suzuki swift cultus convertible build

Post the details of your Suzuki build progress
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

ok on to engine build
after finding out the forged conrod bolts hit the mains brace, i had the main caps machine flat and made metal straps[ 10mm thick] so i clear the brace and in turn strengthen them at the same time.

big thank you to cappy and dmw dave for brilliant idea and suggestion, =D> =D>
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

after putting the crank pistons etc in i notice the oil squirters where also hitting the crank #-o .so i delicately bent the pipe into position to clear the piston and the crank. not much room there

a big thankyou to miniswift idea for using the renault oil squirters
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

engine build came to a stop, waiting for the postman for more parts,
free up the avi wires for dbw and cruise and fitted the 8 tca ,
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

dialed in the cat cams today, because i already checked the lobe profile last time[ which was spot on ] all i needed to do was get TDC , adjust to BDC measurements and lobe centerlines
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

finally santa got me what i wanted for christmas a custom made ATI SUper damper
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

made a turbo mount out of the original gti exhaust mount,
Didnt like the idea of all the weight of the turbo hanging off the 4 8mm bolts on the turbo manifold
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GT4LIFE
Posts: 98
Joined: Sat Feb 24, 2018 5:27 pm
Location: Washington State

This one super clean amazing build. I was thinking about doing something similar with that stock exhaust hanger mount. Although I'm running a different turbo it is nice to see how you configured it.
gtpswift
Posts: 1638
Joined: Mon Aug 25, 2003 12:00 am
Location: Australia

Need to be careful with turbo brackets. Due to the heat the manifolds expand and contract and if there is nowhere to go they will crack and distort. The turbo hanger I use on the Cosworth has a sliding friction clamp that holds weight but allows the change in dimension.
GTP
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

I agree with gtpswift, you have done an excellent job on the turbo support brackets and look super strong. However something must give with manifold expansion. Could only be a cracked manifold or worst case an crack in you nice red paint job around the block mount :( You could pick up the whole car on those 4 M8 bolts, so the turbo hanging off them is nothing.
I would remove the support bracket and make a support strap around the exhaust after the first bend under the engine. That will allow plenty room for expansion/contraction yet still support the turbo and manifold. Behind that have your flex joint for engine movement.

You've done everything 100% to date, =D> no doubt you'll come up with a solution if you feel the need.
GTI CAPPO
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

very good , yes i was thinking the same after i built it . the bracket holes have plenty of clearance on the bolts on the block . the bolts in the block are lock tight loose with spring washers but i might use longer bolts with springs.
what do you think? 8-[
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

room to move
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

ready to tig weld the thermo coupling ss bosses on
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GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Brackets looking good now and should work a treat. I see you had some left over key steel pieces from main bearing caps to use :idea:
GTI CAPPO
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

thanks cappo, you dont miss a trick
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

still waiting for engine parts, so i started on the rear suspension
fitted nolathane bushes
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

found these coil overs in the back of shed, :D
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

i was worried on the fit of the rear coilover. but it slotted straight in
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

hi freak , freak pm me wanting the nolathane part no. for the rear . this is for everybody s reference
control arm -lower outer- 46101
control arm-inner front- 46100
rear wishbone front bush-46099
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

New coil overs,wheel bearings ,discs and pads, bush kit
And full brake seal kit.
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

After finishing the other side I noticed I
Have the disc rotation the wrong way (grooves
Are directional) #-o
freak2demon
Posts: 133
Joined: Thu Aug 18, 2005 10:05 am
Location: Singapore
Location: Singapore

gticon wrote:hi freak , freak pm me wanting the nolathane part no. for the rear . this is for everybody s reference
control arm -lower outer- 46101
control arm-inner front- 46100
rear wishbone front bush-46099
Appreciate it. Thanks.
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

fresh from the tig welders and ceramic coat .
The inlet mani has a different ceramic coat to draw the heat away , instead of drawing heat in like turbo mani.
see how long the e bay ss turbo mani will last with the ceramic coat .
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

Turbo oil return and oil temp thermo coupling
On sump tigged up
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

full clutch kit for a sf413 engine to a sf416 gearbox conversion.
exedy cushion button kit and a light weight 3.5kg npc flywheel.
thankyou bewitched for putting me on to npc [QLD] for the flywheel. =D>
im thinking that dwm dave had something do with npc, as there is a part no, even for a gti to 1600 gearbox conversion.
NPC part no. is RNF66-1 THIS IS FOR A GTI TO 1600AWD BOX it needs to be machine from 33 mm to 30mm thick to fit the 1600 FWD
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

:D
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

back to rear coilovers,
the protlum coil overs are custom made for the gti with a offset top shock mount, so it fits into the shock tower without cutting and shutting,like ive seen on other rear coilover fits on the forum.
but there is still not much clearance in the tower when i jacked it up, so i use a jack in the tower tunnel hole and added heat to give more clearance.
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pictureshowman
Posts: 1505
Joined: Fri Sep 03, 2010 10:41 am
Location: Bunya QLD 4055

Where are you mounting the remote cans? Will the remote banjo fitting hit the shock tunnel?
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.
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

the rear shock tower is not engineered for coilovers. so i turned the ultra race 4 point brace , into a 8 point brace.
as for mounting it i only drilled two holes in the boot floor inline with the existing chassis holes and used rear seat belt mounts which are not used in a convertible
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

Where are you mounting the remote cans? Will the remote banjo fitting hit the shock tunnel?
hi pic,show
yes thats the next job , the picture shows the shock jacked up and on its lowest adjustment , so its not going to hit.
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

thanks to answer for putting me on to a full 1600 gearbox conversion kit.
comes with all the goodies and full rebuild
4.4 ratio suzuki sport lsd
suzuki sport gearset
suzuki sport shifter and cables
1600 drive shalfs
mod intermediate drive shalf bracket
hydraulic slave and master cylinder
1600 pedals
just got the flywheel and pressure plate balanced all ready to put together.
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answer
Posts: 189
Joined: Fri Oct 20, 2006 12:08 pm
Location: NSW
Location: NSW

Any time mate 8)
Beat em in2 submission
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

i think placing the remotes off the sway bar mounts was my best option without cutting and shutting. a couple of bullbar to lightbar mounts and spare arp studs did the trick.
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pictureshowman
Posts: 1505
Joined: Fri Sep 03, 2010 10:41 am
Location: Bunya QLD 4055

Yes, interesting.
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.
GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

professional all the way =D>
GTI CAPPO
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

thanks cappo , not really its all smoke & mirrors
after fitting the rear tower brace, i had to relocate the battery , tyre well was it. NO SPARE TYRE.
also made up a simpler battery box as well.
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bostssgt
Posts: 61
Joined: Thu Oct 12, 2006 11:58 pm
Location: quebec/canada
Location: quebec/canada

careful with th ebattery positive rubbing on foam, it's fine now but can make it's way through the foam with vibration and catch fire :P

always a pleasure to follow your builds, it's like the centerfold of playboys magazine :lol:
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

thanks mate , the foam rubbing through not a problem its thick enough and wont make contact even without it.
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

CRANK TRIGGER DONE ,after messaging haltech, the vitara trigger wheel was no good for sequential fuel and ignition , the trigger wheel is set up originally for wasted spark .
Cut and shut a 36-1 e-bay crank trigger to fit a suzuki timing pulley .
also using a high rpm hall sensor from EFI HARDWARE ,which can read and is in tolerance of tooth depth, width etc of my 36-1 trigger wheel, and modified a sensor mount.
also modified the original suzuki analog sensor , just in case there is problem at the tuners with the hall sensor.
tested the trigger wheel and hall sensor set up with a drill, on a oscilliscope it showed a missing rising edge , haltech said its not a problem , just program the ecu, using the falling edge. COOL
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

BASE TIMING DONE, had to relocate the base timing mark due to the super damper .
to read it ,you have to place timing light in the right front wheel tub.
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

CAM SENSOR DONE , haltech recommended a 36- 1 crank sensor and a one trigger home cam shaft sensor for sequential ignition and injection and to pick up the difference in cam /crank timing due to timing belt deflection [could be up to 10% power lost due to timing belt deflection]
modified a suzuki esteem cam shaft sensor , turned and faced it and added the o ring slot identical to the gti distributor .
this has been done by others on the forum ,pretty sure credit is due to BEWITCHED for being the first to experiment and modify =D> , im just adding my 2 cents
the optical sensor has a four window trigger , haltech recommended to cover the other 3 windows with tape , didnt like that option.
did some home work and found the nissan sr20 uses the the same optical sensor and AGM make a one window home for the nissan ,SWEET bolts straight in .
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

finally slotted engine and box :D
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

suzuki sport brakes with 276mm big disc
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GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Brakes looking good with large rotors. What are their dimensions or part number/model?
I want to check if I can fit to cappo
GTI CAPPO
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

hi cappy ,i did a a bit homework on these rotors to work out which rotors i could work with on the gti. dont know how the cappuccino is set up and if it takes the suzuki sport calipers. i found the a repco site where you punch in diameters ,hat size , width etc to give you a option of rotor with make and model.
go to https://www.repco.com.au/en/parts-servi ... 1862918118
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

looking for better brakes options , answer (thanks mate) put me on to another of bewitched"s brilliant discovery back in 2014, that the suzuki sport calipers bolt straight on to the gti.
after getting a set of near new 2011 suzuki sport calipers i notice the full pad isnt used , checked out that the suzuki sport rotors are and 276mm dia (gti 250) 20mm thick (gti 18.5) and 5 stud
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gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

ATT BEFORE ANY BODY GOES WITH THESE MODS , I HAVE NOT TESTED THEM YET , BUT I CAN SAY THE ROTOR/ CALIPER SPINS FREELY AND IS CLOCKED UP AND IN TOLERANCE.
WILL TEST ANY WHERE BETWEEN 2 MONTHS TO 2 YEARS 8-[
went to the repco site to track down a rotor to fit , found that with 4 mods the
NISSAN 180 SX S13 2.0 L YEAR 1991 ROTOR will work.
the nissan rotors are also 22mm thick compared to 20mm thick for the suzuki sport sport and the caliper piston has to be all the way in to fit, also the weight for the nissan rotors are 6.1kg compared to the 4.1 kg for the gti . bit of up sprung weight there , hopefully the remote coilovers can sort that. 8-[
MOD 1
ROTOR MACHINED FROM 280MM TO 276MM DIA
MOD 2
CENTER HOLE NEEDS A SPIGOT TO GO FROM 68.1MM TO 62.2MM DIA.
I MACHINED A 68.1 WHEEL SPIGOT , BORED IT OUT TO 62.2 AND FACED THE THICKNESS
TO SUIT
MOD 3
BRAKE CALIPER MOUNT TO BE MACHINED ACCURATELY CLOCK UP MACHINED SURFACE
1MM OFF , TO BRING THE THE RIGHT CENTER LINE OF PADS AND ROTOR
MOD4
DRILL AND COUNTERSINK FOR ROTOR RETAINER BOLTS . I USED A OLD GTI REAR HUB TO
TRANSFER THE HOLE LOCATION
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GTI CAPPO
Posts: 131
Joined: Sat Aug 22, 2015 4:01 pm
Location: Australia WA

Many thanks for all the data, it all take a lot of time and effort to gather.
GTI CAPPO
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

thanks cappo , yes did take while, going on to ebay, looking at each disc/ rotor specs one at time .
but then i found the repco site , and found the rotors , i could work with in minutes
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

went to wreckers and found a suzuki swift sedan glx with the 1600 gearbox and found out it has an extra gearbox mount on the bottom of the gearbox which bolts to a bracket in the middle of the tunnel .
my convertible was a automatic and has a bracket in the tunnel to left side for a mount .
so i cut and shut the 1600 gearbox bracket to suit.
not sure if it needs it but cant hurt to have more support
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bostssgt
Posts: 61
Joined: Thu Oct 12, 2006 11:58 pm
Location: quebec/canada
Location: quebec/canada

was about to send you a PM regarding this,

you need it for unleash the beast mode, without it it will crack the casing from the rear mount to the axle seal

i dont have this body mount so i did a steel brace that connect the 2 rear bolts of rear mount (on the transmission) to the 3 bolt mount you use for your 1600 4th mount

this perch is long so i think it will take all the load when accelerating,
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