How to Build a Westfield (Mazda Sdv)

Step-by-Step Guide

1. 1

   Step 1: 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. , 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 ,, There are a number of options available.
   
   The following are recommended for new builders:
   Powder coating chassis Exterior panels Fit riv nuts Chassis stands. , 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., 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.,,,,,,,,,,,,,,,,,,,,,,,,,,
2. 2

   Step 2: Strip donor vehicle.

3. 3

   Step 3: Label everything

4. 4

   Step 4: especially wiring.

5. 5

   Step 5: Order a "Starter" kit.

6. 6

   Step 6: Collect "Starter" kit.

7. 7

   Step 7: Paint chassis.

8. 8

   Step 8: Fit body panels.

9. 9

   Step 9: Fit pedals

10. 10

    Step 10: Fit brake & clutch master cylinders

11. 11

    Step 11: Fit brake pipes

12. 12

    Step 12: Order "Completion" kit

13. 13

    Step 13: Collect "Completion" kit

14. 14

    Step 14: Fit fuel pipes

15. 15

    Step 15: Modify/fit rear wiring loom

16. 16

    Step 16: Fit rear suspension

17. 17

    Step 17: Fit differential

18. 18

    Step 18: drive shafts & rear uprights

19. 19

    Step 19: Fit front suspension & uprights

20. 20

    Step 20: Fit steering rack

21. 21

    Step 21: Fit engine & gearbox

22. 22

    Step 22: Fit prop-shaft

23. 23

    Step 23: Fit air-box

24. 24

    Step 24: Fit steering column

25. 25

    Step 25: Fit radiator & fan

26. 26

    Step 26: Fit fuel system

27. 27

    Step 27: Fit handbrake

28. 28

    Step 28: Fit windscreen washer bottle

29. 29

    Step 29: Fit horn

30. 30

    Step 30: Fit tunnel top panels

31. 31

    Step 31: Fit seat-belts

32. 32

    Step 32: Modify/fit main wiring loom

33. 33

    Step 33: Fit bodywork

34. 34

    Step 34: Fit battery & battery tray

Detailed Guide

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