TeamSwift

Home of the Suzuki mini-compacts ! Your Home for all things Suzuki Swift, Geo Metro, Holden Barina, Chevy Sprint, Pontiac Firefly, and Suzuki Cultus. TeamSwift is a technical performance oriented community!
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Underbody braces, turbos and more!

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PostPosted: Fri Jun 22, 2007 11:10 am 
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Joined: Wed May 02, 2007 4:34 pm
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Location: Northeastern Ohio
johnsn,

What doesn't kill you only makes you stronger. Practice makes perfect.

Does that help any. :wink:

Sorry to hear about the troubles. I'm glad to see that you're slugging through it in any case.


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PostPosted: Sat Jun 23, 2007 1:13 am 
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Location: portland oregon
Voynik, Thank you for your kind words. It helps.

I cut the cowl off, and a big part of the firewall under it.
Image
I welded up a bar that bolts to the front sub-frame bolts, and measured the door mounts.
The left door was 1/4" further back than the right. :shock:
It was also down a lot maybe a 1/2".
So I cut the hinge mount brackets off.
Then I welded the top one back on so it matched the left side.
I bolted the bottom bracket on the door, and bolted the door on the car with just the top hinge. Then I shimmed the back of the door to make it parallel to the left one. And welded the bottom hinge on.
I now have two doors the same front to back, and up and down.
That's all for now. My son finely came home so I can go to bed.
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:28 am, edited 5 times in total.

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PostPosted: Sat Jun 23, 2007 7:49 am 
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Location: Eastern Ontario
Woohoo! Glad to hear things are working out and moving ahead again. I don't comment much, but I read your updates regularly.

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 Post subject:
PostPosted: Sun Jun 24, 2007 9:32 pm 
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Location: portland oregon
ImageImage Image Image Image
OK! I'm back on track. Got the right frame rail pulled up. Now it lines up with the left. I had to almost cut it off where it connects to the cowl and used a big turn buckle to pull it up.
I had to cut the floor away from the center stiffener all the way around it, and cut it from the Honda frame.
I'll post some pictures tomorrow.
john :D
BTW I'm officially behind schedule. =)
PS. Thank you geometro, I watch your project too. More Pictures please.


Last edited by johnsn on Thu Apr 24, 2008 12:13 pm, edited 3 times in total.

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 Post subject:
PostPosted: Mon Jun 25, 2007 11:17 am 
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Location: portland oregon
Photos from this weekend.
Image
Cut on red line.
Image
Cut on red line.

Image
Cut center stiffener. Also cut hight side diagonal stiffeners.

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Cut frame rail loose, pulled it up, and welded it .

Image
Frame straight.
Honda frame not straight... Yet. :wink: But it's vertical.
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:30 am, edited 2 times in total.

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 Post subject:
PostPosted: Wed Jun 27, 2007 10:21 am 
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Location: portland oregon
Image
I got the cowl level and you can see the curve in the A pillar is too high.

Image
So I cut the cowl off the A pillar and slid the A pillar back down and welded it in position. Next I trimmed the cowl and tacked it to the b pillar.
I ordered a new cowl corner. The right one is not right.
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:33 am, edited 3 times in total.

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 Post subject: Work
PostPosted: Wed Jun 27, 2007 12:55 pm 
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Joined: Wed Apr 25, 2007 7:41 am
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Location: Virginia Beach VA
Your work is awesome! I was thinking of doing a project just like yours. I have a CX500 Custom and I was thinking of making a 3 wheeler using a front frame from a Geo. I was thinking of making it with a fiberglass body though. Your project has definately got me thinking! What kind of electric motor are you going to use? I think you could get away with an ADC 8" or a Netgain 8" DC motor and a Curtis or Alltrax controller. Where do you plan to put your batteries? You might want to consider them into your plan before you get to far. I would have thought you would have integrated your battery racks into your frame. That way their weight is down low and will help you with your CG. What kind of batteries will you use? Trojan T-145 perhaps? T-105 6V batteries? 120 volts is 20 6 volt batteries. They are HEAVY too. I think the last time I checked they were 50 pounds each! My 1990 Nissan 240SX electric has Hawker Genesis 26Ah batteries, 12V, each weighs 23 lbs. They are light but are crap for range.


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 Post subject:
PostPosted: Wed Jun 27, 2007 2:57 pm 
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Location: portland oregon
jodydewey,
Thank you. Lots of questions :D
To start with, I'm going to get it running with a CX 500 engine.
Later on I'll convert to hybrid or all electric.
My electric motor is a ADC 8"
The batteries go in the front, beside the driver, and behind the driver.
I designed the frame so that Trojan 6V just fit beside the driver (me) :D .
My original calculations showed the batteries where 75% of the vehicle weight. 96V = 16 batteries @ 65pounds each =1040lbs. :shock:
I think my original estimate of the vehicle weight without batteries is high.
john :D


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 Post subject:
PostPosted: Thu Jun 28, 2007 2:53 pm 
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Location: portland oregon
Worked on the L door and door frame.

Image
Looks cool. see that empty space where the quarter panel meets the roof post? I need that part for both sides.

Image

Image
E-mail me if you have them.
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:38 am, edited 2 times in total.

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 Post subject:
PostPosted: Sat Jun 30, 2007 10:43 pm 
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Location: portland oregon
Put the engine in today.
Image
The engine went in OK, but I can see I will have to make the hole in the bottom bigger to get it out. Or make some other way to get it out. :shock:
Put the front sheet metal on. The cowl was about 1/2" short. Do I know what I'm doing? Guess not. =)
Let in new cowl corners and cut the front lip off the cowl. :evil: AGAIN :evil:
Image
Image
Image
I think I may have to change its name from Sparky to Patches. :roll:
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:39 am, edited 4 times in total.

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 Post subject:
PostPosted: Mon Jul 02, 2007 11:21 am 
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Location: Boston, MA, USA
Hi John,
the admins have finally blessed my account so I can post here.
I was going to ask you how you were going to put the engine in, but that's done already. Nice!
Just a few questions:
What kind of spot welder did you get and how do you like it? Worth it?
How are you going to attach the windshield?
Is your floor level?
Will your seat have a head rest to protect against neck injury /whiplash?
Tom.
PS:
For those of you following John's thread, I'm also building a hybrid-electric car, but it'll be a four wheeled car. I'm posting updates on gassavers.org:
http://www.gassavers.org/showthread.php?t=3070


Last edited by tom_eberhard on Mon Jul 09, 2007 9:46 am, edited 1 time in total.

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 Post subject:
PostPosted: Mon Jul 02, 2007 12:44 pm 
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Location: portland oregon
tom_eberhard wrote:
Hi John,
the admins have finally blessed my account so I can post here.
I was going to ask you how you were going to put the engine in, but that's done already. Nice!
Just a few questions:
What kind of spot welder did you get and how do you like it? Worth it?
How are you going to attach the windshield?
Is your floor level?
Will your seat have a head rest to protect against neck injury /whiplash?
Tom.

Tom, welcome to Team swift.
Answers.
I got my spot welder off ebay. I had to work on it to align the electrodes. It works good, and I like it a lot. It is very heavy and that makes it awkward. It is worth it. But I think I would just go down to Harbor Freight and get one on sale.
The windshield will go in using a standard rubber gasket.
The floor is supposed to be flat and level. :lol:
I will be putting a head rest on the roll bar.

Yesterday I tacked up the cowl.
Image
Image
Image

I mocked up the front end sheet metal and saw the nose is to the left a little. More work. :wink:
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:42 am, edited 1 time in total.

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 Post subject:
PostPosted: Wed Jul 18, 2007 11:35 am 
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Location: portland oregon
I've been on vacation. Now I'm back.
This is what it looks like now.
Image
Image
I built a tent so it's safe from the rain, and I'm safe from the sun and rain. :lol:

I'm working on the front panel now. I'm trying to get it straight. :ez_tongue:
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:44 am, edited 1 time in total.

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 Post subject:
PostPosted: Tue Jul 24, 2007 3:23 pm 
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Location: portland oregon
I've been working on the hood.
I cut a chunk out of the middle. But I like the ridge in the center. So I'm trying to weld it in.
Image
I'm also trying to make the hood follow the curve of the fender.
So I got a new tool (toy) :razz: .
Image
They are a shrinker stretcher set from Harbor freight. About half the price of the set from Eastwood.
I really like it, it works so nice.
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:45 am, edited 1 time in total.

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 Post subject:
PostPosted: Mon Aug 06, 2007 3:03 pm 
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Location: portland oregon
Hi, I got some more work done.
Image
Welded in the door step and replaced the inner sill I had to cut out.

Image
Welded in the B pillar and support post.
Image
I clamped on the right quarter panel and started working on the rear sheet metal.
Image
Image
I'm using the hood off a 1941 International Harvester pickup.
Image
Lots of room.
What do you think?
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:50 am, edited 1 time in total.

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 Post subject:
PostPosted: Mon Aug 13, 2007 2:59 pm 
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Location: portland oregon
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I'm going to trim the bottom of the hood at the green line and make it open here.
No comments from anyone?
john :)


Last edited by johnsn on Mon Nov 26, 2012 11:51 am, edited 1 time in total.

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 Post subject:
PostPosted: Thu Aug 16, 2007 12:30 pm 
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Location: portland oregon
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Image
I cut the hood side.
I made some sheet metal angle and used my shrinker to match the curve of the hood side.
Then I spot-welded them on.
john :D


Last edited by johnsn on Mon Nov 26, 2012 11:53 am, edited 1 time in total.

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 Post subject:
PostPosted: Tue Aug 21, 2007 5:31 pm 
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Location: portland oregon
It's on wheels! ImageImageImage
Image
Image
Image
Now I need to get the front wheels pointing the same way.
I think I have the wrong rack. :huh:
Now back to ImageImage
john :D :D :D :D


Last edited by johnsn on Mon Nov 26, 2012 11:59 am, edited 2 times in total.

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 Post subject:
PostPosted: Fri Aug 24, 2007 2:02 pm 
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Location: portland oregon
It turns out the tierods on the rack I used are longer. So I cut them. :D
I made an adapter from the Mini rack to the Sprint steering.
Image
And plugged in the steering.
Image
It's too long. So I'm going to shorten it and make something to hang it from.
john :D :D


Last edited by johnsn on Mon Nov 26, 2012 12:04 pm, edited 1 time in total.

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 Post subject:
PostPosted: Sat Aug 25, 2007 5:19 pm 
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Location: Enhaut PA (usa)
looks great! nice job, hope to see it done

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 Post subject:
PostPosted: Mon Aug 27, 2007 2:28 pm 
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Vtek wrote:
looks great! nice job, hope to see it done

Thanks Vtek.
Put the front sheet metal on.
Image

The wheels stick out a bit :shock: :razz: :mrgreen:
Image
Got the steering mocked in place. Cut the column down to fit. Now if I can get someone to push ... :ez_wink::bump: :shock:
Image
BTW that's a Chevy Sprint steering column and wheel.
john :D :D


Last edited by johnsn on Mon Nov 26, 2012 12:05 pm, edited 2 times in total.

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 Post subject:
PostPosted: Sat Sep 01, 2007 10:02 pm 
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Turned it around and put the rubber springs on with Hi-Lows set all the way low.
Image
That's too high! :shock:
Image
And the springs are way too stiff. I'l have to figure out how to soften them up. :thwack:
john :D :D


Last edited by johnsn on Mon Nov 26, 2012 11:48 am, edited 1 time in total.

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 Post subject:
PostPosted: Fri Sep 07, 2007 7:43 pm 
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and you need rims with backset
lots and lots and lots of backset :lol: :lol: :lol:
keep up the good work


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 Post subject:
PostPosted: Wed Sep 12, 2007 2:15 pm 
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Location: portland oregon
hillbilly 993, can you draw me a picture? :-P

I lowered the suspension about 2 inches. This is about where I want it.
Image

Image

Got the parts to finish the B pillars. All the way from England. Thank you Greg! :D
Image
john :D :D


Last edited by johnsn on Mon Nov 26, 2012 11:47 am, edited 1 time in total.

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 Post subject:
PostPosted: Fri Sep 14, 2007 3:29 pm 
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That's a lot of good work! I've never seen this post before. Keep up the good work. Are you still interested in electric components? Will you make it a hybrid?

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