GTI into Cappuccino

Post the details of your Suzuki build progress
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey guys I've started a build with a GTI engine mated to a early Jiminy gearbox going into a Cappuccino. Engine is standard at this stage but plan on putting a IHI RHF4 VF25 turbo on it if its any good for the GTI engine. The turbo had been fitted to the 3 cylinder 660cc Cappo engine by previous owner, so that's why I plan to re-use it unless convinced otherwise. My Kind visiting brother in-law from the UK managed to blow the Cappo engine whilst I was working away and left it parked in my shed dirty and not a word said. Lucky he returned to the UK before I got home.

I have a few basic questions as I'm new to GTI's and the forum, so any sound advice will be appreciated.
I got my son to buy the GTI engine/loom etc (crashed) from guy in Perth off Gumtree as I work in Indonesia. Was advertised as 1994 Mk3 and ecu chipped.
How can I tell it is a MK3 and that the ecu is same?
What does the VF25 TURBO come off and will it suit the GTI?
I opened the ecu to see what chip was in it but cant find the socket with modified chip in it, unless chip has been soldered in?
I saw the steel layered head gasket on the forum for sale, are they better than standard as I bought some in Indonesia as they were cheap and brought back to WA. I hope to use one when the Cappo is running to build purpose turbo engine.

First time on forum so don't know if photos are attached or if I'm even in the correct section.
Regards GTI Cappo
Attachments
4 layered steel gasket
4 layered steel gasket
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Can't wait for it to come off stands
Can't wait for it to come off stands
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GTI engine going into Cappuccino
GTI engine going into Cappuccino
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GTI CAPPO
User avatar
DrelvisGTi
Posts: 1084
Joined: Sat Mar 08, 2008 1:07 pm
Location: Western Australia

Hi Mate,

Welcome! :D

A Mk.3 ECU is labelled I2 in yellow letters on the casing. If the ECU chip is still soldered in without a socket and looks stock; then I might suggest that the EEPROM 'chip' advertising is possibly... *ahem*.... bullshit.

For engine identification here you go: http://www.redlinegti.com/forum/viewtop ... =7&t=33988

I seem to remember that the VF25 comes from a SH-9 Subaru Forester XT (found this out because my wife drives a Fozza) and is quite well suited when combined with a reputable chip. They (the chips) are available from persons such as: http://www.redlinegti.com/forum/viewtop ... =3&t=34209 :wink:

The MLS will NOT let you down. But successfully going turbo always depends on the tune I guess.

Looking forward to seeing your progress. Are you located in Perth?

Cheers,

Drew
スズキ カルタス GT-i
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hi Drew, thanks for detail and links in forum. I can remember the lug on the R/H side of the engine so should be MK3 and assume ecu is same. Once I get home, I will send ecu off to have socket fitted so I have the option to run turbo or N/A.
Progress has been slow looking for bits, plus working away doesn’t help. The conversion started out with a 12A rotary and Mazda R8 6 speed box, but with the g/box far too big for little Cappo tunnel and I saw the GTI engine on Gumtree the rotary was scraped. Now has a spot in the corner for a one day project. I also decided to keep it all Suzuki and look like a genuine Cappuccino GTI. and 2 spoons of sugar
Progress to date been fairly easy and straight forward.
• GTI engine to Jiminy g/box is plain bolt up but must use GTI p/plate with Jiminy c/plate as spline is larger.
• Cappo/Jiminy rear g/box mount modified into one. Completed.
• Cappo remote gear linkage assembly reused but torque rod & linkage extended. Complete.
• Cappo & Jiminy both run cable clutches so only need to make sleeve/spacer at g/box end.
• Drive shaft will be Jiminy extended.
• Purchased polyurethane bushes & sleeves to fab engine mounts. Required to be rigid as only 12mm clearance between cam belt & bonnet ribs plus same between sump, side of block and steering rack mounts.
• GTI sump redrilled, reversed, front cut down to clear rack & rear bowl cut to level with bell housing & front cross member. Serria oil pick up pipe to be modified.
• Cappo throttle cable too short so once its out will check end/length & hopefully can use GTI
• Radiator will be Honda civic 2 row 40mm alloy type with thermo fan from ebay. Ports are same side as Cappo.
• Turbo manifold will be the tricky bit for me but may buy S/S turbo one off ebay and mod it to fit the VF25 3 bolt turbo. I think the bends are too large and turbo will foul chassis rail. Also will try move it around and top mount it but don’t know how tight a bends I can get yet. Better still is get exhaust shop to make and wife to pay.
• Will use GTI ecu with turbo chip.
• Will use Mazda 323 turbo dizzy cap for now but would like to remove the dizzy and move engine back further. Costs are too high for aftermarket ecu and all that goes with it. I did think of driving the dizzy with a belt from the ex cam but then it would have looked like farmer browns shed special.
That’s all I can think of for now but will update once more has been done. Yes I'm WA but down south in Busso 3 hrs from Perth at snails pace.
If anyone knows or has done this conversion I would appreciate some advice or short cuts if I’m heading down the wrong track. Also thinking of getting a light weight alloy flywheel and front pulley from the USA if there are no negative reports on them??
Regards GTI CAPPO
Attachments
self draining no drip sump
self draining no drip sump
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vented free flow sump
vented free flow sump
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Cappo/Jiminy g/box mount
Cappo/Jiminy g/box mount
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VF25 Turbo
VF25 Turbo
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gear linkage
gear linkage
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rack mounts to be cut & welded
rack mounts to be cut & welded
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GTI CAPPO
gtpswift
Posts: 1641
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

Good work all looks well thought out, keep the pictures coming and dont let the brother drive it again.

GTP
DoubleShot
Posts: 6
Joined: Tue Aug 25, 2015 9:49 am
Location: Australia

Hey mate.

Planning the same conversion in my cappuccino as well.
Will be watching this thread if plenty of intent to contribute but I'm still very much a newbie with engines.
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey Doubleshot,
Get your ducks in a row, buy the bits you need then get into it. I put mine off for some time and really just missed driving it. I was going to kart tracks to get the same buzz. Hopefully with the GTI engine it will be double the buzz.
Once you have a plan its not hard. I will try record all I've done and what parts used for future reference and to share. No doubt I will stuff up along the way, but there are some smart cookies with all the experience on this forum and willing to share. Don't think we will be stuck for long if run into a problem.
Get into it and don't give up or someone else gets a bargain.
Cheers GTI CAPPO
GTI CAPPO
User avatar
AWDmoke
Posts: 547
Joined: Sat Jun 17, 2006 10:49 am
Location: WA
Location: Cloud Break mine or Safety Bay, WA
Contact:

Great project. These are a fantastic looking & handling little car.
There used to be one running in the Speed Event Series - it now has a mid mounted 'busa engine!

Hope to see it when you're done.
Mk2 Gti khana car, various minis & mokes & German cars, a G13b Mini Sports Sedan, and a G13b Goggomobil hillclimb special
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

The Cappuccino is closest thing to road legal go-kart and you don't get wet if the roof is on. Mine had a whole wopping 51kw at wheels and now with the GTI-T engine in, hopefully it will think its on steroids. Once you drive one, the bug bites and you gotta have one. I was going to build another Lotus 7 but drove the Cappo and done deal Lotus hasn't had 2nd thought.
I know the Busa Cappo you mentioned, which is dry sumped and engine sideways in passenger foot well and is lethal. He has 2 Cappo's, the Busa one and a road legal one. I think he had the Busa build thread on here few years back. If I find a wrecked Cappo at the right price I would like to build purpose track one with cage, chopped firewall/tunnel for a wild G13b-T or Rotary 13b-T set back and low. Nice to dream, I haven't even finished what I got.

Regards GTI CAPPO
GTI CAPPO
miniswift
Posts: 219
Joined: Fri Jan 07, 2005 9:44 am

Any update?
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Sorry no real update or significant work done on car this break. I did build a Jarrah deck for the wife and other jobs around the block, so next break will be all car time. Full 2 weeks I hope???
Did manage to build a 1/2 ton 6m mono rail with electric hoist over work area in new shed so Cappo can stay on stands now and engine can come in/out easier and not move car.
Got some manifold & turbo flanges water jet cut, thanks for the DFX files. Ordered 35mm ID mandrel bends so will practice my tig welding and give the manifold, engine mounts and sump a go. Been 15+years since last tig welded, like riding a bicycle you never forget, just a few falls or burns.
Sitting on the fence about leaving turbo off to speed things up and get finished so I can get it to the track or just drive it again. Turbo just lying there, turbo power or NA??????
Now that I have mono rail I will weigh cappo motor/box complete and same with GTI/jiminy box to see what difference is.
GTI CAPPO
ishigakisensei
Posts: 54
Joined: Tue Jan 21, 2014 1:12 pm
Location: Japan

You may have already registered, but http://www.clubcappo.co.uk is a site with some Hayabusa an G13b powered Caps. Worth checking out if you haven't been yet.
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

I joined the clubcappo forum few years back but not much activity there lately. Anyway engine is the heart and a GTI so will follow Reline forum and learn more about the GTI engine. :D
GTI CAPPO
DoubleShot
Posts: 6
Joined: Tue Aug 25, 2015 9:49 am
Location: Australia

Hey mate, Brian from the capp forums,

Yeah I know what you mean about just getting stuck in and doing it. Just struggling with funds right now but once they're in check again, it will be on the cards and charging through!
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey Brian,
Sent you a reply & pm on capp forum about cappo body parts.
My struggle is to get things done/find parts etc. working away 6 weeks on and 2 off. I tend to burn the candle both ends, doing house hold things during day and into my shed when every one goes to bed.
I try get all bits I need delivered so when home I can get moving. No complaints just frustrating as I like to do things myself once, and only myself to blame too. Starting to farm things out where budget allows and to save time.
Something I did get done Last break and forgot to mention was: area where clearance was tight in tunnel and behind distributor has now been panel beaten. Was going to cut and weld, but no need now. I made a smooth convex shape tool to go in a small pneumatic hammer chisel I had. Worked a treat and looks factory.

I should get a fair bit done over Xmas as prep work been done, will post pic's and progress.
GTI CAPPO
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey guys, finally some progress in the shed with a few photo's. :D
Engine & box been in/out a few times trial fitting things, easy with electric winch/mono rail working on your own.
Progress to date:
Engine & gear box mounts done plus linkages with torque rod completed. Cappo gear leaver in same position & same H pattern. Jiminy drive shaft currently being lengthened/balanced with adaptor plate to suit Cappo diff to Jiminy tail yoke.
Mazda dizzy cap modified to suit GTI dizzy rather than right angle drive. Thermostat housing having ears welded on to allow it to be redrilled for 3 o'clock water out let for better cooling pipe alignment and to clear heater pipe from firewall.
Oil pickup modified to suit cut down and reversed GTI sump. Sump baffled turbo drain and dipstick tube welded each side.(2L oil capacity plus remote filter housing with oil cooler maybe another .5L ???)
Bored inlet manifold & Fitted SR20 60mm throttle body easy 5 min job with 60mm holesaw, didn't even remove the manifold, but engine was on stand. In a GTI could be done a right angle drive on battery drill see photo.
ECU chipped with CJ turbo chip and waiting. Putting off wiring till last and will need help there if anyone can help in WA, for a fee of course, or endless supply of the amber liquid stuff :lol:
Turbo Exhaust manifold being made now so should be ready in 6 weeks when next home.
Engines weighed.
Cappo 3cyl 660 complete with g/box, alt, s/motor turbo @ 109kg
Gti G13B complete with jiminy g/box, std f/wheel clutch assy, alt, s/motor, turbo and manifold flanges/pipes. 119kg
Rotary 12a engine carb/manifold, w/pump, dizzy & f/wheel clutch assy. @121kg NO G/BOX
So g13b looking good at 10 kg's more for hopefully twice the power of the Cappo?? or more

Some advice please on what else should/could be done to the injection/inlet side? Have 450x300x76 intercooler coming with 2.5 " in/outlets
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Mazda dizzy cap
Mazda dizzy cap
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cut & welded GTi sump reversed
cut & welded GTi sump reversed
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SR20 60mm T/B bolts straight on
SR20 60mm T/B bolts straight on
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Manifold bored out with 60mm holesaw & batt drill
Manifold bored out with 60mm holesaw & batt drill
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difference between Gti & SR20 T/B
difference between Gti & SR20 T/B
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linkage & mounts complete
linkage & mounts complete
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

wow thats a engineering nightmare makes my suzuki swift gti convertible build look like changing a alternator belt.not much room there at all , ever thought about putting a motorcycle motor in there ? .looks like your getting sorted . very impressed =D> =D>
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

running that sr20 thottle body 60mm bored out manifold ,you must have big plans, big turbo boast,big $$$$ for the rest of the engine, head, fuel system. turbo chipping to suit. cant run that throttle body on a stock engine
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

So far there's been nothing difficult in the project, that's still to come as in wiring and the injection side, only scary cause its new to me.

Project was going to have a crashed Honda Blackbird engine in it but got shelved cause Blackbird ECU miss matched to engine and cost climbing. Re sold the wreck for same price. Then came the rotary 12a with 6 speed box, but cappo tunnel too small to house such a big box. Now sitting in corner of shed for a one day project. Then missed out on complete Suzuki 1300 Hayabusa engine package, sold under my nose for next to nothing $1200 :cry:
Gti engine on Gumtree Perth and that's where I'm at now, rest is history. Might still try make a sequential box from a large m/c engine once Cappo is up and running.

Plan for now is get it running with all bolt on bits I can get on a budget and then build purpose turbo engine if really needed. To keep costs down I stayed with MK3 ECU(chipped for turbo) & standard dizzy. On that setup the hope is for 8--12 lbs boost and a reliable engine?? Already have a high maintenance ride and the reason its taking so long, don't want a second.

Why won't SR20 T/B work on what I've got/done so far & should I go back to the standard T/B ?? Open to any sound advise and willing to learn apart from taking up golf.
GTI CAPPO
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

I'm no expert but what I've seen the 60mm sr20 throttle body is for big cams, high fuel.the fuel/ air ratio is going be out if you don't match it . as for the wiring i would get the whole gti wiring loom off a wreck to make it much easier.also get a workshop manual for the wiring diagram. i would leave the engine stock till you get it up and running, the stock engine is still very good and I'm not sure how the jimmy gearbox will handle the load.the gti gearbox is the weakest link in the drive train of a gti
miniswift
Posts: 219
Joined: Fri Jan 07, 2005 9:44 am

Hi,

I have been told that Turbo chip are good for 185-190Bhp witn standard CR G13B with no mod.
I think if you increase air flow by fitting SR20, your injector might be not big enough. I would suggest go back with standard TB setup with your turbo chip to see how it goes. Making any mod from standard like I did will make your life so much harder to get it running.

I like the way you modified your oil sump, I used MIG and it is leaking so I need to make it again.

Good luck with your mod, I thought you could fit Cappo gearbox direct to G13B?

Cheers
Atchi
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey Guys, thanks for reply's.
I think will try as suggested with better f/pump, FPR, fuel rail and back to standard T/B. If I can get 185-190bhp with that then I'll be happy for the time being. Would love to go all out in one step, but unfortunately wife thinks house mods come first.

The sump not difficult once I had a plan, cutting with 1mm cutting disc makes it easier. Welding was a different story. Thought I could make it neat without grinding. 20 years since I last tig welded, like riding a bicycle! yeh right, not quite. Burns all over the place and forever regrinding the tungsten and still went back to trusty point and shoot mig. I did water test it a few times then paint in/out side. With a grinder and black paint you can still polish a turd.

Cappo g/box bell housing smaller than g13b, but UK guy has cut and grafted g13b bell housing to cappo. Used g13b clutch but with cappo centre spline. He say been running 200hp turbo no problems. If I had a lathe big enough to spin the casing I probably would have tried that option too.
GTI CAPPO
dbennett
Posts: 438
Joined: Mon Mar 19, 2012 12:38 pm
Location: 2770

Following
99' Gti

CONVO RACING
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey guys more progress, but not my doing. My son came home to visit and got banished to my shed while his girlfriend & mother went shopping. No help from me as I'm still at work in Indo. and only got sent the photo's. Cant wait to see it ceramic coated and installed.
He also ordered bits I needed, so should be waiting when I'm next home.
B/O valve
F/P Reg
Walbro GSS342 F/Pump
Intercooler 550x180x65 x 2" inlets

Well done Ryan, excellent job on Spaghetti junction.
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GTI CAPPO
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey Guys,
No mechanical progress but did redo the wheels and get some new feet for the Cappo.
Got latest Achilles 195/50/15, any one tried them?
Will be home in 3 weeks to fit to car and push around the shed until engine runs :lol:
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GTI CAPPO
User avatar
AWDmoke
Posts: 547
Joined: Sat Jun 17, 2006 10:49 am
Location: WA
Location: Cloud Break mine or Safety Bay, WA
Contact:

I haven't tried them, but they look the goods. What size are they?
The rims really suit the car I reckon.
Mk2 Gti khana car, various minis & mokes & German cars, a G13b Mini Sports Sedan, and a G13b Goggomobil hillclimb special
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Tires are 195/50/15 on 6 1/2" wide rims so guards will need a slight rolling plus I will probably fit 16mm wheel spacers to widen the track a bit. Got to get it running first then test & test to see what else needs doing.
GTI CAPPO
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

been a while since your last post , any process ?
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Sorry, no progress still trying to gather parts, and still at work until 23 Dec.
Cappo waiting in shed for me. Over Xmas, plan is to install alloy flywheel/clutch assembly, sump gasket and mount eng/gearbox for final time with all axillary bits also bolted on. Just want to get it running then make it look better with paint and bling bits.
GTI CAPPO
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

i know where your coming from ,i recently left my job of 20 years for a job with more time off but less money [catch22]..With just a tight a squeeze in your engine bay the axially parts would have to go on first , i could imagine something as minor as a belt change you're have to pull the motor. great car project ,love to rear wheel drive again
Dan`
Posts: 20
Joined: Wed Mar 23, 2016 1:47 pm
Location: SA

its been months, any updates?
94RHDMetro
Posts: 81
Joined: Mon Dec 17, 2012 12:32 pm
Location: Vail AZ

I love the look of these Cappuccinos and wish we had them in the states too. This thing is gonna be sick once completed. Subscribed.
.
ImageImage

1994 LSi 'Green Machine'
'94 RHD (Totaled)
DoubleShot
Posts: 6
Joined: Tue Aug 25, 2015 9:49 am
Location: Australia

Great pictures mate! Very helpful!

Has their been any further progress in the past few months? :D
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey Guys, sorry Cappo took a back seat for a while.

Back on track with few things finished off.

Engine, gearbox with most axillaries bolted up and installed as a unit for the last time.
Water plumbing sorted and original radiator/fan reused over the alloy one to save space for the intercooler. Got a short stubby 90deg inlet pipe for water pump from Suzuki wrecker. Don't know what Suzi it comes off but suited my needs. Machined ends on some alli tube for outlet that runs within the cavity of the inlet manifold rear to front.
Intercooler mounted with ends cut and welded to 90deg. Pipe work completed.
Mounted alloy sheet for intercooler support, engine tray and start of front splitter. Still to be trimmed back and 8mm plastic added to complete splitter.
New drive shaft made with spacer plate to adapt Jiminy rear yoke to Cappo diff flange.
Gear linkages, clutch cable and throttle connected.
Purchased a Vipec 88 ecu.
Cappo trailered up to Hyperdrive Motorsport week before Xmas. Having Vipec ecu wired in,4 X coil packs to be installed, bigger injectors, Garrett GT25R turbo and to get it up and running.
Attachments
Turbo spec engine waiting. Forged L/C pistons, forged rods, ARP studs & bolts. Just need cams & lifters.
Turbo spec engine waiting. Forged L/C pistons, forged rods, ARP studs & bolts. Just need cams & lifters.
New Garrett turbo so may need new ex manifold too
New Garrett turbo so may need new ex manifold too
Hoses to be connected and clamps
Hoses to be connected and clamps
Start of splitter, Plastic sheet to be added then trimmed to shape
Start of splitter, Plastic sheet to be added then trimmed to shape
Water discharge pipe from rear to front running through manifold
Water discharge pipe from rear to front running through manifold
Xmas deliveries from few years ago
Xmas deliveries from few years ago
Motor/box ready to go in for last time until its been running & motor change
Motor/box ready to go in for last time until its been running & motor change
GTI CAPPO
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey Guys, only small steps going forward due to work commitments.
Exhaust manifold cut off flange and flipped over from the under mount to top mount style and to accommodate the bigger Garret 25 turbo. Lucky not to much work in flipping it over, better than starting from scratch again. Compressor housing required 90 deg bend welding in to clear shock mount and bonnet rib when closed. All bends ready to complete remainder of inter-cooler piping and air cleaner to be mounted in front of cam wheels which will be in cool air flow.
Ex dump pipe still to have probe fitting and welding completed.
Have had massive clean out in shed with unused stuff gone, but already collecting for next project.
The GTI NIKI T
I dont know of anything uglier then that, but will be a first and different.
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GTI CAPPO
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Hey guys,
Is there any reason not to run an oil line from the cylinder head oil gallery plug to feed the turbo?
It looks to be fed from the main block oil gallery up to the front of block to the cylinder head on the exhaust side.
GTI CAPPO
DoubleShot
Posts: 6
Joined: Tue Aug 25, 2015 9:49 am
Location: Australia

Hi Grant!
Awesome to see this is coming along!
I'm still watching with keen eyes and trying to save to start mine.

I'm not mechanically minded enough to help you with your oil feed question though.

Do you have any shots of engine clearance to the bonnet? Does it suit much higher than the f6a?
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Its taking longer than expected, but will get there in the end even with all the changes on the way.
G13B is taller than the F6A so not a lot of room under the bonnet and between the cross member.
Cross member has 12mm spacer to lower from chassis rails which gains more clearance from the cam belt to the bonnet ribs now at 10mm clearance. Sump and oil pick up needed fair amount of work to clear cross member and steering rack. Cannot run top cam cover with out cutting bonnet rib, bonnet is alliy and flimsy as is, so not going to cut it for a belt cover. Above the now top mount turbo I will need make a tool/die to put in some reverse vent louvers to suck turbo heat out and probably also fit a turbo beanie.
Rocker cover modified with alliy sleeves and threaded spacers bolted from underside for coil packs. 750cc injector and 255 lph fuel pump in
Inter cooler Pipe work, oil feed and drain completed, just turbo water cooling, heater hoses and fuel lines to do.
Air flow ducting to cut from alliy and a tidy up that all the bits fit together, then back onto wiring up the Vipec ecu.
Still lots to do and no time when working away.
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cam belt clearance to bonnet rib
cam belt clearance to bonnet rib
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sleeves and spacers for coil pack mounting
sleeves and spacers for coil pack mounting
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DoubleShot
Posts: 6
Joined: Tue Aug 25, 2015 9:49 am
Location: Australia

Gary, those photos are perfect.
Thank you.
I'll also be looking at running coil packs to give more space towards the firewall.

It looks like you have some ally sheet their for airflow around the intercooler.
Is the oil sump still above this ally sheet?
My mate makes front splitters and I'll wait to get him to measure the car up incase fitting one now then fouls with the lower sump on the 1.3... thanks.
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Howsie13
Posts: 469
Joined: Mon Oct 12, 2015 11:30 am
Location: Napier

DoubleShot wrote:Gary, those photos are perfect.
Thank you.
I'll also be looking at running coil packs to give more space towards the firewall.

It looks like you have some ally sheet their for airflow around the intercooler.
Is the oil sump still above this ally sheet?
My mate makes front splitters and I'll wait to get him to measure the car up incase fitting one now then fouls with the lower sump on the 1.3... thanks.
Ally sheet you can see is the splitter for airflow under the car. You want airflow going through the intercooler, not around it.
A Kiwi learning to fly in a Mk1.
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Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Guys, some better photos showing more or less what splitter should look like when finished.
All air above the splitter and within the rad/inter opening will be forced to go through the intercooler & rad. Flow under the splitter, I'm hoping will cause negative pressure behind the engine tray to help suck hot out under car. Tail end will have ally venturi type defuser when I get to that end. Silencer is already mounted high and tail pipe out mid way up the bumper to allow for ally defuser. Non of it may work but it might all look the part.
Sill to come once its been running and bugs sorted, is a Subaru rear diff assembly as they offer many ratios and LSD options at next to nothing price wise. Also started looking at how I can graft a 6 speed 1300/1400cc M/Cycle sequential box into the the rwd g/box housing. Some M/C boxes are cartridge type and I think its achievable. Any thoughts or been done already?
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GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

First there was one, but wait then two for the price of one. GTI CAPPO II

Came at a price I couldnt refuse, so got rid of the Fiat Niki project.
Its a bit tatty and was in need of some repairs, but up and running now with rego and wife using is to fetch her daily Cappuccino's.
Have started rounding up bits for it and will convert once Cappo# 1 is finished.
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Howsie13
Posts: 469
Joined: Mon Oct 12, 2015 11:30 am
Location: Napier

What I could do in a shed like that....
A Kiwi learning to fly in a Mk1.
Tassie_mk1
Posts: 2096
Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

Great work mate! Would be an awesome little daily and some inspiration to finish #1! Keep at it.
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Howsie13 wrote:What I could do in a shed like that....
Shed's not big when you compare Cappo to something real size.
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GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Got the quote back from Holinger for their smallest sequential gear box, glad I was sitting down. $15,600 and no bell housing or output flange yet. It is nice and a piece of art but I think I will pass on that one and follow up on UK units at 4000 pounds.
I will also continue motor cycle options as the BMW RS1200 unit is looking the most viable at this stage at only $600 from ebay in Aus and then a reversing box from Uk at 600 pounds. Will require an adapter from the very short BMW spigot shaft to match the GTI clutch assembly.
Also on ebay was a BMW M3 car manual sequential box from Lithuania which also looks promising but could be too big for the Cappo's little tunnel. If anyone knows of something suitable for inline mounting would appreciate feed back.
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Howsie13
Posts: 469
Joined: Mon Oct 12, 2015 11:30 am
Location: Napier

Motorcycle options could be the best bet. I doubt very much that the German M3 gearbox would fit in the tunnel unless you want it in the cabin with you! I could be wrong but Germans do not often build little things.
A Kiwi learning to fly in a Mk1.
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Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

No real progress on the Cappo-I. Did find out that the BMW M3 sequential box I was looking at isn’t a true sequential box, it’s a normal H pattern box fitted with sequential shifter. Advise to steer clear by ex BMW specialist as they are up to about version 5 on the control side.
Received spec and price from Elite racing for their 6spd seq box with potentiometer, wiring loom and gear display at £4000 which I think is a good price compared to others.
However I’m going to focus on getting the Vipec88 ecu wiring sorted and Cappo-I running. I’ve been avoiding and hiding behind all the black box magic stuff. Crunch time now and will just have to pay to get wiring sorted. Would really like to do it myself but being realistic don’t have the time on a 6/2 week roster.
Which sensor and trigger wheel size/# is recommended and what should be done to the dizzy to run the 4 coil packs? Would like to purchase and install any outstanding hard-ware so it’s ready for wiring.
Cappo-II has been fitted with 2nd hand 15’195/50 rims/tires which make huge difference to handling even though tires old and half worn. Can’t wait to put some sticky tires on it and compare it against other cars on a track day. Think I’ll get a whipping down the straight with only 3 pots and 660cc but cornering should different story.
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GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Some progress late last year on Cappo I. Only small steps, but its on the go.
Its off the stands out the shed and trailer-ed up to my son;s house in Perth who will finish wiring in the Vipec ECU and get it running.
I got some RX7 4 pot alloy calipers for it and will fit Honda 282 diameter x 21 thick drilled/dimpled vented discs which have same 4 stud PCD and 64 mm hub bore. So going from 231 dia and single pots it should stop a bit quicker. Must stay with 15" wheels though.
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GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

I bought some 4 pot radial mount Wilwood calipers, dog bones, braided s/s lines & GTI 250dia rotors. The RX7 calipers would have be a mission to fit so shelved them. The Wilwood's are smaller than the RX7 but will bolt up to the Cappo and no hassle easy to fit.
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