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Learning how to build Lotus Seven replicas...together!
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PostPosted: September 24, 2023, 5:15 pm 
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Location: Boise, Idaho
I'm helping a friend put an upgraded powertrain in a Bugeye Sprite he recently obtained as a roller. After discussing the goals and some options, it was decided to use an early 90's Mazda BP 1.8 liter DOHC mated to a Miata NB 5-speed. The engine came out of a '92 Protege.
Both of these were found reasonably close to us and the trimming began until it fit (just like several of you have been doing with MGB's). The engine position was settled and mounts were made. Then an exhaust system was created beginning with a 4 into 1 header that was split by the steering column. Since the shift lever ended up in ones armpit, a remote linkage was fabricated to a more comfortable location. The cooling system entails an aftermarket aluminum civic radiator, a 60's Mustang 6-cyl gooseneck and lots of hose bends coupled with aluminum tubing for the upper hose. One of the bends that I purchased based on a picture and the filter of 1.25 inch ID ended up being perfect for the lower hose. :D
Engine controls are going to be done by a used Electromotive TEC-S from E-bay. I wasn't able to find a used DFU coil pack to go with it. However, one of the reasons for selecting this engine is the stock dizzy driven off the back of the exhaust cam. I figured at a minimum, a Bosch dizzy could be adapted. After some digging, a system made by Pertronix was found that fits a Bosch 009 distributor with just the sensor in the abbreviated "cap" and a twin tower coil pack. A 60-2 trigger wheel was adapted to the crank pulley and a holder for the mag sensor was made.
The fun continues.


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Last edited by seven13bt on September 24, 2023, 7:30 pm, edited 1 time in total.

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PostPosted: September 24, 2023, 5:28 pm 
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Location: Wilson, NY
Very cool! I will be following with much interest. I always enjoy your work and posts.

I’m putting a ‘99 Miata motor and transmission into a ‘57 MGA right now. My gearshift ended up almost exactly where the stock one did in my installation.

Cheers,
Eric

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PostPosted: September 24, 2023, 5:41 pm 
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Hi Eric,
The 14 inch difference in wheelbase would explain that. I'll have to join the MG site to catch up on your project. :cheers:

Ron


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PostPosted: September 24, 2023, 6:09 pm 
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seven13bt wrote:
Hi Eric,
The 14 inch difference in wheelbase would explain that. I'll have to join the MG site to catch up on your project. :cheers:

Ron

Hi Ron,
I’m sure you are right on that :)! I always loved the bugeyes. That little Sprite is going to fly.

A word of warning on my project thread it’s kind of long, it also includes a complete restoration. Getting closer though as I’ve started painting.

Cheers,
Eric

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PostPosted: September 25, 2023, 12:27 pm 
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Location: Guadalupe, CA
This is fun! I was just parked next to 2 bugeye Sprites this past Saturday at a local event.. cool little cars. It will be fun to follow along as you get this up and running with the Mazda drivetrain..

Eric's build with the Mazda/ MGA marriage is extensive.. these little Mazda lumps seems to work well as a donor.. It's a path I'm considering for my next build, but I'm hesitant as I find the electrical/ engine harness adaptation task to make it run standalone intimidating..

Please keep us updated on this little sweetie.. Looks fun :cheers:

--ccrunner

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PostPosted: September 26, 2023, 4:53 am 
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I have a large stack of spare rear axles, cheap.
You will be needing a few.

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PostPosted: September 26, 2023, 2:56 pm 
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ccrunner, I'll spend more time detailing the standalone installation. The TEC-S is a bare-bones, 4-cyl only unit. I use inputs for crank position, throttle position and manifold pressure.

Richard, Thanks. It's good to know you are a source for the axles.

Ron


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PostPosted: September 29, 2023, 9:28 am 
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Luckily, you're a lot closer to Richard than I am.

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PostPosted: November 19, 2023, 3:40 pm 
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The drivetrain installation is complete. Now it's on to the electrical systems.


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PostPosted: November 20, 2023, 7:05 am 
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Looks great! Very clean. What can you tell me about the ceramic/silica cloth, foil backed insulation?

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Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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PostPosted: November 20, 2023, 8:36 pm 
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Hi MV8. Thank you. The product is DEI Floor and Tunnel Shield. It's 3/16 inch thick and self-adhesive. It works great as a heat barrier.

https://www.summitracing.com/parts/dei-050501


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PostPosted: December 5, 2023, 6:08 pm 
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Finally got to make some noise. It wouldn't run with the separate ignition system. Even though the ECU could see the engine rpm, It wanted to see the ignition system. I found a used 4-cylinder DFU on eBay and that made it happy. No-load tune is acceptable now. Have to get brakes working and fresh tires on it before load testing it. Still lots of aluminum panels to make for the center gage panel, radiator ducting, master cylinder cover, air box and firewall behind the seats.

https://youtu.be/5jbXCly-x5Q


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PostPosted: December 5, 2023, 6:38 pm 
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Yahoo, it’s alive! Congratulations :cheers: Sounds good
-Eric

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PostPosted: December 5, 2023, 7:31 pm 
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Nice gauges. Dancing steering wheel bolts! :cheers:

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Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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PostPosted: December 5, 2023, 9:29 pm 
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Eric, Thanks

MV8, The gages are from VeeThree Instruments. The dancing bolts are the current quick release steering wheel setup. Thighten the nuts and it's not so quick.

:cheers:


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