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Underbody braces, turbos and more!

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PostPosted: Wed Jul 04, 2012 12:15 am 
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Joined: Tue Oct 03, 2006 10:43 pm
Posts: 720
Location: Texas 75150
So After reading the post on Ebay clutches I ordered one.
Throw out bearing is correct. Pilot bearing is correct. Clutch splines are correct.
My flywheel is off of a 3 cylinder 98 1.0L engine.
This flywheel measures out for a 7" diameter disk, they sent me a 7.9" disk.
The pressure plate they sent me is as big as the outside diameter of the flywheel.
The hole spacing for the mounting bolts on the new pressure plate is 8.75"
On this 98 flywheel it is only 8" diameter for the hole spacing to mount the pressure plate.
Alignment dowls are also on a 8" diameter and will have to be moved.
What to do?
A: reface the flywheel for the larger disk, and drill new holes to mount the larger pressure plate?
I have the mills and lathes to do this.
B: try and find a flywheel that will work with this larger clutch?
C: return the clutch disk and pressure plate and get a smaller one?

This setup will be going into a 97 geo metro 1.3L 4cylinder. I am swapping out the automatic for a standard transmission. I only want to do this once. I want to get it right on the first try.

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Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


Last edited by fainya on Tue Jul 31, 2012 2:24 am, edited 1 time in total.

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PostPosted: Wed Jul 04, 2012 1:50 am 
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Joined: Tue Oct 03, 2006 10:43 pm
Posts: 720
Location: Texas 75150
Never mind guys. They sent me a clutch disk and pressure plate for a turbo car.
I will cut the flywheel to make the clutch work.

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Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


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PostPosted: Fri Jul 06, 2012 12:03 am 
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Joined: Tue Oct 03, 2006 10:43 pm
Posts: 720
Location: Texas 75150
I have the 1.0L flywheel cut to fit the larger turbo clutch disk now.
Before I pull the flywheel off the lathe, I was wondering if anyone can tell me how deep the step in the flywheel should be for the turbo clutch?

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Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


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PostPosted: Fri Jul 06, 2012 12:12 am 
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Joined: Sat Mar 27, 2004 4:15 pm
Posts: 3130
Location: Brantford, Ontario, Canada
the turbo cars and the 1.3 use a bigger diamater clutch/pp and flywheel

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93 Swift GT White 3Tech cams, Sandro's chip, Lightned flywheel, Genie exhaust, Cultus header, Intrax springs.
08 Civic Wife's car


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PostPosted: Fri Jul 06, 2012 2:39 am 
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Joined: Fri Apr 02, 2004 5:56 am
Posts: 2328
Location: Christchurch NZ, quake capital
Here's a comparison, despite the work you have already done I would just find a 4cyl flywheel.


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PostPosted: Fri Jul 06, 2012 12:48 pm 
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Joined: Tue Oct 03, 2006 10:43 pm
Posts: 720
Location: Texas 75150
Thanks for the pictures of the two different flywheels. The 1.0L disk is about 7" in diameter. The turbo clutch is about 8" in diameter and has a larger pressure plate also. I turned down my flywheel to lighten it up and accept the larger disk and pressure plate.
My big question is how much of a step does the 4 cylinder flywheel have on it? Or is it just flat?
The 3 cylinders ones measure about 0.100" deep recess for the clutch disk.
I still have the flywheel in the lathe so if I need to remove more metal to get this right I can.

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Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


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PostPosted: Fri Jul 06, 2012 1:33 pm 
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Joined: Fri Feb 13, 2009 7:10 pm
Posts: 880
Location: Vancouver, WA
just get the 1.3 flywheel. youll thank yourself later.


not to be a dick but if you try to hack this swap together with your axle situation you mentioned a few weeks ago and this flywheel issue now.....youll never finish it or if you do itll never be good. the bolt on parts are out there (and very readily available) so why not use them instead of forcing yourself to work harder to save a couple bucks and possibly have the parts not even work. then you are out time and more money.

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98 swift 1.6 16v swap
03 cobra bolt ons
97 3000gt vr4 e85, high comp, bolt ons
too many others to list


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PostPosted: Fri Jul 06, 2012 2:52 pm 
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Teamswift Racer
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Joined: Fri Apr 02, 2004 5:56 am
Posts: 2328
Location: Christchurch NZ, quake capital
Pretty sure the 1.0 pressure plate is much shallower and the flywheel thicker to space the clutch plate splines in the right place
You'd need to machine 10mm maybe more off the entire surface of the flywheel as the much deeper 1.3 clutch and pressure plate will end up sitting too close to the gearbox when mated to the extra thick 1.0 flywheel.

I'm not knocking your skills as I'm a great beleiver in doing things yourself but in this case you'll save your self a lot of time and frustration by buying a 1.3 flywheel, at least you know the spacing is correct.


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PostPosted: Mon Jul 09, 2012 11:33 pm 
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Joined: Tue Oct 03, 2006 10:43 pm
Posts: 720
Location: Texas 75150
Turning the flywheel is done. It came out great.
I also had to drill and tap new holes for the larger pressure plate bolts and alignment dowel pins.
I also balanced the flywheel and pressure plate assembled. 3 grams had to be drilled out of the flywheel to get a perfect balance at 4,000 rpm.
With the clutch disk assembled to the flywheel and pressure plate. I inserted the whole assembly into the bell housing and onto the input shaft of the transmission. Everything spins free and looks good.
The transmission came apart tonight and I have 3.79 final gears with a 0.75 5th gear.
1st, 2nd, and 5th gear show signs of grinding when shifting. But that is to be expected with the Geo 5 speeds. All of the internal shift linkage retainer bolts where loose. The gears look good. The bearing are noisy and will be replaced along with the syncro's and seals.

What is your favorite case sealant that you have used with great results?

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Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


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PostPosted: Tue Jul 10, 2012 12:18 am 
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Joined: Fri Feb 13, 2009 7:10 pm
Posts: 880
Location: Vancouver, WA
Ultra grey the first time. Ultra black the second time. No problems either time.


Not "the right stuff" either. just standard ultra grey or black

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98 swift 1.6 16v swap
03 cobra bolt ons
97 3000gt vr4 e85, high comp, bolt ons
too many others to list


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PostPosted: Thu Jul 12, 2012 2:55 am 
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Joined: Tue Oct 03, 2006 10:43 pm
Posts: 720
Location: Texas 75150
Thanks for the case sealant suggestions. I went with Black.
Clutch and tranny are done.
Now to find the time to install all the parts.
I lucked out on the tranny I got.
Ring and pinion 3.79
5th gear is 0.75 to 1
no gear damage.
no spun bearings in the housings.

_________________
Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


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PostPosted: Sat Jul 14, 2012 11:36 pm 
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Joined: Tue Oct 03, 2006 10:43 pm
Posts: 720
Location: Texas 75150
brake pedal support, clutch, and tranny are in.
The bad news... the left front and middle rear adaptor plates for the mounts are wrong. I evidently got the ones for a 3 cylinder. I need them to be for a 4 cylinder.
Shift linkage and drive axles tomorrow.

_________________
Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


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PostPosted: Fri Jul 20, 2012 11:01 pm 
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Joined: Tue Oct 03, 2006 10:43 pm
Posts: 720
Location: Texas 75150
Project is finished.
Everything works as it should.
No vibrations of any kind. But the speedo is off.

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Fainya
97 Geo Metro LSI,1.3L-GT-DOHC-16v,4.10 5-speed,A/C,170,000,suspension lowered 1",4 wheel disk brakes,15"alloy wheels with 185/50-15 Toyo's,GT bucket seats,analog oil pressure gauge,cruise control, new paint job. 40 mpg at 65 mph.
Good, fast, cheap. You only get two.


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PostPosted: Thu Feb 07, 2013 5:44 pm 
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Joined: Mon Feb 28, 2005 7:43 pm
Posts: 789
Location: lisboa;Portugal
got any pics , how did you do it?
i´m planing on doing the same to my 1.0 fly...................

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