4.1mm drill bits & hub puller

More shopping… ordered a couple of 4.1mm drill bits (for the rivet holes) and a hub puller to remove the drive shafts from the hubs.

Starter Kit part identification

Spent some time trying to identify all the parts in the starter kit. Westfield provide a list but the descriptions are quite cryptic and do not always make it clear what the item is used for.





left (top to bottom): upper diff mountings; rear lower suspension
centre (top to bottom): front lower suspension; rear upper suspension
right (top to bottom): cycle wing brackets; front upper suspension; engine mountings (3 brackets); diff mounting; headlamp brackets (to right)

Here is the full list of items you get with the starter kit:

General
1 x MANUAL MAZDA-SDV
1 x CHASSIS PLATE 900KG
1 x WESTFIELD BADGE 50 S-A BLK-SIL
1 x WESTFIELD BADGE 25 S-A BLK-SIL

Chassis & Panels
1 x CHASSIS-SEIW MAZDA SDV EPX
1 x PANEL SET-SEIW 1800 IN-PENDANT
1 x TUNNEL TOP FRONT - MAZDA
1 x GRP-PEDAL BOX COVER MAZDA-SDV
1 x GRP-SAFETY BELT COVER

Engine Mounting
1 x ENGINE MOUNTING MAZDA RH MK2
1 x ENG MTG PEDSTL EPX OHC LH MK2
1 x ENGINE MOUNTING MAZDA LH MK2

Diff Mounting
1 x DIFF MTG BRKT LH-MAZDA SDV-EPX
1 x DIFF MTG BRKT RH-MAZDA SDV-EPX
1 x DIFF MTG BKT FRT-MAZDA SDV-EPX
1 x SLEEVE-FRT DIFF MTG MAZDA SDV
2 x BUSH-DIFFERENTIAL MTG

Other Mountings
1 x PLATE-G-BOX MTG-MAZDA SDV-EPX
1 x PLATE NOSE MOUNTING
1 x CYCLE WING BRKT MAZDA SDV LH
1 x CYCLE WING BRKT MAZDA SOV RH
1 x BRACKET-HEADLAMP LH EPX
1 x BRACKET-HEADLAMP RH EPX
2 x SLEEVE-DAMPER-MAZDA SDV
2 x SPACER-WING BRACKET-DAMPER PL
4 x METALASTIC BUSH MTG-W-SPORT-ZC
2 x STEER-G RACK EXTENSION-MAZDA

Suspension
2 x W-BONE-TOP FRT MAZDA SDV-EPX
2 x W-BONE-LOWER FRT MAZDA SDV-EPX
1 x W-BONE-TOP RH R MAZDA SDV-EPX
1 x W-BONE-TOP LH R MAZDA SDV-EPX
2 x W-BONE-LOW REAR-MAZDA SDV EPX
4 x BUSH-REAR UPRIGHT-MAZDA SDV
20 x SUSPENSION BUSH

Pedals
1 x ACCELERATOR PDL MK7 FMTD EPX
1 x PEDAL-CLUTCH HYDRAU FLRMTD EPX
1 x PEDAL-BRAKE FLOOR MTD MK6 EPX
2 x PEDAL RUBBER CLUTCH-BRAKE-BLK
1 x SWITCH-BRAKE LIGHT PRESURE M10
2 x BUSH-PEDAL PIVOT
1 x BUSH-STANDARD COMPONENT
1 x STUD - HYDRAULIC CLUTCH PEDAL

Brakes
3 x M10 X 1 FEMALE 3 WAY BRASS TEE
1 x BRAKE PIPE KIT 1800 INJ-1800Q
2 x HOSE-FRONT BRAKE SDV MAZDA
2 x HOSE-BRAKE SEi REAR
1 x MASTER CYLINDER BRAKE TANDEM
1 x CLEVIS-MASTER CYLINDER H.BRAKE

Accelerator
1 x ACCELERATOR CABLE-SDV MAZDA
1 x TRUNNION - ACCELERATOR CABLE

Clutch
1 x MASTER CYLINDER 075
1 x HOSE-CLUTCH SDV-MAZDA

Bolts-Screws-Nuts-Washers
1 x FASTENER KIT - SEI WIDE BASIC
2 x 5-16" HEX LOCK UNF NUT BZP
2 x 7-16" UNF X 4" BS1768 HT BOLTS
2 x STUD 7-16" UNF MAZDA SOV
1 x M5 X 8 CUP PT SKT GRUB SCREW
2 x M6 X 45 HEX HEAD BOLT P&P
2 x M6 X 1.0 NYLOC P TYPE PP NUT
2 x M6 T & CHAMFERED WASHER
6 x M8 X 30 HEX HEAD BOLT P&P
8 x M10 X 30 HEX HEAD BOLT P&P
12 x M10 X 1.5 NYLOC P TYPE NUT
1 x M10 2.0MM THICK COPPER WASHER
2 x M12 X 1.75 X 120 BOLT BZP HEX HD
2 x M12 X 1.75 X 100 HEX BOLT BZP
2 x M12 X 1.75 X 80 BOLT HEX HD
2 x M12 X 65 HEX HEAD BOLT P&P
2 x M12 X 1.25 HEX PLAIN P&P NUT
6 x M12 X 175 NYLOC P TYPE NUT
12 x M12 T&CHAMFERED WASHER
2 x M14 X 2.0 HEX LOCK S-C NUT
3 x SPLIT PIN 2DIA X 20MM
2 x CLEVIS PIN- 6 DIA X 20
2 x CLEVIS PIN-8 DIA X 20

Starter Kit Collection

Collected the kit today. Went to Westfield with a friend who has a Volvo estate.
Had a great tour round the factory and got loads of useful tips from the guys there.

Here is the kit ready for collection:


The chassis fitted quite nicely on top of the Volvo with all the other bits in the boot. The phrase from the Westfield guy was "it looks quite good on there".


All safely in my garage ready to start the build:

Start Kit Confirmation

Confirmed the collection date of the kit. As I am getting the body panels later, I can collect the kit using and estate car with the chassis on the roofrack. This will save having to rent a van.

Dismantling - Day 7

Attempted to remove the drive shafts from the hubs but couldn't get them to move, even after some brute force.


And there was no more clues from the back!


I will have to get a hub puller to get them off.

Changed tack and removed the steering rack. One clever trick to get the pins out is to hit the end of the casting really hard with a hammer. The pins just pop out.


Drained the brake & clutch fluid, removed the master cylinders and the last few bits and pieces in the engine bay. It's looking quite empty now!






Removed the fuel pump, filter, all the brake calipers and had the usual boot full of stuff to take back home:

Dismantling - Day 6

Started to remove the diff.

The drives shafts pulled out of the diff by removing the top bolts and pulling the hubs out:


Then by putting a jack under the diff to support it and removing the 2 main bolts and 4 bolts holding the supporting bracket:


Managed to lower the whole thing (with prop shaft still attached) to the floor:

Then removed the prop shaft from the diff:


A differential:


End of the prop shaft that attaches to the diff. I put one bolt back in the prop shaft and 3 in the diff mount so I would know which way the prop shaft aligns to the diff: