Dick Flower  -Mazda conversion-                  update: 22-01-2004


 

I had possibly the first Ro 80 in England which I collected from Neckarsulm in Sept 1968. I now have 1974 Ro 80, in which I have just fitted a Mazda 13B engine, and remains of a 1973 car I broke up.  I have done no other modifications, so can always put the original engine back in.
Also have lots of spares which I will probably keep until I decide to sell the car.
I bought the last 2 new windscreens in England when I broke both of mine in 1991 - they are very easy to break when you take them out!
I fitted new w/screen with old rubber, soaked in castor oil and it is still OK.  Is it possible to get new rubbers?

Above a photo of car back on the road after stored 12 years.

Regards Dick Flower


The webmaster asked Dick to tell something about his Mazda conversion.


Mazda conversion:  Specialists are Hurley Engineering www.hurleyrotary.com , click on "Rotary Engines" at the bottom of homepage.  Lists all options and prices.  These are for conversion on the premises, they keep the old engine and accessories.

I think you get standard Mazda engine using NSU ignition system, with contact breaker distributor.

I kept my engine and negotiated a price for a Mazda 13BG1 sports engine (175 bhp) plus everything to install it.  Cost me , as far as I can remember, GBP3,900 plus VAT.  This included rebuilt engine with Hurley seals, adapter plate for NSU gearbox, new seals for  torque converter, manifold with SU HIF44 carbs., air cleaner & filter, oil cooler & filter, alternator, belts, latest type Mazda distributor with electronic ignition and igniters, ignition coils & leads, Mazda exhaust manifold,  2 Hurley silencers, exhaust pipe bends, (which I did not use), adapter bracket for steering pump, modified NSU front engine mounting frame, water pipes, some hoses, oil pipes, etc.

I bought Haynes Manuals for RX7, which I needed for wiring changes and tuning information, and SU Carburettors (Actually included in the Weber Manual), as I was not familiar with the HIF series SU carbs.

he job took some months, but I only worked when in the mood.  The fan hub is very close to the radiator, as the 13B engine is longer.  Fitted Mercedes electric fan, used as booster for air conditioned models.  I got one from a breaker's yard, but it quit, and unrepairable (brush holder assembly was melted), so I bought a new one, it's too important to risk breakdown.

Hurley does not actually sell "kits" for conversions, so I had to make some things myself :- 

Water hoses - some problems to find suitable bends, rest standard straight hose, and made tees etc from copper pipe

Exhaust system :-  I could not find anyone to make it here,  borrowed a hydraulic bender and made it myself.  I could only find 2mm wall pipe here, so it was hard to bend & is heavy - will take a long time to rust away, though !  Found a flange to fit the manifold in a breaker's yard.

Choke cable;- Too short, made up a frame to join on another section, as I wanted original knob on the dashboard.  You can see it in centre of photos (choke cable is blue)

Petrol pump:-  Fitted SU electric pump I had lying around, but plan to get a new one www.burlen.co.uk make SU now

Rewiring:- Studied NSU & Mazda manuals, copy of my result enclosed -->

Engine side supports/dampers:-  Right side fouled exhaust manifold, removed it and bent brackets clear of manifold.  Crude, but they can be bent back into place to reinstall NSU engine

Tachometer:- My old one was cable driven, Mr Hurley sold me a dashboard from a late model with electronic tach.  I changed the speedometer also as the later instuments do not match the old ones

I had enough pads & seals which I had hoarded for years to overhaul brakes, new pads are available from EBC in Scotland www.needforspeed.co.uk they have 4 grades of pads, from normal, up to competition.

Fuel consumption on first proper trip was about 15.5 L / 100km, but this included a huge traffic jam crawling over the frontier into Spain, a lot of city driving in Figueras, and only about 300 Km of open road.  I hope to get the promised 11 L / 100 km promised. 

 


NSU Ro80 OVERHAUL (MAZDA ENGINE)  2001 – 2002

 Engine    

                Install Hurley converted Mazda Rx7 engine

                Renew clutch intermediate cover & flange c/w seals

                Renew bearing on clutch input shaft (inside stator carrier)

                Renew seal in end cover (gearbox seal) used 2 narrow seals

                Renew all water hoses

                Flush cooling system refill VW refrigerant (green)

                Renew drive belts

 Electrical

Strip & clean alternator, renew bearings

 Brakes

               New seals master cyl., front & rear brakes. (purchased 1991)

               New pads front (stock) new pads rear (purchased Narbonne)

               New hoses rear (purch Narbonne)

               New fluid

Steering

                Chip & paint pump, renew fluid

Cooling

                Fit Mercedes fan p/n A 00 500 60 93 in front of radiator


Regards Dick Flower          ---          E-mail: richard.jean.flower@wanadoo.fr