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Underbody braces, turbos and more!

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PostPosted: Sat Dec 16, 2006 12:23 am 
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maybe I should update this thread a bit ...

I've already dropped in a stage 2 clutch kit and a BMR lightened flywheel, I've got an underdrive/single pulley on it's way and a header and I'll most definately be getting a cam and larger tb from suprf1y :)

But ...
One of my co-workers has offered me a brand new in the box turbo from a saab aero and I'm trying to decide what to do about a piggyback ...

any updates on your project blur ?
I'm curious what you're doing for 'tuning' it ?

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PostPosted: Sat Dec 16, 2006 3:06 pm 
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Location: winona mn
I have Weoh's "old" 2 door 2000 car. It's had about 500 miles put on it so far. It's been pretty sheltered. The slushbox is gone now. I sold it to a friend for $200, and he pulled it out. Can't lose. I tell you what, those auto's are damn heavy. The manual weights about 30 pounds, and the auto must weight about 125 pounds or so. There's a good 2 tenths in wieght difference in the trannys alone, much less the lousy auto gearing. I got a 4.39 box from a 3 cyl Metro convertible for it now. Then I ordered a Suzuki RD Al flywheel for it. Quite nice I must say. It's a good 2 lbs lighter than the stock one we got to 8 lbs in my 99 4 dr. I have a centerforce clutch coming for it now too, as I drive these little guys hard. I have the axle shafts also. All I need now is a shifter and a clutch pedal. I have about 3 months to get 'er back together before autocross season starts.

Re: my 4 door 99Lsi. It has the aforementioned 8 lbs flywheel and an underdrive pulley, with the power steering disonnected. The Auto 2 dr will beat it every time. And the 4 dr is no slouch, as I do quite well in HS class in autocross, and it holds itself well against some far more expensive hardware:
http://www.scclac.org/SCCLac_Downloads/oct_win_res.pdf


The 4 dr does have the numerically low trans though, which is great for my 56 miles commute each way, but hard on acceleration. (42-45 mpg @ 75 mph on I90 though)

But the 4.39 trans in the 2dr, with the much lower weight, cam, header, springs, and sway bars are gonna make the 2 dr a tough car to beat in STS next summer.


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PostPosted: Sat Dec 16, 2006 4:31 pm 
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Location: Winnipeg
Nitro, you might be interested to know that my 1999 computer is quite happy with up to 4psi of boost without any piggyback or mods of any type. It does however start gradually getting leaner after 3-4 psi.

You could do as i did, and just add the piggyback later when you get around to it.
I use an SMT6 as a fuel adder now...connected to the crank trigger under the oil pump, and firing an extra set of four injectors.
...next mod might just be a 1.6!
Darcy


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PostPosted: Sat Oct 27, 2007 11:01 pm 
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Not sure whatever happened to the other thread Mike & I had about our builds.
I lost a lot of interest in working on the car after getting ripped off by Ghostfacekillah (Tim Canales, from TX). So no header & exhaust & no single underdrive pulley & never got any of my money back :twisted: If someone ever finds him...

I have done a bunch of little things to the car over the past year;
from lowering it a bit
fitting the cross-drilled & slotted rotors from the group buy
fitting the repainted mag wheels (another old group buy)
new 185/55/r14 federal ss595 tires
installed a lightened flywheel & stage2 clutch kit
Poly Sway bar mounts & endlink bushings
modded & installed a 130mph speedo w/ tach
built in a killer sound system, amps under the seats, MA 6.5"s in the doors, MA 6x9's in the rear seat areas, & dual JBL 10's fitted flush into a spare tire enclosure (no lost space) & a couple huge amps mounted under the seats.
professionally tinted the windows
fitted a 3-tech 45mm throttle body (swift gt throttle plate)
short ram/cold air intake (depending on the season)
Headlights re-wired w/ relays & HID's fitted
... and dumped a couple coffees on the drivers floor :P
& the clearcoat continues to retreat (at least it's not rust & still looks great on a rainy seattle day) :P

Mike's just finished developing a new camshaft for the g13bb (sohc 16v) engine and the first one's winging it's way to me right now.
Quote:
.340" lift, 192/198 duration ... Awesome lift gain, + 8 degrees intake (should give you 500-800 more topend without harming bottom end), and + 14 exh.
Should work perfect with your OBD 2.
Better than the stock GT grind.


of course Mike finished up the cam a couple days after I put my deposit down on a new R56 Cooper S ;) so I've got another 5+ months to enjoy it before it'll hit the classifieds section.
Still needs a custom exhaust (with a header) to really open things up & make it possible to fit the Turbine Tech lower control arm brace.

here's a few pictures, generally a really fun little go-kart.

Image
Image
Image
Image


Last edited by n1tr0 on Sun Oct 28, 2007 8:25 am, edited 1 time in total.

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PostPosted: Sat Oct 27, 2007 11:36 pm 
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WOW! That is one nice looking ride. Simple, clean, and ready to rip it up. Nice work. That stinks you are gonna get rid of it. Good for the person who scores such a nice car though. Wish it was me. Again, looking awesome. Can't wait to hear how it runs after the cam.

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Currently driving a 1996 Geo Metro 1.0L
Mods coming...............


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PostPosted: Sun Oct 28, 2007 7:36 pm 
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Car looks good Kris!

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PostPosted: Sat Nov 03, 2007 7:51 pm 
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installed the 3tech camshaft today & the butt-dyno results were impressive :)
throttle seemed snappier, traction is still a problem, but coming home from Costco w/ a full load & my wife, plenty of acceleration merging onto the I-5 from an uphill on-ramp. good idle & driveability, this could've been a factory mk5 gt spec ;)

sorry, no baseline, no real numbers, but it feels as quick or quicker then my old swift gt.

Total install time took ~4hrs with a trip to the parts store & some bs'ing with the guys in there.
replaced the accessory belt & cam seal at the same time. I had the plugs out & the timing belt off & could have replaced a bunch of other parts while it was all opened up. pretty straight forward, I took a lot of that time tweaking/adjusting the valves.

key torque values
cam caps 8ft/lbs (very little)
cam gear 47ft/lbs
crank pulley 11ft/lbs

maybe mike can post his stock camshaft specs/measurements for comparison.
i'd really love to throw a header/exhaust on it to see how it goes, but with the new mini on order, it'll have to wait for a future owner ;)


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PostPosted: Sun Nov 04, 2007 7:15 pm 
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Thats good news about the smooth idle.
That was a problem with my original 16V SOHC grind.
The intake lobe is a fairly specific style, that has a big flat on one side. Its very similar to alot of the small bore bike cams.
It was not easy finding a lobe with the right amount of lift, yet a reasonable amount of duration.
These motors, being small displacemt, and 16V are very duration sensitive, and the stock cam is very mild.
Stock duration is 184 degrees at .050"
This is actually milder than both my econo cam, and the xfi cam.
Stock lift is IIRC, .300" intake, and .280 exh.

The new cam has .340" lift, 192int/198exh duration
Thats a 8 degree gain on the intake and a 14 degree gain on the exh.
The exh. duration, and extra .060"(!!) lift gain will help offset the stock manifold.

It sounds like its working OK with your OBD2, and that was my goal. Live with it for a week, in everyday situations, and see what your impressions are then :-P

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PostPosted: Sun Nov 04, 2007 10:35 pm 
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went for a long drive with it today, Jimmy/Tuffcarguy came along for part of it. The car sounds great & has tons more highway passing/accelerating power. I love the way it revs now !
:thumbsup:

it's a gt/gti with airbags now !
no check engine light or stored codes, when the engine's hot, the idle will drop into the 650rpm range when sitting for a bit (eg. waiting for a train to pass)


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PostPosted: Thu Nov 08, 2007 12:28 am 
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a couple pictures from the weekend.
original on the left, 3-tech regrind on the right (nice oem finish)
Image

here's the stock tb vs. the bored out 45mm (gti throttle plate) also from mike
stock is TINY, and with the mk5 map based system, it's the primary restriction in the intake system.
Image


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PostPosted: Thu Nov 08, 2007 12:45 am 
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Quote:
Not sure whatever happened to the other thread Mike & I had about our builds

It got deleted a long time ago.
I think it was your fault.
I still have this, though...
Image

If I don't stop looking at that car, I'm going to end up with another one :-P

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PostPosted: Thu Nov 08, 2007 10:32 pm 
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suprf1y wrote:
If I don't stop looking at that car, I'm going to end up with another one :-P

fly out & drive it back ;) half the parts on it came from your workshop ;)
and there's no rust or corrosion, the usual shopping cart type damage left from the previous owner :P


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PostPosted: Thu Nov 08, 2007 10:45 pm 
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looking good kris.

the 45mm tb works great on these, had one on mine now im running a twin cam.

do you remeber what the offset is on those rims.


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PostPosted: Thu Nov 08, 2007 11:03 pm 
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pat did you put a twin cam throttle body on your mk5 or twn cam motor in it? my guess are the tb tho. :D


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PostPosted: Thu Nov 08, 2007 11:05 pm 
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motor


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PostPosted: Thu Nov 08, 2007 11:09 pm 
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no idea on the rims, had to trim the rear bumper a hair & roll the fenders a bit to prevent the occasional rubbing with 185/55/r14's. wasn't required on the mk3 I had them on before, but the mk4/5 has a touch wider suspension.


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PostPosted: Thu Nov 08, 2007 11:20 pm 
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geopat wrote:
motor



nice :thumbsup:


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PostPosted: Thu Nov 08, 2007 11:24 pm 
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n1tr0 wrote:
no idea on the rims, had to trim the rear bumper a hair & roll the fenders a bit to prevent the occasional rubbing with 185/55/r14's. wasn't required on the mk3 I had them on before, but the mk4/5 has a touch wider suspension.


same thing on mine, im running 65s though. still i bit of rubbing on the rear.


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PostPosted: Fri Nov 09, 2007 12:17 am 
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Did you use the 98 computer, wiring, and injectors, or do the complete GT swap?

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PostPosted: Fri Nov 09, 2007 10:31 pm 
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complete swap, it would be interesting to see if the mk5 electronics would run a gt motor, mostly just to keep the obd2 setup. probably going to swap it back to the stock motor, just need to get parts for a rebuild.


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PostPosted: Fri Nov 09, 2007 11:45 pm 
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I tried to start a post awhile ago about that. I just got an MK5 off ebay about 2 weeks ago for $900. I'll think about a gti swap with MK5 electronics if I get bored.


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PostPosted: Sat Nov 10, 2007 12:18 am 
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geopat wrote:
complete swap, it would be interesting to see if the mk5 electronics would run a gt motor, mostly just to keep the obd2 setup. probably going to swap it back to the stock motor, just need to get parts for a rebuild.

Don't see why not, as long as you use the Mk5 injectors.

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PostPosted: Mon Dec 24, 2007 11:16 pm 
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Mike just pointed out to me that we don't have the mk5 16v valve adjustment specs ..

Suzuki wrote:
Note: When checking valve clearance, insert thickness gauge between camshaft and cam-riding face of rocker arms
cold
intake .005 to .007"
exhaust .009 to .011"
hot
.007 to .009
.011 to .013


As great as the cam is, the car really feels like it needs the exhaust opened up, it has a great intake noise.

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PostPosted: Tue Dec 25, 2007 1:38 am 
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The Suzuki RD 4-1 header with a 2" OD exhaust works great with the 'Cove cam. With the original profile I had, it had a lumpy idle depending upon the lash adjustment. It would throw codes for rich idle though but I had installed a cap & resistor that kept the rear sensor happy then. It had a 60mm TB on it also. More than plenty airflow with that one. I always suspected a 45-50mm TB would have been better as the idle was touchy to get right and it had a very on/off transition to it.

I do miss the gas mileage the Metro had even though it was 20 something MPG. The Ion Redline eats gas like a smallblock when running heavy boost. If I drive it like a granny, it'll get 24 MPG...More fun with a heavy foot and filling the tank often. LOL...Sure like that Eaton sound 8)

Mike

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PostPosted: Tue Dec 25, 2007 2:00 am 
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the new profile's plenty smooth enough & no codes/faults, I'm still getting about 30mpg city with a heavy foot and a bit more highway averaging 75-80mph.

with a light foot and the original pizza cutter tires I've gotten as good as 50mpg. You can't beat the physics of a lightweight aerodynamic car, great gas mileage and still able to be zippy around town.

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