1991 Mazda MX5 1.6
Discussion
Thought I had better update the last couple of months rather eventful ownership of the MX5!
Starting with a nice easy cure for the leaking boot floor. New tail light gaskets fitted as the old ones had seen better days.
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Dry as a bone since then with just some fun enjoying driving it until...
Starting with a nice easy cure for the leaking boot floor. New tail light gaskets fitted as the old ones had seen better days.
[url]|https://thumbsnap.com/VM1MNY2x[/url][url]|https://thumbsnap.com/JcpN1k6Z[/url][url]|https://thumbsnap.com/gMNULWT7[/url]Dry as a bone since then with just some fun enjoying driving it until...
Driving home from work one morning, enjoying a bit of a blast along the A30, car feeling brilliant and then stopped at some roadworks.
Few seconds later, slipped into first, went to pull away and the loudest bang and clatter ever!
Awful noise so switched off and got out expecting to see a pool of oil or something on the ground but nothing!
Checked all over the car and nothing obvious.
Popped the bonnet and some hazy smoke but all looked good!
Stupidly, went to start it and obviously the same incredibly loud, banging noise so switched off.
Having a good nose around I just saw that the the spark plug lead had popped off so pushed it back down but thought no way that a plug lead off would make that noise but hey ho.
Started again and yep, same noise but noticed the plug lead had popped off again.
Cue lots of head scratching and getting pissed off at 4 am I remembered I had a small torch in my bag so had a good look around and guess what I found.
Or didn’t find.....
The bloody spark plug was missing! Seriously, deep down in the recess, instead of a spark plug there was an empty thread!
Car was running great 30 seconds earlier so that awful bang must have been the spark plug flying out and hitting under the bonnet. Sure enough, about 30 yards behind the car the still warm plug was siting in the middle of the road.
In fact in the photo above, it can just be seen on the road behind the car before i’ve even noticed the problem.
Threads looked fine and plug was intact so had the plug but no way of seeing if it would thread back in as no tools. RAC were useless as 1 hr turned into 2 hrs then before they turned up a white knight stopped with a full toolkit and helped out!
Dropped the plug down into the recess and slowly tightened up and it went in ok! No problem at all and started it up and fine, back to normal and drove home with no issues.
Checked the car over, took all the plugs out, reinstalled them and all went in and torqued up ok. Kept an eye on them after every drive for the next couple of hundred miles and no issues at all.
The most bizarre thing I’ve ever had happen to me with a car.
More to come involving boroscopes, rust and many snapped bolts.......
Few seconds later, slipped into first, went to pull away and the loudest bang and clatter ever!
Awful noise so switched off and got out expecting to see a pool of oil or something on the ground but nothing!
Checked all over the car and nothing obvious.
Popped the bonnet and some hazy smoke but all looked good!
Stupidly, went to start it and obviously the same incredibly loud, banging noise so switched off.
Having a good nose around I just saw that the the spark plug lead had popped off so pushed it back down but thought no way that a plug lead off would make that noise but hey ho.
Started again and yep, same noise but noticed the plug lead had popped off again.
Cue lots of head scratching and getting pissed off at 4 am I remembered I had a small torch in my bag so had a good look around and guess what I found.
Or didn’t find.....
The bloody spark plug was missing! Seriously, deep down in the recess, instead of a spark plug there was an empty thread!
Car was running great 30 seconds earlier so that awful bang must have been the spark plug flying out and hitting under the bonnet. Sure enough, about 30 yards behind the car the still warm plug was siting in the middle of the road.
In fact in the photo above, it can just be seen on the road behind the car before i’ve even noticed the problem.
Threads looked fine and plug was intact so had the plug but no way of seeing if it would thread back in as no tools. RAC were useless as 1 hr turned into 2 hrs then before they turned up a white knight stopped with a full toolkit and helped out!
Dropped the plug down into the recess and slowly tightened up and it went in ok! No problem at all and started it up and fine, back to normal and drove home with no issues.
Checked the car over, took all the plugs out, reinstalled them and all went in and torqued up ok. Kept an eye on them after every drive for the next couple of hundred miles and no issues at all.
The most bizarre thing I’ve ever had happen to me with a car.
More to come involving boroscopes, rust and many snapped bolts.......
Edited by nessiemac on Friday 20th November 03:07
I've had three A's and they're so much more fun than the NB I'm currently driving. I'm planning to try and get back into one asap.
This one looks great, especially now the tat has gone. We have a few around here that have suffered similar, usually with gash lexus lights as well. Never had the spark plug issue, usually the alternator belt giving out for me!
Enjoy the winter with the roof down, especially if it's snowing, great fun!
This one looks great, especially now the tat has gone. We have a few around here that have suffered similar, usually with gash lexus lights as well. Never had the spark plug issue, usually the alternator belt giving out for me!
Enjoy the winter with the roof down, especially if it's snowing, great fun!
Jonmx said:
I've had three A's and they're so much more fun than the NB I'm currently driving. I'm planning to try and get back into one asap.
This one looks great, especially now the tat has gone. We have a few around here that have suffered similar, usually with gash lexus lights as well. Never had the spark plug issue, usually the alternator belt giving out for me!
Enjoy the winter with the roof down, especially if it's snowing, great fun!
Cheers, there won't ne much driving over the winter though..... You will see why in next update!This one looks great, especially now the tat has gone. We have a few around here that have suffered similar, usually with gash lexus lights as well. Never had the spark plug issue, usually the alternator belt giving out for me!
Enjoy the winter with the roof down, especially if it's snowing, great fun!
I'll have you beaten all ways up on rust I'm sure! Got a welder not long back and going to venture into the world of melting metal soon hopefully. Looking forward to updates!
I'm shocked you've broken several bolts though, mine is in a right state on the underside and I think I've only encountered 1 snapped bolt and 1 bolt so stuck in I had to cut it off!
I'm shocked you've broken several bolts though, mine is in a right state on the underside and I think I've only encountered 1 snapped bolt and 1 bolt so stuck in I had to cut it off!
RazerSauber said:
I'll have you beaten all ways up on rust I'm sure! Got a welder not long back and going to venture into the world of melting metal soon hopefully. Looking forward to updates!
I'm shocked you've broken several bolts though, mine is in a right state on the underside and I think I've only encountered 1 snapped bolt and 1 bolt so stuck in I had to cut it off!
It's not too bad underneath really. Snapped bolts were all on the passenger side wing! Couple of them the heads just came off like cheese! I'm shocked you've broken several bolts though, mine is in a right state on the underside and I think I've only encountered 1 snapped bolt and 1 bolt so stuck in I had to cut it off!
Just trying to get pics together!
With the car back to running well, thoughts turned to some subtle mods but before that I wanted to make sure the shell was solid before spending any money.
Apart from slightly scruffy paintwork in places it all looks good from the outside.
I knew the rear sills have been welded before but arches and spot welds all original and underneath looks good, apart from crusty suspension so I bought a cheap endoscope from Amazon to have a proper look inside.....
And then wished I hadn’t!
Both rear inner sills were “replaced” in 2016 at a cost of £1400 by the previous owner. Let’s just say the company that done the work are absolute cowboys.
The pax side has no issues apart from some surface rust
Which has been coated in rust converter and cavity wax but the drivers side....
It looks they they cut the outer skin, had a look in, tried to weld it then thought f
k it halfway through. And just left all the rotten metal and bits of welding rod inside!
Funny thing is they done a brilliant job on the outer skin, perfect from outside and that’s the hard part.
So inside the drivers side....
Bloody awful!
Luckily a neighbour owns a welding company and restores the odd classic car so we are going to replace that side in the near future.
Also found a large amount of debris under the bottom lip of the front arches, a common trap that can lead to serious issues.
So even after a hoover out, this lot still fell out.
This led to me taking the front wings off to check underneath. This led to taking the front bumper off as well.
Many snapped bolts later.
luckily everything else looks ok, inside the wings and chassis rails etc.
Now I was down to this stage it was a choice of just put it all back together or tackle the crusty running gear and chassis now.
Which is where I will get to next.
Apart from slightly scruffy paintwork in places it all looks good from the outside.
I knew the rear sills have been welded before but arches and spot welds all original and underneath looks good, apart from crusty suspension so I bought a cheap endoscope from Amazon to have a proper look inside.....
And then wished I hadn’t!
Both rear inner sills were “replaced” in 2016 at a cost of £1400 by the previous owner. Let’s just say the company that done the work are absolute cowboys.
The pax side has no issues apart from some surface rust
Which has been coated in rust converter and cavity wax but the drivers side....
It looks they they cut the outer skin, had a look in, tried to weld it then thought f
k it halfway through. And just left all the rotten metal and bits of welding rod inside! Funny thing is they done a brilliant job on the outer skin, perfect from outside and that’s the hard part.
So inside the drivers side....
Bloody awful!
Luckily a neighbour owns a welding company and restores the odd classic car so we are going to replace that side in the near future.
Also found a large amount of debris under the bottom lip of the front arches, a common trap that can lead to serious issues.
So even after a hoover out, this lot still fell out.
This led to me taking the front wings off to check underneath. This led to taking the front bumper off as well.
Many snapped bolts later.
luckily everything else looks ok, inside the wings and chassis rails etc.
Now I was down to this stage it was a choice of just put it all back together or tackle the crusty running gear and chassis now.
Which is where I will get to next.
Wow, is that one of those jobs you wish you never started?
I would love to get another Mk1 some day after having one 20 odd years ago, but appear to have missed the boat on the cheap stuff and lots now seem to be quite rusty.
Your thread gives me hope there is still some half decent stuff out there
I would love to get another Mk1 some day after having one 20 odd years ago, but appear to have missed the boat on the cheap stuff and lots now seem to be quite rusty.
Your thread gives me hope there is still some half decent stuff out there
mattman said:
Ok - you are to blame for me being in the trouble with the wife. eBay purchase tonight of a Mk1 SE, same model as we had to sell 20 years ago when my eldest was born.
Wasn’t expecting it to finish quite as low as it did, hope it’s as good in the flesh as the photos
Sorry buddy! Wasn’t expecting it to finish quite as low as it did, hope it’s as good in the flesh as the photos
Bet you can't wait to get it!
mattman said:
Wow, is that one of those jobs you wish you never started?
I would love to get another Mk1 some day after having one 20 odd years ago, but appear to have missed the boat on the cheap stuff and lots now seem to be quite rusty.
Your thread gives me hope there is still some half decent stuff out there
Nah, glad I caught it now and enjoying doing something to distract me from everything that is going on in the world right now!I would love to get another Mk1 some day after having one 20 odd years ago, but appear to have missed the boat on the cheap stuff and lots now seem to be quite rusty.
Your thread gives me hope there is still some half decent stuff out there
Front suspension all done now, pics to follow.
Great buy there.
I quite like the Mk 1 MX-5, mainly because the design was based on the original Lotus Elan..... one of which I used to own.
if you compare the side view, the nose with the pop up headlights, the interior layout ( instrument cluster) gearstick placement, central tunnel.....etc etc, they are all very similar too the Elan 63-73.
Even the cam covers look similar !
But the good thing is.... they are much easier to look after ( ask me how I know ! ) : they have the Mazda reputation for bullet-proof mechanicals, and I would guess that the spares are a lot cheaper than Lotus aftermarket parts.
They don't have the infamous 'Rubber donut' drive couplings that were famed for driveshaft 'wind up' ( to be fair I never experienced that with mine.....although I quickly replaced them with solid conventional ones)
Or the pop up headlight system that relied upon induction vacuum to lift ( and retain in position !) the very heavy "pods"....
so you would be unlikely to get stuck in The Lakes one evening after a cracked T piece resulted in no vacuum, and hence no available headlights at all....!!!
I think that there is now an electric conversion ( based upon your Mk1 car) that solves that issue !
Also the MX-5 is a steel bodyshell..... (unlike the 'plastic' fibreglass dismountable Elan one), which is very much stronger than the Lotus ( in fact there was no metal (at all) between the outer door skin and the central 'backbone' of the chassis ! That was taking the concept of ' adding lightness' to a new level in the 1960's !
Anyway, apologies for going off Mazda Topic, but just though you may like to know where the heritage came from !!
I am getting tempted to get an early mk1...... Just so that I can have a project at this time....
I presume that the spares are reasonably priced for your model of MX-5 ?
I quite like the Mk 1 MX-5, mainly because the design was based on the original Lotus Elan..... one of which I used to own.
if you compare the side view, the nose with the pop up headlights, the interior layout ( instrument cluster) gearstick placement, central tunnel.....etc etc, they are all very similar too the Elan 63-73.
Even the cam covers look similar !
But the good thing is.... they are much easier to look after ( ask me how I know ! ) : they have the Mazda reputation for bullet-proof mechanicals, and I would guess that the spares are a lot cheaper than Lotus aftermarket parts.
They don't have the infamous 'Rubber donut' drive couplings that were famed for driveshaft 'wind up' ( to be fair I never experienced that with mine.....although I quickly replaced them with solid conventional ones)
Or the pop up headlight system that relied upon induction vacuum to lift ( and retain in position !) the very heavy "pods"....
so you would be unlikely to get stuck in The Lakes one evening after a cracked T piece resulted in no vacuum, and hence no available headlights at all....!!!
I think that there is now an electric conversion ( based upon your Mk1 car) that solves that issue !
Also the MX-5 is a steel bodyshell..... (unlike the 'plastic' fibreglass dismountable Elan one), which is very much stronger than the Lotus ( in fact there was no metal (at all) between the outer door skin and the central 'backbone' of the chassis ! That was taking the concept of ' adding lightness' to a new level in the 1960's !
Anyway, apologies for going off Mazda Topic, but just though you may like to know where the heritage came from !!
I am getting tempted to get an early mk1...... Just so that I can have a project at this time....
I presume that the spares are reasonably priced for your model of MX-5 ?
Paul S4 said:
Great buy there.
I quite like the Mk 1 MX-5, mainly because the design was based on the original Lotus Elan..... one of which I used to own.
if you compare the side view, the nose with the pop up headlights, the interior layout ( instrument cluster) gearstick placement, central tunnel.....etc etc, they are all very similar too the Elan 63-73.
Even the cam covers look similar !
But the good thing is.... they are much easier to look after ( ask me how I know ! ) : they have the Mazda reputation for bullet-proof mechanicals, and I would guess that the spares are a lot cheaper than Lotus aftermarket parts.
They don't have the infamous 'Rubber donut' drive couplings that were famed for driveshaft 'wind up' ( to be fair I never experienced that with mine.....although I quickly replaced them with solid conventional ones)
Or the pop up headlight system that relied upon induction vacuum to lift ( and retain in position !) the very heavy "pods"....l
so you would be unlikely to get stuck in The Lakes one evening after a cracked T piece resulted in no vacuum, and hence no available headlights at all....!!!
I think that there is now an electric conversion ( based upon your Mk1 car) that solves that issue !
Also the MX-5 is a steel bodyshell..... (unlike the 'plastic' fibreglass dismountable Elan one), which is very much stronger than the Lotus ( in fact there was no metal (at all) between the outer door skin and the central 'backbone' of the chassis ! That was taking the concept of ' adding lightness' to a new level in the 1960's !
Anyway, apologies for going off Mazda Topic, but just though you may like to know where the heritage came from !!
I am getting tempted to get an early mk1...... Just so that I can have a project at this time....
I presume that the spares are reasonably priced for your model of MX-5 ?
There is a huge aftermarket scene for parts and prices from reasonable to not so reasonable, depending on what you are buying.I quite like the Mk 1 MX-5, mainly because the design was based on the original Lotus Elan..... one of which I used to own.
if you compare the side view, the nose with the pop up headlights, the interior layout ( instrument cluster) gearstick placement, central tunnel.....etc etc, they are all very similar too the Elan 63-73.
Even the cam covers look similar !
But the good thing is.... they are much easier to look after ( ask me how I know ! ) : they have the Mazda reputation for bullet-proof mechanicals, and I would guess that the spares are a lot cheaper than Lotus aftermarket parts.
They don't have the infamous 'Rubber donut' drive couplings that were famed for driveshaft 'wind up' ( to be fair I never experienced that with mine.....although I quickly replaced them with solid conventional ones)
Or the pop up headlight system that relied upon induction vacuum to lift ( and retain in position !) the very heavy "pods"....l
so you would be unlikely to get stuck in The Lakes one evening after a cracked T piece resulted in no vacuum, and hence no available headlights at all....!!!
I think that there is now an electric conversion ( based upon your Mk1 car) that solves that issue !
Also the MX-5 is a steel bodyshell..... (unlike the 'plastic' fibreglass dismountable Elan one), which is very much stronger than the Lotus ( in fact there was no metal (at all) between the outer door skin and the central 'backbone' of the chassis ! That was taking the concept of ' adding lightness' to a new level in the 1960's !
Anyway, apologies for going off Mazda Topic, but just though you may like to know where the heritage came from !!
I am getting tempted to get an early mk1...... Just so that I can have a project at this time....
I presume that the spares are reasonably priced for your model of MX-5 ?
Suspension bushes for example, huge range available from oem to many different types of polybush. Which range from £100 a set to over £500 for a set for the whole car!
Which brings me to the next set of piccies.
With the 5 in the garage the decision was made to go over the car with a fine tooth comb and see what other issues I had.
This revealed very crusty and worn looking bushes and shocks and decided to start here.
Impact wrench bought ( best tool ever) I have spent the last few weeks stripping down the front suspension and getting everything cleaned up and painted and replacing the bushes with the best you can get. An Aussie company called Superpro apparently are the best money can buy so all control arm and anti roll bar bushes replaced.
New coilovers from Meister R were more than I was initially prepared to spend but only want to this once and want to do it right so here they are!
Brake callipers refurbed and painted and inner arches cleaned of any surface rust and painted with POR15 range of cleaners, etch primers and paint.
Just finished the front end and got to clean up under the wings and paint them, and then get them and front bumper all back together and tackle the rear end where I will be doing the same but dropping the whole subframe and diff as well and going over the whole lot.
So this is how the last few weeks have gone....
And ending up here....
This revealed very crusty and worn looking bushes and shocks and decided to start here.
Impact wrench bought ( best tool ever) I have spent the last few weeks stripping down the front suspension and getting everything cleaned up and painted and replacing the bushes with the best you can get. An Aussie company called Superpro apparently are the best money can buy so all control arm and anti roll bar bushes replaced.
New coilovers from Meister R were more than I was initially prepared to spend but only want to this once and want to do it right so here they are!
Brake callipers refurbed and painted and inner arches cleaned of any surface rust and painted with POR15 range of cleaners, etch primers and paint.
Just finished the front end and got to clean up under the wings and paint them, and then get them and front bumper all back together and tackle the rear end where I will be doing the same but dropping the whole subframe and diff as well and going over the whole lot.
So this is how the last few weeks have gone....
And ending up here....
Today’s job is tidying up under the wings. A very common rust spot as it’s a real trap for collecting leaves, dirt, small children etc! 
With the wings off it luckily doesn’t look bad at all. I’ve seen some videos where you can literally put your hand through the inner arch but this is solid.
And under the wings there is only a small bit of surface rust.
So out with the POR15 again.
Both wings the same and hopefully front end all together next week but looking good.
With the wings off it luckily doesn’t look bad at all. I’ve seen some videos where you can literally put your hand through the inner arch but this is solid.
And under the wings there is only a small bit of surface rust.
So out with the POR15 again.
Both wings the same and hopefully front end all together next week but looking good.
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