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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sun May 18, 2014 11:39 am 
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Location: StAlbans Vic
Since the last round I have spent most of my time trying to sort out an ecu issue not being able to rev out past 6800-7000 rpm.

I tried swapping out igniters. Adjusting the VR sensor. Fixing electrical connections. Nothing seemed to work.

On advice from a megasquirt forum I tried the enhanced firmware, MSEXTRA, I literally pulled over on the side of the road on the way home and flashed the ecu on friday night.

When I started the tuning software up again it was like a completely different ecu. :shock: So many new features. I had a heart attack because my project file was not compatible and I was on the side of the road with a blank and unfamiliar ecu. It took me about 20 minutes to get it all setup again and i managed to import my fuel table from the old table but a new correction MAP/MAT correction factor mechanism beant my table needed to be scaled by about 75%. took off and merged back into traffic and woohooo.... 7500 rpm!!!
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I was a bit worried about the LH CV and 3rd gear holding up but the made it. I think there must be about 5% left on the 3rd gear dogs though as it needs a very sympathetic shift to engage. It will definitely need to be sorted before the next event.

Worse is the overheating engine that we battled all night. Fortunately a cancelled stage and a no penalty transport gave us an opportunity to cool the car down open the cap and throw some water at it. Without which we wouldn't have finished i think. I'm suspecting head-gasket at this stage as I should have re-torqued the head after the last event.

Other issues included a trip meter cutting out on the second stage and a driving light relay that had enough after 4-5 minutes in each stage. These weren't enough to slow us down though. Instead, it was an coil lead falling off twice that lost the event for us. A bit of race tape sorted it the second time but it was too late.

I'm looking for head studs and a good gasket now it seems. maybe an oil cooler and some ducting as well.

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Thu Jun 12, 2014 12:53 am 
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Location: StAlbans Vic
I pulled the head off tonight and I was disappointed to find almost no sign of a blown head gasket, no sign of it running too lean and no reason for it overheating. :(

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Fri Jun 13, 2014 10:14 am 
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Location: Canberra
I had the same problem with my rally car. I think the problem is the sump guard not letting the heat escape. Fit an oil cooler and your overheating problems should be solved.


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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sat Jun 14, 2014 7:55 pm 
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I have been thinking the same about airflow., i'm going to try and vent the bonnet and i have an oil cooler on order already.

Where did you mount yours?

I got the arp head studs fitted and the head back on..... I xan testify that arp studs are a right pain to get the washers and nuts on.

Now to build a gearbox!

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sat Jun 14, 2014 8:23 pm 
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Location: Canberra
My setup isn't done that well,but it came with car, so I was glad the work was done for me.
the oil cooler is mounted in a metal frame, which is next to the radiator.
PM your email address and I'll send you some photos.


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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sun Jun 22, 2014 5:42 pm 
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Another Rally down! And we're starting to get the car going well. Yay!~!~!

At the last round I battled overheating issues and driving light failures. I couldn't find it loosing coolant so i thought the wort and suspected a head gasket so I pulled it down and it was fine. No sign of detonation on the head either.

To be safe I fitted some ARP head studs and torqued the head up good and propper. I dropped my target AFRs on load to 12.8 and touched up the tune. I pushed the redline a touch further to 7800 to match the Autocross car which I have found works well with the shift points.

To help the cooling I switched to a water wetter style race coolant and turned the thermostat into a restrictor by cutting out the valve. No more over heating issues!!!

A heap of other little things were done that are improving the cars rally ability like switches and interior lights and solid state relays and new drive shafts and underbody protection.

The rally went really well last night even though it was very wet. Despite a tree tap, and getting lost and missing a heap of turns we were the fastest car in class through the event according to the provisional results.

Can't wait for the next one!


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Last edited by SOBIL on Mon Jun 23, 2014 8:18 pm, edited 1 time in total.
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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sun Jun 22, 2014 6:10 pm 
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Location: StAlbans Vic
http://instagram.com/p/pgvSM4iuQc/

Taking it easy through the corners in the slippy conditions.

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sun Oct 12, 2014 9:01 pm 
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just a quick catch up for anybody following. So i did a few events since my last post.

A small autocross event confirmed my overheating issues had not been resolved.

I did a bit of a slap job in the driveway on the door, but it was enough to get it to the next rally.

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I tipped a bottle of chemi-weld into it to hold the head together for the next event. It worked well and we took the round win, taking the series lead.

Leading into the next event I was thinking it would go well with a new set of Sellholme 40mm struts.
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.

On the Friday night before the event, on the way home from scrutiny the gearbox blew forcing a no sleep gearbox rebuild and LSD install. I mixed and matched a few boxes and got enough bits to put a full gti gear-set together. we got it back together and on the trailer with minutes to spare. We did the wheel alignment and tyre swap on the start line.
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OMG what a weapon it is now with an LSD and real suspension.

Alas it's rally though and an electrical fault lost us 20 minutes on the first stage leading me to push it pretty hard in hot weather without a temp gauge. Pop goes the head again and rally over. The season is pretty much in the bin now but i might be able to get it back together before the next one.

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That's Rally.

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Last edited by SOBIL on Sun Oct 12, 2014 11:12 pm, edited 1 time in total.

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sun Oct 12, 2014 10:50 pm 
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Location: Central Coast
I know it's not likely, but regarding your overheating are the driving lights always mounted on the front? Could be affecting airflow..

And yeah, keep us posted with updates. Always good seeing a Suzuki used in motorsport!


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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sun Oct 12, 2014 11:19 pm 
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Pretty sure it is getting enough air. at the last event it was running too cold most of the time(no thermostat).

I'm pretty sure this time the head opened up again after the temporary chemiweld and pressed all the water out of the water pump seal. This motor has had just a few too many problems since i started with it. I suspect it was sold to the previous owner under false pretences.

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 Post subject: Re: SOBIL's Rally Carc
PostPosted: Sun Nov 30, 2014 4:42 pm 
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Soooo. A crazy few weeks have gone past , I tried swapping the head with another second hand head but alas the same outcome. An assessment of the series points showed that a win in he last round could secure he championship. I decided I had to fix it!

I decided to switch the bottom end but didn't actually have one in good condition so I ended up swapping some reasonable g13 crank and rods into a good g13a block with a freshly decked head.
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My budget for this rebuild came to around <400 dollars so you can appreciate I had to reuse a lot of parts but did manage to fit a new timing belt and water pump. Bearings were all select fit second hand and the rings we're select as the best I could find.

Miraculously the engine runs well and seems to be holding power very well. I would go so far as to say its the best it has ever been. I hooked up a digital temp gauge and even on the 30 degree day with a 25 km up hill stage it stayed under 105. The computer is now set to start pulling up to 10 degrees by the time it hits 110 just as a precaution.


I got through two stages but suffered a failed cv joint parked the car 7km from the end. Absolutely devastated! Time for bigger CV joints.
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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sun Nov 30, 2014 9:10 pm 
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Location: Barbados
i run full mk3 gti hubs and axles on my mk1. U have to slot the three holes on the intermediate shaft.


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 Post subject: Re: SOBIL's Rally Car
PostPosted: Sun Nov 30, 2014 11:06 pm 
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Location: StAlbans Vic
Others say the mk2/3 shafts need to be shortened did you need to?

I have also read of a loss of ride height, does this effect you?

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Dec 01, 2014 12:12 pm 
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Location: Mickleham Victoria
Great effort mate!
Shame about the cv's but that's racing

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Tue Nov 03, 2015 10:41 pm 
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Location: StAlbans Vic
2015 was not a good year for this car. With limited budget I entered only two events this year.

The first event started OK, but we were down on power. that wasn' too much of a bother as we had no tyres to be competitive. Then we lost the stupid bolt in the shift linkage. some improvisation got us going but put us in bad weather and we got bogged in transport, running out of late time. :(

The second event was going really well, I had prepped the car well and had sorted out a heap of niggles and was feeling confident but 3rd gear went crunch and then proceeded to take out the final drive before ending the event after only two stages.

Six months later I have put another gearbox into it while i save up for a frankenbox. Donations accepted


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 Post subject: Re: SOBIL's Rally Car
PostPosted: Fri Jan 01, 2016 8:48 pm 
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Location: Newcastle
Bring on 2016 eh, better luck this season!

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