Outer Limits 4x4 Board

don't let it rest man

fit it in!!

pics damnit

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.

good stuff greg!

it's a shame about the gearbox issues but it seems like you're on top of it

this is gonna rock! i'm really digging it.

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

apparently a 5spd box can be made to suit a 1.olitre sierra, if ya would like. speak to suziworld, but I think it uses gears from a super carry, into the sierra box. if the sierra box bolts the same to the block, it may be goodly.

yes i found that there are many people who would go out of their way to give you a hand. not always in grand ways, but they genuinely have an interest in your project. that's always a really good help. FEEL THE LURV!

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

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

a mixed bag... but there's more good than bad

yes but a few more good would be nice...

days since locking hubs now equals 19... :(

how many more days before i loose my title of "wheeler" and officially become a "web wheeler"... that would be the end of it i think.. :(

hold on greg
where here for you man
try going in to the back yard and pretending how good your new rig will be
caution: this will only keep urges away for so long before you will steal a mates car and go bush

camo 8)

Hoorah!!!

Days since locking hubs back to 2 again... we snuck out the smokey truck on saturday night for some light mud running

Not much progress to report....

but new diff gears due to go in on wednesday

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.

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

dont go too large on the intercooler as the turbo is only small and will not boost up with a large intercooler.

It is a common problem with people putting massive front mounts on the 4AGZE supercharged toyota engine.

I have to agrree with Mick here an intercooler that size is to big it will loose you hp rather than gain it.We have dynoed many a car with a huge truck intercooler and they were more laggy and less power than a smaller one.
SAM

thanks guys, i'd get some more investigation done before we go ahead and make / fit it.

I agree too big a intercooler is gonna do more harm than good. Just use the stock one for now - we wanna hear the beast up and running......

Even with the stock cooler it still should be pumping out nearly twice the power of your old stuffed 1.3 engine

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

here are start and finish pics. I'll post some more when i get around to it

damn that droopy pete and his pink tape...

i assure you the pink looked much better once it was muddy

cool!

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

greg wrote:Post Weekend Update:

Looking good Greg, sorry I couldn't come and do that spit roast for everybody, got any pics of the inner guards (Or what is left of them).

Are we still on for the doors??

Big Steve

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

I hope removing the pink gaffa tape exposes some pink primer
Peter.

here are all the pics I took at the body swapalooza

http://www.suzuki-4wd-club.rockcrawler.com/trips/body/index.htm

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,

im confuzed here, why did you do a body swap when you are putting a new engine in anyway? why dont you just put the new engine into the new car along with anything else you want like suspension, rather then swapping the whole danm chassis!!??

Ah, no...

We kept the chassis (inc suspension etc), but replaced the hardtop body with a soft top body.

I decided that the Soft Top body (plus roll cage) was more "rollable" than the hardtop body.

Hope that clears things up.