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Underbody braces, turbos and more!

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 Post subject: Suzuki Justy GTi AWD
PostPosted: Mon May 10, 2010 4:48 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
My gf got in a minor accident a week ago, she's fine but her GTi got hurt pretty badly:

Attachment:
File comment: Ouch. Looks like a big fenderbender, but there is extensive structural damage underneath
Schade.JPG
Schade.JPG [ 219.34 KIB | Viewed 10959 times ]


Damage is structural and too expensive to repair properly. The rest of the body isn't in great shape either, so it's time to say goodbye, but not before we take everything useful out of it. That would be the engine, wheels, hubs, brakes, struts, sway bars, steering rack, wheel and column, dash, swithes, headlights, wiring, bumpers etc. All that stuff is going to end up in and on this car:

Attachment:
File comment: 99 Subaru Justy
Justy.JPG
Justy.JPG [ 257.11 KIB | Viewed 10959 times ]


A 99 Subaru Justy, with a 1.3 8v sohc (the only engine availabe in the "Subaru Swifts", the Suzuki's had the 16v sohc) and AWD :D I took the time to compare the car to mine to check for differences and possible problems and thought the info could be useful to others so I figured I should post it here. This is what I found out up to now, apart from cosmetic differences:

- floor pan is the same, except for the rear part, no spare wheel compartment. Spare goes in the trunk

Attachment:
Trunk.JPG
Trunk.JPG [ 203.95 KIB | Viewed 10944 times ]


- driveshaft goes where Swifts have the exhaust
- fuel tank is different to make room for the driveshaft
- exhaust hangs lower and more to the right and is straight from front to back until just before the rear muffler, which is in the rear left, with the tailpipe ending in the usual place

Attachment:
Onderkant Justy.JPG
Onderkant Justy.JPG [ 300.37 KIB | Viewed 10943 times ]


- cat is mounted solid to the rear engine/gearbox mount

Attachment:
Cat.JPG
Cat.JPG [ 202.59 KIB | Viewed 10938 times ]


- cable shifter, no room for shift rods under the car

Attachment:
Cable shifter.JPG
Cable shifter.JPG [ 254.54 KIB | Viewed 10942 times ]


- speedo cable can be unhooked near the firewall

Attachment:
Speedo cable.JPG
Speedo cable.JPG [ 182.53 KIB | Viewed 10940 times ]


- wiring, fusebox, bulbs, connectors and most of the switches are different

It's too much work to splice the engine and body wiring together and since the interior is coming out anyway, we might as well swap the entire wiring loom. In fact, the only things we will be using are the shell and drivetrain, the rest will become Swift GTi, with a turbo added somewhere in the (near?) future. The front will be MK2/3. That's it for now, updates with pictures will follow =)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Mon May 10, 2010 8:28 pm 
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Joined: Tue Feb 21, 2006 10:47 pm
Posts: 1543
Location: burlington,ontario
new car looks pretty clean. could you take a picture of were the cables come though the fire wall when you get the motor out.

also do suzuki sidekicks/vitaras have folding mirrors in the netherlands?

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1992 geo metro the perpetual project car
1986 suzuki samurai LWB aka beth
1994 suzuki sidekick 4 door


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Tue May 11, 2010 2:36 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
It's a pretty clean car, except for the front. Doesn't matter, because it will get a MK3 front anyway. Saved about 900 euro's that way. If it was in good shape, it would have cost twice as much 8)

I took some pictures of the cables today, but I forgot to take my camera with me, so I'll post them when I get home tonight. The cables go through right beneath the heater hoses.

I haven't seen a Vitara in the wild yet, but as far as I can tell from pics, they have folding mirrors here.

Edit:

Here's the picture, you can see the heater hose above it. I'll remove some parts tomorrow to get a better shot:
Attachment:
Shifter cables.JPG
Shifter cables.JPG [ 267.58 KIB | Viewed 10941 times ]


Here you can see the coolant pipe go over the gearbox, to make room for the shifting mechanism, you can see the cables right behind the clutch cable bracket. Release arm is bent upwards because of the coolant pipe:
Attachment:
Clutch release arm.JPG
Clutch release arm.JPG [ 205.46 KIB | Viewed 10938 times ]

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Sat Jul 03, 2010 7:46 am 
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Joined: Sun Jan 31, 2010 5:17 pm
Posts: 3
Location: the Netherlands
Talking about my new Subaki i see. hmm.
I hope it will be a lot of fun to drive when it's finished.
GTi AWD Turbo

Muhahaha

X Roxy (Peenutzz' GF)

_________________
Image

Cultus GTi AWD AF34S
'97 Justy tranny + AWD setup
'93 GT engine, wire looms, interior, brakes.
3 tech cams
K&N cold air intake
SuzukiRD racing header
Custom 50 mm steel exhaust system
QSP racing steering wheel

Future Plans
Garrett GT1549
Intercooler
HKS BOV
MS2 ECU


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Sat Jul 03, 2010 7:21 pm 
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Joined: Wed Sep 13, 2006 4:19 pm
Posts: 234
Location: atlanta, georgia
hey. keep us posted. looks like a good project.

i've been curious about the justy's.

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92 swift ga coverted to gt. always a work in progress


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Mon Jul 05, 2010 11:39 am 
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Joined: Mon Feb 13, 2006 11:54 am
Posts: 601
Location: Salem, OR
How hard is it to pick up a justy over there? Ive been looking at bringing one over, If I could find one with front end damadge like that, it would be preferable...

_________________
90 Swift parts car
93 sohc swift Ga might part out soon
89 Swift Gti pulled from Arizona Big project


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Mon Jul 05, 2010 5:27 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Justy's aren't that hard to find here, prices vary from 1500 to 2500 euro's for a decent one and sometimes there are cheaper ones, usually with (minor) damage. There's a '97 for sale now for only 750 euro's, looks clean on the pictures: http://link.marktplaats.nl/359004528
Don't know why it's so cheap and now we wish we had bought this one :shock:

This week we plan to swap the engine, we unhooked the last few things today, GTi engine is already out, only need to remove the gearbox.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Mon Jul 05, 2010 6:05 pm 
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Joined: Mon Feb 13, 2006 11:54 am
Posts: 601
Location: Salem, OR
Thats a perfect example of what Im looking for any idea what shipping would look like?

_________________
90 Swift parts car
93 sohc swift Ga might part out soon
89 Swift Gti pulled from Arizona Big project


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Mon Jul 05, 2010 8:53 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I honestly don't have a clue about such big shipments. Now I think about it, I rarely send anything by mail, I only order stuff =)
I believe there are some topics running about importing cars to the US, maybe they can help you there.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Wed Aug 18, 2010 1:51 am 
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Joined: Fri Aug 14, 2009 12:47 pm
Posts: 93
Location: CA
I just found out about those cars; I want to do a swap with the AWD and a G10 motor, into an early mini pick up! is there a positive connection between front and rear, or can one turn without the other? How much does the all wheel drive improve traction? Would it help with off road driving much, or is it not worth the effort? I am familiar with doing complicated swaps, just don't want to waste my time if most of the drive is still going to be up front.
Thanks, Steve


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Wed Aug 18, 2010 1:54 pm 
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Joined: Tue Mar 08, 2005 12:59 am
Posts: 1047
Location: Canby, OR
Steve, some of the pics have gone dead but this thread may answer a lot of your questions:

http://www.redlinegti.net/forum/viewtop ... 1be27a13f1

_________________
Anyone who's been around children will tell you that they are in fact quite stupid. Many of them cannot even read.


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Wed Aug 18, 2010 3:06 pm 
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Joined: Fri Aug 14, 2009 12:47 pm
Posts: 93
Location: CA
thanks alrwerks, good info, if not pics. looked at the u-tube vid link; lots of 4x4 swifts there at the digs! Just need to find a donor cultis or justy now; they didn't get to the States.
Cheers


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Wed Sep 15, 2010 3:52 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
New update :D

We had nice weather the past two days so we got some major work done. Roxy doesn't like power steering and wanted to use the steering rack from her GTi. We test fitted everything and figured it should work. Here goes:

Image

The GTi rack fits, it has the same mounting points as the Justy's. There are two differences: Rack is mounted higher so the linkage to the steering column is too long, can't use the one from the Justy because that one is too short and the splines are sized differently, so the GTi column has to be used also. Other problem is the hole, it's too high as you can see in the pic. This is what Roxy did:

Put on her welding equipment:
Image
They say she drinks high octane fuel on the rocks with breakfast

Remove the hole with a Dremel:
Image

Transplant the hole to a new piece of 0,8mm steel sheet and tack that into place:
Image

And after a few hours of grinding and welding, this is the result:
Image

Outside:
Image

While she was busy with the hole, I took care of some other things. The rod to the steering column was too long:
Image

I solved that by grinding off a piece and making a new slot for the bolt:
Image

The steering column end needed some grinding too. The splines needed to be removed partially so that the shortened rod would go in further:
Image

Now it looks like this. Fits nicely and turns smoothly :D :
Image

Image

I also put the struts and knuckles back on the car, together with GTi brakes. We had a machine shop take a few millimeters off the discs to make it work. Same guy also did the flywheel. Blasted it and took some weight (almost 2kgs) off. Now it's about the same weight as a stock GTi's:

Image

Image

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Wed Sep 15, 2010 9:48 pm 
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Joined: Sat Mar 22, 2008 11:13 pm
Posts: 113
Location: Farmington, MO
WOW man Thanks for posting this!!! Ur pics have been a BIG help to me! I'll Hafta post some up too... I've looked and looked tryna find a pic of the AWD,LHD firewall (as opposed to the AWD,RHD versions...) THANKS BRO!

_________________
All Wheel Drive-187 FWHP @ 18 psi...... SHE LIVES!!!!
METRO SS Certified honda H8R




AHM NOT AN AHSOE!!! DO I LOOK LIKE AN AHSOE!?!?!?


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Thu Oct 07, 2010 2:32 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Got some pictures of the Twincam with Justy gearbox:

Image

Image

We actually got it in the car today, but I didn't have a proper camera with me. It was a very tight fit through the top :P Now all we have to do is plug it in, fill up the gearbox and cooling system and we should be ready to fire it up :D

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Tue Oct 12, 2010 6:01 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
We fired it up today :D :D It took a few days longer than expected, making an exhaust system turned out to be not as easy as it looks. While Roxy took care of that, I took care of the dash and the wiring. I had to replace the headlight plugs, and fix the wiring to them, because it was a bit of a mess. Lights weren't working properly before, so after I fixed the plugs, I opened up the steering column switches to find a loose wire. When that was fixed, there was light again :D
I put the dash back in, figured out the wiring and everything worked, except for the front fog lights and the heater motor. Turned out I forgot the fog light relay and didn't plug the motor in, so that's fine now 8) There's only one strange thing: The rear fog light switch indicator light is lit when the lights are off and when I press the button, the lights go on but the indicator light goes off :? I'll try another switch tomorrow.
Roxy finished the exhaust system today and when we fired it up it turned out to be VERY LOUD. It's made of an SRD header, a GTi cat, 2" steel pipe to the rear and a small fart can at the end. An extra silencer has been ordered about an hour ago :P I'll take my videocamera with me tomorrow and post some videos.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Tue Oct 12, 2010 7:21 pm 
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Joined: Mon Jun 28, 2004 9:27 pm
Posts: 791
Location: Christchurch, New Zealand
I been trying to find the location of the rear fog relay plug for ages. I just need to plug the relay in and I'll be ago go...
Could you describe in quite a bit of detail exactly where I need to look?
Thanks
Jon


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Wed Oct 13, 2010 3:20 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I was talking about the front fog relay before. I haven't run into a relay for the rear fog lights and the wiring diagram doesn't show it either.

We drove it for the first time today, but took it easy because of the noise. We went straight to a garage to check it for MOT. There turned out to be a few minor issues but apart from those it passed. Even emissions were good :D Some pics I took today, before we took it to the garage:

Image

Image

Image

Image

Image

Image

I'll post some videos later, they're on my laptop.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Fri Oct 15, 2010 2:12 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Some videos:

http://www.youtube.com/watch?v=LgcjjaMhqi0

http://www.youtube.com/watch?v=6Ul_8Xvcf-I

http://www.youtube.com/watch?v=o3oTBdSfC1M

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


Top
 Profile  
 
 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Mon Oct 18, 2010 8:28 am 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Now I've driven it a few times, I must say I like it. Ofcourse, it doesn't react like the FWD I'm used to, and that way I accidentily discovered that it's possible to drift :twisted: Best of all is that even in the rain, there is instant grip when accellerating from a standstill. Just drop the clutch and floor it, it will go without wheelspin. Sweet. Now I want AWD for my 1.0 =)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Mon Oct 18, 2010 8:17 pm 
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Suzuki Elder
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Joined: Mon Dec 01, 2003 12:47 pm
Posts: 11669
Location: columbus, ohio
Peenutzz wrote:
Now I want AWD for my 1.0 =)


me too. =)

_________________
1991 Blue Geo Metro Convertible highly modified 1.0L Turbo3 5 spd. - 1991 Red Geo Metro Convertible customized with a Twincam 5 spd.

My Turbo3 Project
My Cardomain Page -Ol' Blue
My YouTube Channel
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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Wed Oct 27, 2010 10:38 am 
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Joined: Mon May 02, 2005 4:23 pm
Posts: 200
Location: Breda, Netherlands
Wow, great project! And your GF rocks, for working on her own car :thumbsup:

Now that I see these pics and hear your comment about being able to dump the clutch without wheelspin it makes me regret I used a GTi shell instead of a Justy :|

Do you happen to post on any Dutch boards?


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Thu Oct 28, 2010 10:10 am 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
DGR wrote:
Wow, great project! And your GF rocks, for working on her own car :thumbsup:

Now that I see these pics and hear your comment about being able to dump the clutch without wheelspin it makes me regret I used a GTi shell instead of a Justy :|

Do you happen to post on any Dutch boards?


I found Teamswift when I was looking into 1.0 turbos. Dutch people don't do that very often :P I don't post on Dutch forums, I take a look sometimes, but that's all. Maybe I will start posting when I start my turbo project somewhere next year :)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Fri Oct 29, 2010 3:20 am 
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Joined: Mon May 02, 2005 4:23 pm
Posts: 200
Location: Breda, Netherlands
I'll send you a PM.


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 Post subject: Re: Suzuki Justy GTi AWD
PostPosted: Tue Nov 02, 2010 10:33 am 
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Joined: Fri Jan 15, 2010 2:26 pm
Posts: 342
Location: TX-USA
did you use the GT brakes/calipers both on the front? do the calipers bolt on directly to the hubs? I've got a set of GT brakes I've been wanting to put on my car, but I didn't want to have to change the axles(GT hubs have larger splines).

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'99 Metro Sedan Auto 4cyl, '91 Metro Vert 3/5, '91 Metro 5dr 3cyl auto


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