build diary

August 17, 2004:
The instruments are working now!
It turns out there was a badly corroded connection on the back of the instrument panel. Replacing the circuit board with a known good one solved the problem. Now I have a tach and an oil pressure gauge. Still no speedometer but that's not going to change any time soon and really isn't a great priority. I've packaged up the wiring in the engine bay to make everything look neater. I might even take advantage of the new giant 20,000+ CFM fan at Flyin' Miata to work out a decent little wind deflector. Am I just doing small things that will improve people's impressions of the car? Why, yes I am! There are a lot of folks who will be checking the Seven out this weekend at the Flyin' Miata Open House.

I also weighed the car last night. It's a little heavier than anticipated - I probably underestimated the exhaust system. Still, a full wet weight of 1257 lbs isn't bad at all. That's with a full tank of gas, water, all the body parts and even a fire extinguisher. The empty car is slightly tail heavy (52.7% on the rear) and almost perfectly balanced left to right. The cross weights are also very good. The moral? It'll handle best with a passenger. I don't think it will be a problem finding one this weekend.

Pulling into my garage last night, it looked odd. It was too big and too empty. It's the first time the Seven hasn't been there since January! All that's left is a bunch of debris.
entry 583

Bill does some investigation on the wiring.
It's quick and easy to remove the scuttle and it makes working on the car far, far easier.
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The circuit board looks better in this photo than it did in person.
The left two pins were all green and we weren't able to clean them up.
entry 585
Time to hit the scales!
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The final weight and balance.
Not too shabby, really!
entry 587

August 18, 2004:
Is it possible to accidentally work on a car? Last night I was finishing up at work and made the mistake of wandering back to look at the Seven in the shop.
An hour later, I was putting the final touches on a new exhaust tip. I'm not as happy with how it looks as the original but it should both be slightly quieter and will prevent the tire from overheating. Thanks, Ander, for confirming this in my guestbook. A bit of trimming on the side panel for the exhaust exit and the car is getting more and more civilized. Well, relatively civilized.

After some talks with my friends down at Scotty's Muffler, I've worked out a slip-on exhaust tip that should drop the sound level a bit. The track day is under some extreme noise restrictions due to small-town politics - a community across the interstate, underneath an airport approach path have decided that their ambient noise cannot go above 55 dB. The use of the track this Friday is a test to see if cars can use the kart track without causing noise problems. Only Miatas are allowed to take part but we're going to run the Seven. Obviously there is some concern about the side exhaust being loud although I believe it is now at the same level as the turbo Miatas.
entry 588

The brake bias adjuster has been labelled.
It's surprisingly common for people to get this backwards. Hopefully I didn't...
entry 589
Pedal cam! I don't think I've shown a photo of the final result before.
entry 590
The new exhaust tip.
It's a 90 degree bend and aimed slightly downwards. When I look at it now I realise I probably should have angled it back about 10 degrees to line up with the rear fender. Maybe later. It looks a little odd in this photo.
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Another view of the exhaust.
entry 592
The fan I'll use for designing a wind deflector.
Yes, it's taller than the Seven!
entry 593
In the parking lot at work.
The scary thing is that this Jeep is only average around here!
entry 594

August 19, 2004:
So I'm sitting at my desk at work and my boss Bill comes up and asks, "So, have you got the plate for your car yet? We need to do sound testing at the track at 6 tonight." You can imagine that I had the borrowed dealer plate on the car shortly after that!
So the Seven got an early workout. The track is actually a large-ish kart track so it's tight and well suited to small light cars. At least that's what I'd been told. I'd never driven it before.

How did it work? In short, I never expected the car to be this good, this early. Through a series of downhill S bends that involved some good berm hopping, the car swallowed up the bumps and the tail stayed faithfully on line despite my fairly ham-fisted driving. The suspension was obviously working well although it has a lot of lean. It was easy to break the rear end loose with power but the front was well planted. The brakes have a firm, firm pedal and I never really got on them too hard - I was a little tentative with such an unknown car of course! A couple of harder stops showed me that I had to add a little more front bias so I did that on the next straight :)

Noise? Well, the first session was a worst case scenario. The dB meter was set up halfway down the straight, right where I was reaching about 6500 rpm in 2nd. Yes, it's a slow track! The meter was on the left side of the track. Now think about where my exhaust points...Yes, I failed pretty badly. For a second session I popped on my diffuser tip. It's a bit low to the ground and scrapes on all right turns, but it dropped my sound level by 6 or 7 dB - that was enough to make me legal. A BIG thank you to Rodney at Scotty's for the help in setting that up.

There were a couple of problems with the car of course. My right rear brake caliper needs a rebuild as it's leaking slightly. A gasket on a water fitting started to drip a little and the car started to miss under load as time went on. The gasket was fixed this morning and I'll try a good set of coils to see if one of my junkyard units is bad. The most entertaining failure of the night was when my tachometer needle blew off! No, I don't have glass on the gauges yet. That was a bit of a problem but I have to laugh. Now if only I can find another set of needles! Oh, and I can also report that driving this car in the rain is not a terribly pleasant experience even with good wraparound glasses.
entry 595

The diffuser tip.
entry 596
The diffuser tip installed.
It looks goofy, yes. But I'd rather look goofy and be on the track than look cool and be confined to the pits! It pulls off easily.
entry 597
Going to play at the track in the company of the a 2.0 turbocharged Miata and one of the Ubercharger supercharger prototype cars.
Quite a convoy and certainly a quick bunch.
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Time for some fun - hitting the track for the first time.
I'm surprised you can't see the grin inside my helmet!
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Sure the exhaust is funny looking but who cares?
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Bill takes the Seven out for a few laps.
You can see the diffuser tip self-machining in this photo.
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Somehow the size difference doesn't seem as much as I expected!
entry 602

August 22, 2004:
It's been a hectic few days.
The Flyin' Miata Open House descended along with dozens of people who have apparently been following the Seven buildup. The car was a pretty big hit. Let's see if I can remember what happened...

On Thursday, I put the car on our dyno ("rolling road" for those in the UK) to see if we could find the missing power. Bill Cardell took a lot of time he really couldn't afford to try and solve the problem, but it kept on getting weaker. There appears to be a fuel delivery problem that gets worse with the heat. This meant that my engine was only putting out 107 hp at the wheels instead of the 130 it has achieved in the past. The next morning I popped in a new fuel filter and determined that the tank wasn't starting to pull vaccuum. The tach needle was found under the driver's seat and some glass was added to the gauges. I then headed to the track.

After the first session on the track, I was second fastest behind Bill! This filled me with much happiness. I was still feeling my way around and managed to cut a good chunk off my time as the day went on. I had a passenger every time I went out (of course!) and was having a complete blast as I tore around. The front was solidly planted and I could steer the rear at will. The car was more composed than the Miatas through the bumpy downhill chicane. Unfortunately, my fuel delivery problem started to come back to the point where I was only able to achieve a couple of good laps each (short) session. It was enough to give me the 4th fastest time of the day although a naturally aspirated Miata did manage to beat me despite a 1000 lb weight penalty. I don't care - there's no way the other drivers were having as much fun as I was. Even if I hadn't built the car I'd be grinning like an idiot but since it was the realisation of years of dreaming it was even better. The corner workers were giving me big thumbs up signs as I went by. I felt it necessary to give them some lurid tail slides on my cool-down lap in return. I think the kids call it "drifting" but it's what I always called "power oversteer"...

The next day I was working hard in our shop and didn't manage to get the Seven out on the road at all. It simply sat in the shop and was drooled upon. I did take a few folks out for test drives in our supercharged Miata and came back smelling like tire smoke for some reason. At the end of the day I jumped in the Seven and headed out to a Sonic drive-in restaurant where the Miata folks were gathering. On the way, something went awry in the electrical system and the headlights went out. For some reason the hazards decided to come on instead which was a pretty good fail-safe when I think about it. I frantically tried to fix the problem as the dusk got duskier but despite all the Lucas jokes from the bystanders I wasn't able to find the problem without tools. I had to quickly run the car home in shame. An embarassing end to a very good weekend.

We did manage to get a bit of video and sound from inside the car. Outside video will be coming soon. Now, if you'll excuse me, I need to go relax for a while.
entry 603

On the dyno, tring to find out what's happening to the power.
Bill Cardell runs the keyboard as Bill Bowser looks on.
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The once-pristine fenders of the Flyin' Miata "Track Dog" race car.
This is why I was concerned about protecting the fenders from rocks! That is also a Lotus paint colour, actually.
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On the track.
You'll notice the counter-steer - I'm having fun! Also notice the amount of mud on the car.
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Some spectators were surprised at how much the car rolled, others were suprised at how little.
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The approach road to the track was unpaved and it rained that morning.
That's a Seven that's getting USED.
entry 608
Video!
You can either listen to a 345 KB audio file in WAV format, a 175 KB audio file in MP4 format or watch a 1.6 MB video in Quicktime format. This is simply running through a couple of gears as recorded from the passenger's seat. Don't mind the wind noise - the camera was held outside the car.
entry 609
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