Harry's Project Banana!

For you to showcase what you've done to your car and give other members ideas and inspiration.
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Re: Harry's GL04 MXU Project Banana!

Post by goodeggbob »

It's good to see another elderly vehicle with minimal corrosion, maybe we could share ideas on how to keep it that way, rob.
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

I'm sure you know more tricks than me ;) I see the Vactan already in your sills and probably going to get a bunch of a "fluid film" type on the rest of it, job's a goodun! Or at least, it'll go a long way to keeping them in good nick :D
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

So! Today was a busy day. Not too many photos as I was just cracking on :lol:

Day started with digging out my spare manifolds i've collected from previous engine block purchases and picking the best one that had the least rust on the mating faces and SAI studs/bolts. Managed to crack one nut off the SAI pipe no issue, but the other one rounded. Thankfully the ol' "hammer the lower size socket onto it" trick worked out well =D> 9mm socket may well not be the best anymore, but hey - are there actually any 9mm bolt/nuts that are used? [-X [-X :giggle: more than happy to use as a potentially sacrificial socket.

Got the driver's engine mount and bracket off with the engine resting on a block of wood on axle stands, O2 sensor installed into the manifold (pain in the butt to get that connected without taking the UIM off!), new SAI blank on from RRP with the new gasket they provide with it, and on the block it goes! Tightened to 60Nm as per the specs (thank you OC manuals [-o<) Pettit at the rear and midpipe next up, got them seated, squared up and tightened. Still need to adjust the fitment and sort the exact position of it, but I just nipped up all the joints so it wouldn't leak... Amusingly even though it turns out the front joint is leaking around the new crush washer I installed. Think it may have dropped down as I tightened the three bolts meaning it hasn't snugged up right :^o

Topped up the oil and coolant after re-seating some of the coolant hoses that had been removed, installed the battery, air intake and connected up the coils then it was crank time! :twisted:


Started straight up! With a bit of idle hunting and a christmas tree dash of course, the entire interior is missing, no brake light bulbs, first start after battery reset, headlight levelling arm not connected and wiring disconnected, plus SAI related engine codes. Amusingly not one I expected but I also got a knock sensor code :shock: which took all of about 10 seconds to diagnose because one of the wires was hanging out the connector just chilling in fresh air :lol: so that'll be another one to fix! Not sure how that happened, but easily rectified in the grand scheme of things.


Still got lots to do but that'll be for another day!







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ChrisHolmes (Sun Oct 29, 2023 9:01 pm)
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Re: Harry's GL04 MXU Project Banana!

Post by DrewR3 »

I envy your spare time to play with all that. I managed to wash 1 of the 3 cars on my list in 30 min this weekend and felt I had achieved greatness with my spare time.....
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Re: Harry's GL04 MXU Project Banana!

Post by rotatopotato »

DrewR3 wrote:
Sun Oct 29, 2023 1:45 pm
I envy your spare time to play with all that. I managed to wash 1 of the 3 cars on my list in 30 min this weekend and felt I had achieved greatness with my spare time.....
I'm equally as green - I love working on mine but just don't have the time to do some of the more involved jobs myself.

Really impressive what you manage to achieve on a driveway Harry 👍

Btw, I have a full R3 interior here sans Recaros I'd you're interested (though it looks like you're covered there with the donor car).
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HarSc (Sat Nov 11, 2023 11:51 pm)
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

rotatopotato wrote:
Thu Nov 09, 2023 9:38 am
Btw, I have a full R3 interior here sans Recaros I'd you're interested (though it looks like you're covered there with the donor car).
Oooohh.... Now I definitely love the R3 door cards :shock: :^o shame you're properly oooop north up there :lol: ahaha
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

Ok, so - once again I have torn the nana to bits... Annoyingly it really doesn't feel like i've got a lot done this time round! :|

Pulled the bonnet hinges from the donor car to then fit on the nana, bonus of being black - but mainly the fact that they're now not bent! :lol: and a test fit of the recently acquired Seibon vented bonnet. Now the carbon finish is waaaaay past saving, not just the milky-ness, but the cracks, blemishes and peeling damage. But! If painted yellow with gloss black vents? I reckon that'd look mega. Either that or all gloss black... But i'm leaning yellow :P Had a big fight with it to remove the old bolts, as 4mm domed hex key bolts were used, so after being rusted on, were a royal pain to get out. Resorting to grinding a slot in, or mole grips once that stripped or snapped... Lucky I managed to get one of them out as it was almost a lost cause! #-o

Also thought i'd have a play with a set of ganadors on it (driver's door) :^o can't lie, I like the fancy JDM mirrors :lol: seems like i'll be getting a bit of paintwork done in the future! For now though, gloss black bonnet/bootlid can be fitted until I get the painting booked and underway next year.


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ChrisHolmes (Sun Nov 12, 2023 8:25 am) • McBandy (Sun Nov 12, 2023 10:08 am)
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Re: Harry's GL04 MXU Project Banana!

Post by rotatopotato »

HarSc wrote:
Sat Nov 11, 2023 11:51 pm
rotatopotato wrote:
Thu Nov 09, 2023 9:38 am
Btw, I have a full R3 interior here sans Recaros I'd you're interested (though it looks like you're covered there with the donor car).
Oooohh.... Now I definitely love the R3 door cards :shock: :^o shame you're properly oooop north up there :lol: ahaha
Nahhhh I'm in the lowlands, couriers still deliver to me without caveats so I'm not that far north 😜
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Re: Harry's GL04 MXU Project Banana!

Post by rotatopotato »

If it were me, either yellow with black vents or just all yellow for the bonnet - never been a fan of a black bonnet on an otherwise not black car. But obv do it to your own taste. The yellow with black vents would look cool though 👌
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HarSc (Sun Nov 19, 2023 3:36 pm)
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

So, been a decent bit of work on the banana this weekend. Fixed my self inflicted exhaust leak Pulled the intake off to swap for a filler neck that has the additional breather from the post 2006 models, dug through all my spare vacuum pipes to find the correct original ones that'd fit as this had previously been fitted with aftermarket flexible pipes and with a catch can which I wasn't planning on using, so I also pinched the "Y" pipe for the lower inlet manifold off an R3 spare one I had. While I had that off I repaired the knock sensor wiring by re-crimping the wires and using a new connector, all buttoned up now and works as it should :D =D> also removed the RRP Mk.1 coils in favour of some brand new OEM Mazda Rev C coils and the stock bracket - plus some good used blue magnecor leads I had spare.


Still on the list of things to do:

Sort the coolant leak on the stat housing (hose clamp loose I think, could be top hose split also)
New stat
New radiator
New brakes all round plus braided brake lines
Install rear ARB and new drop links all round
Fix gearbox leak (I believe coming from sensor, so maybe replacement sensor?)
Mount front headlight level sensor arm to LCA.
Fit side skirts
Install interior (seats/door cards)
Install seatbelts (HI CHRISTINE!)
Install steering wheel and program in cruse control
Install new gauge pod with oil & coolant sensors in the appropriate places
Program in some new flip keys to the ECU
Re-instate the lines for the VFAD/front portion of the intake system
Put the set of 18" falkens on some new wheels
Create a permanent mount for the fuel resistor and MAP sensor behind the ECU area
Swap oil coolers from donor car as they're in much better condition
Full service for filters, belts, plugs, wipers and fluids (diff, box, brake etc included)
Clean ESS while i'm in there



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Re: Harry's GL04 MXU Project Banana!

Post by rotatopotato »

HarSc wrote:
Sun Nov 19, 2023 3:57 pm
While I had that off I repaired the knock sensor wiring by re-crimping the wires and using a new connector,
Was it a total replacement connector or just the pins & seals in the existing connector? If the former, where do you find the connectors?

Not for any specific reason, but I suspect I'm bound to need to replace some eventually.
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

Total connector replacement on the harness side. See here. Bought it from 3waycomp on eBay, couple of quid posted. I already had the crimping tool for it, so was no issue. The Majority of car connections seem to use the same double fold over crimp style of varying sizes, so they're pretty simple.

Crimped the new pins on both wires, placed into the new connector and snapped it into place all snug on the knock sensor. Nice feel to it =D>

(that's just for that one, although i'd assume you can grab replacement connectors for a few others, I regularly see coil connectors pop up as they're common ones to break the tabs on.
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rotatopotato (Sun Nov 19, 2023 5:07 pm)
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Re: Harry's GL04 MXU Project Banana!

Post by rotatopotato »

Cheers, I figured they must be fairly standard or somewhat readily available, just having the right terms to search for always seems to be the trick 😂
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Re: Harry's GL04 MXU Project Banana!

Post by warpc0il »

If you're planning to replace the radiator, get yourself some Armaflex from your local commercial AC supplier, as this is way better than the original stuff, that will have crumbled away, to stop the cooling air bypassing the rad core.
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HarSc (Sun Nov 19, 2023 11:56 pm)
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

Ta for the heads up - will get some to plug the gaps round the side to the undertray and uprights :D :yeah:

Rad is 20 years old at this point, and i'm wanting to do a coolant flush anyways - call the new rad preventative maintenance if you will, cos my bets are on the top plastic barb snapping if I so much as look at it :lol: :lol: :lol:
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Re: Harry's GL04 MXU Project Banana!

Post by warpc0il »

I managed to change my header tank without breaking the plastic barb, on my '04 Angry Wasp© a few years ago.

Only that was for "a good used one" from a much later car, that wasn't meant to have the same issues, only the problem came back last year and I have a new tank on the shelf, waiting for me to pluck up courage again.

The trick is to cut the rubber pipe off first, before attempting to remove the tank, so there's no (or little) force on the plastic.
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Re: Harry's GL04 MXU Project Banana!

Post by rotatopotato »

warpc0il wrote:
Sun Nov 19, 2023 11:56 pm
If you're planning to replace the radiator, get yourself some Armaflex from your local commercial AC supplier, as this is way better than the original stuff, that will have crumbled away, to stop the cooling air bypassing the rad core.
I did a search and see you mentioning this multiple times over the years, but no mention of the shape/dimensions of armaflex to use - any tips? While I've got the bumper and undertray off I'll take a look as mine was replaced with a koyorad and I know I'm missing at least the bottom foam piece (but likely the rest too).
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

Little bit more progress on the 'nana. Boot has been cleared out, carpet is a bit of a mess so i've removed it to be cleaned up ready to be reinstalled :D

Also seem to be getting the gist that this car is being very fun for wiring :| :^o tweeter speakers on both doors had the connector cut, so I used red through-crimps to join the connector onto the door harness (thank you donor car once more :lol:) and used electrical tape then tessa tape to keep it together, tidy and reduce chances of vibrations or rattles against plastics or the door itself. Both front door speakers and amplifiers/electronics units were also installed.

Looking closer as I keep working, I found the drivers side ABS wire was broken - now I knew the ABS light was on, my assumption was that was illuminated because there are no brake light bulbs in, as I know the LED 3rd lights or wiring faults can cause it on the bootlid - but I guess that will probably solve that issue once rejoined :lol:

R3 orange dot rear ARB installed along with new drop links, nice easy job minus needing to cut off the old drop link stubs from the arms :^o took a bit of time to make sure I didn't catch the arms or cut anything that wasn't needing to be cut, but got there cleanly =D>

And improvements in the interior of the car =D> got the front door cards and seats fitted, although I've left the rear door cards and seats "placed" in as I need to install the yellow seatbelts before they go in for proper and get bolted down.


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Re: Harry's GL04 MXU Project Banana!

Post by McBandy »

That's weird your boot interior metalwork isn't yellow, I'm pretty sure mine is almost as yellow as the outside, could they have changed how much they painted inside from 04 to 54?
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

It's the same as all 8's i've seen. They just don't paint that from factory :-k just natural overspray into the chassis
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kopite72 (Fri Dec 29, 2023 9:00 pm)
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Re: Harry's GL04 MXU Project Banana!

Post by qwakers »

being a sparky type i thought you might appreciate these...


https://www.amazon.co.uk/Wirefy-Solder- ... h=1&psc=1
absolutely brilliant, adhesive lined and totally everything proof and i've never had one fail..

plus these.


https://www.amazon.co.uk/Wirefy-Heat-Sh ... =8-8&th=1
so much better than the old blue red and yellow crimp on connectors. also heat shrink and adhesive lined.

just ignore the splice taps in the second link :roll:
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Re: Harry's GL04 MXU Project Banana!

Post by McBandy »

Knew I should have grabbed a pic of mine this morning, I will when I'm next back with it as I'm pretty sure mines fully painted. Obvs it's far from stock so it wouldn't surprise me
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Re: Harry's GL04 MXU Project Banana!

Post by HarSc »

Newest addition to all the shinies on the car, a pair of custom carbon effect LED taillights imported from Japan, and a set of banana-fied seatbelts from Christine :twisted: =D> =D>

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Cscameron (Mon Dec 25, 2023 8:56 pm)
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Re: Harry's GL04 MXU Project Banana!

Post by ChrisHolmes »

I bet those babies are bright.
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Re: Harry's GL04 MXU Project Banana!

Post by frozenjakalope »

The lights probably work too!
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