04

 

 

MIatabusa adaptor first cut

 
  The clutch cover adaptor, hewn from a solid brick of aluminum, will hold our flywheel shaft and help locate the bellhousing adaptor.    

 

  Miatabusa covers  
  The original clutch cover, on the bottom, and the starter gear reduction box, on top, both have to go. The starter gear reduction box sticks a full 2.5 inches off the block, and leaving room for it would push the engine way too far forward.  

 

  MIatabusa case waiting for adaptor  
  With both parts removed, you can see the delicate castings we're trying to transfer this load through. The gear on the right is bolted directly to the nose of the crankshaft, in case you're disoriented.  

 

  MIatabusa adaptor clutch cover installed  
  The clutch cover adaptor in place. The raised lip in the middle helps locate the bellhousing adaptor. The angled face of the clutch cover is a damn frustrating feature of most modern sportbikes. If it were flat, this whole thing would be much easier to make.  

 

  MIatabusa adaptor bellhousing plate  
  Tim designed the plates to fit together very precisely, needing just a single, determined whack with the deadblow hammer to get the plate seated on the alignment ring and the two dowels on the crank nose flange.   

 

  MIatabusa adaptor bellhousing side  
  In the end, we'll have a hardened steel shaft poking its head out here, but for the test fit, it's all hollow. Note the ring of bolt holes on the right. These are the ones serving double duty sealing the nose of the crankcase, and resisting the engine's torque output.  

 

  MIatabusa engine installed  
  Success! Tim's prodigious design and fabrication experience paid off in a part that fit together perfectly on the first try. Unbelievable!  

 

  MIatabusa hood clerance  
  Even our hood clearance estimates, which consisted of tape measures and squinting, turned out to be right on. There should be no problem keeping the valve cover and throttle bodies clear of the hood.  

 Now don't let all this success make you think it's all easy from here out. Far from it. There are a number of hurdles left for us to tackle, but we've got plans in place for almost all of them.

  MIatabusa engine tilton starter  
  First, the starter problem. When we eliminated the Hayabusa starter, we had hoped to use the Miata one instead. Turns out it's simply too huge, though. The Tilton starter mocked up here in the SolidWorks model would fit, if they still made it. Sadly, it turns out to have been discontinued. We'll find something soon.  

 

  MIatabusa subframe interference  
  Next up us the subframe, a problem we identified early on. The oil sump sits so far forward in this configuration, that it desperately wants to occupy the same space as the subframe. As it sits here, the subframe is just starting to hit parts of the engine, but look at the top of the tape measure. The subframe is a full 4 inches from the frame rail it's supposed to bolt to. None of the commercially available subframes will clear our engine, strangely. Not even the ones designed to clear an LS1. We've got a subframe design that will work, and we'll be forced to build it ourselves.  

  

  MIatabusa engine front  
   The offset mounting should actually work out well, helping to counterbalance the driver's weight. It also leaves plenty of room for a turbo over on the driver's side, if we can just get the exhaust over there to it. Speaking of exhaust, that's problem #3. There were daydreams of the factory Hayabusa header somehow fitting in the car, but there simply wasn't room. A custom header is being designed as we speak to wrap around the front of the engine. The header should simultaneously extract some power that Suzuki surprisingly left on the table, and end in a perfect location for the turbo we'll someday put in here.  

 

 

All the Miatabusa you can handle:

   

 

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Comments
8695Beaters
8695Beaterslink
Saturday, July 03, 2010 7:01 AM
So in a drag race, which will win? The Metro-Gone, the Angry Hamster, or the Miatabusa? Or how about in an autocross? Or the 24 Hours of LeMons for that matter? Super cool stuff, nobody in Super Street has the balls to try stuff like this.
Jasonrg77
Jasonrg77link
Saturday, July 03, 2010 8:02 AM
The only way this would be cooler is to put the Suzuki in a Suzuki! It must be awesome having access to supercomputers and CNC machines...
brainrush
brainrushlink
Saturday, July 03, 2010 8:11 AM
It looks like it's shaping up real well! I love the methodical approach and can't wait to see the end result!
Fly'n_Z
Fly'n_Zlink
Saturday, July 03, 2010 8:57 AM
I'm pretty sure the only supercomputers in use are in Tim and Dave's heads. In any event, this is an awesome project! Looking forward to part three.
538
538link
Monday, July 05, 2010 3:44 AM
Very very awesome!
Dusty Duster
Dusty Dusterlink
Monday, July 05, 2010 5:42 AM
You know, I was wondering where Dave Coleman, automotive Geek of Geeks, had gotten to after leaving Sport Compact Car. I'm glad to see he's still dreaming up completely ludicrous projects.

This car is going to be sick.
brainrush
brainrushlink
Monday, July 05, 2010 8:11 AM
why not ditch the starter all together and rely on push-starts? That seems to work fine for 410 modifieds. jk
vehicular
vehicularlink
Monday, July 05, 2010 8:54 AM
Wicked gangster. I wanted to do this, as well, but keep the bike trans, with one of the super indestructible drag race gearsets, and take enough weight out of the car to keep it alive. Who needs reverse anyway?
nul
nullink
Monday, July 05, 2010 9:40 AM
Dave, you are missing the obvious. Remote mount the starter and make the output shaft of the starter longer. Done it many times. You could mount it way back next to the tailshaft (good for weight distribution) or shove it way forward. Depending on the length of the shaft, you may have to support it in the middle.
8695Beaters
8695Beaterslink
Monday, July 05, 2010 9:52 AM
How about a fourth pedal for a kick starter?
OMG Its Weasel
OMG Its Weasellink
Monday, July 05, 2010 10:48 AM
a kick starter would be hilarious. especially for a LeMons car, if thats what this is going to become.
Mike Kojima
Mike Kojimalink
Monday, July 05, 2010 11:12 AM
I think the Tilton starter is an old Nissan or Hitachi part. Nissan probably discontinued it so Tilton can't get it.
tyndago
tyndagolink
Monday, July 05, 2010 11:15 AM
Make it a hybrid with a stop/start alternator/starter. BAS(belted alternator/starter and BAS plus. Then all you need is like - a couple hundred pounds of batteries.

Love it, cool project. Still needs a turbo.
Fly'n_Z
Fly'n_Zlink
Monday, July 05, 2010 12:39 PM
Per Mike's comment on the starter being an old Nissan or Hitachi part... if that's the case some cross-referencing might be in order to find out what car model(s) it came on and then it could be sourced from an autorecycler/junkyard.

However if the idea is for the complete kit to be comercially available one day then that idea wouldn't really fly :(
Blue-Civic-Hybrid
Blue-Civic-Hybridlink
Monday, July 05, 2010 8:47 PM
Holy crap, I need to become an apprentice for you guys.
Nick
Nicklink
Monday, July 05, 2010 9:09 PM
Go fast or suck!!!!

This is so absurd and ridiculous there's nothing bad to say about it.
niky
nikylink
Monday, July 05, 2010 9:43 PM
Long-time lurker here (former NPM reader and NFer... yo, Mike!)... gotta say... when you guys build something, you BUILD something... I've seen some wicked custom-fabs on this site, but that clutch cover has got to take the cake!

So... when are you selling the transplant kit?
Dave Coleman
Dave Colemanlink
Monday, July 05, 2010 10:29 PM
Wow, Steve (M-Workz), I've never heard of anyone doing an extended-shaft remote mounted starter. Where have I been?

I'm still holding out hope that there is a small enough starter out there for us. I've been looking at japanese mini trucks lately. Getting warmer...
JDM'ized
JDM'izedlink
Tuesday, July 06, 2010 2:08 AM
Awesome little project Dave. How about torque though?.....a fully gutted Miata can get as low as 1900 lbs....it needs torque......turbo maybe?
As far as small Japanese trucks, check this site:
www.garageminiz.com
Good luck with your project.
Fly'n_Z
Fly'n_Zlink
Tuesday, July 06, 2010 7:31 AM
It's mentioned right in the article that they're eventually planning a turbo. The first step though really needs to be to get it running.
Nick
Nicklink
Tuesday, July 06, 2010 9:38 AM
Why don't you guys just make a pull starter :-P
Eric Hsu
Eric Hsulink
Wednesday, July 07, 2010 12:24 AM
Didin't the Mazda 10A have a tiny ass starter? I remembered saying, "whoa dude, now that is small." Dave just go into the Mazda museum and jack one.
rsmotors
rsmotorslink
Wednesday, July 07, 2010 8:46 AM
@ Dave the mini trucks idea is a good one, but something I thought of when this project started was why not use parts from the cappuccino? I plan one day to either import one completly or just drop the motor from one in the Miata (the turbo set-up sounds to good to pass on). Love the project and can't waiti see the end results. And on a side note I was an avid reader of SCC and was reading the build up of your AE and the last issue I ever got was kinda a cliff hanger about your suspension tweaking, is there and more reports on how it ended up?
OMG Its Weasel
OMG Its Weasellink
Wednesday, July 07, 2010 7:26 PM
i would like to say something kind of unrelated-related to the main article.
i am really happy that mazda still holds automotive enthusiasm in high regards.
i am glad that there is still an auto manufacturer that holds a meet and greet for their quirky little "girls car" that has a cult following, and embracing the engineering that goes into a properly modified vehicle.
its not everyday, especially with the economy the way its been, that large corporations transcend their banker imposed limitations to hold events for people who are loyal to their brand.
you dont see GM hosted Camaro Days, or Ford financed Mustang Corrals.
i commend you Mazda. thanks for being all that is right in corporate-customer relations.

dave, i too would like an update on that AE project from way back.
Jeff Naeyaert
Jeff Naeyaertlink
Wednesday, July 07, 2010 8:03 PM
Really? Looks like GM is putting some pretty good $$$ into their annual LSX Shootout:

2010 GMPP LSX Shootout

In fact, this year they're "celebrating the 5th gen Camaro"

over $50k in prizes. I'm not hatin' but looks a lot bigger than a parking lot party at Mazda HQ ;) Hopefully it will be better than their lame sevenstock events where you can't bring your RX7 in if it has a V8, yet you can bring your vehicle of any other make provided it has a rotary... stupid rotards. ;)
Dave Coleman
Dave Colemanlink
Wednesday, July 07, 2010 8:46 PM
AE project? What's an AE?
rsmotors
rsmotorslink
Thursday, July 08, 2010 11:22 AM
The Corolla projecy lol sorry about that. You where working on the valving of the suspension the last I read.
speed freak
speed freaklink
Thursday, July 08, 2010 4:17 PM
I have a zx14 powered Miata that I have 3/4 of the way built. Since the 14 motor is much stronger and the transmission is tons stronger. I didn't need to do all the drive line silliness. Plus there is not the huge power loss and weight gain with the giant Miata transmission. My other zx14 powered cars have put down right at 190 to 198 RWH. This one is going to get a turbo to help break the silly mark of 300 hp. I have to admit that I made almost all the parts but Muzzy and Schnitz have helped me source all the common performance pieces, as well as some cool one off stuff to. It will be run in NASA in SU or STR1 depending on the configuration and hp of the final setup.
Dave Coleman
Dave Colemanlink
Saturday, July 10, 2010 10:39 PM
RS Motors, the AE project was Jay Chen, not me.

Speed Freak, how about a link? Pictures, or it didn't happen...
TLRracer
TLRracerlink
Sunday, July 11, 2010 1:27 PM
An amazing project!
My kudos to the team with the smarts to even think about something like this. I can't wait for a finished product. Lotus Super 7 clone here I come - what an awesome powerplant and transmission - both bulletproof and proven.

Dan Barnes
Dan Barneslink
Sunday, July 11, 2010 1:51 PM
Summit is your friend for mini starters.
949Racing
949Racinglink
Sunday, July 11, 2010 2:31 PM
When it comes to time to put wheels on it..
speed freak
speed freaklink
Monday, July 12, 2010 12:17 PM
I've tried to post here but they must be to large so I will put them on my facebook and have an update today.


bildojuice
bildojuicelink
Tuesday, July 13, 2010 6:56 PM
There is a waaay easier way to do this. I Put a GSXR in a 81 corolla a few years back. get a driveline adapter and go straight to the rearend. you lose reverse gear, but its an easy way without machining and getting crazy with the tranny/bellhousing. I race cars called dwarf cars, and they have this set-up. for more info call me, I sell the adapters. 7756907223 billy
bildojuice
bildojuicelink
Tuesday, July 13, 2010 6:57 PM
oh, and with that set-up, you use the bike starter.
bildojuice
bildojuicelink
Tuesday, July 13, 2010 9:49 PM
driving the rerarend off the right side(clutch cover side) wont that make the car go backwards? with all the rearend ive done this to, the rearends are clockwise. this ones gonna be counter-clockwise. The adapter I mentioned replaces the counter sprocket. I'm excited to see how this turns out. You guys are actually making parts with CNC. I didnt have that much money to do mine.
Ian
Ianlink
Tuesday, July 20, 2010 11:18 AM
"Speaking of exhaust, that's problem #3. There were daydreams of the factory Hayabusa header somehow fitting in the car, but there simply wasn't room. A custom header is being designed as we speak to wrap around the front of the engine."

Damn. This means there won't be a way to do this and make it street legal in CA. :(
Jeff Naeyaert
Jeff Naeyaertlink
Tuesday, July 20, 2010 12:06 PM
the exhaust is pretty much the least of their concerns if they wanted to make it legal... CARB won't allow you to put an engine from a different vehicle "type" into another (e.g. truck engine into a car). Even if they were able to get around that, you are also required to use the same transmission as the donor vehicle which ain't happening here either.
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