Rebuilding Greg's Sierra

Post by **grimbo** » Fri Jul 11, 2003 10:23 am

The work involved with swapping the body was minimal. it took about 6 of us a day to swap the body over. Whereas swapping the suspension etc over would have involved extending the chassis for the rear springs up front. Wiring up all the air locker stuff etc. The donor car for the soft top body was basically just a chassis and Body no engine no wiring loom etc.

Post by **greg** » Mon Jul 14, 2003 3:26 pm

Fuel tank is sitting nicely in the back floor just behind the rise in the floor from the front seat area.

Engine and Gear box are all mounted up (give or take a few seals etc), ready for the wiring to happen.

It looks like i have finally found a wiring diagram too

As always, no photos :cry:

Just a stack of cuts on my knuckles that i try to explain to the girlfriend and work colleagues.

Post by **grimbo** » Mon Jul 14, 2003 3:37 pm

greg

G E T A C A M E R A !!

Post by **skippy** » Mon Jul 14, 2003 3:41 pm

greg,

what wiring diagram are you after mate?

I might have a few things here on file that could be of use to you.

Post by **greg** » Mon Jul 14, 2003 3:48 pm

skippy wrote:greg,

what wiring diagram are you after mate?

I might have a few things here on file that could be of use to you.

Suzuki Cappuccino... i need one DESPERATELY!!!

I think mine is a 1992 model. F6A Motor.

any help would be great.

Thanks mate.

Post by **skippy** » Mon Jul 14, 2003 5:56 pm

fork....i dun have one.

if you had an SJ or LJ I could prolly help out. no f6a's on file.

I'll put the word out.

::::::::::::::::::::::::::::::::::::::::::::::::::::

actually. I just stumbled accross this. it may be of some use.
www.auszook.com/f6a.zip

Post by **mud4b** » Mon Jul 14, 2003 6:35 pm

i should be able to get one.

Post by **bigsteve** » Tue Jul 15, 2003 12:53 am

grimbo wrote:greg

G E T A C A M E R A !!

Hey Greg,

Will you be venturing up the mountain to the secret Cap-Development site this weekend??

I Just bought a new Camera and am keen to do some documentation work.

Steve

Post by **greg** » Thu Jul 17, 2003 2:52 pm

1 x Cappuccino Manual (including complete wiring diagram and electrical troubleshooting section) is now sitting on the floor in my lounge room.

OMG - I have never been so happy to own a book

thank goodness!

Post by **Damo** » Thu Jul 17, 2003 2:54 pm

greg wrote:1 x Cappuccino Manual (including complete wiring diagram and electrical troubleshooting section) is now sitting on the floor in my lounge room.

OMG - I have never been so happy to own a book

thank goodness!

Floor? Did you have to sell your coffee table to buy the book? :finger:

Post by **greg** » Thu Jul 17, 2003 3:19 pm

Damo wrote:Floor? Did you have to sell your coffee table to buy the book?

Coffee tables are for wimps! I rest my coffee cup on my new tyres before they go onto the car - infact i had my swampers in the lounge for a good 3 or so weeks before the car was ready for them

Would you have guessed that i live in a flat and don't have a garage :cry:

Post by **Guy** » Thu Jul 17, 2003 3:30 pm

I had some loverly wagon wheel decorations in my backyard (that is 1.8 meters wide) for a few weeks till my car was ready for 35s as well ... its a nice feeling .. at least you can be close to the parts .. if not close to using em ..

Hey Greg .. does the book tell ya how to make a short black or an affagato by any chance ???

Post by **greg** » Thu Jul 17, 2003 3:54 pm

love_mud wrote:Hey Greg .. does the book tell ya how to make a short black or an affagato by any chance ???

Yes Guy, it does.

Actually it's not even a Suzuki Manual - it's the manual that came with my Black and Decker Mr Cappuccino Urn and Milk Frothing appliance.

Post by **greg** » Wed Jul 30, 2003 5:57 pm

Well - the deadline for the engine conversion is getting closer by the hour, but thankfully things are moving forward all the time with a heck of a lot of hard work.

Quick update:
1. The CAP and Sierra looms have been reduced to their bare minimum and both installed in the Sierra body. The Sierra Loom has been powered up and we confirmed that all the electrics in the body (lights, dash etc) are all working. The CAP loom has also been powered and all the relays and computer are firing up - we just haven't connected the starter motor wire as yet.
2. Intercooler is getting some mounting points put on it, should be ready to go by tomorrow night.
3. Thermo fan and custom shroud are all in place ready to go.
4. Boost and Oil Pressure gauges have been installed in the dash - sitting a treat in the clock and air vent holes in the centre of the dash area.
5. Pod Style air filter is sitting snug under the dash out of sight - and hopefully out of harms way too.
6. Fuel tank is in place with filler setup and ready to go, wiring is complete and pump appears to be working (i.e. we can hear it), we should get the hosing all hooked up with weekend.

Note: finally some digital photo's were taken, now if i can just get a hold of them i'll post some up so that you can see what the heck i've been on about all this time.

Cheers,
Greg

Post by **Damo** » Wed Jul 30, 2003 9:53 pm

Cant wait Greg!

I also cant wait to pick up my new MIG tomorrow

Post by **greg** » Mon Aug 04, 2003 10:37 am

Here's the photo's i had mentioned, these are from last weekend on Saturday morning, so these photos are really 4 days x 2 people (8 days work out of date.

But atleast you'll be able to get an idea about what is going on.

Quick update to follow this...

Post by **greg** » Mon Aug 04, 2003 10:38 am

2 more

Post by **greg** » Mon Aug 04, 2003 10:40 am

last one.

p.s. thanks Stevoe and Chris for getting the photo's through to me

Post by **greg** » Mon Aug 04, 2003 10:49 am

And now for the quick update from this weekend:

Fuel lines hooked up,
All electrics wired in (some final placement of battery wiring still required)
Intercooler mounted
All Engine hosing connected
Exhaust (from turbo, through Cat, to 1 metre of tube) installed, still needs muffler and more tube.
All other engine doo-dads mounted to fire wall (carbon canister etc).
New Spark Plugs installed

Anyway, so after another full weekend of spinning spanners etc, we stood back at 5pm last night with our fire extinguishers and turned the key - she turned over... - then after about 15 minutes of turning over, and with a little kick in the pants via a jump start from a G-Wagon, she fired up...

Ran a little rough for about 10 mintues, but after that it was great guns... all is well with the engine... :lol:

Still heaps to do though, and it looks like the rebuilds of the cap gear box has been unsucessful (it's sticking in the synchros) so i'll try to get my hands on another g'box this week... but otherwise, it's been very successful.

etc...

More updates and photos to follow i'm sure.

Post by **skippy** » Mon Aug 04, 2003 11:40 am

fawk dude ...that's lookin shmick.

Post by **christover1** » Mon Aug 04, 2003 11:52 am

gear boxes, like all mechanicals, need to be used, it may just come good with driving, getting the new oil round all its internal bits, but I understand ya got no testing time left, before snow trip, and spare bits are always a good thing, anyway, christover

Post by **greg** » Mon Aug 04, 2003 12:03 pm

skippy wrote:fawk dude ...that's lookin shmick.

i'll try and get another more recent shot of it - wait til you see the intercooler - it's enough to make all da boys on da chapel street* jealous

* - In melbourne, chapel street is where all the ricer cars cut laps on friday and saturday nights.

Post by **greg** » Mon Aug 04, 2003 12:04 pm

christover1 wrote:gear boxes, like all mechanicals, need to be used, it may just come good with driving, getting the new oil round all its internal bits, but I understand ya got no testing time left, before snow trip, and spare bits are always a good thing, anyway, christover

quite true, and i reckon once we have an example to look at, we may be able to re-build the current one so that it will again be useable as a spare too... not a bad idea having spares around - especially since it's an imported engine / gear box i'd think.

Post by **greg** » Wed Aug 06, 2003 4:57 pm

Well, with one weekend to go before the cut off for the Suzuki Club Snow trip, we've got the list of 'to do's down to this:

1. remove and swap gearbox (including partial rebuilding of box)
2. install battery behind passenger seat
3. install handbrake (w/t hand brake had to be swapped for a n/t handbrake due to mounting shocks at the rear with the fuel tank in its new spot).
4. finish exhaust (add another metre with a few bends and a hotdog)
5. hook up wiring for rear lights
6. cut the front clip back around the grill to fit back on the car (the intercooler is where the bonnet latch used to be)
7. fit bonnet pins (see number 6)
8. make up a cover for the fuel tank in the back - i think we are using some aluminium sheeting or something like that)
9. replace a uni joint in the jack shaft
10. put the steering shaft back in
11. hook up headlights and indicators
12. build the rear shock mounts
13. prep the body for painting
14. paint the whole car, plus some extra doors, tail gates and windscreen surrounds too.
15. put seats and seat belts back in along with doors on and windscreen and b pillar on...
16. install arb compressor and locker switches in dash

17. oh, and find my numberplates that i've left somewhere and get them on too

cripes - looks like another busy weekend of crazy car stuff...

hopefully Chris(tover) will be able to make it up one of those days, so i'll try to sort out some more pics

cheers,

Post by **skippy** » Wed Aug 06, 2003 5:38 pm

greg wrote:Well, with one weekend to go before the cut off for the Suzuki Club Snow trip, we've got the list of 'to do's down to this:

1. remove and swap gearbox (including partial rebuilding of box)
2. install battery behind passenger seat
3. install handbrake (w/t hand brake had to be swapped for a n/t handbrake due to mounting shocks at the rear with the fuel tank in its new spot).
4. finish exhaust (add another metre with a few bends and a hotdog)
5. hook up wiring for rear lights
6. cut the front clip back around the grill to fit back on the car (the intercooler is where the bonnet latch used to be)
7. fit bonnet pins (see number 6)
8. make up a cover for the fuel tank in the back - i think we are using some aluminium sheeting or something like that)
9. replace a uni joint in the jack shaft
10. put the steering shaft back in
11. hook up headlights and indicators
12. build the rear shock mounts
13. prep the body for painting
14. paint the whole car, plus some extra doors, tail gates and windscreen surrounds too.
15. put seats and seat belts back in along with doors on and windscreen and b pillar on...
16. install arb compressor and locker switches in dash

17. oh, and find my numberplates that i've left somewhere and get them on too

cripes - looks like another busy weekend of crazy car stuff...

hopefully Chris(tover) will be able to make it up one of those days, so i'll try to sort out some more pics

cheers,

good stuff greg. looks like you'll be going from friday pm to early monday am without sleep

Post by **bill** » Wed Aug 06, 2003 10:17 pm

greg bill here,great to see your powering up your zook, im keen to here how she performs ,I met you at cruzakana i own the black shorty with the 4age and auto .

Post by **greg** » Thu Aug 07, 2003 9:51 am

bill wrote:greg bill here,great to see your powering up your zook, im keen to here how she performs ,I met you at cruzakana i own the black shorty with the 4age and auto .

Yeah i remember you dude - with the stainless bullbar and snorkel(s) right?

Good to have you on the board.

Cheers mate,
Greg

Post by **bill** » Thu Aug 07, 2003 10:33 pm

yeh thats me,the zooks udergoing a ute conversion at the moment ,i should come down your way one weekend to have a play are you going to the bo ho bounce?

Post by **greg** » Fri Aug 08, 2003 10:09 am

bill wrote:yeh thats me,the zooks udergoing a ute conversion at the moment ,i should come down your way one weekend to have a play are you going to the bo ho bounce?

Another ute? Cripes, what's wrong with you people?!!!!

No plans for the bo ho bounce - haven't heard anything about it as yet.

Let us know a few weeks in advance when you are coming towards melbourne and we'll try to organize something.

Cheers,

Post by **greg** » Mon Aug 11, 2003 10:43 am

Here's some progress photos from the weekend...

I'll get the writeup done later in the day.

Cheers

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Rebuilding Greg's Sierra

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