May 23, 2012, 05:13:09 AM

Author Topic: The revitalization of my 21 year old car (sorry, not Audi content)  (Read 2147 times)

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Offline Castle

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Being in my 30s it saddens me to refer to something only 21 years old as in need of revitalization but alas, my poor Miata just doesn't take the turns like she used to.  Truth be told its not just the turns anymore either.  There are groans, creeks, squeals, a smidge of clattering and the occasional clunk.  It is therefore time I do what any grease loving car guy would do and embark on a project the size and scale of which the Miata has never seen before. 

I often refer to myself as a "Self Proclaimed Professional Driver" (TM) and as such I have never shied away from the challenge of driving anything.  My fiancé however does not refer to her as such and does shy away…far, far away from the Miata.  Once hallowed back in the day as the epitome of sports-car'iness, my 1990 lost that trait a few years ago.  A couple weeks ago the weather broke just long enough for me to pull the car from her winters nest and as excited as I was to cruise the few curvy streets that suburban Michigan offers, I was reminded of the need to undergo this massive project.   The Michigan pot holes were not only annoying to the touch but offered another remarkable result, an unwanted lane change. 

I have been planning for a while now the suspension upgrade event as this is not a recent problem but in the past I was limited as to how I could make the repairs, I had neither a garage nor a driveway to call my own.  There are wonderful people out there that have offered up the use of their garages and driveways in the past but a fix of this scale was much too extreme, labor intensive and time consuming.  I was finally given the last piece of the puzzle mid 2010 when, through prayer to the car gods, I found a new living space complete with a garage suitable for most mechanical efforts.

And so it begins.  I now race the weather in hopes to complete my task and take my first top down drive in 2011 on that first 60 degree sunny day.  In my way lies a path never travelled before on my Miata which assuredly means I will encounter rust, rust and more rust.  Armed with little more than my will to win and an army of rust combatants (the blue tipped torch and PB Blaster), let the games begin!


A couple days after I first got her....darn near 4 years ago



This was the last cruise we took and I don't mean in the daily driving sense.  It was a beautiful day and a drive up Jefferson Avenue from St Clair Shores to Port Huron was the perfect way to spend it. 



In the garage, up on stands.  The first corner of disassembly (front passenger) is always the easiest.  Nothing broke, a little heat and a healthy dose of PB Blaster got everything loose.  From here I'll take the parts, clean them, remove the old bushings and replace them with brand new OEM (not going crazy on these, didn't want to buy poly bushings and deal with squeaks, I have enough of those). 



On to the driver's side and here's where the fun starts.  To get the lower ball joint out you have to remove the lower shock bolt.  Seized.  Got the nut of all right but the bolt had fused itself within the bushing.  Couldn't use the torch to try and break it loose because the bushing would catch on fire.  Thanks to my Audi brethren for advice and tools to borrow cause the sawzall fixed the issue.



Sadly the ordeal is not over.  The rear camber adjusting bolt is locked by rust as well.  Sawzall to the rescue for the second time.  (I plan on replacing all the camber bolts anyways so I'm not loosing too much sleep over this one)



I've found a good use for those DTE Energy Music Theater chairs!



Starting on the rears now.  They are worse than the fronts.  Lets just say, some engineer thought it was a good idea to use an 8 inch bolt to hold the lower control arm to the hub.  They obviously have never dealt with salty winter roads cause this thing is STUCK!  Pics to come.

 
'98 A4 1.8tqm named Jammer
'12 Veloster with style and 6 speed

Offline francois

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #1 on: March 29, 2011, 07:21:54 AM »
Wow nice progress Jeff.

When everything else fails, a big hammer always works!!!
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Offline ken

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #2 on: March 29, 2011, 08:57:06 AM »
You'll need to buy that Miata a beer when you're done with it- after all, it's old enough.

My Miata isn't exactly so great either, but I think it's mostly chassis flex causes a lot of the shaking.  I replaced the shocks soon after I bought the car, and it actually went OK.  The suspension in general on mine is really soft, and there is a lot of body roll, but even so it's amazing how quickly it changes directions compared to the GTI or A4.

I don't know if you follow Edmund's Inside line, but they bought a '97 M project car.   Actually 2 since the first '94 was rear ended by an SUV and totaled.   So far they've supercharged it, and put some coilovers and summer tires on.   It recently pulled over 1G on the skid pad- #2 between the ZR1 and Z06.

The really ratty '94 with 175K for $1700-  http://www.insideline.com/mazda/mx-5-miata/1994/long-term-test-1994-mazda-mx-5-miata-project-car.html

And the nicer '97 M with 125K for only $2000.  http://blogs.insideline.com/roadtests/2010/11/1997-mazda-mx-5-miata-project-miata-lives.html#more   
'10 GTI, Xenons, Dynaudio
'94 Miata C package- black and tan, Kosei K1's
Sold- '97 A4 1.8T Q, H&R, Bilstiens, '17 ACE Lola, Milltek/Borla, APR, Stern Power Ring

Offline Castle

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #3 on: March 29, 2011, 08:57:51 PM »
Very cool Ken.  Wish I had the $$ to buy some of the parts they are using.  I'm going with stock bushings which work really well for OEM, I had them in the Spec Miata I raced and they worked well there. 

I did have one major setback that I think will turn into the best decision I've made for the car so far.  I had originally ordered a set of Koni STR.T shocks to accompany the stock springs but those turned out to be on intergalactic back order.  The result of this is that I manned up and bought the KYB AGX with the 7 point adjustable dampening rate.  Makes me all tingly feeling just thinking about it. 

I know what some of you are thinking, yes I did say stock springs.  I was not dropped on my head as a child (at least not that I can remember), it was a decision based on a few problems.  The first problem is $$.  A new set of springs puts me back a buck and a half, money which need to go toward ball joints and tie rods.  I considered selling a kidney to help fund the project but I may need that avenue down the road a bit when forced induction comes into play.  The second problem is my driveway.  The day the construction crew set about pouring my drive must have been a Friday, the day after St. Patty's day and they were all still hungover and partially drunk.  The good news is that I have a driveway, the bad news is the angle they set is damn near verticle and nothing short of a 4x4 makes it in or out without a tooth cringing metal on concrete scrape.  And the third reason is a Michigan favorite....the potholes (nuff said).
'98 A4 1.8tqm named Jammer
'12 Veloster with style and 6 speed

Offline jaustin

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #4 on: March 29, 2011, 09:12:39 PM »
excited to see more... even with the thought of mine going for sale soon.
I own an audi

Offline jm

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #5 on: March 30, 2011, 04:26:24 AM »
If you need any advice I know a guy named frank who has a ton of experience wrenching go-karts -- may come in handy on the miata......

Sucks to hear about the driveway, you're talking about the transition from the driveway to the street I assume re: vertical?
München U-Bahn.  I'll be home soon M4DH4X.

Offline ken

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #6 on: March 30, 2011, 07:29:22 AM »
Jeff I have the adjustable KYB's on my Miata.  They are really easy to adjust with the dial. I'll be curious what you set yours at. 
'10 GTI, Xenons, Dynaudio
'94 Miata C package- black and tan, Kosei K1's
Sold- '97 A4 1.8T Q, H&R, Bilstiens, '17 ACE Lola, Milltek/Borla, APR, Stern Power Ring

Offline Castle

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #7 on: March 30, 2011, 12:27:18 PM »
Jeff I have the adjustable KYB's on my Miata.  They are really easy to adjust with the dial. I'll be curious what you set yours at. 

What springs do you have on the car? 

If you need any advice I know a guy named frank who has a ton of experience wrenching go-karts -- may come in handy on the miata......

Sucks to hear about the driveway, you're talking about the transition from the driveway to the street I assume re: vertical?

Yes the transition from street to house is rather abrupt.  With more than 2 passengers your car will scrape the exhaust!
'98 A4 1.8tqm named Jammer
'12 Veloster with style and 6 speed

Offline Ingostamus Maximus

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #8 on: March 31, 2011, 04:02:39 PM »
Nice progress, Jeff!  I don't recall you driving it in the winter -- or maybe you did before getting the A4?
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Offline ken

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #9 on: March 31, 2011, 08:45:44 PM »
I have the stock springs, hence the large amounts of body roll.   On the other hand it's a fairly comfortable ride which is nice.  My old roomate had the '94 Laguna Blue R and that had the stock Bilstein shocks with the stiffer R springs and that was very uncomfortable.   Plus no power steering which you would never notice until you need to slow down and turn.  His wife hates the car. 
'10 GTI, Xenons, Dynaudio
'94 Miata C package- black and tan, Kosei K1's
Sold- '97 A4 1.8T Q, H&R, Bilstiens, '17 ACE Lola, Milltek/Borla, APR, Stern Power Ring

Offline Castle

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #10 on: April 03, 2011, 11:39:09 PM »
Santa Claus pulled up in a brown truck on Friday and gave me a present.  The shocks have arrived and awaiting installation.  I may have to borrow someone's spring clamps however....a minor oversight on my part.



Here is the unusually large bolt that has become the bane of my existence.  Its hard to see in the pic but I've started to mushroom the end from continues blows from the BFG.  Cutting it seemed like a better idea however this process eats blades like they are a plate of hor'derves at fat camp.



The problem with working on such an old car is you never know what to expect.  I had hopes that the top shock bolts would be easy (something had to be, right?).  Negative.  As seen in this picture, the bolt is very much corroded and the 14mm socket wouldn't even fit.  Some PB Blaster and a wire brush helped solve that.



Much much more to discuss....a quick preview for the next post.

Topic: Why it is important to fully understand the complexity and scale of the project you are about to under go.
Chapter 1: Remembering to loosen the axle nut BEFORE jacking up the car and removing 50% of the suspension. 
Chapter 2: Proper use of the word F$%K
« Last Edit: April 03, 2011, 11:41:22 PM by Castle »
'98 A4 1.8tqm named Jammer
'12 Veloster with style and 6 speed

Offline francois

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #11 on: April 04, 2011, 06:05:44 AM »
That's OK Jeff, at least you'll remember for the next time ;D

You cans top by, I have a spring compressor if you'd like
http//www.classiceuroandrallycars.com

Offline SpeedyDTP247

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #12 on: April 04, 2011, 10:50:45 PM »
good luck with the suspension project. that'll be my next big project after my engine bay overhaul is finished

Offline Castle

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #13 on: April 08, 2011, 11:55:55 AM »
good luck with the suspension project. that'll be my next big project after my engine bay overhaul is finished

With all that new horsepower you'll be making you'll have to find a way to control it somehow!

Sadly its been too cold/rainy this week for me to convince myself to go into the garage and work on the car.  I'll have more updates this weekend as I attempt to get the rest of the car apart.  Good news is that a good friend of mine has purpose built plates for pressing Miata bushings so I'm having him do them.  I guess its easy to crush the bushing if you don't do it correctly. 
'98 A4 1.8tqm named Jammer
'12 Veloster with style and 6 speed

Offline SpeedyDTP247

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Re: The revitalization of my 21 year old car (sorry, not Audi content)
« Reply #14 on: April 08, 2011, 12:01:18 PM »
With all that new horsepower you'll be making you'll have to find a way to control it somehow!

Sadly its been too cold/rainy this week for me to convince myself to go into the garage and work on the car.  I'll have more updates this weekend as I attempt to get the rest of the car apart.  Good news is that a good friend of mine has purpose built plates for pressing Miata bushings so I'm having him do them.  I guess its easy to crush the bushing if you don't do it correctly.
thats for sure.

good thing i'm leaving in a few hours to get away from this cold rainy weather. listening to the news yesterday while i was at work, its suppose to get to the 70s on sunday. but hey its mi they cant preditct the weather 5 mins from now let alone a few days from now ::)