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Aaron’s FD RX-7: Bringing It Back

March 31, 2012 by Matt

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

Took a little detour today to pay a visit to my friend Aaron and his labor of love: A neglected/abused ’93 Mazda RX-7 Touring.

Aaron and I have both been rotary engine enthusiasts for ages, but he goes back even farther than me—his first car was an ’86 RX-7 GXL. His uncle was the car’s original owner, and he had replaced it with a 3rd generation car, giving his nephew rides and creating a strong sense of “someday…”

And after years of pining, Aaron finally picked up his erstwhile dream car a little less than a year ago. We’ll charitably call the seller a younger individual from backwoods West Virginia. He had festooned the car with diametrical opposite of everything that really fits the car’s character; a giant subwoofer box, huge rear wing, ugly body kit, heavy aftermarket wheels and a nitrous system pretty much kill all an FD RX-7’s innate “driver’s car” appeal, no mean feat. On top of all that, the car had sat immobile outside for several years before the seller decide to unload it. So Aaron got a deal, but had his work cut out for him in restoring the car’s luster.

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

The car’s in the process of being repainted. There was more than a bit of bodywork to address, mounting holes to fill, corrections here and there… Aaron’s waffling between the original Montego Blue and a brighter color such as Mazda’s later Innocent Blue Mica. One of the previous owner’s ugly wheels is visible on the left rear corner.

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

Due to the presence of, shall we say, malodorous organic material, Aaron ripped out the whole interior. One of the most daunting tasks will be reinstalling the dash and associated wiring harnesses.

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

Aaron fabricated an undertray and mounting locations for twin oil coolers, a modification designed to bolster the car’s reliability. Rotaries depend much more than a conventional engine on oil for their cooling requirements.

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

The lower intakes in the stock front fascia were enlarged to allow more airflow to the oil coolers, and front brakes.

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

Aaron’s “V-mount” intercooler solution. FD RX-7 engine bays are notoriously tight, and have a substantial amount of heat exchangers and ducting crammed in the tiny space, so some creative rearranging is often undertaken to allow everything under the hood to breathe better. As installed, air will flow through the front intake, some of it passing through the intercooler on its way out the vented hood, with the rest going through the A/C condenser and engine radiator and out underneath the car.

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

The condenser and radiator angled to accept air. It’s a rather ingenious solution.

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

Apexi RX6 ball-bearing single turbo in place of the stock twins. Not the largest turbo, but efficient and responsive.

Mazda RX-7 RX7 FD 3rd Gen Generation Montego Blue Touring Repair Restoration

I helped position the Autopower roll bar for marking, drilling and bolting into the body. It should stiffen the frame a bit and protect the driver, but Aaron’s not the shortest person and there are some outstanding concerns about seat travel, given the mounting location behind the driver’s seat.

Stay tuned for more updates as this project rolls along toward completion!

Filed under: Mazda, Rotary, Technical, Tinkering

4 Comments

  1. John D says:

    Awesome! Man I miss this…well, except for pulling out the dash…or messing with the intake manifold. I wouldn’t wish that on anyone.

    You can’t go wrong with Montego Blue, but the mica does have a bit of sizzle to it that will certainly get you noticed. I like both, just depends on what you’re going for.

    Of all the cars I’ve had, this one stands out. It is a true drivers car with tons of character and pretty much every attribute one could want in a sports car. Subtle, sexy, sharp, fast, responsive in every way and makes all the right noises. The list could go on. I know I’ll probably never have one again, but I love seeing someone ‘rescue’ a misused FD and build it back to what it could have/should have been from the factory.

    Way to go and please keep us informed!

    PS Aaron will never fit in there with a helmet on. Just ain’t gonna happen…

    • Matt says:

      Haha; yeah, I’m not really optimistic Aaron’ll be able to fit in there. He has enough trouble fitting in a stock car… Bolting the seat directly to the floor pan will be probably help, but you’re right; the helmet is going to be problematic. :)

      Will keep you updated for sure.

  2. Nick says:

    Nice to see you are turning it back into a drivers car once again! The blue mica is a good touch too, only seen one with my own eyes… Second best color to Chaste White though! ;)

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