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 Post subject: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 1:51 pm 
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I've been working on this since May of 2009 so i'll try to go through my ordeals with what I was planning to do and what I am currently doing.

After I got a wicked GST check I decided to waste it all on making my dream build. I sourced out a '92 GTi engine with everything I needed for $500. ECU, harnesses, mounts, steering column, etc. The only thing I needed was a car for the swap and a few other misc parts. I ended up finding a Sprint turbo for $350. It was very rusty, had a smashed windshield, extremely coolant leak and bad brakes. So technically, I had almost everything I needed to get the swap into gear.

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Nick Manning

2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:00 pm 
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Being the hasty person that I am, I changed out the radiator for a spare one that I got from pile of parts for the GTi. After that I went for quick fixes on the exterior of the Sprint and rattle canned it black.

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I then proceeded to take it to Race City and, with bad brakes and a very bad rear passenger bearing, it pulled 17.340 @ 79mph. Pretty decent considering.

After that I addressed the front brake issue. Whoever owned this car before me decided it was easier to add brake fluid to the master cylinder than it was to replace the brake pads.

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So I did what I had to do. It's nice being able to stop without fear.

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:08 pm 
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Shortly after that fix, I drove the Sprint to Crowsnest Pass. On the way back, the rear passenger bearing went and it was $146 tow back to my parents acreage. I deserved that. So I promptly went out and got new drums and new bearings for both sides.

Once that was working well again. I started to realize that this was not the way to go for this project. I decided a new shell with as little rust as possible was the bet route to take. Thanks to Codyb76, I purchased an SOHC shell that was in much much much better shape than the Sprint could ever be. Plus it came with some more random goodies that would aid me in the swap.

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Unfortunately the interior was pretty crappy, but lucky for me the Sprint's interior was in terrific shape, so I wasn't too concerned.
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Nick Manning

2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:11 pm 
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The first thing I got around to was getting rid of that god aweful interior. That was a fun experience. I broke a few things learning how to remove them but lucky me I have a Sprint to replace any part that I didn't want or need. The dash didn't come out for a few months after this.

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I found some rust and holes but they will be dealt with in the near future once the car is up and running.

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Nick Manning

2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:16 pm 
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Things came to a standstill since I had to work in my driveway and had no shelter to work on it over this delightful Alberta winter.

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I did a few random things while there was snow on the ground, including making the ECU harness a little prettier.

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Random pile of parts that came from the GTi and the Swift.

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Once things started to warm up again, I got right back to it. Easiest thing to do on the list was figure out how to remove the dash. Turns out I missed about 8 screws even after I thought I removed every screw I could find. I also did a lot of cleaning and rust inhibiting so that it wouldn't get worse.

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:21 pm 
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After the cleaning and dash removal I got down to business. I swapped the ECU harness which was probably the easiest thing I could do, as well as replacing the SOHC ECU, fuse box and fuse panel for the GTi's.

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Since the weather was still a little on the icky side, I decided to get the little things looking a little better. Cleaned and sprayed the calipers, rotors, and drums with some high temp caliper paint.

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Nick Manning

2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:30 pm 
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Since I was going to be using the tranny from the turbo3, I needed to deal with that. A buddy came over and helped me prep the turbo3 to be extracted. It's a lot easier to take an engine out of a car when you don't give a crap if you cut wires/hoses/etc.

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Holy crap was there ever a lot of caked on oil everywhere.

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Two cans of degreaser (Slapshot will be the only degreaser I ever use from now on) and the tranny was looking spiffy.

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I also found out that it's a good thing I wasn't using the Sprint. I was rusted beyond belief. The side skirts gently fell off the car because of the rust, the back bumper was almost rusting off, there was no front passenger fender, and i'm actually kinda worried to see the condition of the floor under the carpet of the Sprint.

This is a pic of me holding the catalytic converter that wasn't actually attached to the car because of rust. That's my reaction face.

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Nick Manning

2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:37 pm 
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While I was doing a few other things, I ordered a new "Stage 1" clutch off eBay. Figured since I resurfaced the flywheel that a new clutch would compliment it.

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Now down to brass tax. The guy who helped me get the turbo3 prepped also lended me his engine hoist. Thank goodness for that, because i'm pretty sure it would have been impossible to do the drop without it. In one session, I installed the turbo3 alternator, freshly painted engine mounts, flywheel, clutch and tranny onto the GTi engine. I then hoisted it over to the Swift and lowered it into place. The front mounts were super easy to deal with. The back mount took me an hour and a half to deal with. But after all pain and anger it bolted up and the engine was in place.

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Nick Manning

2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:43 pm 
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Forgot to mention that before I dropped the engine in, I swapped the wire harness that goes around to the headlights. That wasn't as hard as I was expecting it to be. Just kinda tedious and made my back hurt.

So the hardest step was complete. Now all that's left to do with the engine is attach the electrical, attach the hoses (PAIN IN THE ASS), and install the exhaust manifold.

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Oh yeah, threw in the steering wheel just so I can move the bitch around a little easier.

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 17, 2010 2:51 pm 
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Location: Calgary, Alberta
AT this current time, this is my final list before I think it will be driveable.

- attach shift linkage
- connect steering column wiring
- install driveshafts
- swap fuel tanks/pumps
- install radiator and hoses to and from it
- block off unused vacuum lines
- install intake piping (coming in the mail) and MAF
- install exhaust mani
- install a seat

EDIT: Figured out the clutch issue. Stupid me didn't realize I had to put the arm on a little further forward then pull it back where resistance is felt before tightening the screw to the clutch line. Feels like a clutch pedal now.

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Nick Manning

2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Apr 24, 2010 4:57 pm 
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Quick update, did a lot of work on it, some rust prevention, got things closer to being complete.

Shift linkage attached, drive shafts in, drivers seat in, swapped fuel tanks, threw on the exhaust manifold, dropped in radiator, found the lower rad hose (thanks Codyb76), ordered some silicone rad hoses hopefully in blue, still waiting for my Stage 2 intake from suzukird (been 2 weeks and order is still "processing"), threw some cheap oils into the engine and tranny to clean them out a little bit before the good stuff goes in.

So as of today, this is where Derp is standing.

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1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Wed May 05, 2010 7:46 pm 
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Update: called Suzukird about my intake and exhaust gasket, turns out they are out of filters with 3" connector so they were just waiting or something stupid. Either way they are going to be making sure it will be completed and sent out by friday. Also received my eBay silicone rad hoses. They do add a bit of flare and will go nicely with the other blue stuff I have. Since the weather in Calgary has been balls the hoses have been resting in my living room.

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I have encountered a potential problem. 4 ribbed pulleys and the alt pulley is offset by one rib so I can fit a 3 ribbed belt but not a 4 rib. Will this work? If not, would using a washer or <insert solution her> set it to the right distance? And what sized washer or whatever would I need to make it all even with the other pulleys? Pic of it here:

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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Fri May 07, 2010 5:10 am 
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Good project! i am going to do same but with later model swift.

Could you tell me where wiring for coil is coming from? i got engine loom and engine bay loom but dont think either of them ahve plug for coil so i though maybe it coming from fuse box?

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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Fri May 07, 2010 8:24 pm 
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daymoon wrote:
Good project! i am going to do same but with later model swift.

Could you tell me where wiring for coil is coming from? i got engine loom and engine bay loom but dont think either of them ahve plug for coil so i though maybe it coming from fuse box?


The plug for the coil comes from the wire harness that goes to the headlights. Wraps around to the headlights and heads back to the firewall and across.

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1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Thu May 13, 2010 12:05 am 
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Hit a road block. The electrical is messed up. I had everything plugged in to where I thought it would go. Turns out I had everything but one thing properly plugged in. But that was enough to make it so the starter wouldn't crank, all the exterior lights wouldn't work, the light switch would occasionally act as if the key were being turned. So we switched the inner fuse panel between the supposed GTi one, the SOHC panel, and the turbo3 panel to see what the differences were and if it would help. Still nothing. Then we tried the turbo3 steering column and still nothing. Now I think I have to swap out the gauge cluster/light/accessory control harness to get things working. Still no idea on the starter issue though. Starter didn't even click despite us bypassing the ignition and using a screw driver.

So yeah, any thoughts?

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Thu May 13, 2010 5:14 pm 
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it sounds to me as if the ignition switch isn't turning on the main relay in the relay and fuse rack under the hood.

the starter switch has a wire that runs directly to the stacon spade connector on the solenoid. the starter has a 6 ga. cable directly to the battery anode and the battery cathode has a cable that runs to a big lug and bolt on the transmission housing.

when you roll the ignition switch to it's first detent it energizes the main relay and when you roll the switch to the starter position it sends 12v directly to the starter solenoid. if the starter doesn't engage and spin the engine, check all of those connections.

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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat May 22, 2010 6:09 pm 
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t3 ragtop wrote:
it sounds to me as if the ignition switch isn't turning on the main relay in the relay and fuse rack under the hood.

the starter switch has a wire that runs directly to the stacon spade connector on the solenoid. the starter has a 6 ga. cable directly to the battery anode and the battery cathode has a cable that runs to a big lug and bolt on the transmission housing.

when you roll the ignition switch to it's first detent it energizes the main relay and when you roll the switch to the starter position it sends 12v directly to the starter solenoid. if the starter doesn't engage and spin the engine, check all of those connections.


Mind throwing some pics over to show me what you mean? I did the positive and negative battery terminals and grounds in the proper places. I got a mechanic friend to bypass the ignition and send 12v to the starter and still nothing happened. We found out the GTi under-dash fuse panel I had was melted at one spot so I switched it out for the turbo3 panel which looked exactly the same and still nothing. Starting to get desperate for help on this one.

Pic of the starter for shits.
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OH YEAH! I got my SuzukiRD Stage II intake after waiting 44 days for it. Looks great but doesn't fit. Plus they forgot to send a clamp for the filter. Plus it's a red filter so I think they were just trying to get my order out the door and gave me whatever fit.

Seems to be too close to the damn headlight.
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Here's a pic of the engine bay and hoses right now. Looks great but has yet to show any life beyond some dash and gauge cluster lights working.
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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Tue May 25, 2010 12:45 am 
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Two steps forward and four steps back. Doesn't it always work that way. Since I am still stuck with the whole electrical thing, I did a few other things to keep me busy. Went out and got the clamp that I was missing and managed to squeeze the filter in place. Turns out it fits just barely. So all that's left for the engine is getting a T-fitting to get the breather going back to the intake through the ISC hose since the intake wasn't built with two lines. Oh yes... eventually I will deal with the crappy valve cover paint.

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I also got me some sandable primer so that, when I figure out what paint to use, I can just tape everything off and go to town on the colour of my choice. In the process I also re attached the bumper, headlights, turn signals and lower lights. I know I just turned the colour of the car back to stock SOHC Swift but it looks a lot better than faded red and it won't be that colour for ever.

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Tue May 25, 2010 10:32 pm 
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Today I finally got around to checking all the grounds. Found out that I missed ONE! Attached that ground and poof, all the lights and signals worked. The only thing that didn't work was the washer fluid but I might have plugged in the wrong wire... or none yet i'll have to check.

Before I was able to figure out about the ground, I had to undo everything I had done the past few days. I was hoping to use the Turbo3's dash buttons instead of the steering columns buttons because I like the look more. Unfortunately a whole shwack of things didn't connect properly and it just became a large hassle so I switched the under dash harness back to what it was. I also did a quick swap of the steering column controls with another set I had because the ones on the GTi column were sort of broken when I got them.

While I was messing with the under dash wiring, I decided to see if the problem with the inability to start the car was due to the clutch sensor. So I pulled the sensor I knew was good from the Turbo3 and attached it to the wire and tried to start it. Still no luck. I'm really starting to think the starter is hooped because, like I said before, even when we tried hot wiring the starter it did absolutely nothing. Not even a click.

SO! Maybe if the weather holds out i'll see if connecting the wires to my Turbo3 starter will determine if it's a starter issue or a wiring issue. If it's a starter issue, starter swap! If it's a wiring issue, shit rigged starter wiring!

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Wed May 26, 2010 9:16 pm 
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Turns out I did something right today. I switched out the starters because I thought that could help. I tried the key turn method and nothing happened, but then I did ignition bypass method and BOOM! Started up like a champ. And here's a vid to go along with it!

http://www.youtube.com/watch?v=hHA9BAPaUHY

All that's left are running some good fluids through it and getting it insured and registered, then off to the exhaust shop.

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Nick Manning

2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sun May 30, 2010 10:44 pm 
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The car is insured and registered so it's allowed on the road.

Today I replaced the crap tranny oil with GM Syncromesh, bled the brakes so now it feels nice and stiff and not all spongy, and attached a starter button that I rigged together from the Turbo3's clutch switch and some 8ga subwoofer wire.

The only things that I have yet to get working on the car are the horn and wiper fluid squiter. Any suggestions on what might be the issue would be appreciated (yes I tried a search for it).

Probably in the next few days i'll source a decent nearby muffler shop to fab up the missing 3 feet of tail pipe so my GTi isn't 3 billion decibels. And then from there, its just a matter of driving it 800km to get the clutch ready for some fun.

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Jun 05, 2010 11:50 pm 
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So, I managed to get 200km out of it before shit started hitting the fan.

Two things are happening now and i'm only somewhat sure where to start.

1) Turn signals have stopped working and have been replaced by the turn signal relay buzzer. Taking it to the muffler shop, I went over some train tracks which caused the relay to buzz. Drove it to work so I could take it to my mechanic friend's shop and the signals started working again. Stopped working the day after. I'm pretty sure I have a wire that's either grounding or crossing but i'm not sure from where. I replaced the relay and fuse panel, checked all the fuses and bulbs. Everything there is good.

2) The car was running great until the day after I put a fresh tank of regular Shell gas in. After that the car started to die at idle. I upped the BISS because I turned it down a lot after I got the engine running but that did nothing to help. As of now at idle it starts fine when it's cold but the moment it starts to get warm the idle becomes erratic and chuggy and eventually dies.

I have yet to get a check engine light for anything and the car still runs well in rpms above 1500 (no tach so not sure exact rpm) and there is no rpm cap either. So yeah... not really sure what to do beyond replacing things one by one. Over the next little while I will be changing the plugs & wires, the PCV, cap & rotor. Not sure if any of that will help but the car needs them regardless.

Any info would help. I tried the search for this problem and the results I got didn't help me much. Apologies in advance if someone does find something I didn't.

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Oct 09, 2010 4:29 pm 
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Okay been neglecting this yet again. It was an interesting time to get things up to par and things seemed to be going well for a while. Took the car out to CodyB, he fixed a ton of electrical issues and the car was doing quite well. I managed to get it to the track for a friday night Secret Street. The car pulled 16.836 @ 78.37mph. I was pretty proud of that time although I know I could have done better if I didn't add $10 premium.

And now to the real crap.

As of this time the car is still driveable, but is having some serious rpm issues. At first the car was doing a crazy rev up and down thing most likely caused by the IAC or PCV. Once it warmed up though the rpm would calm down... a little too much. When it was warm the car would just chug and eventually die. So because of this I took the insurance off the car and it will be going to Ponoka for the winter unless I can get some worth while insight on what the problem may be.

Just for shits I decided to start it up yesterday to see how it was sounding after sitting for a few weeks. BAD. When I started it up it was sound really chuggy, the idle was crappy. I revved it a few times and it evened it out a little but still wasn't sounding too good. So I took it for a spin. It was really jerky and had the same lack of power from accelerating at lower rpm. Once it was warm I let it idle and the crazy rpms didn't stop (1400-1900 every two seconds over and over). So yeah... no idea whats going on. If it's an easy fix that can avoid me sending it to Ponoka then i'm all ears. If not... shit.

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Oct 09, 2010 4:39 pm 
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BTW, some updated interior pics. I actually added the second seat a few months back, but this is pretty much the condition of the interior. Added dash, door panels, GTi gauge console, and turbo3 drivers side mirror.

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As for the engine, I rerouted the breather back into the intake via a T connector to make the vacuums as stock as possible. I'll be adding an oil catch can to the mix eventually. And while we're on the subject of future mods, I want to at least purchase real lowering springs, new shocks, an underdrive light weight crank pulley, and a new shift knob.

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2006 Scion xB (fun-mobile)
1990/92 Suzuki Swift GTi TURBO (The GTiT)


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 Post subject: Re: My SOHC to DOHC swap
PostPosted: Sat Jan 15, 2011 7:31 pm 
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Small update for the winter:

The car is in Ponoka getting fixed up by Codyb76. So for the time being i'm just chillin' and thinking of what I need to do when I get the car back.

As of January 11th, I ordered SuzukiRD's 1.6" lowering race springs, aluminum single crank pulley and belt to go with it. So just waiting for those to come in so I can store them away until further notice.

When more money is acquired, i'll still only do small upgrades and fixes. The biggest issue is the rust and the pools of water that get into the car when it rains. That'll be fun...

Of course I shall keep everyone informed about the happenings.

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