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 Post subject: my build
PostPosted: Tue Jun 05, 2012 9:01 pm 
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Joined: Tue Feb 07, 2012 7:53 pm
Posts: 28
Location: nsw
hey guys i thought id show my build its not much but it is what it is i bought this car a couple of weeks ago needing repairs so i towed it to my workshop and began work
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so i thought while i had the engine and gearbox out i would do the clutch and lighten the flywheel about 700 grams came out of it and it was out of balance by about 45 grams. bolted a new clutch in it i decided on a exedy standard clutch and increased clamping pressure with the pressure plate figured out the gearbox i had was busted so i hunted down a 2nd hand one
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coming together
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got it all back together new clutch gearbox timing belt water pump siliconed the sump back on couse it was leaking rocker cover gasket rear main seal cam seals crank seal doesnt leak oil at all now oil pressure switch O2 sensor spark plugs fuel filter and air filter
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got it running and decided to run a upper cylinder clean to get all the built up carbon off the ports and valves
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its an american product called BG luquitech
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i then tried to hunt down the engine steady on here and had no luck in the search forum and stuff with no luck so i thought id make one fit it came off a toyota camry v6 i had to cut one end of the bush and turn it round 90 degrees and make up a piont where to bolt it to plus mod the origanal brack on the strut tower bar it still needs painting while i was at it i over did the engine earth
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once all this was done the car was ready to go the first drive i toke it on i had steering wheel shake so it didnt go far and figured out i needed a steering rack end on one side and a tie rod end on the other so go figure i replaced them all and gave the car a wheel allignment was a bit scared at first but i got the wheel alignment lasers on and found out the car was square and not been in a major accident

attempt 2 drives good handles good alot more then what i expected from a gti and definetly alot more rattles then i expected so i thought i would put it on the dyno and it made a whole 46.5 kilowats i couldnt beleive it they seem so quick to drive yet so little power we later had my mates ke55 1.6L single cam holley carb a camshaft and exhuast that made 39 rear wheel kilowats we then had an xr6 turbo on there whitch made 195 rear wheel kilowats just with a boost controller no other mods but i still would rather my swift over an xr6 i just cant get my head around how little power they make is it just mine? besides the point

another thing i found interesting was we had a vacum hoked up from the engine to the dyno's computer and a standard airbox air filter intake manifold and throttle body posed no restrictions at all at wide open throttle manifold pressure and atmospheric pressure where the same

im now working on rebuilding another gearbox for it with an lsd center
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i know gearboxes are a real issue on these and im looking into a way on maybe making stronger parts for them i got access to a lath and a friend with a cnc machining bed

got my gearbox rebuild kit
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got the synchro rings seals and the bearings all diliverd for 300 bucks cheering
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suposably by deburing and polishing the synchro you can strengthen it and help it shift smoother ive got nothing to lose so i thought id give it a go
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this is one synchro ring compared to another the one at the back has been polished and rounded and alot smoother to touch compared to the one infront of it

thats all i got for now but give me a few more days and i will get some more pics up


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 Post subject: gearbox rebuld
PostPosted: Sun Jul 29, 2012 11:19 pm 
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Joined: Tue Feb 07, 2012 7:53 pm
Posts: 28
Location: nsw
hey guys thought i would share my gearbox rebuild and what i found

so i thought i would repair this gearbox couse it had a bit of a noise
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jokes this gearbox was completly stuffed so i started pulling down another i wasnt going to waste the gearbox rebuild kit i bought for it like 200 bucks start by removing the black cover
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then start work on removing 5th gear assembly
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once that is pulled apart the sychro hub pulls off then i rattled off the lock nut
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before going too far remove the reverse sensor
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so what i found 3 diffrent gearbox's all the same problem some worse then others so 5th gear is always touching the bolts on the retainer plate as seen here
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and then in all the gearbox's i found metal filings from 5th gear whitch led me to think the bearing that i found in all 3 of them that sits on the same shaft on the other side is always ruined and split the case on one of my gearbox's
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is this why these gearbox's are soo bad? could it be from 5th gear rubbing couses a vibration that ruines the bearing leading to the rest of the gearbox to destroy itself???

soo first thing i did was fixed up the plate too allow the bolts to sink further down rather then sitting above the plate
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now 5th gear is clearened up and not touching anymore i continued on with my build

more to come soon . . . .


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 Post subject: Re: my build
PostPosted: Mon Jul 30, 2012 10:52 pm 
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Joined: Wed Sep 05, 2007 8:19 pm
Posts: 489
Location: sydney
feel how much play there is in the diff sun gears thats the problem


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 Post subject: gears
PostPosted: Tue Jul 31, 2012 10:14 pm 
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Joined: Tue Feb 07, 2012 7:53 pm
Posts: 28
Location: nsw
you mean in the gears inside the carrier the ones the cv joints sit in? either way im not sure whitch gears you are talking about but the gearbox has been rebuilt and is in the car now i shimed everything up to what i have been taught and so far is preety awesome shifts really smooth no crunching grinding abnormal noises and has received an absolute caneing

i found in all the ones i had alot of the gears had been touching and the bearing on the countershaft in the bellhousing side of the case was always broken the cage on the roller bearing was either twisted or ripped.

what i did was debur and polish all the gears including the crown and pinion including the ones inside the carrier from what i know by doing this i remove any surface impurities that a crack can start at


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 Post subject: continuing gearbox build
PostPosted: Thu Aug 02, 2012 9:02 pm 
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Joined: Tue Feb 07, 2012 7:53 pm
Posts: 28
Location: nsw
continuing on with my build just quickly the diffrences between the gti and cino diff cino on the left gti on the right gears are alot bigger also the amount on teeth on the crown
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the next step is to load everything up in a press and change the parts i started with the diff bearings
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the new bearing and the old bearing
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then i pressed off all the gears and bearings and synchro's so they could be replaced
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assembling the gearbox
diff gear first and also drop in the shift rail fork to make things easier when putting reverse in later
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grab the 2 gear assemblies and hold them together as if they where to sitting in the gearbox and lower them in carefully
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now to drop reverse in
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now to silicon the 2 halves together im using wurth special 250 also put silicon on the thread of the bolts remmember a little goes a long way
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now to put 5th gear back together also make sure you loctite these bolts last thing u want is a bolt to come lose
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put the gears and the synchro back also do up the nut and peen it over with a drift so it doesnt come lose
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File comment: 5th gear
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now to install the 5th gear synchro hub and cerclips
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obviusly silicon the black cover back on to install the seals use the old seal ontop of the new one so it acts like a cushion so u do not bruise the new seal and hammer it in
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a few more things here and there and it was ready to go back in the car 160 dollars for the rebuild kit from ebay plus the one bearing whitch was wrong and a few hours hard work everything was all good again


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 Post subject: awesome tail lights
PostPosted: Mon Aug 06, 2012 7:26 pm 
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Joined: Tue Feb 07, 2012 7:53 pm
Posts: 28
Location: nsw
hey guys so i had some spare time on the weekend and thought i would fix up my tail lights a bit
what they used to look like
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and then a bit of paint alot of clear coat and alot of buffing and sanding this is how they turned out
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with the parker lights on
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the pictures do not do them justice during the day u can still see a bit of red but in these pictures they seem completly blacked out.
what do you guys think?


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 Post subject: Re: awesome tail lights
PostPosted: Mon Aug 06, 2012 7:35 pm 
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peterg2121 wrote:
what do you guys think?


You must be new here. :lol:

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 Post subject: Re: awesome tail lights
PostPosted: Mon Aug 06, 2012 8:10 pm 
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Location: blue mountains
I didn't like them in the 90s and I like them even less now. But it's your car and that's all that matters.

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 Post subject: Re: awesome tail lights
PostPosted: Mon Aug 06, 2012 9:11 pm 
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Posts: 68
Location: ipswich
u got my vote, i like em. i have a set on both my cars and il defo be tinting the tail lights on my swift too. nice ride btw


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 Post subject: Re: awesome tail lights
PostPosted: Mon Aug 06, 2012 9:59 pm 
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Posts: 28
Location: nsw
i was on here before but i lost my acc so i guess i am kinda new then. i hate the rims i got on there its how i bought it i like the style hate how they are all chrome

people where tinting tail lights in the 90's??? i would have just been born


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 Post subject: Re: awesome tail lights
PostPosted: Mon Aug 06, 2012 10:05 pm 
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You will be booked in no time if you were in qld

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 Post subject: Re: awesome tail lights
PostPosted: Mon Aug 06, 2012 10:17 pm 
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Amazing build thread I have read it from front to back , I cant wait for more of my friends to see the amazing build.

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 Post subject: Re: awesome tail lights
PostPosted: Tue Aug 07, 2012 10:27 pm 
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papa wrote:
Amazing build thread I have read it from front to back , I cant wait for more of my friends to see the amazing build.

We need a like button ;)

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 Post subject: Re: awesome tail lights
PostPosted: Wed Aug 08, 2012 9:43 am 
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Yeah I really liked the bit where he tinted his lights.

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 Post subject: Re: awesome tail lights
PostPosted: Wed Aug 08, 2012 10:28 am 
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papa wrote:
Yeah I really liked the bit where he tinted his lights.

Yeah thats my favorite part. Really good quality build thread. Keep up the good work. :)

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 Post subject: Re: awesome tail lights
PostPosted: Wed Aug 08, 2012 2:09 pm 
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(on my phone, so I can't link it without taking 20minutes) but there is a full thread somewhere dedicated to this.


Also, swifty has it done on his black gti. Suits it really well.

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 Post subject: Re: gearbox rebuld
PostPosted: Wed Aug 08, 2012 5:45 pm 
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peterg2121 wrote:
is this why these gearbox's are soo bad? could it be from 5th gear rubbing couses a vibration that ruines the bearing leading to the rest of the gearbox to destroy itself???

soo first thing i did was fixed up the plate too allow the bolts to sink further down rather then sitting above the plate

Looks like someone has replaced the factory bolts in the 5th gear retaining plate, the original are philips head and sit completely flush with the plate, there are many cases of the factory bolts coming loose , personally I have reused them sucessfully for thousands of racing kms with no issues, a small punch betwen the threads 2/3 the way up the shaft gives plenty of bite, of course the right size allen key bolt makes torqueing up and undoing much easier

The issue of 5th gear spur rubbing on the plate is due to the tapered roller bearings, as they wear they end up with plenty of float, it stresses the case, shimming the countershaft up properly solves that.

There are so many issues with these boxes but if you build them right and don't abuse them they are fine, most of the whingers are ones that buy a 2nd hand box with 150km on it and flog it, the reality is there are no good gti boxes left, the high rpms wear out the synchros and hubs and the constant wheelspin is hard on the spider gears.
Basically if you want a good box you need to buy a low km cino or 3 cyl box and use it as an organ donor to rebuild your gti box.

To summarise these boxes, the gti with 4.1's wear hubs and diffs, the baleno g16 versions wear the bearings badly with the tall 3.7 and extra weight, Nana owned cino or 3 cylinder is your best bet for a donor.

As for making them stronger, since the centre distance between the shafts is a very narrow 60mm you can't make the shafts thicker or the bearings bigger, hubs wear as it is a very narrow design.
The best long term solution is to go to the cable shift swift sedan box, it does require work to fit but the 70mm centre distance gives a huge improvement in strength and realibility, plus the internals are interchangible with the new swift/swift sport gearboxes


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 Post subject: Re: awesome tail lights
PostPosted: Wed Aug 08, 2012 5:46 pm 
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Awesome! I've done this as wel.... back in 2006... -_-' (but I didn't dedicated a whole build thread to it)

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 Post subject: Re: awesome tail lights
PostPosted: Wed Aug 08, 2012 5:50 pm 
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papa wrote:
Yeah I really liked the bit where he tinted his lights.

Maybe you should use Italics

He has actually put a lot of effort into documenting his other build thread, not sure this tragic throwback to the early 90's needed a build thread thou.


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 Post subject: Re: awesome tail lights
PostPosted: Thu Aug 09, 2012 2:50 pm 
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Im sure he meant this to be continuum in the other thread but why should we let that stop us having fun it is an internet forum after all :)

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