it's not an uncomfortable question, I'm expecting to have the car on the road around May next year, in time for the start of the decent weather.

Not been a lot of updates lately, but here's a couple of photos of what has been happening.

Bought some 2004 ZX10R clocks



The custom braided brake lines were finally made up and collected



Collected a petrol tank from Mac#1



It's flanged/grooved to accept a standard ZX10R fuel pump/seal arrangement



Clutch cable and accelerator cable kits



Flush fitting AeroCatch bonnet catches, instead of those horrid sticky out clamps people usually use



Got some paint matched to the body colour, fired up my compressor and tried out painting with a newly acquired Devilbiss gun, I'm rather pleased with the results



With the weather being nice, while painting I pushed the car out onto the drive and thought it would be rude not to take some more photos

[mickrick]

Very nice. Love the colour. and as has already been said, some very neat cutting there. Keep the pictures coming. We like pictures.

[bonesX]

Now I know why my MAC #1 petrol tank costs £19 to fill... ;-)

[Red16]

bonesX said:

Now I know why my MAC #1 petrol tank costs £19 to fill... ;-)

Is that a good thing or a bad thing? lol

mickrick said:

Very nice. Love the colour. and as has already been said, some very neat cutting there. Keep the pictures coming. We like pictures.

Thanks for the positive comments Here are the updates I forgot to add...

Some 76mm/3" bore exhaust parts



a 2.75"/70mm diameter aluminium pipe to modify the inlet manifold with



The original pipework feeding the inlet manifold was 51mm/2" diameter



The plan is to to bring the inlet manifold inlet pipework up to the same size as the intercooler by cutting and welding this new piece into it. You can see the size difference in the photo below.



The inlet manifold now looks like this

[Red16]

I've also bought an alloy fuel pump cradle to mount the Bosch 044 pump with.



Brake light switch, T piece and link hose connected to the master cylinder



The rear hoses are mocked up now, ready to be fitted properly when I next work on the car



Fitted the front brake hoses to the calipers, drilled the side panels and fed the hoses through with a grommet.