Roll cage construction under-way

DP MIATA BUILD AND BACKGROUND
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Other photos, click here

Chassis: Purchased new in 2001. Current weight is 2015#, class limit 1997#

Engine used - core from 2000 1.839L BP engine not VVT or VTCS equipped

Engine prep outline:

High Compression naturally aspirated fully engineered and designed

Head - ported and polished
Valves - stainless steel nitrided oversize back-cut and undercut
Cams - custom grind on new blanks, high-lift moderate duration and overlap
Stiffer valve springs, after-market titanium retainers and 'under bucket' shim setup
Pistons - custom designed and engineered JE
Rods - Carrillo A Beam
Toda Kevlar cam timing belt (expensive!)
Crankshaft - lightened/knife edged, micro-polished, cross-drill plugs removed, cleaned, tapped and plugged
All 5 billet main caps
2001 main-bearing support plate, new pan and windage tray to match
ARP main and head studs
FM adjustable cam sprockets
Cams properly indexed
Billet motor mounts
Custom fabricated torque arm(s)
Intake - TWM new generation individual throttle bodies, new injectors and sensors
Engine management - Haltech EK6, MSD DIS-2 ignition (new spare) with Chevy coils, TPS, IAT and Water temp sensors
In-car Air-Fuel Ration Meter by ECM...the best available...NTK Oxygen sensor
Electric Davies Craig water pump (new spare)
Running "constant loss" hence - no alternator or water pump driven off engine (or power-steering pump). Utilize Odyssey PC2150 large battery in passenger compartment
Bore is 1mm/.040" over
Clutch - 5.5" double disk Quartermaster with aluminum pressure plate and custom throw-out bearing
Flywheel - Aluminum
Header - Boig with custom 2.5 and 2.25" exhausts. 2.25" with twin resonators and muffler for San Diego. 2.5" with one rear muffler for other events. Headers are ceramic coated by Jet-Hot.

Chassis:

Brakes - Stock 10" fronts, oversize LS 10.9" rears (spare larger front LS brakes) spare stock pads
Twin stock fans installed and operated by the engine management computer at any determined temperature, with override
2" thick aluminum radiator (new) with custom ducting for hotter weather, stock radiator currently in use for quicker warm up
Stock 5 speed gear-box
Torsen differential with lower gear ratio (4.875)
Aluminum Koni 3012 custom double adjustable shocks with Eibach ERS coil-over springs, heim jointed bottom, TEIN pillow-block tops
Delrin control arm bushings with brass inserts (no rusting)
Fiberglass fender flares from Japan
5 gallon fuel cell in rear...stock tank removed. Twin fuel filters one before and one after the fuel pump. Fuel pressure regulator
Aeroquip hoses for fuel and oil
Remote oil filter in passenger compartment (Chevy race filter)
Accusump oil accumulator with pre-start manual valve
All new AutoMeter gauges
Quick release steering wheel
Kirkey race seat
Simpson belts and harness (new spares)
Substantial stiffening of the chassis with the roll cage design. Integrated jacking points
Inner and outer fender modifications for tire clearance
Ballast hopper in passenger compartment able to hold 150# of lead shot
Currently, the car is 24# heavier in the rear than the front (better than 50/50 weight distribution) when ballasted
New control arm eccentrics
New 5th and reverse gear lockout mechanism (see: updates for photos)

Some Build Photos:

Fender flares are Tuckin '99 from Japan...took 3 months to get...in the process of making molds for resale.

CHASSIS CONSTRUCTION AND CAGE BUILD PHOTOS

Note: headers were subsequently ceramic coated since photos above...

Other details:

Electric Davies Craig water pump and custom programmed Electric Water Pump Controller

Running "constant loss" hence - no alternator or water pump driven off engine (or power-steering pump) . Had installed the alternator while sorting out running problem and during second dyno run. Now running with large battery constant loss.

Battery - Odyssey PC2150 http://www.odysseybatteries.com/battery/pc2150.htm

Header - Boig with 2.25" collector - ceramic coated and 2.5" exhaust after 2.25" collector. Have spare 2.25" lower dB exhaust with twin resonators and muffler for quieter venues

ECM - Air/Fuel ratio meter and gauge and NTK oxygen sensor
http://www.ecm-co.com/afg100ac.asp

Wheels - are Pro-Race 2 hub-centric 7X15 with Hoosier Cantilever 9.5 x 23-15 slicks.

Brakes - are standard Miata fronts and LS larger rears with stock pads

Shocks - are Koni 3012 custom built aluminum double adjustable, shortened 1" front/ 3/4" rear.

Springs - are Eibach 900# front 600# rear (changing to softer springs for slicker black-top surfaces...probalby 700/450) - no rear sway bar, Racing Beat 1.25" front with 3/16" wall tubular and Polyurethane bushings on racing brackets and custom made adjustable end links with welded support on lower control arm

New Delrin bushings on all control arms

Steering rack is modified power-steering rack made manual for quicker ratio with properly removed valves and plugged

Momo quick release steering wheel, custom shimmed to eliminate play and slop

Aluminum pedal covers and dead pedal

Carbon fiber hood (custom built skin with light stiffening)

Custom radiator shroud

Be-Cool race aluminum large capacity (2" core) radiator/now running stock radiator - warms up quicker with stock fans

Rear head exit water-flow (custom routing for better cooling) as in original engine design (rear mechanical thermostat) and custom plenum.

1/4" intake manifold insulator

Cold air intake through front right headlight to air-box

Modified rear control arms to take out negative camber. Moved upper rear control arm pivot point out 3/8"

Custom rear sub frame support with integrated tie-down loops.

Ignition info

Cam angle sensor info