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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Sun May 11, 2014 5:33 am 
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Location: Netherlands
New red stripe on the freshly painted bumpers
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Prepping the engine bay for paint
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Painting the engine bay
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Finished!
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Now it's finally time to start mounting some stuff, such as the engine..

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Fri Jun 13, 2014 8:46 pm 
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Finally the transmission is rebuilt en the engine is mounted!

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Mon Jun 23, 2014 4:44 am 
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I know, it's breathtaking..

Front sway bar is in place. Found a new spot for the coolantbox. Re-wrapt the roof in gloss black. And theres a lot of wire-tucking taking place.
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Daily Drive: Toyota Avensis 2.0 Executive wagon '06
Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Mon Jun 23, 2014 3:54 pm 
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WOW!!! This is turning out really well. I admit I had some doubts after the rust, but you rave really bade it look slick....

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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Mon Aug 25, 2014 4:25 pm 
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Location: Netherlands
Lowered the daily with BC-Racing coilovers.

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It corners like hell! :mrgreen:


Got my hands on genuwine unique power-windows for the mk1 swift.
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Also I've sold the Ally Cat Rims and got me a unique set of 13" SSR Dunlop T-E 3-piece rims.

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They'll need a little bit TLC, but will look sick under the mk1 swift.

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Sun Jan 25, 2015 11:12 pm 
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Slow progress, finished the wiretuck, everything is now hooked up!

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Sun Sep 06, 2015 12:23 am 
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Well long time no update! Not much is done, but work continues.

Refurbished the carbs:
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Made the SSR rims 3-piece again:
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Started on installing central locking:
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And power windows:
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Fuelpump installed:
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Battery in the boot:
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And after a lot of work today the car finally started! Still needs more finetuning and an exhaust

Video: https://youtu.be/lgroEEemzy4

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Sun Sep 06, 2015 12:27 am 
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And I completly forgot, I slammed the Baleno wagon on some 16" DZexklusiv rims, 7,5J front and 9J back and rolled the guards.

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Wed May 25, 2016 12:01 am 
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A lot of work went into the mk1. Ran into lots of issues, took a while to fix them all. I had the car running, insured, MOT, but I still had a oil and coolant leak.

So, disassembled the cylinderhead, refurbished it, reassembled it and got it working. During this I found out that the headbolts where shot, so put in new ones. And then found out I had a crooked camshaft gear. So I fixed that and yes, the car was running great with no leaks.

Went to my first event since 2 years!

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Wed May 25, 2016 12:17 am 
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Replaced the rear subframe of the Baleno. And refurbished the wheels.

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Thu Oct 20, 2016 9:46 pm 
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So far for the conrodbearing. That's the piston hittin' the head.

https://youtu.be/hdlRGQmdutQ

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Thu Oct 20, 2016 10:06 pm 
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Conrod bearing and damaged conrod
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Lots of metallic in the oilsump:
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Damaged crankshaft, unrepairable (worn over 0.50mm):
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How all the pistons look:
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And how all the cylinders look:
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Cleaning the s**t out of everything, all the debris needs to be gone. I’m using a big ass washingmachine and ultrasonic cleaner.

Why the engine got damaged? I will never no for shure, but I did found bead blasting debris inside the engine. The seller who I got the engine from, did some bead blasting on the cylinder head, wich of course ended up inside the whole engine true the coolant canals.

While into this, I’m checking and testing everything I’ve bought from this imcompetent bastard. Wich lead to, a new alternator and starter. Bough new oversized pistons, the cylinderblock gets bored and honed, still looking for a crankshaft wich will also get new bearings.

Sigh....

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Thu Oct 20, 2016 10:10 pm 
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Everything I've bought from that guy is gone to s**t! Got my alternator and starter tested, yes they are s**t! So, new alternator and new starter.

Cleaned the sump, got rid of some rust and put a number of layers of black on it:
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Disassembled the oil pump, cleaned it, cleaned it again and once more. Reassembled, new seal en gasket.
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Bored the engineblock to 0.50mm oversize piston:
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Honing engine block:
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Cylinders are better then new now!:
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Skimmed the engine surface:
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Lots of new parts:
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Everything ready for the crankshaft:
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Still need to meassure the rods. And my crankshaft was unrepairable. Finding another one was a pain in the ass, but I found one I can use!

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Daily Drive: Toyota Avensis 2.0 Executive wagon '06
Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


Last edited by Pauluzz on Thu Oct 20, 2016 10:21 pm, edited 1 time in total.

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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Thu Oct 20, 2016 10:13 pm 
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Measured the crankshaft and had it polished:
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Measured the conrods and cleaned them up, before and after:
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Mounted new pistonrings on the new pistons and mounted them with new piston pins on the conrods
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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Thu Oct 20, 2016 10:16 pm 
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Started to build things up again. Received the wrong mainbearings. Mounted the rods and pistons anyway.
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Day later I received the right mainbearing, together with the conrodbearings and thrustbearrings:
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Mounted the crankshaft and everything:
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Oilpump, sealhousing and oil sump in it's place!
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Disassembled the cylinderhead, cleaned it and cleaned it once more and assembled it.

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Daily Drive: Toyota Avensis 2.0 Executive wagon '06
Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


Last edited by Pauluzz on Fri Oct 21, 2016 12:23 am, edited 1 time in total.

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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Thu Oct 20, 2016 10:20 pm 
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Location: Netherlands
Head is on, distribution is on, etc etc.

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Aaannndd in:
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The shop:
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Daily Drive: Toyota Avensis 2.0 Executive wagon '06
Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Fri Oct 21, 2016 3:05 am 
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Posts: 187
NIce work.

If you need any more engine parts, let me know.
I have 3 crank shafts which are good use as it is and I have 3 sets of std con-rods,

Cheers
Atchi


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion
PostPosted: Wed Mar 29, 2017 12:37 am 
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Finally got the carbs tuned. First run, before tune, was 61 whp :shock: so it was necessary

Final run:
85,6 whp at 6141,8rpm
111,3Nm at 3274,5rpm

Am I correct that the GTi has 76Whp standard? If so, what does it make for mine on the engine? 113HP?

Click here for the video, skip to 2min for the action:
https://youtu.be/-TZk0xu1Kt4

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And I scaled it down a bit
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Daily Drive: Toyota Avensis 2.0 Executive wagon '06
Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion with mikuni carbs
PostPosted: Fri Mar 31, 2017 5:58 am 
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Posts: 187
Hi,

Standard mk1 Gti has 97PS which is 95Bhp.
mk1 Cylinder head has less flow than mk2 item so you will see some improvement with mk2 head.
If you are getting 113Bhp, that's more or less to Cultus Gti power.

Is you spec using standard camshafts?

Generally speaking, mk2 Cultus Gti has better cams, both exhaust and inlet manifolds to get 115PS which is 113Bhp.

So if you upgrade your camshafts, you might see bit more ponnies.

Cheers
Atchi


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 Post subject: Re: Project: Dutch '86 mk1 -> gti conversion with mikuni carbs
PostPosted: Mon Apr 03, 2017 4:41 pm 
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Engine is stock, cyl.head is mk2. Engine is completely rebuild and new though. But the exhaust is the stock exhaust of the old 8v engine.

Sooo, new exhaust next year! And maybe different camshafts. And then back on the dyno.

For now the car finally runs good, so I can enjoy it! 8)


Exterior is next.

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Project: Suzuki Swift GS '86 (SA413) -> GTi conversion project


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