Salto's Swift GTi endurance project

Post the details of your Suzuki build progress
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

Small update:

Me and 2 team members are going to do a 3-day race Licence/training on the circuit of Zolder (belgium) so we can enter the 24h race in september.
The car has been kind of assembelled for that, and after the weekend we will make the swift a bit prettier on the outside, and then its testing testing testing for the 24h race.

few pictures:

got a "balli" Torsen LSD:

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Had it built in (dont really have the right tools etc) and the gearbox checked, new bearings put in, and the bolts holding the plate behind 5th gear have been replaced with hardened ones.

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ready for action:

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got the PU steering rack bushings and installed those:

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new control arms with PU whiteline bushings:

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actually, some more shiny new stuff:

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Supafly from teamswift shipped me a nice set of mk2 regrind camshafts, so we installed those

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The interior is almost done, we painted the cage, floor and firewall, trimmed the dash further, mounted the heater/fan, cleaned up the wiring loom, fixed some old gremlins etc.

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And because we will be driving the car with four guys, we were gonna need clear warning signals for overtemp and loss of oil pressure and simple layout of alle the information etc., so we bought a Koso RX2 dash unit to do all that.

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but that will be built in after our circuit training.

The exterior of the car is put together kind of sloppy, but it will do, I drove a few hundred kilometres, and the diff and Cams feel great together with the carbs..

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last but not least, we have had some trouble with the fuel rail and injectors vibrating loose, and we are not using them anyway, we decided to semi-permanently fix this issue by plugging the injector holes.

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pictureshowman
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With four drivers, have you built in adjustability to the seat for different size blokes? Instead of plugging the injectors holes perhaps screw in vacuum ports for brake booster. Are you allowed to build in sub tanks for fuel as having a reserve tank that holds at least one lap would be advantageous on a long circuit. Beats trying to predict when your fuel will run out. Just thoughts.
If "X" is an Unknown quantity, and a Spurt is a drip under pressure, then an "EXPERT" is an "Unknown Drip Under Pressure".
Why dont they just call it "Womenapause" instead.
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

Yes, we need a FIA-spec seat, and seat adjustability is an issue.
I'm 180cm 60kg(skinny) my mate is 180cm 100kg(heavy and wide), my other mate is 2m and 90 kg(really fooking tall and athletic) 4th driver is unsure for now.
So we need a wide, tall chair, with adjustable seat rails, and I will need a foam seat to fit in. And even multiple steering wheels and hub lengths.

I have the brake booster connected to the runner of the 4th cilinder, and that has worked for some time now, so will probably keep it like that.

We are keeping our stock tank, but are adding a swirl pot so we can keep driving till fuel basicly runs out instead of at a quarter tank in long sweeping right hand corners. The Koso unit has a fuel supply meter aswell, with warning function, so it shouldnt happen.
Aaand we have a hour-and-a-half stint limit. So should be ok on that too.

Thanks for the input though.
Dutch Swift Gti endurance project
Bionic
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Looks good.. Alot of good ideas on you have done on your car.. Hey Salto what distributor are you using with your Carbi setup?
1995 GTI cheap Track\Hillclimb racer
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Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

We use a Swift mk1 dizzy, works on vacuum instead of ECU
Dutch Swift Gti endurance project
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

We did our Licence training weekend and got our EU-licence, so we're able to compete at the 24h race now! :)

Got black flagged for being 1.4 DB too loud at 96.4.
We immediately got an offer from a company who wanted to build us a new quieter system.. so curious to find out how that sounds..

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Dutch Swift Gti endurance project
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

We finally had another open pitlane trackday again, at circuit park Zolder.
We had a brand quiet new stainless steel exhaust fitted, so shouldn't be black flagged for noise..

Soo. Highlights :)

-first lap out, first time on full slicks we blew a tire (turned out the adjustment ring on the shock sliced it open, yeah.. i know.. we suck)
-first time we timed a lap and got decent result with that
-first time in the gravel since I started driving on track (didn't quite make the chicane)
-Black flagged for noise again, but now from the intake/carbs(haha)
-Did a few passenger rides in the Swift and they actually loved the underpowered shoebox!
-my mate is getting seriously fast in the car too, so thats a really good thing.
-Drove the swift 2 hours to the track and drove it back home too
-Did a passengef ride in a 1jz BMW e36 with 400+ pk (wich also ended in the gravel :))
-passenger ride in a 200+ pk golf mk1 wide body beast
-6 hours of tracktime in the pocket again

click for a short video

Next up is practice with our full 24 hour team ;)
Dutch Swift Gti endurance project
Salto
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Location: Netherlands

I took a little trip to the nurburgring last weekend, and did another 14 Laps.. here are two Laps on-board 1sr Lap is a bit of a relaxed Lap to check the conditioning and chasing a BMW, second Lap was my fastest of the weekend.

https://youtu.be/q2x0vORbjiY

Here is me Flying by one of the guys filming at foxrohre corner (my swift at 1.45)

https://youtu.be/63iNaaiO-HQ

Before the weekend we had the carbs set up and made 105 whp and 120 NM.
And painted it Black again

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pictureshowman
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Are your torque and power curves intersecting at 3650rpm?
If "X" is an Unknown quantity, and a Spurt is a drip under pressure, then an "EXPERT" is an "Unknown Drip Under Pressure".
Why dont they just call it "Womenapause" instead.
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

If i look at it now.. yes.
Haven really looked at it because it runs really good now.

I dont know what that says though.
Dutch Swift Gti endurance project
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

I've looked at it, and the toque scale is different from the HP scale.

HP scale is 10-20-30 etc
TQ scale is 20-40-60 etc.
Dutch Swift Gti endurance project
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

We did our first 24h race at oschersleben, Germany and we finished!
That was our main priority, especially after the gearbox failed.
Our spare gearbox didn't have a proper LSD, but a phantom grip, but it finished the rest of the race without any issues, and about 4-6 seconde a Lap slower.

Now we are looking into being more competitive next year, with a bit more power, and some upgraded suspension and more reliability..
Dutch Swift Gti endurance project
gtpswift
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well done salto/guys, So a mid race gearbox swap I gather, how long did that take, where did you place overall
Photos are needed!

GTP
Salto
Posts: 164
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Location: Netherlands

When the car was pretty much finished.. before it went off for the livery we had a photo shoot with Alex from the Wangan Warriors page:

http://www.wanganwarriors.com/project24 ... o-reality/

when we drove it from the sticker company to get the car aligned we noticed oil coming from the gearbox.
when we took off the gearbox, we found that there had been a piece of metal bouncing around in the clutch compartment(this was 10 hours before we had to leave to the track)

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So we had no choice but to take the gearbox to a welder and had the hole welded and mount it all again.
We threw everything on really quickly and went to germany

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Then we set up camp, unpacked our stuff, arranged everything in the pitbox and prepared for a 30 minute warmup session.
So 10 minutes before the start of that session we started the car to warm it up.. and right away oil started leaking on the distributor side of the engine.
it turned out to be the crankshaft seal.. wich wasnt leaking when we drove 100kms the day before, or driving the car up and down the trailer.. just started leaking when we started it right there.
and.. we had a lot of parts present.. but not that one.
So we had to find one in a strange country, and we dont speak the language, but after an hour or so we found one.. and replaced it.

then it was time for a 2 hour qualifying/night training session.. well..

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A broken alternator cable of all things shut the car down the first stint.
When that was fixed, fuel started leaking from the filler neck, and with it leaking on the rear-left tire we had to stop and fix that too.
the team were awake now and started to tripple check everything, and found some loose bolts we forgot the night before when we were tired and rushing to get stuff done.
After that we set up the lights properly, because the track was dark as fook.

next day at 3 'o clock it was time to start(last ofcourse):

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but after 3 hours the gearbox didn't want to go anymore

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Some time later we were on track with a PG gearbox.. and everything went well until the throttle cable broke at 5 in the morning.
An with the carbs its a pain in the arse to fix, so took almost as long as the gearbox change.

And since the cable we have had smooth sailing, finishing 26th out of 36 with almost 4 hours lost with stops and the repairs.
The result is not too great, but for our first 24 hours with a freshly bilt car with a freshly built team.. not too bad either.
And our team just clicked, so that made it an epic experience! when we went over the finish line after 24 hours..

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we celebrated like we won it!

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aaand some random pics:

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FlyingGrape
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Great read dude and well done! =D>
ImageET 13.138 at 120.2mph
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moylee19
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=D> =D> =D> =D>

Fantastic effort!!

To finish is 90% of the challenge, you guys should be wrapped!
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Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

Thanks guys, it was absolutely epic.. we cant wait till next year.
We already took the car apart, as the engine is pretty much unopened Since 1995 and was boost fead for half its life.

Plans for next year are to add a little bit of N/A power with injection instead of carbs and make it more reliable(mostly without gearbox issues).

Fun facts
-We consumed about 20 liters of fuel per hour
-We used only one set of rear tires (interstate semi slicks in 205/50/15) which were already on the car for 12 hours with testing.
-We used 3 sets of front tires (interstate semi slick 205/50/15)but could have easily done it with 2 sets.
-We used one set of (mk6 spec) brake pads (carbon lorraine CL6) and they could do another 24 hours easy
-Brake disks (international grooved) were a bit coloured, show a little bit of wear but are still straight and could do another 24 hours easy
-we picked up more than a kilo of rubber in the sideskirts, front guards, bumpers and in the wheels
-we had a 16 man crew(all friends)
Dutch Swift Gti endurance project
Devil-GTi
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Location: Ten Boer, Groningen, Holland

gtpswift wrote:well done salto/guys, So a mid race gearbox swap I gather, how long did that take, where did you place overall
Photos are needed!

GTP
Car in & out box, swapped tranny & refueled (outside) ect in an hour and 15 minutes.

It was so awesome, finally something fun to do, well, at least for us mechanics :lol: :lol: :lol:
GTi Turbo running 10PSI :D loads of fun :D
bzchi
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Nice work, thanks for posting =D>

The Wangan Warriors photos are awesome!
Salto
Posts: 164
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Location: Netherlands

Yeah, Alex makes absolute killer pictures.
I think tomorrow is the next blog about the project will go online.
Dutch Swift Gti endurance project
Tassie_mk1
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Location: Launceston, Tasmania

Great work team that is awesome! =D>
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

Here is our story though the eyes of Alex from Wangan Warriors:
http://www.wanganwarriors.com/project24 ... hat-could/
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racer5
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Salto wrote: Now we are looking into being more competitive next year, with a bit more power, and some upgraded suspension and more reliability..
Any chance you could fit an Australian Driver like ME into your team next year?
Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05
Salto
Posts: 164
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Location: Netherlands

We can always build a second car ;)
There probably wont be a 24h next year, which sucks.. but we'll do a 6 and a 12 I think.
After that we want to look at fia-grade stuff, but I think we cant make the swift work for that .
Dutch Swift Gti endurance project
Salto
Posts: 164
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So, preperation has started for next year!
We pulled th car apart for an engine rebuild, gearbox rebuild,shock rebuild, new joints for the toe arms etc.

We also are extending our control arms for a bit more camber and a bit more caster.

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And also are making a fresh bonnet, because our old one will be signed by all team members and will be put on the wall of the garage

Inner frame:
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Inner frame with holes
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Complete with a bit of drawing
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Complete with vents cut:
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Dutch Swift Gti endurance project
dgr
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Impressive job on the bonnet =D>
What's the weight difference? Stock is 10kg if I remember correctly?

Let us know how you like the extended control arms!
Salto
Posts: 164
Joined: Tue Jul 17, 2012 4:56 am
Location: Netherlands

Thanks!

When we weighed our original bonnet, it was 11 kg.
Our last one was 4 kg, and we werent really nitpicky with making it as light as possible.
We used gelcoat on the outside AND coated the Inside to make it look smooth then.

After our 24h race the full team signed that and it wil be put up on the wall of our garage.
We had an outside skin laying around the garage for some time, so we thought we'd make the new one a bit lighter.
But when we picked up the skin to glue it to the Inside, it turned out we used a few layers of fibreglass more than with our other bonnet.

So this one will be between 5 and 6 kgs.. but provide better cooling (we hope) and look a lot cooler :)
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Dattman
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Great read thanks, just be careful extending your lower arms too much as your driveshafts will be too short, I believe the gti auto driveshafts are 5mm longer.

With your front tyres, did you scrub them in before hand or throw them on 'green' during the race?
Salto
Posts: 164
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Location: Netherlands

We are extending the arms just a little bit, just so we have a slight bit more camber, and we dont have to angle the hubs so much and still keep solid topmounts.
we have to test if it will work, but it looks great sofar.

a little bit about the tires:

We were only allowed one brand of semi slick tires for the endurance series called interstate. they are a budget semi-slick, comparable to the nankang (should be same factory, same compound), cost about 80 euro a piece.
they were only available in 205/50/15, so stupid large for a swift, but since they fit we had to run them.
BUT, suprise surpirse, these tires were awesome. best semi slick tire we've ever had between the four of us.
I've ran most of my trackdays on toyo 888 and a few on advans, but the Interstate/nankang were faaaaar better.

I've had the pleasure of starting on a fresh set of tires, we never scrubbed them and werent allowed to use chemicals, but the grip from the get-go was fenoninal.
it needed about a lap of warming up (something I forgot 4 in the morning and took a bit of a shortcut through the kitty-litter) but were consistant all the way untill canvas came through (we were really impressed by them).
we did the full 24hours on our rears and about 12 hours with fronts, but we decided to change early for insurance and used an extra set of fronts.
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Dattman
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I found with my car being so low the driveshafts are quite extended and under braking the lower control arm mounts would spread slightly extending the shafts and causing me to pull the gearbox side shaft out of the box, a solid brace has stopped pulling the shaft out but I'm aware there isn't a lot of spare length in the driveshaft and cv's.

Those tyres must be very durable, (ie Hard) to last 12hrs, there's nothing quite like racing on a fresh set of tyres, I trust you had a warm up lap or two to knock the mould release off? I was going to suggest if you needed more life out of the fronts to scrub them in for two laps the day before and letting them cool overnight, that initial heatcycle will help stabilise the rubber compounds and you'd get considerably more life out of the tyre with a fractionally slower lap time for the first 20-30 laps, after that it's likely the grip level would be the same but the scrubbed tyre will last longer.

Not a huge fan of the 888's personally I think they are over rated and over priced, I remember when Toyo's, Kumho's and Hankooks were considered cheap and budget brands and priced accordingly, nowadays it's Achilles and Nankang and others at the bottom of the racing tyre stack.
Salto
Posts: 164
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Location: Netherlands

Our car is basicly stock height to fit the 205/50/15 tires, so never had a big problem with the joints or anything.
with the bumpers and stuff it looks sorta low..ish, but actually when you take those off it looks.. not so nice

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We dont exactly know how those things work with the tires :)
The stupid thing is we never did anything to the tires, and we all drove consistant times all the way.
I drove the same laptimes the middle of the night on brand new tires for an hour, and drove about the same times in the morning, and with the track heating up in the sun.. was still consistant.. and the other 3 guys did absolutely the same, and now that I think about it its quite bizarre.

they actually werent that hard of a compound. we could choose between a hard and a soft compound and we had the "soft" compound, but with a 750 kg car, 105whp and 205/50/15 tires and an open diff for most of the race (damnit) they just didnt wear.. especially the rear ones
and we could outbrake about anything, corner in and mid corner were great, but with the open diff coming out of corners cost us about 3/4 seconds a lap.. but still

888s in my opinion are great, but they arent really consistent.
they worked for me at time attack when I did a few hotlaps and cool.. hotlaps and cool etc.
Dutch Swift Gti endurance project
ADV
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Joined: Thu Dec 19, 2013 7:51 am
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Salto wrote: Image

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Hi,

Where can I find a set of those toebars for the rear suspension of my swift gti MK3?
And are a direct fit without extra modifications?

Thanks a lot,
And good luck to your project!
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