AWD GTI

Post the details of your Suzuki build progress
waylow
Posts: 6689
Joined: Mon Aug 25, 2003 12:00 am
Location: Camden
Location: Sydney, in the Shire, on the good side of the bridge

Was a perfect fit for my skinny frame! I'll buy it off you if you want to sell it.
Swift gone.
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

its been a while since I did anything, but got busy today.
Welded on the side skirt brackets along the sill.
cleaned out nearly 2 kg's of leaves from the front 1/4's behind the wheels, tried the carbon fiber rear wing, Thanks Taylor, fitted the cambered rear strut tops and vacuumed the plenum to remove the rest of the detritus left by our tree.
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GTP
gtpswift
Posts: 1643
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Location: Australia

got the angle grinder out again with nice slitting disks but had to decide on which vents
escort cosworth
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or XR4i Cosworth
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went with the smaller ones as I doubt anyone has them in OZ
buzz buzz
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grind grind
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wallah
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glue and sand back
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then touch up with satin until I respray in a little while
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GTP
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southy
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Location: Cessnock

Im not a fan of most vents, but they actually turned out nice.. Looks good! =D>
TEAM RIFF RAFF
Rasputin wrote: Yes. I like hard parking faggots and want to be one. It's my dream
Thanks,
Dan.
gtpswift
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Location: Australia

Thanks southy!
At 20 bucks for a bonnet it was worth the effort to try it
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GTP
Tassie_mk1
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Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

Looking great! Keen to see this progress some more :)
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

ever start a job, and get halfway through and ask yourself Why?
Why the hell did I do this.
I have many times and again recently.
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So new clutch, new driveshafts, modify crank accessory pulley to suit power steering and airconditioning, lighten and machine Justy AWD flywheel new Walbro 255 in tank fuel pump,
will need to sandblast and paint all the brackets, new bearings for GTi front hubs, new gaskets fit the ECU re-route the existing wiring as I want to keep it capable of going back to single cam.
An easy swap I thought. Im just getting old I think.

more as I progress

GTP
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southy
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Location: Cessnock

So are you sticking with a standard ish motor or are you going with that N/A beast of a thing you brought back with you?
TEAM RIFF RAFF
Rasputin wrote: Yes. I like hard parking faggots and want to be one. It's my dream
Thanks,
Dan.
gtpswift
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Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

the 'race' engine until I find Ive been robbed and its junk then we shall see.
But it just gets harder...
TBC
GTP
Tassie_mk1
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Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

oh so keen to see that engine in!

Completely understand things getting harder! I make them hard for myself all the time :P
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

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What a pain in the ass this was. Flywheel bolts wrong, timing belt wrong, power steering belt wrong length, and generally nothing from the last installation fits on this one. Have to modify power steering pulley adjuster and find right length belt to clear the crank angle sensor bracket. Have to remote mount the oil pressure switch and sender. And remote mount the brake master reservoirs as the throttle bodies clash. Modify the throttle cable bracket despite coming from same car family. Also had major problems with camshafts and valves. Engine had sat for a few years and on turning it over once off the engine stand some valves would stick open and slam shut. Pulled the head off, pulled each valve, re lapped them in and fully lubricated them. Bench test all good until I connected the timing belt then bang, bang, bang...as it transpires, Moyle looking down the throat noticed the exhaust valve catching and holding the inlet open. The custom camshafts firstly had the locating dowel almost opposite a standard one and the inlet cam is retarded 3 teeth on the pulley. Once we worked that out sweet as. Wiring and fuel pump next.
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Zuboo
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Location: Brisbane
Location: Brisbane

Just remember what does not kill you makes you stronger
A dyno will tell you anything you want, the 1/4 mile will tell you the truth!!!!
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[email protected] ST, 58.98 sprint [email protected], 61.6 Lakeside, 294HP ATW
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southy
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Location: Cessnock

It does look good though!
Will make the end result all that much better having a sh!t time putting everything together.
TEAM RIFF RAFF
Rasputin wrote: Yes. I like hard parking faggots and want to be one. It's my dream
Thanks,
Dan.
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

Yeah and I'm currently the strongest man in the world!
Its silly stuff really.
Why would a billet camshaft be made not using the factory timing set up.
The dowels in the end of the cam need to face upwards in the pulley at TDC, contrary to the workshop manual then the inlet cam needs retarding 3 teeth...according to the old pulleys? Why, what were they thinking.
But I know more about this engine and its in now.
Anyone done a remote master cylinder reservoir?

GTP
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southy
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Location: Cessnock

Brad Harris from Harris Motorsports has the remote mount res for master cylinder, I've enquired about them myself but I think he needs numbers to do another CNC run of them.
TEAM RIFF RAFF
Rasputin wrote: Yes. I like hard parking faggots and want to be one. It's my dream
Thanks,
Dan.
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moylee19
Posts: 1682
Joined: Mon Aug 25, 2003 12:00 am
Location: Adelaide
Location: Adelaide

we will get there! Just hopefully before that baby arrives.
IPRA MK3 Gti ~ Mallala 19/11/11 1:23.5915
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Tassie_mk1
Posts: 2096
Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

Looking good mate! I totally feel your pain on the annoying things slowing you down (those cams! :shock: ) Keep at it! It's a great build and you will enjoy it when it's done :)
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
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Bewitched Gti
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Location: Tamworth NSW

gtpswift wrote: Anyone done a remote master cylinder reservoir?

GTP
I prepped one from factory parts while I was at wreckers,
The reservior you can get from a 1999+ Carry van, the fittings for the Mc you can get off the earlier carry vans (they had mc under the dash)
I'll post pics if you like.
gtpswift
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Location: Australia

sorry mate missed your reply, yes photos would be great

It runs! woohoo and runs quite well up to 4000 rpm.
but the cat converter went bright orange so we stopped play for the night as the maps must be all wrong.
But most importantly I have the confidence the engine isn't rubbish and I can finalise the plumbing, wiring reassemble the interior, fit the new fuel pump and send it to the tuners.

Moyle said it sounded angry!

GTP
Tassie_mk1
Posts: 2096
Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

So keen to see the results for this! Looks so good with the Quads and the green on matt black =D>
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
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moylee19
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Location: Adelaide
Location: Adelaide

https://www.youtube.com/watch?v=93vq_8LUiTo

I apologize for the sound quality, it was a phone after all!
IPRA MK3 Gti ~ Mallala 19/11/11 1:23.5915
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gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

So fuel pump upgrade time.
had to strip the entire rear suspension and drivetrain out to get to the tank. had to cut a few of the factory hose clamps due to corrosion
at least its a nice and clean floor above the tank
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the tank is quite complex
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with three opening in the top. Delivery pump with its own internal sump, a lift pump to feed the delivery side which also includes the fuel gauge sender and a low level trigger for the supply side
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and the rear sub-frame seems to be surviving well since the rebuild
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The Justy pump is tiny compared to the GTi pump. its high pressure but obviously low volume. So a Walbro 255L replacement was quite an easy fit as its smaller diameter then the GTi pump so no adaption was necessary.
So hopefully it stays together as Its a day job to repair again if necessary.

GTP
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Bewitched Gti
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Location: Tamworth NSW

Yea, I know the feeling, pull 80 parts off just to replace one underneath :lol:
Atleast you've now ruled out clamp failure down the track.
Looking good
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sk4wd
Posts: 2173
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Location: Sunny Perth, West Australia
Location: Sunny Perth, West Australia

With my AWD I cut a nice access "hatch" above the fuel pump in the floor. First of all it avoided pulling the whole rear out and now if anything goes wrong, I can now access the pump from under the back seat. It would be very easy for you to do now you have stripped everything.
GTi MOTORSPORT
Been quiet lately..still going to rallies.
gtpswift
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Location: Australia

Thought about it but decided the nice clean floor will remain intact. This is not the cut-big-holes-car
Now its done with new jubilee clips and lubricated bolts its a bit easier , probably a 3-4 hour job. and if the new fuel pump fails the car is getting junked :twisted:!

GTP
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

Slow going at the moment on this...don't ask about the race car.
New Baby at home means time spent on this is limited and the spend less project has my imagination at the moment...Oh and nothing seems easy.
Its all together, has run and made the cat glow orange. Addressed a few issues and now it pours fuel out the exhaust so need to trim a bit out of the E85 base map to get it to idle and run a bit cleaner before heading to the tuner.
But now the starter motor appears shot so Just ordered another one should see it in on the weekend...maybe!
Also awaiting some braided fuel line to convert to earls style fittings as I need to move the fuel lines as the air filter hits them in their standard position
A pretty blurry picture too
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GTP
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

slightly better phone photos this week.
ECU mount to straddle the gear change cables under the heater box
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with ecu mounted
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In place in front of airbag sensor
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Oil cooler, I think some better brackets are needed ultimately but will allow it to be tuned
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Engine shot 1 all plumbed and wired up. Had to cut and shorten the fuel supply and return pipes and run braided flex as the air filter hit them.
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and the throttle bodies, just need to rework the accelerator cable as it clashes with the filter as well. Once its all up and running and showing signs of reliability ( ie wont be swapping the old engine back in) Ill tend to the old engine wiring loom and strip it out.
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so also replaced the starter motor and the battery and it wont run!!!!!!! F*&^(*^&%(* it

GTP
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

So after another blown coil igniter I have converted it to 4 LS1 coils which meant rewiring the coil side of the loom. Then with Moyle19's gracious help this afternoon (thanks simon) we got it running and idling without huge plumes of unburnt fuel out the exhaust, just enough to burn the eyes. The ecu map is for E85 so is pretty rich for 98 premium.
Then I drove it out of the shed for the first time in months and discovered no brakes and loose front end...oh yeah forgot about that. plus a massive oil leak pressure side of the oil cooler so packed it away as it was too cold to lie under it to investigate the once slow but now severe oil leak. Brakes need remote reservoir plumbed in and bleeding. but most importantly it drives in both directions so once these things are fixed its to the dyno.

GTP
Tassie_mk1
Posts: 2096
Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

Good to hear this is moving forward again. I can't wait to see it in action, it should be a real weapon!
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

Thanks Tassie. I cant believe how long and how much money it has cost given I 'had' everything...most of which needed replacing as it was wrong! don't believe everything you read on the internet. but its nearly there and so is the escort!

GTP
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Bewitched Gti
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Location: Perth WA
Location: Tamworth NSW

I feel for ya.
Every day at work there's little setbacks, and that's working with bolt on factory gear,
Let alone teething a new custom install
:) keenly awaiting vid with good audio
Tassie_mk1
Posts: 2096
Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

gtpswift wrote:Thanks Tassie. I cant believe how long and how much money it has cost given I 'had' everything...most of which needed replacing as it was wrong! don't believe everything you read on the internet. but its nearly there and so is the escort!

GTP
Ha! Dont get me started on "having everything" :P it'll be worth it in the end (for both of us hopefully!) I'm really keent o see what sort of track times this puts up compared with similar 2wd GTi's, it should be very quick despite the extra weight and the extra grip should make up for the weight gain over a GTi I would have thoguht, plus it sounds mental! :mrgreen:
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
cbmotorsport
Posts: 16
Joined: Tue May 19, 2015 1:56 am
Location: Chepstow - UK.

Hi,

Nice build - Where did you relocate the brake reservoir to? I'm looking at trying to move mine for the same reasons. I would be keen to see more pictures / more info on this!

Thanks

Chris
gtpswift
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Location: Australia

Ill tell you next week, when I work it out!

GTP
gtpswift
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Location: Australia

so bloody cold in the shed today.
Fitted these though
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well when I say fitted, took the clear lenses of the new bodies and installed with orange globe onto original bodies. the aftermarket ones are junk fitting and reflectance of lens.
and Im messing about with this trying to get the right ratio for the throttle movement
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found the oil leak and tested the air filter which is a tight fit against the bulkhead. then played around with brake master cylinder remote reservoir...no photos as I had no solution.

GTP
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DrelvisGTi
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Location: Western Australia

Hi gtp,

A quick question if I may?

I've noticed you are using SAMCO radiator hoses. I have the same set (albeit in black).

I've recently bought an AWD gearbox that hasn't been installed yet and was wondering how easy it was for you installing your hoses (?) Apparently there is a slightly differing cast joiner piece underneath the gearbox exclusive to AWD models...

Were there any issues of note that you had?

Cheers,

Drew
スズキ カルタス GT-i
gtpswift
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Drew,
the only hose that fits is the top one, the rest are standard subazuki.
Typical.
GTP
gtpswift
Posts: 1643
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Location: Australia

fucking thing!
Why is the brake booster 25mm thicker than an australian delivered one, why is the master cylinder only 20mm diameter and 20mm longer with different brake pipe configurations
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But its getting there
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awaiting new remote reservoir then these holes can be plugged and maybe It can be driven more than 200meters
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GTP
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

sorted the brake remote reservoir today
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seems secure enough and should work fine
had the trumpets welded to a filter base, then I sand blasted it and polished the important parts up
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tested them in the bay and it fits!
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and started on the bracket for the throttle linkages.
had previously cut and tapped the throttle bodies for a mounting plate
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will trim this one up once the throttle cable stay is welded on, can see the start of it on there just ran out of day.
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.

GTP
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southy
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Hey GTP, where did you end up sourcing the throttle linkages?
TEAM RIFF RAFF
Rasputin wrote: Yes. I like hard parking faggots and want to be one. It's my dream
Thanks,
Dan.
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

southy,

This linkage kit is from RHD engineering (http://racehead.com.au/)
Seems like it should work OK. the kit looks well made just hope I can tighten the 'clamping' well enough to prevent slip on the shaft. Might look at a better method of permanent slip free fixing once its all up and running...

Chris,
as you can now see I used a remote reservoir from FTE, which incorporates low fluid warning light switch. I ordered this from the UK (merlin motorsport) as they could deliver it quicker and for less than half price than Earls could through local distributors for exactly the same thing.
then some low pressure rubber hose onto some banjo bolts. I made up the master cylinder adaptor using some machined steel bungs welded to the plate. If it all works well Ill have the adaptor gold passivated as paint doesn't work !

GTP
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

it drove up the street and back with not many dramas. even managed to wash it
No brakes, bled them but will have to do it again. Could be dodgy new mastercylinder?
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need to shorten the plug leads
accelerator cable linkage finished. will paint later
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GTP
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

Just cause I can! some more photos
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GTP
Tassie_mk1
Posts: 2096
Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

Looks awesome mate! Keen to see it finished :)
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

Its a rare day the black one is out and about, its been to the tuner and come back with a small list of things needing attention, most problematic is a breaking down of the crank angle signal. Ive secured enough meters of the most expensive shielded multi core signal wire I could find to run from ecu, out the door across the front guard under the bonnet an to the sensor. this way we bypass any 'noise' from other components to test. if this fixes the problem then a rewire internally for the signal lead and back to the tuners.
so while it was coming off the trailer a wash and pose with the red bomber.
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GTP
gtpswift
Posts: 1643
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Location: Australia

deep dig from the archives...its tuned
So a bit of fire damage clean up, 4 hours of unproductive work spent disassembling and putting back together throttle bodies and filter all the way to the back of the valves!
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and new filter is green!
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but end result is this whatever it all means
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GTP
Last edited by gtpswift on Fri May 06, 2016 10:00 pm, edited 1 time in total.
gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

well it lasted for 35 km's before the crank angle sensor stopped sensing the crank angle! and I had to walk home!
It appears after the deutch plug that filled with water! was replaced by a new alternate type of connection the vibrations rendered the plug useless. stripped the wires, twisted the ends and hey presto its alive again
so I'll hard wire the sensor to the lead and be done.

GTP
Tassie_mk1
Posts: 2096
Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

Good to see it's running and useable now, despite the teething issues :) Great work! Now hopefully you can enjoy it for a while!
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
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moylee19
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Location: Adelaide
Location: Adelaide

IPRA MK3 Gti ~ Mallala 19/11/11 1:23.5915
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gtpswift
Posts: 1643
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

Oh dear!
Mallala 1- Justy 0
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WOT Flat out boom!
back in the pits it was loosing oil while running
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this is not right! and source of oil leak
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seems to be also leaking conrod caps
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head survived
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so what to build?

GTP
Last edited by gtpswift on Thu Nov 14, 2019 5:02 pm, edited 1 time in total.
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