Build a Westfield (Mazda Sdv)
This article describes how to build the Westfield Sports car kit car model which is based on a Mazda MX-5 (also known as a Miata or Eunos in various markets).
Steps
- Locate donor vehicle. An MX-5 is required to provide the necessary donor parts. A crash damaged/insurance write-off will usually provide the cheapest option. Check the list under "Strip donor vehicle" to ensure the donor has all the necessary parts in un-damaged state. The kit provided by Westfield was originally intended for an NA model (pop-up headlights). Later models (NB and NC) can be used although some additional modification/steps will have to be made.
- Strip donor vehicle. The following items are required:
- Engine and Gearbox - complete with inlet track & exhaust manifold and lambda sensor
- Airbox and air flow meter and both pieces of pipe work and retaining clips and Airbox mounting rubbers
- Complete wiring loom, Ecu, fuse boxes, dashboard switches, clutch pedal switch, sensors and relays (NOTE: Label every connection when disconnecting for ease of reconnecting)
- Instrument panel cluster
- Upper steering column including steering wheel, crash pad, indicator stalks, ignition barrel and key and top and bottom cowl
- Lower steering column (needs to come to WSC for modification)
- Diff and Casing complete with rubber mounting bushes and buffer plates
- Rear uprights, hubs, discs and calipers including top upright rubber bush still fitted
- Handbrake lever and cables, compensator and all fittings including retaining spring clips
- Steering rack track rod end joints and nuts
- Front uprights, hubs, discs and calipers
- Wheels and tyres and wheel nuts
- Propshaft (needs modifying but not by WSC)
- Driveshafts including joints, lock nuts and hub nuts
- Front bottom ball joints including castle nuts
- Horns;
- Cooling Fan
- Side Repeaters
- Fuel filter and bracket
- Carbon Canister, pipe work and mounting bracket
- Catalyst converter
- Interior mirror
- Screen washer bottle and pump
- Battery and mounting tray including clamp and fixings
- As many nuts, bolts and fasteners as you can save
- Label everything, especially wiring.
- Order a "Starter" kit. There are a number of options available. The following are recommended for new builders:
- Powder coating chassis
- Exterior panels
- Fit riv nuts
- Chassis stands.
- Collect "Starter" kit. Unless you have a lot of storage space it is recommended you do not collect the outer body. If the full kit is being collected, a van will be required, e.g. Transit. If the kit is being collected without the outer body, a large estate with roof rack can be used.
- Paint chassis. If the chassis was ordered without the powder coating option, the chassis will be in bare steel and will require painting with a good exterior metal paint.
- Fit body panels.
- Fit pedals
- Fit brake & clutch master cylinders
- Fit brake pipes
- Order "Completion" kit
- Collect "Completion" kit
- Fit fuel pipes
- Modify/fit rear wiring loom
- Fit rear suspension
- Fit differential, drive shafts & rear uprights
- Fit front suspension & uprights
- Fit steering rack
- Fit engine & gearbox
- Fit prop-shaft
- Fit air-box
- Fit steering column
- Fit radiator & fan
- Fit fuel system
- Fit handbrake
- Fit windscreen washer bottle
- Fit horn
- Fit tunnel top panels
- Fit seat-belts
- Modify/fit main wiring loom
- Fit bodywork
- Fit battery & battery tray
Things You'll Need
- Tools Required:
- Combination spanners: Metric & Imperial
- Socket set: Metric & Imperial
- Toque wrench: 0 to 100 lb ft, to 250 lb ft
- Drill bits: 5/32”, 3/16”, 5.16”
- Allen keys: Metric
- Socket drive Allen keys: 6mm, 8mm
- Circlip pliers: Internal & External
- Taps: ½” UNF, M18 x 1.5mm
- Hole cutters: 1¼”, 1½” (45mm), 2”
- Pop riveter
- Pipe bending tool
- Riv nut fixing kit
- Electric drill
- 12" hacksaw
- Engineering hammer
- Centre punch
- Hide hammer
- G clamps: min 2
- Bench vice
- Screwdrivers: Flat & Phillips
- File: Round & Flat
- Tape Measure
- Metal cutters
- Consumables:
- Copper Slip
- Silicone Sealant
