Exhaust...
...The rest of the exhaust system is best left to the professional. The best underbody exit path for the exhaust that maintains maximum ground clearance is down along the passenger side of the
transmission tunnel. A good smog legal plan would route the exhaust/downpipe thru a single hi-flo catalytic converter (uses existing RX-7 heat shields), which is then split again using another "Y" in front of the
rear differential (just like the stock RX-7 system). The (2) 2-1/2" pipes leaving the "Y" should carry on to mufflers in the stock RX-7
locations. Beware of chambered mufflers w/o packing, as they can cause a bit if resonance inside the passenger compartment at highway
speeds.
Throttle cable...
Accessory mounting brackets and pulleys...
Alternator...mounting options must be considered together with what radiator you plan to use. The options include...
Custom PS hoses are easily made by salvaging the existing fittings from your original hoses. Simply slit the outer "crimp sleeves" to remove the fittings.
Air Conditioning Compressor...
To make low-cost custom AC hoses for your conversion, use the same method as used to make custom PS hoses, listed in the section above.
BE SURE THERE IS ENOUGH CLEARANCE BEFORE CLOSING THE HOOD!
Battery Re-location...
2....Considerations & Requirements....
4....Engine / Transmission Installation....
5....Exhaust / Throttle Cable / Accessory Drive / Pulleys....
6....Cooling / Fuel Systems....
7....RX-7 Wiring Harness Connector ID and Circuit Locations....
8....Electrical System Modifications By Circuit....
Option #1- stock exhaust manifold...Stock exhaust manifolds typically fit, as long as they exit down and to the rear.
Option #2- Header...Most any of the "shorty" style headers that loosely resemble the factory exhaust manifolds will fit. Many customers are going to do their own custom turbo install, so care should be given to make sure that the turbo location is compatible with the chassis.
Throttle linkage...
For a carbureted engine, the stock RX-7 throttle cable can be used with our Throttle Cable Adapter kit.
The kit includes a cable extension that can be crimped onto the end of the RX-7’s cable with a 7mm
spark plug wire crimp, and a bushing to adapt to the throttle arm of a Holley or Carter/Edelbrock
carburetor. For an injected engine, a Ford throttle cable can be easily adapted to the RX-7’s throttle pedal with
the spacer at the pedal end of the cable.
...Option #1- radiator w/ generic Ford outlets...these rads locate the upper radiator hose on the upper passenger side. The lower outlet will be down low on the driver's side.
...Option #2- Our double pass Ford style radiator...has both the radiator inlet and outlet located on the driver's side. Our radiator includes brackets that bolt directly to the stock RX-7 radiator mounting points. Our brackets are also designed to block-off the alternative air flow paths in the engine compartment that can drastically reduce cooling system effectiveness.
This includes sealing plates for the area below the stock mounting points where the harness and oil cooler hoses passed thru, as well as a seal plate for the front upper radiator core to the hood latch/core support. These brackets save a lot of time and are VERY effective at improving cooling system efficiency.
Power Steering...
...Option #1- Mazda Power Steering Pump...involves adapting your RX-7 pump to the Ford bracket, and installing the proper style drive pulley. We currently have no ready-made bracket to make this option a bolt-on. The reason some choose this route is that the RX-7's speed sensitive steering remains intact.
...OPTION #2- Ford Power Steering Pump... the RX-7 steering rack can be plumbed to the Ford pump using custom hoses. The Ford pump even uses the same style fittings as the RX-7 pump. The Mazda rack came in 2 versions, one that had 2 hoses, and one that had 3 hoses going to the pump/valve body assembly. The 2 hose version can be plumbed in directly. The 3 hose version can be plumbed into the Ford pump as follows...
..."A"- small pressure hose- this is a high pressure return line that went from the RX-7 rack to the return metering valve that was mounted on the side of the RX-7 pump.
A stepper motor controlled the needle shaped valve to control the volume of fluid that was bled off to vary the amount of power assist. The stepper was controlled by the RX-7's "power steering control unit", a computer located under the dash to the left of the steering column.
This hose should be connected to a "T" installed in the low pressure return line "C", allowing excess pressure from the rack to bleed off, returning fluid to the pump's resevoir.
..."B"- larger pressure hose- this is the pressure line from the pump to the rack. Plumb this hose directly to the Ford pump's pressure fitting using a custom fabricated hi-pressure hose.
..."C"- large low pressure return hose- this is the return line to the resevoir. This hose should have a "T" installed with the open leg of the T connected to hose "A".
Plumbing the PS system as noted above will result in a reduced amount of power assist, perfect for high speed driving.
Steering effort at low speeds will be reduced to about 1/2 the assist provided by the stock RX-7 power steering. Drivers not familiar with the RX-7 rarely detect that the power steering assist has been reduced.
...install the fittings in place on the pump and rack, and measure the length of hose required to get the hose to lay where you want it to.
...buy some new hose and crimp sleeves of the proper sixe from your local hose shop.
...install new crimp sleeves on the hose, and install the fittings into the new hoses. Twist the hose ends until the hoses lay in the right places on your car.
...remove the hoses, then take them to the hydraulic hose shop and have them "set" the crimp sleeves in place. You will now have a couple of "exact fit" custom hoses without spending money on new fittings.
...Option #1- Ford AC compressor... in some cases such as the EFI engines, it is not practical to adapt the RX-7 compressor. In these cases, the Ford OEM compressor is used as long as it's mounting location is compatible.
...Although it is not always necessary to re-locate the battery, doing so is a good move with regards to
maintaining the RX-7’s fine overall balance. The battery should be a sealed unit, such as a “gel-cell”, and
should be le-located as far back as practically possible for the most results (this one move can have
about the same effect as switching to aluminum heads)