Medusa Fabrication

20/01/2022

Carl’s MX5 has just hit the rollers - very happy with the results! He has taken it straight off the dyno, loaded up his belongings and is driving it to North QLD as we speak.

This was definitely a challenging but rewarding project with lots of tight spaces to work in, but were all very happy with how it’s turned out.

That’s a couple of Mazda BP’s down, I’m sure there are more coming up in the future 😁

Well done to the guys at T&D for the tune
Aeroflow Performance Turbo
Turbosmart CompGate
Mishimoto Automotive Intercooler

This MX-5 came in for a quick tune just before heading up to Queensland to it’s new home

Leaving with 300hp / 224 kws

This beast should be a very fun car to drive considering the weight

21/12/2021

Quick shout out to the guys over at Sydney Cerakote! The team there took on some work on short notice, spent a lot of time discussing options with me so that we could deliver the customer the finish he was after, and turned around the job in record time!

Ceramic coated:
- tubular manifold (exterior)
- turbine housing (interior and exterior)
- wastegate dump tube (exterior)

Will be using them again for future projects.

😎

09/12/2021

Fabrication work is coming to an end on Carl’s turbo MX-5. A lot of time was spent figuring out the best path for the wastegate dump tube - it needed to look neat and plumb back into the dump pipe. After many, many bends (and even a scrapped initial prototype), we finally got there in the end. This should keep the noise from the Turbosmart Comp40 to a minimum!

MX-5 owners will now how the factory cast water neck interferes with most low mount turbo setups - we could have potentially made it work, but we created something custom instead. This pipe now routes more directly to the lower radiator port, while also using some Raceworks weld on fittings for the heater line and the turbo water return.

A custom intake was also fabricated out of alluminium. Although deceivingly simple, it has a -10AN fitting welded up to connect it to the catch can breather (for engineering purposes), and a separate 32mm tube to plumb back the BOV.

Overall really happy that it’s all coming together in what is a pretty cramped engine bay. Can’t wait to hear this thing on the rollers! Going to tackle some intercooler piping and new intercooler next.

For those wondering, the turbo is an Aeroflow Performance 4849.

All materials from ECS Exhaust | UNIMIG Razor 200ACDC | Oz Welding supplying the cups and Weldporn tungsten

30/11/2021

Finished up some more exhaust work on Carl’s awesome first-gen MX-5! Still a bit to go on this exhaust system before we can call it done.

We TIG welded a 3” stainless dump pipe, and then a 3” stainless system. To help save some costs for the customer, we used some of the existing 3” mild steel system. However, we still decided to TIG weld the new stainless sections to the existing mild system (using 309 filler as the materials are mismatched).

Likewise, we replaced the existing exhaust tip with a custom stainless tip, slightly angled to protect the bumper.

The whole system was tucked up quite high for ground clearance, as well as clearance to the chassis brace.

The last BPT motor we fabbed a 3” stainless system for sounded very crisp, so we’re looking forward to seeing how this sounds out on the road and track!



UNIMIG Razor 200ACDC | Oz Welding Supplies supplied the Furick cups and Blue Demon Welding Products tungsten | Stainless Steel

21/11/2021

Exciting update on the TE Cortina - completed the Tremec Transmissions TKO600 conversion behind the 250 Crossflow. As far as we are aware, this is the first time a TKO has been paired up with a crossy. Wish I could say it’s the first one behind a Cortina, but Growl Racing beat us to it with his awesome Barra TF! When he decided to go automatic, we bought the box off him to keep it in the Cortina family.

We opted for a Direct Clutch Billet Chromoly flywheel and single disc heavy duty clutch - Drew and Jerry were an awesome help. This TREMEC uses a 26 spline input shaft so we had to also use a 26 spline clutch disc.

Bellhousing is a single rail unit that we drilled out to the TKO/Top Loader pattern.

TREMEC’s require strict tolerance on the runout, so we quickly fabbed up a little tool that mounts onto the flywheel and holds a dial gauge. Super lucky that both our crossflow blocks were well within tolerance so there was no need to machine up offset dowels!

ARP flywheel bolts and ARP pressure plate bolts (Nissan RB26) keep it all together with an upgraded tailshaft to finish it off.

As you can see, after turning the shifter housing 180 degrees, the shifter pops out of the standard hole. The Hurst shifter does work, but we have decided to go a different route (next update).

Super happy with the outcome - have personally wanted this gearbox in the corty for many years, so was stoked to finally make it happen.

Now just need to figure out a way of making some more torque to make use of it 👨🏻‍🏭

08/11/2021

Minor update on the 250 Crossflow. No fabrication this time around, but managed to machine up a little spacer for our custom alternator and water pump setup. The spacer slips into the eyelet, reducing the ID to match the bolt. This eliminates the ‘play’ while also bringing the eyelets to a more level position.

Also purchased an Aeroflow Performance billet oil filter block adapter. This is significantly shorter than the standard Z9 filter and will make room for the Davies Craig EWP. Credit for this idea goes to Oscar from Tough Garage, check out his channel on YouTube for some custom Cortina work.

Looking forward to continuing this project after we wrap up some customer work!

Also a good excuse to get some more time on the lathe - this one is a Hare & Forbes Machineryhouse unit!

17/10/2021

Loving the new pipe vice combo from Sscustoms! Big help when trying to tack without an extra pair of hands around. Also saved a lot of time welding too with the pipe vice.

Unfortunately all out of argon before I could finish this dump pipe...

10/10/2021

Here we have Carl’s absolutely stunning Mazda MX-5 - in for some custom fabrication work! The car was already turbocharged, but he decided it was time to take it to the next level - very glad he has chosen us to help turn his dream into reality!

The custom tubular manifold (low mount) has been largely completed using 1-1/4” SCH40 mild steel bends and our own custom 4-1 collector.

Some machining had to be done to the V-Band weld on fl**ge to get it to seat nicely into the turbine inlet.

The turbo is an Aeroflow Performance 4849 with a 0.72 rear housing. As always, boost control is taken care of by a Turbosmart Gen V CompGate40

Still a fair bit of work to do, but there’s never a dull moment with this MX-5. Carl has put a lot of effort into this car over the years, and we love the DIY attitude. From front to back, we love this car and look forward to delivering something unique that he will be proud of!

Steel supplied by ECS Exhaust | V-band fl**ge by Garrett - Advancing Motion GCG Turbochargers Pty Ltd | Welding Supplies by Oz Welding Supplies Weldporn

29/09/2021

Some more fabrication on the 250 crossflow. Welded on some -10AN fittings for the breathers as well as a filler cap - just need to finish the surface and then powder coat!

Started off with an Aussiespeed Performance Products cast rocker cover, grabbed some -10AN fittings and machined up some aluminium rings. The logic behind the rings was to weld them to the fittings from the underside, then weld the ring to the rocker cover. This gives enough room to then take back the weld and create a ‘flush’ finish. This involved drilling and adding some fresh filler material to the rocker cover casting before welding.

We then drilled a new hole for the filler cap thread - which was also welded in and cut back to create that seamless look.

Have a couple of awesome Proflow -10 right angle fittings for the breathers.

Welded using Ally5 cups supplied by | Razor 200ACDC

23/09/2021

Some more progress on the Cortina project - custom Water Pump and Thermostat Housing block plates with -16 fittings! Still some finishing to do around the edges before powder coat.

We will be installing a Davies Craig EWP150 on this with all braided lines and AN fittings. This meant that the mechanical water pump and thermostat housing were no longer needed.

We used some 12mm alluminium plate and cut out the shape of both components that were removed. We then fabricated some -16AN fittings to match the fittings on the new water pump.

All of this will eventually be controlled by the ECU, so the pump will only be activated under certain pre-determined operating conditions. Being able to circulate coolant after shut-off will be another advantage. Another huge bonus is the amount of room saved at the front of the motor too.

Welding equipment by Oz Welding Supplies including Ally5 cups | Blue Demon Welding Products tungsten | UNIMIG Razor 200ACDC | Aeroflow Performance Alternator

17/09/2021

We had Dimitri bring in the water box from his Seadoo RXT 300. The casting had completely corroded and wouldn’t hold the water temp sensor anymore.

Rather than buy a new one, we were able to repair his existing one. Contaminated cast alluminium isn’t the easiest thing to weld and it rarely turns out pretty. Luckily we were able to ‘replace’ some of the alluminium with some fresh filler material before welding in a new thread fitting from Raceworks.

He’s put a few hours on the ski since and happy to report the repair went flawless!

13/09/2021

Custom front mount intercooler setup for Matt’s Hilux!

We started off with a Proflow intercooler, shortened the outlets and fabbed on some Aeroflow Performance 90 degree cast elbows.

Matt was after something a little different to the off-the-shelf options, so we came up with this design. We welded in the right b**g for the factor AIT sensor - tuner was happy to report back some very efficient temperatures post cooler.

What a tuff looking Hilux!!

Oz Welding Supplies supplying the cups and Weldporn tungsten | UNIMIG Razor 200ACDC