RX-5 140 Build Manual (Example)
Proprietary Information
The Information and descriptions described herein are the property of MK Sportscars. Such descriptions and information may not be copied or reproduced (duplicated) by any means (in any form) or disseminated or distributed without the express prior written permission (consent) of MK Sportscars. The information contained in this document is subject to change without notice. MK Sportscars assumes no responsibility for any errors that may appear in this document.
Copyright Notice
This document contains propriety information, which is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced by any means, or translated into another language without the prior written consent of MK Sportscars.
Table of Contents
- Introduction
- IVA
- Safety First
- Torquing of Bolts
- Donor Car Paperwork
- Initial Setup
- Fitting Of The Floor Mounted Peddle Box
- Making The Brake Lines
- Fitting The Electrical Lines Mounting Brackets
- Fitting The Fuel Pipes
- Fuel System
- Dry Fitting The Interior Panels
- Fitting Floor Pan
- The Differential
- Fitting The Fuel Tank
- Rear Suspension
- Fitting The Rear Braking System
- Fitting The Side Panels
- Fitting The Rear Panel
- Fitting The Roll Bar/Cage
- Fitting The Front Suspension
- Fit The Front Brakes
- Fitting The Front Wing Stays
- Fitting The Steering Rack
- Fitting The Upper & Lower Steering Column
- Fitting The Rear Wheel Arches
- Fitting The Engine and Gearbox
- Cooling System
- Fitting The Horn
- Fitting The ECU Mounting Panel
- Fitting The Dashboard
- Coolant System Continued
- Fit The Battery Mounting System
- Fit The Bulkhead Panel
- Fit The Chassis Plate
- Fit Air Flow Meter
- Fitting The Nose Cone
- Prepare The Bonnet and Nose Cone
- Fit The Underside of The Side Panel
- Fit The Bonnet Catches
- Fitting The Fuel Cap
- Fitting The Exhaust & Bracket
- Fitting The Stripe Kit
- Fitting The Side Panel Caps
- Fitting The Boot Cover
- Fitting The Lights
- Fitting The Dashboard
- Interior
- Rear View Mirrors
- Fluids
- Preparing For the IVA test
- Basic Setup
- Number Plates
- Weather Gear Fitting
1. Introduction
MK Sportscars has produced thousands of cars since the company launched the MK Indy in 2000. We are constantly striving to improve our cars and options list available to further enhance the affordability and desire of the car our main goal driver behind the RX-5 project. The enjoyment of the car should be in its actual construction, This Build manual has been produced to assist with this part of the project. The purpose of building a MK RX-5 140 is to realise a car that will suit the purpose for which it is intended. If this is a Road car or Track-based car, we have many thousands of satisfied owners in all categories both here and overseas who have had the enjoyment of building a MK. MK Sportscars will continue to offer the support to help deliver to you the means and advice of building a car, simply and quickly, with minimum complication and a maximum amount of fun. This manual is for the guidance of building the MK Indy and should also be used alongside the current IVA manual if you are looking at building a road registered car. If at any stage of the build you are unsure, please contact MK Sportscars for guidance or seek professional mechanical knowledge from a reputable and qualified company or individual. MK Sportscars hope you enjoy the experience.
1.1 Manual Conventions
Throughout this manual there are important details which must be followed. These are highlighted with the following icons.
2. IVA
For amateur build IVA compliance, you will need to have photographic evidence throughout the whole build process. Please ensure you take sufficient photographs of each step in the build. These will need to be submitted with your IVA application form. Each section where you need to take photographs will be marked in the manual – but you can never have too many pictures of your build, it’s great to look back on in years to come.
3. Safety First
ALWAYS WEAR:
- GOGGLES OR PROTECTIVE GLASSES AND SUITABLE FOOTWEAR IF YOU ARE USING WELDING OR GRINDING EQUIPMENT, THERE MAY BE OCCASIONS FOR THIS IF YOU ARE OUTSIDE OUT BUILD PARAMETERS,
- PROTECTIVE GLOVES WHEN HANDLING FIBREGLASS OR CARBON.
- DUST MASK AND EAR PROTECTION WHEN WORKING WITH FIBREGLASS OR CARBON.
IT IS ESSENTIAL THAT THE SUPPORTS YOU USE UNDER THE CHASSIS DURING THE BUILD PROCESS ARE SUITABLE AND SAFE FOR USE. DO NOT CONNECT THE BATTERY +VE LEAD UNTIL THE WIRING LOOM HAS BEEN FULLY INSTALLED AND ALL EARTH CABLES HAVE BEEN CONNECTED. THE BATTERY MUST NOT BE CONNECTED UNTIL ALL TESTS HAVE BEEN COMPLETED. DO NOT FILL THE FUEL TANK UNTIL THE CAR IS COMPLETE. PLEASE TAKE CARE WITH BRAKE FLUID AND BRAKE FLUID SPILLAGE AND ALWAYS FOLLOW THE MANUFACTURES GUIDELINES. IT IS ADVISABLE TO HAVE A SUITABLE FIRE EXTINGUISHER AT HAND. ENJOY YOUR BUILD AND BE SAFE AND MOST IMPORTANTLY HAVE FUN
4. Torquing of Bolts
Always refer to the Torque Settings in the manufacturer’s manual If you do not own a Torque Wrench, WE STRONGLY ADVISE YOU TO PURCHASE ONE FOR THE BUILDING AND MAINTAINING OF YOUR VEHICLE.
4.1. Torque Setting Guidelines
| Settings Values | ft-lbs | Nm | |
| Three Way Brake Pipe Unions | 5 | 7 | |
| Rear Brake Caliper Mounting Bolts (Steel) | 40 | 54 | |
| Steering Rack Mounting Bolts to Chassis | 20 | 27 | |
| Track Rod End Nuts to Steering Arm | 28 | 38 | |
| Wishbone Securing Bolts to Chassis | 30 | 40 | |
| Lower Ball Joint Securing Bolts to Wishbone | 25 | 34 | |
| Lower Ball Joint Nut to Upright | 28 | 38 | |
| Steering Column Upper Mounting Bolts | 20 | 27 | ** |
| Steering Column Shaft Couplings | 20 | 27 | ** |
| Steering Column Securing Clamp | 28 | 38 | ** |
| Front Brake Caliper Mounting Bolts (Steel) | 40 | 54 | * |
| Shock Absorber to Chassis Mounting Bolts | 30 | 40 | |
| Prop shaft to Differential Securing Bolts | 40 | 50 | * |
| Handbrake Mounting Bolts | 22 | 30 | |
| Seat Belt Mounting Bolts | 26 | 35 | |
| Steering Wheel Nut | 35 | 47 | |
| Wheel Nuts (Rimstock) | 65 | 90 | |
| 6mm Bolts | 9 | 12 | |
| 8mm Bolts | 18 | 24 | |
| 9mm Bolts | 20 | 27 | |
| 10mm Bolts | 28 | 39 |
Notes:
* Apply a Thread Locking Adhesive to threads when fitting bolts and Nyloc Nuts will be Torque tightened during the Set-Up stage. We advise during the assembly of the suspension that ALL suspension bolts and Nyloc Nuts are `NIPPED’ ONLY and NOT Torque tightened until full build complete with the weight of the car is completed, once you have torqued your bolts be sure to mark them with a paint line to ensure you complete the torquing of the car and for future checking and maintenance,
5. Donor Car Paperwork
To avoid any issues in the future, make sure you update your V5C and SORN declaration to your name and address only. It is possible to SORN the donor car from the website
https://www.gov.uk/make-a-sorn
It is possible to Transfer the vehicle into your name from the website https://www.gov.uk/sold-bought-vehicle
Alternatively, you can send the relevant V5C in the post to Swansea (details on the V5C logbook)
6. Initial Setup
Lift and Position the Chassis onto your suitable support. You will require additional help with this and ensure you do not over stretch yourself with the weight of the chassis ensure there is enough room to allow fitment of various parts.
Do Not Attempt to Modify Any Of The Items Supplied Without Contacting MK Sportscars
6.1. Bodywork Storage
The Bodywork MUST NOT be Stored in Plastic Sheet, in Damp or Humid Conditions. DO NOT Store Bodywork in Direct Sunlight, in Greenhouses or Conservatories. MK Sportscars WILL NOT accept any WARRANTY CLAIM for Damage to Bodywork where the Damage has been caused by any of the above conditions.
6.2. Chassis Information
The Chassis is supplied bare unless the powder coating option is specified at the time of ordering.
6.3. Tools
- Haynes manual for the appropriate year of your donor car
- Combination Spanner Set: 8mm to 19mm
- A/F Metric Combination Socket Set
- Drill Bits Metric
- Allen Key Set
- Circlip Pliers
- Internal And External Taps (Note: The taps are only required to clean out the residual powder coating)
- Hole Cutters (Various sizes)
- Pop Rivet Gun
- Brake Pipe Bending and Flaring Tool
- Rivnut Fixing Kit
- Electric Drill, with a 90° adaptor
- 12" Hacksaw
- Hammer Centre Punch
- Rubber Mallet
- 'G' Clamps
- Bench Vice
- Flat and Phillips Screwdrivers
- Set of Round Files
- Steel Tape Measure
- Metal Cutters
- Copper Slip
- Silicon Sealant (Tiger Seal PU18 Black Flexible Polyurethane Adhesive)
- Silicone Grease
- Torque Wrench, ½” Square Drive with a range to 250 lb ft.
- Dremel (ideal for trimming bodywork)
- Heat Gun
- Touch-up Paint Stick (To mark bolts after tightening)
- Thread Lock (Low, medium and high strength)
6.4. Donor Vehicle
Stripping the required parts from the Donor Vehicle ALWAYS refer to a relevant workshop manual for technical guidance and safety advice. MK Sports Cars have produced guides to assist with the stripping of the donor cat and preparing the parts. Upon removal, check the condition of the donor parts for wear or damage and replace as necessary. Listed below are the parts that you will typically require from the Mazda MX5 to complete your build.
- Vehicle Registration Document
- Engine and Gearbox with the following Ancillaries
- Alternator,
- Fuel Injection System & Plenum Chamber
- Starter Motor
- Clutch Slave Cylinder
- Gear Lever
- Exhaust Manifold
- Front Uprights including Brake Discs & Calipers
- Ball Joints, Steering Arms and Locking Nuts
- Rear Uprights including Brake Discs and Calipers
- Handbrake Cables and Lever
- Prop Shaft
- Differential
- Drive Shafts
- Upper and Lower Steering Column.
- Steering Wheel
- Wheels and Tyres
- Wiring Loom and Fuse Box
- Hazard Light Switch
- Fog Light Switch
- Dashboard Dimmer Switch
- Horn
- Dashboard Gauges
- Fuel Filter
- Fuel Filter Bracket and M6 Bolts
- Fuel Pump
- Any Fasteners.
6.5. Donor Part Modifications
Some donor parts require modification, The prop shaft will need to be shortened. This should be done by a reputable company, or MK Sports Cars can provide this service. Please see our price list for modification. The steering link bar will need to be extended, MK Sports Cars can also provide this service, please see our price list for modification. The parts, which need removing from the donor vehicle, can be seen in Figure 1.
Figure 1 - MX-5 Steering Link Bar (Exchange Component)
Figure 2 – MX-5 Steering Link Bar (Exchange Component)
6.6 Nut and Bolt Fixings
Located in your kit (Box 1) will be the nuts and bolts required to build the rolling chassis of the car.
| Bag | Size | Bolt | Washer | Nut | Location |
| 01 | M10 x 110 Hex | 2 | 4 | 2 | Top Rear Upright |
| 02 | M12 x 1.5 Nyloc | 2 | Lower Front Ball Joint | ||
| 03 | M12 x 110 Hex | 2 | 4 | 2 | Rear Diff Mount - Front Bolt |
| 04 | M12 x 130 Hex | 2 | 4 | 2 | Diff Mount - Main |
| 05 | M12 x 160 Hex | 2 | 4 | 2 | Bottom Front Upright |
| 06 | M12 x 50 Hex | 2 | 4 | 2 | Bottom Front Ball Joint |
| 07 | M12 x 60 Hex | 12 | 24 | 12 | Suspension |
| 08 | M12 x 70 Hex | 14 | 28 | 14 | Wishbones |
| 14 | M12 x 75 Hex | 2 | 4 | 2 | Wishbone + Headlight Bracket |
| 09 | M14 x 200 Hex | 2 | 4 | 2 | Bottom Rear Upright |
| 15 | M6 x 16 Hex | 8 | Fuel Pump | ||
| 10 | M6 x 20 Hex | 2 | 2 | 0 | Rocker Arms |
| 11 | M8 x 25 Button | 3 | 6 | 3 | Handbrake |
| 12 | M8 x 30 Button | 6 | 12 | 6 | 4x Steering Rack, 2x Column |
| 12 | M8 x 30 Button | 4 | 8 | 4 | Roll Bar Shoulder Fixings |
| 12 | M8 x 30 Button | 18 | 36 | 18 | Internal Roll Cage |
| 13 | M6 x 20 Hex | 2 | 4 | 2 | Roll Bar Fixings |
7. Fitting Of The Billet Aluminium Pedal Box Floor Mounted
As standard, the billet aluminium pedal box comes complete as a kit with two master cylinders for the front and rear brake circuits and an additional master cylinder for the clutch.
Figure 7 - MK Branded Pedal box