fit it in!!
pics damnit
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Rebuilding Greg's Sierra
soory guys, i don't have immediate access to a digital camera, but i'll try to get it organised some time soon.
Todays Update from the weekend, we got the engine and gearbox out of the front cut along with the wiring loom.
The wiring loom has been cleaned of all the electrical tape and wrappings and has been partially stripped. Apparently we are planning to get access to a cap wiring diagram tomorrow (tuesday), so from that we should be able to get the whole loom down to the bare minimum.
The gearbox has caused a problem. The box is essentially the same as a 1L box but with an extension attached to the end (where the 5th gear sits) and another extension on it to put the shifter in the right place in the cap. However, in the sierra, this is going to put the shifter where the hand brake is, this is not ideal, and unfortunately the 1L gearbox will not bolt onto the engine... so, after much checking and bolting up and unbolting, the new plan of attach is as follows:
Get a 1L gearbox that is in good condition, get the 4 speed gears out of it and put them into the cap box, then stick the extension housing from the 1L box onto the end of the cap box (it will fit now except that the gears in the cap stick out into where the housing would bolt on, this is why we need to swap the gears).
But, appart from that, the build up is going pretty smoothly.
We opened up the EFI tank and everything in there is in as-new condition which is always nice to get.
As for the body swap, i'm currently trying to get organised to get the whole body swapped over at the same time as the engine swap which may all get started (not necessarily finished) on the weekend of the 31st may (fingers crossed).
so currently everthing is going very quickly
Days since offroad is now up to 15... i'd love to keep it below 45
Anyone in melbourne have a 1L box in good nick? let me know.
Thanks.
Todays Update from the weekend, we got the engine and gearbox out of the front cut along with the wiring loom.
The wiring loom has been cleaned of all the electrical tape and wrappings and has been partially stripped. Apparently we are planning to get access to a cap wiring diagram tomorrow (tuesday), so from that we should be able to get the whole loom down to the bare minimum.
The gearbox has caused a problem. The box is essentially the same as a 1L box but with an extension attached to the end (where the 5th gear sits) and another extension on it to put the shifter in the right place in the cap. However, in the sierra, this is going to put the shifter where the hand brake is, this is not ideal, and unfortunately the 1L gearbox will not bolt onto the engine... so, after much checking and bolting up and unbolting, the new plan of attach is as follows:
Get a 1L gearbox that is in good condition, get the 4 speed gears out of it and put them into the cap box, then stick the extension housing from the 1L box onto the end of the cap box (it will fit now except that the gears in the cap stick out into where the housing would bolt on, this is why we need to swap the gears).
But, appart from that, the build up is going pretty smoothly.
We opened up the EFI tank and everything in there is in as-new condition which is always nice to get.
As for the body swap, i'm currently trying to get organised to get the whole body swapped over at the same time as the engine swap which may all get started (not necessarily finished) on the weekend of the 31st may (fingers crossed).
so currently everthing is going very quickly
Days since offroad is now up to 15... i'd love to keep it below 45
Anyone in melbourne have a 1L box in good nick? let me know.
Thanks.
DMA Founding Member #1 - Now Retired
thanks NAM, yeah it's moving along fairly quickly... thankfully the fellow who is doing most of the work for me is super keen to get it going too which always helps...
plus i'm finding that the more people i tell about the project, the more i find people who want to help out... for example, a mate of mine that works in a support crew for the v8 supercars said that he could build me an intercooler for it - all we have to do is provide him with the measurements and he'd whip it up for me
plus i'm finding that the more people i tell about the project, the more i find people who want to help out... for example, a mate of mine that works in a support crew for the v8 supercars said that he could build me an intercooler for it - all we have to do is provide him with the measurements and he'd whip it up for me
DMA Founding Member #1 - Now Retired
Today's Update
The 1L gears fit straight into the cap box ... this gives us two options
1. run the 1L gears in the cap box, this is not ideal because the 1st gear is 3.1xx i think, where the cap 1st is 3.4 which is really going to improve the crawl ratio of the car...
2. the best option, to take the individual gears off of the cap shaft and put them onto the 1L shaft... this will mean we get the lower 1st and all the gears are bigger than the 1L versions...
Both of these setups allow us to run the 1L gear shifter stick so it looks like the delemar may be over and the cap box should line up nearly exactly where the gear box was before
as you may be able to tell, i'm rather pleased
Apparently we are also getting our hands on the Cap wiring diagram today too so the stripping of the loom should get a whole lot easier now
The 1L gears fit straight into the cap box
... this gives us two options
1. run the 1L gears in the cap box, this is not ideal because the 1st gear is 3.1xx i think, where the cap 1st is 3.4 which is really going to improve the crawl ratio of the car...
2. the best option, to take the individual gears off of the cap shaft and put them onto the 1L shaft... this will mean we get the lower 1st and all the gears are bigger than the 1L versions...
Both of these setups allow us to run the 1L gear shifter stick so it looks like the delemar may be over
and the cap box should line up nearly exactly where the gear box was before
as you may be able to tell, i'm rather pleased
Apparently we are also getting our hands on the Cap wiring diagram today too so the stripping of the loom should get a whole lot easier now
DMA Founding Member #1 - Now Retired
End of Week update...
Well, unfortunately everything has slowed down a little this week - which i guess is to be expected at some stages...
1. The 1L and Cap gears weren't an exact match :( , so the cap box was reassembled and some work will have to be done to it to make the gear stick line up with where the 1.3 5speed gear stick would sit...
2. The wiring diagram has gone missing from the source so we are continuing to hassle the fellow with it :(
However, in the good news department:
1. The cap box is going to line up perfectly with where the 1.3 5speed was... so the whole in the floor is right as is, the 5speed gearbox cross member is in the right position.
2. The engine mounts are the right width for the sierra chassis.
3. The two engine mounts will have to be moved - but not by much... one will be brought back 50mm, the other will be 100mm... This suggests that this engine swap would actually be easier in a 1L body/chassis...
4. The soft top body is now in our posession. and it looks like the plan will be to get the body swap done ahead of the engine swap...
5. I have tracked down a windscreen frame without any rust in it
Well, unfortunately everything has slowed down a little this week - which i guess is to be expected at some stages...
1. The 1L and Cap gears weren't an exact match :( , so the cap box was reassembled and some work will have to be done to it to make the gear stick line up with where the 1.3 5speed gear stick would sit...
2. The wiring diagram has gone missing from the source so we are continuing to hassle the fellow with it :(
However, in the good news department:
1. The cap box is going to line up perfectly with where the 1.3 5speed was... so the whole in the floor is right as is, the 5speed gearbox cross member is in the right position.
2. The engine mounts are the right width for the sierra chassis.
3. The two engine mounts will have to be moved - but not by much... one will be brought back 50mm, the other will be 100mm... This suggests that this engine swap would actually be easier in a 1L body/chassis...
4. The soft top body is now in our posession.
and it looks like the plan will be to get the body swap done ahead of the engine swap...
5. I have tracked down a windscreen frame without any rust in it
DMA Founding Member #1 - Now Retired
Greg,
Speaking to the guys up here at Suzisport about what they're building in their new race car, and they're seriously considering one of the high tech import twin cam 1 litre engines, and then turbo charging it (as opposed to a 1600 with a GTI head).
You've halved your capacity so it's gonna be hard to make up for that. Having said that there have been people who have got over 200 horsepower out of those cappacino engines - base power is 64hp (48kw) so heaps more than a standard sierra 1.3 or 1.0 is gonna happen without too much effort, although they do miss out on torque relative to the bigger capacity.
Dunno how they'll cope with the load at low speeds though. I heard about 800cc bottom end crossbreeding but dunno the final results.
Good luck and keep us posted.
Speaking to the guys up here at Suzisport about what they're building in their new race car, and they're seriously considering one of the high tech import twin cam 1 litre engines, and then turbo charging it (as opposed to a 1600 with a GTI head).
You've halved your capacity so it's gonna be hard to make up for that. Having said that there have been people who have got over 200 horsepower out of those cappacino engines - base power is 64hp (48kw) so heaps more than a standard sierra 1.3 or 1.0 is gonna happen without too much effort, although they do miss out on torque relative to the bigger capacity.
Dunno how they'll cope with the load at low speeds though. I heard about 800cc bottom end crossbreeding but dunno the final results.
Good luck and keep us posted.
post weekend upate:
Had Rodified put in the 5.12 diff gears, and while he was at it, had the brakes worked on and some front wheel bearings replaced too...
drives as nice as ever
- stops quicker than ever - drives slower than ever
Measurements have been done for the intercooler - its going to be the exact same width as the sierra 1.3L radiator (inside core measurements of 420mm x 200 (approx) )... which i believe is about 2.5 - 3 times the size of the cappaccino gearbox... sweet
Looms for the air lockers and winch were also removed in preparation for the body swap.
Body swap is planned for 14th June
oh, i finally took some photos - but only with a normal camera - sorry
Had Rodified put in the 5.12 diff gears, and while he was at it, had the brakes worked on and some front wheel bearings replaced too...
drives as nice as ever
- stops quicker than ever - drives slower than ever
Measurements have been done for the intercooler - its going to be the exact same width as the sierra 1.3L radiator (inside core measurements of 420mm x 200 (approx) )... which i believe is about 2.5 - 3 times the size of the cappaccino gearbox... sweet
Looms for the air lockers and winch were also removed in preparation for the body swap.
Body swap is planned for 14th June
oh, i finally took some photos - but only with a normal camera - sorry
DMA Founding Member #1 - Now Retired
Post Weekend Update:
Finally some real physical progress... we got a few members of the vic suzuki club together on the weekend and did the body swap...
Don't fear though - there were plenty of photos taken this time so once i get my hands on them, i'll get them posted up.
A quick write up on what else is happening is as follows:
1. Intercooler being built - slowly
2. Front inner guards on the new body were completely removed
3. Battery and air compressor were relocated to behind the passenger seat (temp placement).
4. Currently soucing my whiz bang Duel Stage Boost Controller and a few guages to hide in the dash somewhere.
5. Also sourceing some seats for the new body too.
6. Part way through building up the adaptor plate for the cap gear box.
7. Dump pipe and exhaust being built also - exhaust is being made from 2.25" tube. Using a cat from a Commodore.
8. Planning the fuel tank placement - going to go infront of the rear axel, behind the seats - sub mounted in the floor - as low as we can go without it being hit by the diff / drive line.
The whole thing is taking a long time, but it was great to get one of the two big jobs out of the way
Finally some real physical progress... we got a few members of the vic suzuki club together on the weekend and did the body swap...
Don't fear though - there were plenty of photos taken this time so once i get my hands on them, i'll get them posted up.
A quick write up on what else is happening is as follows:
1. Intercooler being built - slowly
2. Front inner guards on the new body were completely removed
3. Battery and air compressor were relocated to behind the passenger seat (temp placement).
4. Currently soucing my whiz bang Duel Stage Boost Controller and a few guages to hide in the dash somewhere.
5. Also sourceing some seats for the new body too.
6. Part way through building up the adaptor plate for the cap gear box.
7. Dump pipe and exhaust being built also - exhaust is being made from 2.25" tube. Using a cat from a Commodore.
8. Planning the fuel tank placement - going to go infront of the rear axel, behind the seats - sub mounted in the floor - as low as we can go without it being hit by the diff / drive line.
The whole thing is taking a long time, but it was great to get one of the two big jobs out of the way
DMA Founding Member #1 - Now Retired
i especially liked the bikini top.
1. softop with stuffed windows, zips and buttons
2. a rusty exacto knife
3. 2x pieces of rope
4. 2xstraps with clips
5. cut off bits you dn't want
6. cut love heart in rear roof section for custom rear window
7. cut custom rear straps from rear roof section
8. attach rope to cut up rear roof straps with a truckies hitch or something like that
9. attach rope to straps and clip to body
10. use pink gaffer tape to attach the flaps around the door bits as velcro is stuffed
11. remove love heart rear window as it may appear to be a bit silly
12. leave custom pink pin striping
1. softop with stuffed windows, zips and buttons
2. a rusty exacto knife
3. 2x pieces of rope
4. 2xstraps with clips
5. cut off bits you dn't want
6. cut love heart in rear roof section for custom rear window
7. cut custom rear straps from rear roof section
8. attach rope to cut up rear roof straps with a truckies hitch or something like that
9. attach rope to straps and clip to body
10. use pink gaffer tape to attach the flaps around the door bits as velcro is stuffed
11. remove love heart rear window as it may appear to be a bit silly
12. leave custom pink pin striping
Ransom note = demand + collage
Schedule Update:
Boost Controller, Boost Gauge and Oil Pressure Gauge ordered today, expecting them by wed next week.
Removing Engine, Gear Box and pink gaffer tape this weekend (fingers crossed)...
Ah progress, is there any other action that makes you feel like something is actually happening
Boost Controller, Boost Gauge and Oil Pressure Gauge ordered today, expecting them by wed next week.
Removing Engine, Gear Box and pink gaffer tape this weekend (fingers crossed)...
Ah progress, is there any other action that makes you feel like something is actually happening
DMA Founding Member #1 - Now Retired
here are all the pics I took at the body swapalooza
http://www.suzuki-4wd-club.rockcrawler.com/trips/body/index.htm
http://www.suzuki-4wd-club.rockcrawler.com/trips/body/index.htm
Ransom note = demand + collage
Post weekend update:
Old engine out, new engine in. Mounts moved to suite the mighty 3 cylinder screamer.
Gear shifter issue has been fixed. Old fuel tank removed. A hole has been cut in the floor to fit the new fuel tank into.
May have found some seats, windscreen, full doors and tail gate (finally )
Don't worry, i've already reminded myself about getting access to a digital camera.
We have access to an engine crane too, so i might just have to do that "pick up a tyre trick" to see how it looks
cheers,
Old engine out, new engine in. Mounts moved to suite the mighty 3 cylinder screamer.
Gear shifter issue has been fixed. Old fuel tank removed. A hole has been cut in the floor to fit the new fuel tank into.
May have found some seats, windscreen, full doors and tail gate (finally
)
Don't worry, i've already reminded myself about getting access to a digital camera.
We have access to an engine crane too, so i might just have to do that "pick up a tyre trick" to see how it looks
cheers,
DMA Founding Member #1 - Now Retired
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