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Exocet Update 7: Reassembly

  • Jan 1, 2025
  • 21 min read

Putting things together isn't as easy as taking them apart.


With the Exocet frame mated the the powertrain, the list of things to-do greatly expands and the path of progress becomes non-linear. Things to do include (the list below is not exhaustive):

  • Foundation Brake System:

    • Mount front brake soft lines to frame (both sides)

    • Create front brake hard lines (both sides)

    • Secure any loose lines to the car

    • Mount brake booster vacuum line

  • Secure, fasten clutch line

  • Mount engine bay components:

    • Intake and Mass Air Flow sensor (MAF)

    • Exhaust Gas Recirculation (EGR) sensors

    • Fuel tank emission recirculation sensor

    • Power steering (P/S) reservoir

  • Close the cooling system:

    • Mount radiator

    • Plumb coolant system including a heater core delete

    • Install a coolant overflow reservoir

  • Close the fuel system

    • Install fuel tank

    • Route fuel soft lines at the rear of the car

    • Install a fuel filter in the fuel send line

    • Attached soft lines in the engine bay

    • Route a rollover valve and fuel vent system on the fuel tank

  • Install the steering column and gage cluster

  • Clean up battery wiring harness at rear of car

  • Reinstall the donor wiring harness

  • Install a functional exhaust before starting the car


Some of the above items were straightforward reassembly of donor components. Others needed unique solutions to complete. Challenges we faced and our design choices include:

  • The frame was powder coated already meaning we did not want to weld mounting points for things to it:

    • We used split clamp tube mounts of various sizes to create a mounting point where needed on the frame, these are commonly sold for ATVs and UTVs to mount lights and other accessories to their tube frames

    • Placement of the mounts needs careful consideration so that the mount can be removed if needed (try not to place the mount where you cannot access the hex key cap head bolts holding it together)

  • There is no front brake soft line mounting point, the soft lines much be mounted so at full steering lock, they are not in tension or are not rubbing suspension/chassis components:

    • Multiple ideas and iterations of designs were tried before we found a solution using split clamps and fabricated brackets that worked and also allowed clearance for installation, modification of other components, and attachment to hard lines

    • We needed the car in the air with wheels on to turn the wheels lock-to-lock and verify that tension wasn't on the lines and they didn't rub the front A-arms or chassis

  • The rear bulkhead of the Exocet is within a few inches of the rear subframe (there is significant clearance on the donor Miata):

    • The rear parking brake cables will rub against the frame and there is no design consideration for mounting them so they rest on the driveline if not supported

    • The rear subframe brake splitting block is almost against the rear bulkhead making a traditional hard line impractical, we used a banjo bolt and braided line (custom) to attach the rear split block to the rear hard line coming from the transmission tunnel

    • Specific, thicker crush washers were needed to install the banjo bolt on the rear split block

  • The steering geometry is different between the Exocet and donor Miata:

    • We had to use a vice grip and dead blow to extend the splined column (that sits in the engine bay)

    • We had to use a metal pipe fitted over the column while it was rested steering wheel down on cardboard, hit with a dead blow, to properly fit the column between the firewall and dash cross member mount

    • A small corner of the header heat shield was trimmed away to clear the column in the engine bay

  • The engine bay is much tighter between the shock mount points, the height of the Exocet hood is much lower, and the radiator mounting point is 3+ inches closer to the engine than in the donor Miata:

    • The OEM intake box does not fit at all in the Exocet

    • We used a cone filter clamped to the nose of the MAF, a specific size is needed to fit between the header heat shield and shock tower

    • The intake mounting needs to consider that the MAF and intake filter need to be fixed between the header and shock tower

    • The power steering lines interfere with the OEM NA Miata hard line and soft lines for the lower radiator connection, a Flyin' Miata NB style hose cut down slightly was able to clear the P/S equipment and subframe

    • Any items mounted in the engine bay had to be low enough not to interfere with the hood, this includes the radiator which must be mounted in a very specific location for the 1.8L style air intake (this may not be the case for the 1.6L style intake), see the next point

  • The clearance between frame members at the front of the Exocet is minimal, placing the radiator mounts is very restricted by clearance for drills / rivet tools:

    • We used a 90-degree drill bit extension to drill the rivet holes for the supplied mounts

    • We mounted the supplied upper radiator mounts in the middle of the front frame square member so we could gain enough clearance to drill the holes, install rivets, and install the fastener to hold the radiator

    • This required us to design and fabricate mount extensions on the radiator to reach the mounting points on the frame, this also required us to modify the radiator to install these mount extensions

    • The radiator placement is dictated by the intake and upper radiator hose location, on the 1.8L intake the upper radiator hose will contact the intake with the radiator closer in the car - mounting the radiator in any other location than where the upper hose clears the intake will result in non-assembly and you will have to redo all of your radiator mounting

      • One of the most tedious parts of this process was mounting the radiator, it must be located in a specific way and failure to do so will cause other assembly problems in the future - it is highly recommended you chose an aftermarket radiator and use this to start as you may create more work for yourself in the future if you reuse the OEM parts

  • The frame clearance to the shock mounting point is minimal on the Exocet frame:

    • While it is stated by Exomotive that NA style shock top mounts (top hats) fit, ours did not at the front - there may be variation in aftermarket mounts that cause slight interference with the upper tube member

    • We had to use NB style shock top mounts that came with our Flyin' Miata V-Maxx coilovers

  • The Exomotive shock spacers require modification to install:

    • Some of the fastener holes butt up to weld beads, we ground corners off weld beads to make clearance for the bolt heads

    • The rear spacers cannot be assembled without cutting fasteners down in length, careful trial and measurement is needed to cut just enough off without going too short

    • Bolts need to be inserted into the rear spacers before placing them on the frame or installing the shock, otherwise there is not enough clearance to install them


Time Prepping Donor: 11.5 hours (06/11/2023-08/28/2023)

Total Teardown Hours: 45.75 hours (08/29/2023-11/04/2023)

Total Exocet Build Hours: 148.5 hours (11/07/2023-09/05/2024)

Total Hours on Project: 205.75 hours (9/5/24)


Exocet Build Journal:

01/27/2024 - Paul

 - 12:15PM Start

- Unclipped items zip-tied to engine, transmission

 - Installed vacuum tube between intake & brake booster

 - Installed Lizard-Go clamps on driver side for visualization of next steps

 - Visualized / conceptualized to-do items:

 - Engine bay coolant line routing, fuel line routing, radiator location

 - Brake line routing to front calipers

 - Measured existing braided front brake lines against Flyin' Miata set (FM is 2" longer)

 - 2PM End

 - 1.75 Hours of Labor


02/04/2024 - Peter, Paul, Sam

 - 9:45AM Start

 - Unpacked Mishimoto Aluminum radiator, test fit by hand

 - Verified intake, coolant rout clearances with radiator in position

 - May need to cut coolant hoses shorter

 - May need to reroute intake tubing (vacuum lines)

 - Removed front wheels, installed Flyin' Miata braided lines

 - Utilized Cardboard Aided Design (CAD) to develop multiple brake line brackets

 - Discussed brake line routing options with different brackets

 - 12:30PM-1PM Break for Lunch

 - Iterated more front brake brackets; fabricated x2 brackets from sheet aluminum

 - Unwound and rerouted battery wiring harness (running along PPF)

 - Reattached PPF ground (termination of negative battery terminal wire)

 - Began stripping fittings and brackets off main wiring harness; save all brackets

 - 3:30-4PM break

 - Installed final iteration of bracket; damaged bracket (torn radius in bend) during install

 - Discussed bracket design, tested functionality by turning the wheels by hand

 - 4:15PM End

 - 5.5 Hours of Labor


02/07/2024 - Peter

 - 9:30AM Start

- Completed final iteration of brake bracket for front brake soft to hard line mount

 - Fabricated brackets out of sheet aluminum

 - Installed front sway bar fasteners

 - 11:30AM End

 - 2 Hours of Labor


02/10/2024 - Peter, Paul, Sam

 - 2:30PM Start

 - Test fit rear brake banjo bolt + braided line for distribution block

 - Test fit parking brake cables to check for clearances to foundation brake lines

 - 3-3:15PM Break

 - Test fit steering column firewall bearing - does not fit (did not expect it to)

 - Test fit clutch line, vacuum line (intake to booster)

 - Finalized front brake brackets

 - Using coat hangers, bent driver side brake hard line dummy to estimate length needed

 - 5:30PM End

 - 2.75 Hours of Labor


02/11/2024 - Peter, Paul

 - 8:45AM Start

 - Installed driver, passenger front brake brackets on Lizard-Go clamps using M10 fasteners

 - 9AM-10:30AM Break

 - Adjusted brake retainer clips (existing from donor) in bench vice (more bend)

 - Installed front brake braided lines (no torque)

 - Bent driver side front brake hard line, flared line, installed into car (no torque)

 - Discussed passenger side front brake hard line routing

 - Noon-1PM Break for Lunch

 - Installed M5 Rivet Nut in firewall on passenger side for brake line P-clip

 - Bent passenger side front brake hard line, flared line, installed into car (no torque)

 - Positioned vacuum tube between intake and booster, marked bolt hole locations on frame

 - Drilled hole for clutch line P-clip rivet into existing bracket on vacuum booster line

 - Installed x2 M6 Rivet Nuts in driver and passenger firewall for vacuum line mounting

 - The firewall in the driver's footwell is too thick for a Rivet Nut

 - The rivet nut in the driver's footwell is held in place by the squeeze outward (press)

 - Installed vacuum tube, riveted clutch line w/ P-clip to the vacuum tube bracket

 - Doubled P-clips on the clutch and brake, riveted them together to create a line spacer

 - No torque applied to anything at this point

 - 4PM End

 - 4.75 Hours of Labor


02/15/2024 - Peter, Paul

 - 3:30PM Start

 - Installed Flyin' Miata rear braided brake lines; did not install new banjo / washers

 - Banjo bolt is too long in Flyin's Miata rear brake split block

 - 4:30PM-6PM Break

 - Disconnected front sway bar

 - Attempted to install shock spacers, top mounts on coilovers do not fit

 - 6:30PM End

 - 1.5 Hours of Labor


02/18/2024 - Paul

 - 30 minutes

 - Measured dimensions on rear brake split block, banjo fitting

 - Determined we need either a shorter banjo bolt or thicker crush washers

 - 0.5 Hours of Labor


02/25/2024 - Peter, Paul

 - 9:30AM Start

 - Measured Flyin' Miata rear brake block, banjo fitting, crush washers

 - Determined that a 1.5mm crush washer should meet our needs

 - Discussed rear brake routing around parking brake, suspension, subframe

 - Test fitted radiator, reviewed mounting options; place hood on car loosely

 - Estimated clearance to hood: 3" above top cross member, 6.5" below bottom member

 - Unfastened line mounts, dropped lines down and double P-clipped fuel lines under car

 - Fitting parking brake cables into chassis, hand tightened at calipers, inserted retainer clips

 - 1PM-3PM Break

 - Remounted fuel lines in rear of car

 - Cut, flared fuel lines in front and rear

 - Discussed fuel filter placement

 - 4:30PM End

 - 6 Hours of Labor


02/27/2024 - Peter

 - 9:30AM Start

 - Cut & formed spacer for drive pedal assembly to firewall

 - Cut one end at an angle to match firewall

 - 11:30AM-1PM Break

 - Drilled hole in firewall for M6-25mm fastener to pass through spacer

 - Coated bare metal hole with black paint as RP

 - Ground spacer to match gap and angle, installed hand tight into car

 - 2:30PM End

 - 3.5 Hours of Labor


03/03/2024 - Paul

 - 8:30AM Start

 - Installed grommets on upper radiator mounts

 - Test fit intake, air filter box does not fit

 - Disassembled intake filter box, removed air flow sensor component

 - Create mount using fastener points on this component later

 - Test fit radiator, will require alternative mounting design

 - Measured Banjo Fitment on rear brake block

 - Test fit banjo on rear block using normal, copper crush washers

 - Utilize thicker crush washers if necessary

 - Test fit steering column (engine bay half), works with bearing/grommet from donor

 - May need to cut back heat shield on header to clear column

 - Double P-clipped fuel lines at engine bay terminus to provide structure

 - Removed rear coilovers from car

 - 10AM End

 - 1.5 Hours of Labor


03/04/2024 - Peter

 - 12:30PM Start

 - Unbox and assembled Flyin' Miata V-Maxx Coilovers

 - Assembled front coilovers; need spring compressor for rears

 - 2:15PM End

 - 1.75 Hours of Labor


03/11/2024 - Paul

 - 8PM Start

 - Installed front coilovers - no torque on anything

 - 8:30PM End

 - 0.5 Hours of Labor


03/12/2024 - Peter

 - 1PM Start

 - Fabricated fuel filter bracket

 - 2 Hours of Labor


03/17/2024 - Peter, Paul

 - 10:30AM Start

 - Assembled driver rear coilover

 - Top hat studs interfere w/ rear shock spacer bolts

  - Cut shock top mount studs

  - Cut mounting bolt

 - Assembled passenger rear coilover

 - 12:30PM-1:15PM Break

 - On second coilover, cut top mount studs; cut mounting bolt

 - Loosened both rear sway bar end links

 - Installed both rear coilovers loosely

 - Removed front spacers from car; ground out weld that hits flange nut on mount stud

 - 2:15PM-3PM Break

 - Reinstalled front spacers

 - Loosened both front sway bar end links

 - Applied Torque to Shock Spacer Mounting Fasteners:

 - Shock Spacer to Chassis:

 - M8 w/ Lock Nut: 25 lbf-ft

 - Bolt Head = 12mm; Nut = 13mm

 - Marked w/ Yellow Paint Pen

 - 3:45PM-4:30PM Break

 - Cut new M8 flange bolts for the rear shock spacer mount

 - Reinstalled rear shock spacers

 - Applied Torque to Shock Spacer Mounting Fasteners:

    - Shock Spacer to Chassis:

        - M8 w/ Lock Nut: 25 lbf-ft

        - Cut Bolt Head = 13mm; Nut = 13mm

        - Marked w/ Yellow Paint Pen

 - Note: Bolts turned upside down so that torque can be applied to nut

 - Hand tight using wrench on all top mount nuts

 - Reattached sway bar end links

 - No torque applied to any bushings that were loosened

 - Set front coilover height to 8.5"; rear to 5"

 - Measured from center of bottom bushing mount to underside of spring perch nut

 - Installed wheels, torqued lug nuts to 76 lbf-ft

 - Reset front coilovers to 9" (weight of wheel caused suspension droop)

 - Removed car from lift, placed on ground; put car on dollies

 - 6:30PM End

 - 5.75 Hours of Labor


03/19/2024 - Peter, Paul

 - 1:30PM Start

 - Modified fuel filter bracket to protect top edge from interference

 - Added padding to bracket

 - 2:45PM End

 - 6:45PM Start

 - Setup radiator on blocks for support

 - Measured clearances between radiator and hood using borescope and tape measure

 - Removed wood, radiator; measured hood clearances to frame

 - Placed radiator on floor jack for adjustment, checked clearances with adjustments

 - 4"-5" of clearance at top; 7" below

 - Cut aluminum plate to create x2 brackets for top radiator mount

 - Bent aluminum brackets, drilled holes

 - Mounted brackets to radiator

 - 9PM End

- 3.5 Hours of Labor


03/24/2024 - Paul

 - 10:15AM Start

 - Marked holes on radiator brackets, radiator itself

 - Drilled holes on radiator for mounting brackets

 - Drilled holes in brackets for mounting to radiator

 - 11-11:30AM Break

 - Attached brackets to radiator, using floor jack, positioned radiator

 - Measured and marked hole locations on brackets for M6 rivet nuts

 - Attached upper radiator hose and air intake, remeasured everything checking clearances

 - Cut radiator brackets to length

 - Installed M6 rivet nut on radiator brackets

 - Drilled out Exomotive top mount radiator bracket for rivets (#11 bit)

 - Drilled out driver side holes in frame for bracket rivets

 - Lowest hole is difficult to reach, damaged powder coat; hole is off position

 - 2PM End

 - 3.25 Hours of Labor


03/26/2024 - Peter, Paul

 - 5:30PM Start

 - Drilled x6 holes for top radiator using 90 degree DeWalt drill attachment

 - Still had to open up the holes on the bottom for each side

 - Drilled Exomotive bottom radiator brackets for rivets (#11 bit)

 - Painted all holes in brackets & frame with rust preventative black paint

 - Riveted top Exomotive radiator brackets to frame

 - Hung radiator from top mounts on Exocet

 - Put Exocet on 2-post lift

 - Marked spot for bottom brackets on the Exocet frame

 - Drilled holes first on the square frame tubes, then the round frame tubes

 - Used bracket to center bit on round tubes - good enough, not perfect

 - Finished drilling all lower radiator mount holes in the Exocet frame

 - Marked radiator mount position drilled hole on the lower bracket

 - Painted all frame holes and bracket holes with black paint

 - Riveted bottom brackets in place on Exocet frame

 - Installed bottom radiator mounting fasteners to finish radiator mounting

 - 8PM End

 - 2.5 Hours of Labor


03/28/2024 - Peter

 - 10:15AM Start

 - Laid wiring tray onto Exocet frame, marked all hole positions for M5 rivet nuts on frame

 - Drilled all holes in the Exocet frame, painted, installed M5 rivet nuts

 - Installed wiring tray using M5 button head (allen key) bolts

 - 11:30AM End

 - 1.25 Hours of Labor


04/07/2024 - Peter, Paul

 - 10AM Start

 - Removed rear wheels

 - Removed gas tank

 - Tightened rear parking brake cables at calipers

 - 11:15-11:30AM Break

 - Bent, cut, flared rear brake line end previously installed on the frame

 - Attached rear brake braided hose to brake hard line using fitting and union

 - Installed banjo bolt to attached braided hose to rear split block closing rear brake line

 - NO TORQUE ON ANY BRAKE FITTINGS

 - Reinstalled rear wheels

 - Installed wiring tray; wiring tray top does not fit (poor kit design)

 - Tried cutting radiator hose for lower radiator connection - did not work with stock hoses

 - 1PM End

 - 2.75 Hours of Labor



04/08/2024 - Peter, Craig, Paul

 - 8:45AM Start

 - Cut exhaust manifold (header) heat shield for steering column clearance using dremel

 - Installed lower steering column (engine bay)

 - 10AM-1PM Break

 - Loose fit upper steering column (passenger cell half with steering wheel)

 - Fabricated power steering reservoir bracket using tube clamp mounts and angle aluminum

 - Need to extend lower steering column - sprayed with PB blaster

 - Discussed how to mount emissions equipment on the passenger side engine bay

 - 7:30PM End

 - 7.25 Hours of Labor


04/28/2024 - Paul

 - 3:30PM Start

 - Test fit Flyin' Miata NB lower radiator hose

 - Trimmed lower radiator hose to prevent rubbing in engine bay

 - Installed lower radiator hose loosely (5/16" socket for hose clamps)

 - 4PM-5PM Break

 - Installed heater core delete line (Gates P/N 19666)

 - Needed band hose clamps (5/16" socket on back of engine PITA)

 - Tightened hose clamps on lower radiator hose; installed compression clamps on upper

 - Installed overflow tube to radiator and then to Mishimoto overflow tank

 - Loosely installed split tube clamp mounts onto frame to hold overflow tank

 - Mocked paper bracket to hold tank to clamp mounts

 - 5:30PM End

 - 1 Hour of Labor


05/05/2024 - Peter, Paul

 - 4PM Start

 - Using vice grips on lower steering column, hit with dead blow to extend column

 - Pushed bushing in on upper column using socket over spline end (expose spline end)

 - Installed entire steering column (upper and lower) loosely

 - Upper column angle is off, Exomotive supplied mounts do not sit flush

 - 4:45PM End

 - 0.75 Hours of Labor


05/07/2024 - Peter, Paul

 - 1PM Start

 - Fabricated coolant overflow tank bracket

 - 3PM-4:50PM Break

 - Bent, cut bracket to finalize for overflow tank

 - Installed coolant overflow tank (no torque on fasteners)

 - 6:50PM End

 - 4 Hours of Labor


05/11/2024 - Peter, Paul

 - 2:30PM Start

 - Installed steering column, gage pod bracket loosely - discussed mount angle

 - Discussed how to mount emissions equipment in engine bay on passenger side

 - Cut fuel soft fuel lines using PVC pipe cutter

 - Mounted emissions equipment using split tube clamps and angle aluminum

 - 4PM End

 - 1.5 Hours of Labor


05/19/2024 - Peter, Paul, Craig

 - 12:15PM Start

 - Installed soft fuel hose from filter to feed hard line

 - Installed soft fuel hose from return hard line to tank

 - Wrapped soft fuel line in convoluted wiring harness shielding to prevent rubbing

 - 12:45PM End

 - 0.5 Hours of Labor


05/29/2024 - Peter, Paul

 - 7:15PM Start

 - Placed upper steering column, wheel down, onto cardboard

 - Clamped upper column split section crimp with C-clamp

 - Placed aluminum tube over spline shaft end of upper column (against outer tube)

 - Used wood on other end of aluminum tube and dead blow to compress upper column

 - Fitted upper column into car - angle is better but mount isn't quite flush

 - Cranked down fasteners on upper column mount, things sitting flush enough

  - Steering does not bind; column sits a slight angle (send it for now)

 - 8PM End

 - 0.75 Hours of Labor


06/01/2024 - Paul

 - 9:30AM Start

 - Loosened top bolt on alternator (12mm)

 - Bottom 14mm pivot bolt on alternator is locked (maybe seized - didn't try too hard)

 - Loosened alternator tensioner bracket, replaced bracket M10 bolt on engine

  - Used M10 x 1.25 bolt and washer

 - Installed all alternator bracket bolts, hand cranked everything with tensioner set

 - Alternator never shifted due to lower pivot bolt, did not check belt tension

 - 10AM-11:45AM break

 - Added 5mm split lock washers to split tube mount clamp fasteners as needed

 - All clamp fasteners have lock washers

 - 12:30PM End

 - 1.25 Hours of Labor


07/05/2024 - Paul

 - 3:45PM Start

 - Installed intake & MAF sensor

 - Created mock cardboard bracket for MAF

 - Cut last fuel line hose, need final compression clamp (13-12mm)

 - Tried to fit rollover valve filter, need different fuel hose

 - Attempted to mount gage pod, need M4 hardware

 - 5PM End

 - 1.25 Hours of Labor


07/10/2024 - Peter, Paul

 - 6:45PM Start

 - Reviewed next steps for air filter, intake bracket, gage pod, radiator fan

 - Reviewed items needed (coolant, P/S belt, compression clamps, fuel line)

 - 7:15PM End

 - 0.25 Hours of Labor


07/13/2024 - Peter

 - 10:15AM Start

 - Fabricated extended P/S reservoir and intake mount L-bracket

 - Created mock cardboard bracket for MAF

 - 12:30PM End

 - 2.25 Hours of Labor


07/14/2024 - Peter, Paul

 - 8:45AM Start

 - Designed multiple iterations of an intake mount bracket with cardboard

 - Created radiator fan top mount for Mishimotor 12" fan

 - Cut M4 fasteners to mount gage pod

 - Mounted gage pod

 - Mounted radiator fan from top of radiator

 - 11:15AM-2:15PM Break End

 - Created lower radiator fan mount

 - Added rubber reinforcement stopper to coolant overflow mount

 - Final intake mount mock up with cardboard

 - Cut pieces of intake mount bracket out of flat aluminum

 - Bent, riveted together intake mount bracket

 - Installed intake bracket and mounted intake with air filter (see links for filter used)

 - 7:30PM End

 - 7.75 Hours of Labor


07/27/2024 - Paul

 - 2PM Start

 - Tried 3/16" ID fuel line on fuel tank rollover valve (does not fit, need slightly larger)

 - Designed retention bracket for front brake braided lines from cardboard

 - Installed split tube clamp mount on rear of car for fuel tank vent termination point mount

 - Attached fuel tank filler neck

 - Designed fuel tank filler neck bracket (temporary) from cardboard

 - Designed engine bay electrical relay box bracket from cardboard

 - 3:15PM End

 - 1.25 Hours of Labor


07/30/2024 - Paul

 - 5:45PM Start

 - Installed 1/4" fuel line on tank rollover venting barb, installed 1/4"-5/8" barb at end

 - Installed UP-101 fuel vent breather filter

 - Replaced short ground on back of engine (dipstick mount) with 15" ground wire

 - 6PM End

 - 0.25 Hours of Labor


08/01/2024 - Peter, Paul

 - 1:30PM Start

 - Fabricate engine bay fuse box bracket

 - 3:30-6:30 Break

 - Placed front passenger bulkhead (will need trimming) to ensure fit with other components

 - Marked holes for fuse box mount in frame

 - Drilled and installed M6 rivet nuts, installed fuse box mount

 - Installed fuse box in engine bay on passenger side

 - 7:15PM End

 - 2.75 Hours of Labor


08/17/2024 - Paul

 - 12:15PM Start

 - Installed and tensioned power steering belt (4PK-860)

 - Attempted to tension per the Haines manual - just gonna send it

 - Tightened P/S mounts (x3)

 - Installed wire tray with engine ground

 - Laid out donor car wiring harness on the floor preparing for install

 - 1:45PM End

 - 1.5 Hours of Labor


08/19/2024 - Peter

 - 11:30AM Start

 - Laid main wiring harness onto car

 - Began stripping tape & protective wraps off wiring harness as needed

 - 2:30PM End

 - 3 Hours of Labor



08/25/2024 - Peter, Paul

 - 9AM Start

 - Identify Wiring Harness Grounds (1996 Donor - may be different for other MY):

 - 1: Dash, Passenger Side, Cut (need to add connector)

 - 2: Dash, Driver Side, Cut (need to add connector)

 - 3: Ground bus, driver side firewall

 - 4: Engine Block

 - 5: Ground bus, dash area

 - 6: Passenger Footwell (Unique End)

 - 7: Passenger Footwell (second ground)

 - 8: Battery Harness

 - 9: Passenger PCM Ground

 - 10: Driver Side Door Harness

 - 11: Trunk Harness Ground

- Created shopping list of connectors and wiring needed to ground everything

 - Idea is to create x2 bus bars (front, rear) and ground everything to the battery itself

 - 9:45-11:30 Break

 - Cut flat steel to create bus bars, installed across rivet nuts for wiring tray

 - Created ground wire to bridge front and rear bus bars

 - Attached all grounds to bus bars

 - 12:45-1:30PM Break

 - Attempted to install throttle cable - too short!

 - Put car on the lift, used wire brush to clean header exhaust flange

 - Attempted to fit stock catalytic converter, does not fit under the Exocet

 - Attached battery, turned ignition to ACC & ON, dash lit up w/ airbag light

 - All lights appear to work (based on lights on dash)

 - Disconnected battery

 - 4PM End

 - 4 Hours of Labor


08/27/2024 - Peter, Craig, Paul

 - 2PM Start

 - Review wiring diagram printouts, test fitted tail lamps and their function

 - Laid out internal fuse box wiring

 - 5:30-6:30 Break

 - Tightened clutch line fittings

 - Filled and bled clutch line (DOT4)

 - Visually verified that clutch pedal disengages the clutch

 - Hooked up battery, verified reverse, brake, turn signals are functional with lights

 - 8PM End

 - 5 Hours of Labor



08/28/2024 - Peter

 - 12:30PM Start

 - Stripped tape, clips, shields from wiring harness inside interior

 - 2:45PM End

 - 2.25 Hours of Labor


08/29/2024 - Paul

 - 7:30PM Start

 - Test exhaust straight pipe (Spec Miata cat delete)

 - Cutoff mid-pipe hangers to fit under Exocet frame

 - 8PM End

 - 0.5 Hours of Labor


09/02/2024 - Paul, Samuel

 - 10:30AM Start

 - Loosely fitted exhaust

 - Filled cooling system with ~2 gallons of 50/50 coolant

 - Installed fuel tank, wrench tight

 - Hooked up front and rear fuel lines to the hard lines

 - 1:15-2:45 Break

 - Installed 90-degree bent on tip of mid-pipe (no muffler) to direct exhaust

 - 3PM End

 - 3 Hours of Labor



09/05/2024 - Pete

 - 11:30AM Start

 - Continued removing wiring harness tape and plastic

 - Organized spare electrical component and fasteners

 - 2:30PM End

 - 3 Hours of Labor


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