Jeff's Technology Weblog

Finally, an easy job!

Putting in a fuel sample port is required under the SCCA general competition rules (GCR). I did this quick task the other day and found it to be relatively easy task. I got my kit from SafeRacer ($80!!), but you can also pick it up from MiataCage.

The only gotcha in the process was that the kit didn’t include the proper number of hose clamps. It was two short which necessitated yet another trip to the local auto parts shop. One of the things I’ve found frequently with auto parts is that parts rarely include any needed, related items like gaskets and washers, so I find myself running to the local Kragen, AutoZone, or NAPA Auto Parts way too often.

With any project requiring fuel line modifications, it is crucial to check for leaks afterwords. You don’t want any nasty surprises when the engine is hot and there is a risk of a fuel fire. I’m trying to get in the habit of carefully monitoring for both fuel leaks and even brake line leaks since I’ve done a lot of work of both of these recently.

Anyway, here’s the final installed product:

Removing all the non-essential items from the interior of the car was yesterday’s big task. It was surprisingly more difficult than expected. I probably spent about 4-6 hours gutting the interior.

The hardest part of all was removing the dash. There are many bolts and wiring harnesses to undo, airbags to deactivate, and instrument panels to remove. These all add up to make it a tedious process. In my case, there was also the addition of an aftermarket alarm wired into the system to complicate the removal picture even more.

Interior with Dash Still In

During the gutting process, I also had a major battle with one of the seat mounting bolts. This one particular bolt refused to give way for: a) an impact wrench, b) an impact driver, and c) bolt removal kit. I finally got it out with some liquid wrench and drilling. I probably should have started with the liquid wrench. But this is one of those lessons that is learned the hard way. This project is full of these opportunities.

There is no question that patience is required during dash removal and mine was finally rewarded with a undamaged dash sitting alongside the car and an interior ready to be de-grimed.

Dash, Carpet, and Seats Removed

Once the dash was out, then it was time to put it back in! Normally, this wouldn’t be done until the roll cage is installed. But I’ve got to drive mine to the installer, so I did a re-install. It went back in much more easily than it came out.

Dash Re-installed

Anyone doing this project themselves would be advised to: a) be very patient, b) thoroughly review the relevant sections from the Mazda Miata Workshop Manual. The manual isn’t perfect and isn’t’ always as detailed as I’d like; however, it generally covers the main points and sequences for removal/installation.

Last night, I tried changing out the fluids in the brakes, transmission, differential, and engine. I got 3 out of 4 done but could not get the fill plug off the transmission and had to let that one go until another day. The bolt is on solidly and won’t give way. I’m going to let some Liquid Wrench soak in and give it another try tomorrow.

Fluid-wise, I used Ate Super Blue for the brakes, Redline 75W90 for the differential, and Mobil-1 10W30 for the engine. Afterwords, I continued cleaning up oily bits of the chassis and engine — focusing on the differential, brake lines, oil pan, and area around the oil filter. I’m doing this partly to make it easier to spot any leaks but also because working in all the dirt/grime drives me crazy.

Finally, I also installed new towing hooks, a radiator screen, and changed out the fuel filter.The fuel filter was a serious pain. The “quick” release fittings on the fuel lines are VERY hard to disconnect. What finally worked for me was to use some surgical clamps I use for electronics work. With these, I was able to more easily squeeze the release tabs.