Tuesday, October 22, 2013

Baby Steps

Continuing on with the whole mentality of small things that make a big difference, I've been slowly chipping away at some very small things just to make Tegan both nicer to be in and nicer to look at. The list seems to constantly change as I spend more time driving her... due to the fact I haven't had her for long it's been growing faster than it's been shrinking. Nothing serious, just small things as you find out what kind of life it has lived.


The motorised antenna is one of those things that is ultra cool as a 90's item... well, it would have been if it actually worked. I got reception, but the motor seemed to be incapable of making it extend and retract. Instead of replacing it with another option, I decided to take the opportunity to tastefully modernise it instead - with a small, stubby carbon fibre item off of eBay. Unfortunately these are typically designed for newer cars, with ideal installation times being in the order of 5 minutes as opposed to 5 hours... what can I say, I like a challenge :) Let's begin interfacing!


The first step was to mate the antenna cable to my new solution. I didn't want to ruin the original cable just in case I felt the need to go back to the factory solution, so I bought 1m extension cable that I could bastardise instead.


The next step was to work out how to attach it to the body using the existing hardware I had from the previous aerial. I ended up being able to make something work with a selection of rubber grommets, washers and nuts.


I crimped on a ring terminal and attached that as well so I could actually use it as an aerial. The old aerial actually screws in and is nice and secure - I lost the ability to secure it when I made the switch, so I had to improvise with what hardware I could salvage from the old aerial in the hope of making something that would work... Kwik Grip to the rescue!! At least that's what I thought... turned out it didn't bond as strong as I would have liked... Sikaflex to the rescue!!!


Quite a nice little update I'm sure you'd agree :)

Next on the list was the shifter and shifter boot. Given that it's something that my left hand is pretty much on the entire time I'm driving, it's something that needs to be comfortable, functional, and aesthetically pleasing for me. The old items were wearing pretty bad, with the shifter boot getting dangerously thin in some spots with cigarette holes in others thanks to a previous owner.


If you've never heard of Redline Goods, I suggest you educate yourself very quickly. They do all sorts of fantastic accessories for cars in terms of replacing items with leather, alcantara, suede etc. in any number of colours, patterns and stitching variations. They custom make for pretty much any car too! This little bad boy above cost me a grand total of $50 inc. postage from the UK - genuine leather with white stitching. If you consider you'd get a generic faux leather boot from Super Cheap Auto for $30, this is really not bad at all :) 


The glue holding the old boot to the bracket was that shot that it just peeled off - nice and easy, and no snapped plastic. I lined up the new boot, making sure the stitching matched the corners of the bracket, and waited for the glue to dry before pressing the two surfaces together. A heat gun made life a hell of a lot easier too, making the normally stiff leather become much more malleable.


Old vs. new... cannot argue with the results. The smaller shift knob works very well, as it gives you a lot more options when man-handling it. I did have to add the shift pattern sticker you can see down the bottom though... it's the law in QLD that you have to be able to see the shift pattern - so if you swap the knob to something that doesn't have one on it (like the old shifter on the left), this is the only option. Not the end of the world, but just something to keep in mind.


From here I moved onto the final step of the audio system - amping the speakers. If you spend good money on speakers you want to make sure they're being looked after - headunits can only give so much power, and aftermarket speakers generally need 2-4 times that amount of power to operate effectively. Unfortunately, amplifier mounting locations are pretty limited in the MR2... under the seat requires spending a lot of money on a slim-line amplifier. Behind the seats means you lose the ability to store the targa roof. You could put it in the boot, but it's a very long cable run as the battery is still in the front of the car, and all cables (including audio) have to run through the engine bay, not good at all. Next best option? In the frunk - it's sealed from weather, and has enough room to be useful for what I needed. It also means that I don't have to run any cables past components that would induce noise :)


I found a guide for mounting the amp in the frunk, and pretty much disregarded all of it with the knowledge that I could probably do it better... to be fair he was also going for a completely different setup, so I'm not being too arrogant here ;) Can't knock that it wasn't a good place to start though. I grabbed a piece of MDF from Bunnings and set to work sizing everything up. Measure, cut, test fit, trim, test fit again, trim again... etc etc.


The trickiest part was getting the MDF to sit flush with all of the different shapes and accessories in the frunk. I must have pulled the MDF out over a dozen times just to make sure I got everything sitting right.


Once I had it all figured out I set about painting it. You can get a bit of an idea of how much modification was required just by looking at all the different edges and what not along the front of that board. I also added 2 cut-outs to help with cable running.


In between coats of paint I set about starting the wiring. I've never pulled the plastics out before, and was absolutely amazed at all of the auxiliary systems that are housed up here! Yes it makes sense for a lot of them, but when you picture an engine in the back of the car you kind of picture everything else moving with it. 


As is always good practise, measure twice cut once - same rule applies with cables, especially when they're going to be cable-tied to a bunch of different components just so they're tidy. I will state at this point, I wanted to leave myself with enough cable length so that I could pull the amp out and access the spare tyre/battery without needing to disconnect anything.


Next up came the cable pull - never ever a fun job, but has to be done so might as well get on with it. I used an old wire coat hanger as an initial pull wire, taped the remote cable to that and taped everything else to the remote cable. This was going to be my pull wire once I found it on the other side of the car... The theory here is that I didn't particularly want to pull the entire coat hanger through, especially given how tight space is on the other side - you certainly run the risk of damaging something.


Yep - this position is always great for your back... Once I had the remote cable in hand I set about pulling everything else through. A few hiccups along the way but nothing a bit of wriggling can't sort out!


I was actually amazed at the space once I got the wiring through the firewall - was even able to get my full hand through the centre console to grab all the cables - nice! Not something you see every day... surprise!


From here it was a case of wiring everything into the headunit - splicing and soldering cables, none of this twist and tape business going on here... I am a professional after all! I had to do the headunit side of things first though, as I needed to make sure I had enough cable length to still be able to remove the amp without disconnecting...


... turns out I didn't. I had to cut 4 more sections of speaker wire and extend them. In the long run I'll look at re-running all the cables with single sections, just for the sake of quality and peace of mind. Light was running out though, and given how close I was to finishing it, this would have to do for the time being.


I also took the liberty of looming all the cables together - like I said, professional ;)


With the mounting board now dry I secured the amp to it, and set about wiring everything up. Man how I don't miss working under fluoro lights... Given that every single speaker wire was the one colour I had to mark all the cables with what they were connected to via a series of stripes marked with a Nikko. That little piece of paper you can see there was a life saver... e.g. 'II -> Grey -> Front Right'


While it was sitting up here I made sure I had enough cable length... evidenced by the fact that everything is connected up while the amp sits outside the car. Amp done!! Now to put everything back together...



Heck yes :) :) cannot argue with that! Cabling all out of sight, and it doesn't move thanks to the weight of the amp and the fact that it's held down by the radiator hose. Win!


Next comes the actual fun part... testing. First things first is to make sure everything is connected up correctly, i.e. that the front right speaker is actually the front right speaker. With that test done it was onto tuning and auditioning - and I really cannot argue with the results. I now have the capabilities to hear what's being played when I'm at full pelt on the freeway with the roof off and the windows down, woot!!!

Another thing that's been bothering me is a lack of functioning windscreen washers... try as I might I just couldn't get any water out of them. After checking that the water reservoir had water in it, I decided the pump must be at fault. 


I've got to say I'm learning very quickly that parts for these cars are a hell of a lot harder to find than they were for the Silvia... when I went to Global Auto Spares (read: absolutely awesome spare parts supplier), they didn't even have this part in their computer. Autobarn (read: hit and miss for spare parts) ended up coming to the rescue, although I still had to wait a couple of days to get one in.


To get to the washer bottle and motor, I would have to come at it from underneath the car. Holy plastic!!! It seems that there is a bash plate for absolutely everything under here =\


Given I'd only recently filled everything up, there was a fair bit to drain before I could pull it out... turns out this sucker took 2.5L! 


The photo doesn't really show it too well, but there was a lot of crap that dropped out with the water. I took the opportunity to give it a good flush before swapping the motor out and putting it all back together. Tested it again and - nothing. What the hell??? I had a closer look at the washer stalk and found another button that I'd never seen before... pressed it and voila! *facepalm* turns out the old motor could have been working all along, I just wasn't using it right. With most washer stalks, you pull the stalk towards you to engage the washer motor. Turns out in this car it just activates the windscreen wipers once - e.g. for a mist or that situation where you don't need them on fully. Ah well, at least I know I have a clean washer bottle and a fresh motor. At only $30, not a great loss at all.


The next thing I wanted to sort out was the Toyota badge on the backside of the car. Toyota colour coded them back in the day - while this was all good and well, the colour didn't fade as quickly on plastic as it did the rest of the car. Consequently, the paint fade was a lot more obvious (even though the photo doesn't show it) and as a result a bit of a sore thumb. We'd recently obtained some plasti-dip for the first time, and decided to give it a whirl as it would be perfect for what I was trying to achieve.


Take 1 - ignore this, I only put it in because I thought it was pretty rad =P I kind of rushed it the first time and stuffed it up completely, so I ended up having some fun with it for the sake of shits and giggles.


Take 2: not at night time and it was actually warm. I began by masking off the surrounding area, and went nuts with the plasti-dip. 30 minutes between coats, requiring 3-4 coats and a setting time of 4 hours... not the quickest of products to work with, but for those of you who don't know what it is, it's kind of worth it. Why did I paint the body as well as the badge?


Here's why: it just peels off - leaving no damage to the paint whatsoever. It also separates really easily from variations in surfaces, in this case leaving the TOYOTA black and everything else goes back to yellow :)


If at any point if I want to take it back to yellow I just peel it off, no harm done. That, ladies and gentlemen, is plasti-dip. People do whole cars in the stuff without requiring any prep, and just peel it off if they get sick of it. Not a bad product at all. At the very least it's made a massive difference to the ass end of the car, now matching the 'Toyota' logo with the 'MR2' logo colour wise. Yeah? Yeah.

While there are a few more things in the works, I'll save them for another time, as this post is already a tad lengthy. I've spent a fair bit of time focusing on little jobs that haven't cost a lot of money, all with the intention of slowly sorting things out one at a time... and while I don't necessarily care what other people think, I do believe that my car is most certainly a reflection of me, so yes aesthetics do come into it a lot. Coming up next is a few more bigger things to help the driveability and reliability of the car - stay tuned :)

Tuesday, September 24, 2013

A post of small things that make a big difference

My whole week was more or less spent counting down to when I could work on Tegan again. Now before we go any further, I know some of you aren't crash hot on the name, but to be honest that's not my problem :) Although for some reason, the numberplate 'TCP' has been given the acronym 'The Custard Pod'... for some reason that's sticking pretty well! Anywhoo I was only really able to drive her on Tuesday to get the rego swapped out and also to tennis, but practicality meant I had to use the X-Trail for the rest of the week... until I got to Friday :) Thankfully I had a pretty quiet day on so I decided to chuck just a couple of things into the boot and see what she was like in some stop-start driving on my way to the office in Brisbane.


While the boot isn't massive there is still a boot. This photo doesn't really do it justice - there's room for 2 sets of golf clubs in there. There's also enough room for my backpack, some tools and some test equipment so I'll call that a win!


Content is how I'd sum up the above picture :) Yes selfies while driving is a heaps bad idea, I know that... but the moment was too good to not share. Driving to work on a sunny Friday morning with the roof off, hells yeah!! I will say the drive home was stressful though, it's stressful at the best of times because people seem to be in too much of a rush to drive sensibly - let alone when you're in a tiny car with pretty average visibility. But... worth it.

Saturday rolled around, and before I could do anything my first stop was supplies. Car mats and a clay bar kit was on the shopping list...


... $450 later I also had some plasti-dip, wheel paint, a replacement light for the boot and new speakers (front and rear)... freaking whoops! It was not my intention to get any of that, but there was a sale on and I saw lots of things that were going to be fun projects and... yeah, no excuses. Naughty me. Kind of screwed myself financially for the rest of the month. Calm down Clinton, you've got time... 

All stupid-ness aside, the speakers I knew were going to happen at some point. The old ones sounded absolutely rubbish, and after having a track car that couldn't be streeted, I wanted a street car that I could occasionally take to the track. The car so far has felt pretty damn good mechanically, so I wanted to improve my personal driving enjoyment in another way, by starting off with the audio. Autobarn had an awesome sale on some banging speakers, and back from my days of being young and dumb playing with car audio, I knew it was going to be a case of quality gear or nothing at all. With a price drop from $400 to $270 on the front speakers alone, I couldn't let that go unnoticed.


Even though the MR2 is only a 2 seater, they still manage to fit in front and rear speakers. Admittedly the rears are only little 4" drivers, but they do a decent enough job of giving you a bit more fill.


At least Toyota were kind enough to give me front splits - makes getting quality audio that little bit easier, and in a manner that doesn't require cutting holes in things to get everything to fit!


I thought the terrible sound quality just came from cardboard cones. While I was kind of right, the problem stemmed from something a little bit more dramatic... the rubber surround that attaches the cone to the body of the speaker was no longer - you can see what's left of it on the ground next to the it. She ain't gonna be making any noise ever again! You can see the difference in quality here though... just a little upgrade ;)


The tweeters required a little bit of tweaking - the old one on the left and the new one on the right. While there was a bracket there I could use, they of course had completely different mounting solutions. Nothing a pair of engineers couldn't fix though, after about 30 minutes of experimenting we had a solution that meant we didn't have to change a thing.


Here's the whole door wired up - woofer, tweeter and crossover all put into factory mounting holes without fouling on anything, yew!!! The woofer did require a little bit of screwing around as the speaker basket ran too close to the edge of the speaker, so we had to space it out so it would actually fit in the door. Turns out there was a bit of wood we could salvage from the old speaker that did the job nicely! We even managed to mount it using the factory mounting holes... Most factory audio speakers mount using 3 bolts, yet most aftermarket speakers use 4. Joys of using good quality gear, we could make it work with 3 which meant no drilling into the door. WIN!


Someone was a little bit bored while we were doing this though... not looking at anyone (Casey).


Best bit is you'd never even notice there's some decent speakers behind that door card. I unfortunately didn't grab any photos of the rear speakers but they were most certainly an upgrade from the factory solution and fit with only a few small modifications, nothing a drill and a screwdriver can't handle. Overall result? Massive improvement :) Certainly need to look at adding an amplifier to get the most out of them but I can definitely live with it for a while.


Sunday we decided to finally get into the paint. It was faded, and although the previous owner looked after it very well we suspected he didn't use the best quality products to do it - something that can actually have a significant impact on the condition of the paint. Regardless, before starting anything, the car needed to be washed! I used dishwashing detergent, as most good quality car washes now add protection to the paint which we didn't want. I must say, not a bad car to wash! Nice and small :)


This is why I got wheel paint - in spite of putting a lot of elbow grease into the wheels some stains just wouldn't come out. I suppose 20 years of road dirt will do that.


We started off by claybar-ing the car. For those that don't know, this is a wonderful little invention that when rubbed against the paint (with some detailing spray for lubricant) it works at pulling all the surface dirt off the car. This was just off a quarter of one panel... yep we had a lot of work ahead of us. What's probably most amazing is that the car didn't look dirty at all, yet this still came out of the paint.


This is what we were dealing with - quite a significant colour difference between different panels. We knew the paint would be faded, but we also suspected that a fair bit of the discolouration was coming from hazing in the clear coat. We set about rectifying it as follows:
  • Meguiar's Professional Grade Swirl Remover 2.0 (Cut)
  • Meguiar's Professional Show Car Glaze (Polish)
  • Meguiar's NXT Generation Tech Wax 
Needless to say we love Meguiar's products, although there are a few Turtle Wax products we use quite liberally, such as their tyre black and foam applicator pads. Anyways I digress!! 4 hours later we had ourselves one very nice feeling surface, which actually brought out a fair bit I must say! 


The photo doesn't really show it but you'll notice that the bonnet in this photo is nowhere near as dull as the photo above. Yes it's not the same yellow as the bumper, there's several other areas where the difference is just as obvious if not more, but overall the difference in colour is a lot less noticeable than it was before - more graduated if you will, so I'm going to call that a success :) I'd be inclined to say that that's something I can deal with for a couple of years at least.


The wheels got done in a Metallic Graphite colour, which actually has a really nice fleck to it in direct sunlight. I tried to mask off the rubber, but there was that much grime in the rubber that no amount of masking tape was going to stick. I ended up deciding to wing it and just attacked the hell out of it with paint thinners, which while it was a bit more involved I achieved the same result in the end.


The interior carpets are in awesome condition, and a very nice-feeling carpet at that being a cut plush pile. Unfortunately there's a hell of a lot of wear near the drivers feet, and this isn't something I can justify replacing all the carpet for, especially when the rest of it is almost like new. That and I also haven't had any luck finding any (just for curiosities sake).


Nothing some universal floor mats can't fix :) Not the best fit of course, but they'll do the job!


I also wanted to replace this pathetic excuse of a boot lamp. It sits up there in the left corner and would be lucky to throw out the same amount of light as a tealight candle.


LED strip to the rescue! FYI it is white, not blue like the photo shows. Due to the shape of the boot there weren't many places I'd be able to hide it, so I ended up going with at the back under a recess in the carpet. Sure you can see it in this photo but honestly how many times would you pull something out of the side of the boot? Certainly throws a lot more light, so I'm happy :)


I then turned my intention to the interior. I could tell the previous owner loved his Armourall products, simply by feeling how much grease was engrained into the various interior panels. I'm not going to say Armourall products are bad, I'm just saying that there is a hell of a lot better out there. Proof? This rag contains all of the product I was able to lift from the panels, which was then replaced with some quality stuff. Same look, but a much better finish. There was also twists in the seatbelts that had been bugging me ever since I got the car, so 30 minutes, some silicon spray and a hell of a lot of determination finally got the both of them sorted!


Yep. Much, much, much better. And to think all we've done is chuck some elbow grease into it both inside and out, and a fresh coat of paint onto the wheels - what a difference it has made :) I've still got to black out the front indicators to match the black stripe down the side of the car, but all things being equal this will be it for quite a while - spent too much money recently and now need to just recover and pay off some of that debt on the credit card!

Mind you, now we've actually had a chance to pull things properly apart we have a better idea of where everything stands. The next thing will most certainly be brakes. The pads don't have much meat on them, and the rotors are in dire need of being machined. But I did have the pleasant surprise of finding twin pot callipers up front and vented rotors front and rear, so that's a win :) Just needs a bit of work to stop the squeaking and squealing that goes on when it's cold.

Next update will probably be a while off, but stay tuned! I'm going to be busy enjoying :)