Project mid life crisis

[Jken24]

So I purchased my little black MR2 as a 40th birthday present to myself around December time, a little project to have a little bit of fun working on, then enjoy ownership - hence the term my wife has coined for this as my 'mid life crisis car'!.

I had never before considered an MR2. I was looking for something that would be relatively easy to work on, be a lot of fun, and as a second car be something a lot of bang for buck.

I had read about the Audi 1.8t conversions and thought that would probably be right up my street (forgive the pun).

Found one not too far from me, overall looks wise in pretty good condition! that only reason the seller was selling is due to a bad blow in the exhaust flexis and they were quoted a lot of money for exhaust cat replacement. Ideal for me as with the idea of the 1.8t conversion, exhaust would be coming out anyway.

Other things to notes were corrosion underneath, crucially all looking to be surface rust and no actual rot. Badly corroded standard wheels.

Plus points:

• Bodywork very good condition, no obvious dings or dents, just the obligatory stone chips
• Seats in fantastic condition. Possibly retrimmed? fairly sure its not standard.
• Original roof in excellent condition

This is the only original photo I have which is actually a screen shot from the advert that the previous owner had posted when they had it listed for sale

[Jken24]

First task, improving the sound. I do like my music, and using the car occasionally on a run to work (approx 1 hour journey each way) the standard head unit and speakers were pretty unbearable.

This series of jobs I decided to combine with battery relocation to the front (in preparation for eventual engine swap). Made sense to do it all at same time.

Removal of frunk revealed a not so nice looking front bay so decided to give it a bit of treatment. Before and after shots

[Jken24]

Battery relocation utilising original battery tray with a bit of simple modification!

Have used a circuit breaker instead of fuse for the battery 12v wiring. In hindsight it has been invaluable. Can isolate the battery from the car at the touch of a button. Perfect for when you do a lot of work on the car, no longer have to keep disconnecting battery terminals etc!




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[Jken24]

Went for a simple but effective sound system setup.

Modern head unit with essential DAB and bluetooth. DAB aerial discrete attaches to front screen.

New component speakers running from dedicated amplifier. Seperate active subwoofer. Amp and sub both out of the way above driver footwell!!

Bit of sound deadening in doors while I was there.

[Jken24]

Also took the opportunity to remove the redundant cigarette lighter, and modify the circular opening to fit a dedicated USB charger and voltmeter, found on ebay.

The interior pic is just after I had completed all the wiring, which was satisyfying and the first time of the car interior looking normal again in about 2 months in the cold winter weather when I could find the time to get outside and get all of this work done!

[Jken24]

Next phase of the project - New engine and preparation for the swap

Former Audi TT 225bhp 1.8t engine/gearbox/loom/ancillaries purchased blind from a car breakers for a very very good price. This was just after collecting into and putting into my garage.

Next steps-
Remove all the redundant crap from around the engine.
Research as to what all the connectors on the loom are for, and label the loom up then take it off
Start doing checks to see what ive let myself in for, and what am I going to need to buy!

Gearbox off, not a good start looking at the clutch and flywheel!

Having said that the breaker I bought the engine from said the TT owner was breaking due to a clutch issue, fingers crossed that's true and the only issue i'm going to come across?!

[Jken24]

Also first impressions the PCV system has been clogged for a VERRRYYYY long time. Thick sludgy oil deposits completely all over the inlet side of the engine, and also all over the gearbox!

Purchased Autoglym engine degreaser based on absolutely brilliant reviews online.
Literally didn't even touch the years of layers of oil sludge!!

Had to resort to the hard stuff, had a couple of unopened bottles of paraffin knocking around in the shed. About 4 cycles of scrubbing with paraffin to loosen up the oil, followed by the autoglym, followed by washing off with hose, and repeat! (used the fingers cut off from disposable nitrile gloves with small cable ties to keep connectors and sensors etc  free of water!)

Finally, once clean, a bit of high temp spray point to make things look fresh

[Jken24]

Engine now looking respectable, next step making sure it runs equally as good. So new valve cover and camshaft tensioner gaskets (evidence of previous leaking). Valve cover painted while off.

Sump removed to check for evidence of oil sludge and blocked pickup, all looking good there which suggest regular servicing with decent oil, good news!

Turbo checked for play, all within tolerance. Finally leak down test carried out, readings looking VERY good! phew.

[Jken24]

MOT expired in march. Car taken off the road, therefore no excuse but to make a start on the removal of the standard 1ZZ!

Before long, engine out, not too bad a task, although trying to manhandle the complete engine and gearbox out from underneath the car with no-one to assist was a bit of a challenge!

That is pretty much up to date with where things are now!

Next steps is to make the most of having the engine out to mainly tackle the corrosion underneath - power tools to remove any loose and flaky rust, then rust converter, primer, paint

noticed when I was on the floor that one of the handbrakes has seized, as has the caliper handbrake mechanism. New calipers and handbrake cables ordered and en route from Germany. This will be finished off with braided brake hoses.

Also going to fit drop links and whiteline front an rear ARBs which have been sitting around since Xmas which I have the good access.

[Ardent]

Bravo.
What a great write up.

Well played.

[jvanzyl]

A decent amount of work there! Well done, looks like you're cracking along nicely!

[Carolyn]

I totally agree with your approach to dealing with corrosion. Beats the hell out of covering the underside in goop.

[Mark A]

Interesting read, thanks and some useful tips.

I really like the idea of a 1.8T conversion, I've watched the Stav-Tech Videos and may have a go next year with the spare shell I have.

Keep the updates coming. 

[Jken24]

Last week cleaned up the rear including inside the engine bay.

Inspected the Subframe, not to bad condition at all, surface rust mainly on the side that would have been facing the engine but not at rot stage.

Went over everywhere there was flaky rust around the whole rear end with wire wheel. This was mainly subframe, arms, hubs, brake disc dust shields.

After, treated with a couple of sprayed coats of Jenolite rust converter & left to work it's magic for a day.
This stuff appeared to work great, basically all areas of rust turned black!

Finally the bits that were rusty Finished off with some primer then satin black paint.

A point to note, I was surprised to see areas around the engine bay that received little or no paint obviously from the factory!

Some before and after photos..

[Jken24]

Forgot to mention rear calipers (handbrake mechanism seized one side) also off, anti roll bar, and finally had some fun with the angle grinder getting the old links off

Have ordered some Bilt Hamber stuff online that is meant for cavities to try and protect the inside of the subframe from rotting

[puma2]

  a good bit of working going on there and the effort will pay off for you  
keep this up and your be up for A* plus     

[Ardent]

+1 on the bilt hamber.

[Jken24]

Front ARB off (amongst a few other things at the front). Despite semi regular anti seize treatments over a period of a few months! EVERY SINGLE bolt holding in the front ARB snapped so will need to drill them all out!

Strange considering everything else has been pretty easy, even all of the wishbone bolts were a breeze and have read a few horror stories on here!

Finally, was going to leave the suspension itself all round but talked myself into buying new KYB shocks and springs all round considering I've got most other things unbolted and shouldn't have to touch it ever again. Anyway rear suspension off yesterday and discovered a pesky little snap in one of the springs!

Feeling good that the decision now completely justified

[Jken24]

All front suspension components off now. Drilled out seized ARB bolts. All front end underneath and hubs given anti rust treatment of wire wheel on the drill then Jenolite rust converter.

Trip to my local fastener shop yesterday, bought some m8x30 bolts, washers and nyloc nuts to secure the front ARB. After drilling out the old seized bolts I'm keeping the old welded captive nuts in place and securing over the top to save going to the trouble of trying to remove the captive nuts. Hoping this should be OK?

Next steps today will be primer and paint all of the areas that were showing corrosion at the front end, then bilt hamber s50 to the inside of the rear subframe.

[Jken24]

Found this chassis leg or whatever it is called, as well as the areas just above, and just behind this leg to have the worst corrosion on my MR2, although still all just surface corrosion..

Is this the experience of others out of interest?

[Hawko]

Strange but mine was very similar. 

I was going to post an update on my progress since purchase just before Christmas, so now's the opportunity.

What started out as a quick front end clean up a couple of months ago turned into a full front end underneath repaint and overhaul.  The chassis legs and steering rack support were be far the worst, the drivers side had rusted through right behind where the radiator hose bolts on.  I guess moisture and road dirt can accumulate, causing the issue.  Anyway the mig welder had to be deployed and a small patch welded in.  The rest of the metalwork although rusty was sound (didn't take many pics unfortunately).  The car had relatively new springs and shockers, a new hub on one side and new discs and pads.  I have added and am adding new wishbones, drop links, refurbed set of callipers, stainless brake lines and various other minor bits.  Now finally almost there, just the back end now!

[Hawko]

Looks like the images I tried to upload didn't work first time

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[Ardent]

Now there is a rare sight. A fresh brake dust back plate.

[Hawko]

All the way from Japan in just over a week  - cost £72 shipped for all 4 corners including 8 new front hub bolts.

[Topdownman]

Now there is a rare sight. A fresh brake dust back plate.

Oh, is that what it was!