suzuki swift cultus convertible build

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

room to move
Attachments
IMG_0784 (2).JPG
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

ready to tig weld the thermo coupling ss bosses on
Attachments
IMG_0785 (3).jpg
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
Attachments
IMG_0801 (2).JPG
Last edited by gticon on Mon Jan 06, 2020 9:16 pm, edited 1 time in total.
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

found these coil overs in the back of shed, :D
Attachments
IMG_0791 (3).JPG
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
Attachments
IMG_0802 (2).JPG
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.
Attachments
74C579B7-AADB-4CBC-AF89-A0D61AC5205C.jpeg
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 .
Attachments
IMG_0843 (2).jpg
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
Attachments
AA0B00CB-2308-41AB-8830-E59AFB42A6AA.jpeg
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
Attachments
IMG_1069 (2)_LI.jpg
Last edited by gticon on Fri May 01, 2020 12:09 pm, edited 1 time in total.
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

:D
Attachments
IMG_0851.jpg
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.
Attachments
IMG_0803.jpg
IMG_0807.jpg
IMG_0806.jpg
Last edited by gticon on Tue Jan 28, 2020 8:16 pm, edited 2 times in total.
User avatar
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
Attachments
IMG_0832.jpg
IMG_0852.jpg
IMG_0857.jpg
IMG_0854.jpg
IMG_0853 (2).jpg
IMG_0861.jpg
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.
Attachments
IMG_0805.jpg
IMG_0807.jpg
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.
Attachments
IMG_0866.jpg
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.
Attachments
IMG_0884.jpg
IMG_0883.jpg
IMG_0890.jpg
User avatar
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.
Attachments
IMG_0927.jpg
IMG_0925 (2).jpg
IMG_0924.jpg
IMG_0929.jpg
IMG_0933.jpg
IMG_0935.jpg
Last edited by gticon on Wed Mar 04, 2020 7:07 am, edited 1 time in total.
bostssgt
Posts: 62
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
Attachments
20190315_143036 (2).jpg
IMG_0964 (2).JPG
IMG_0970 (2).JPG
IMG_0971 (2).JPG
IMG_0967 (2).JPG
IMG_0969 (2).JPG
trigger (3).png
trigger (3).png (107.04 KiB) Viewed 3531 times
20190402_162101 (3).jpg
20190402_162101 (3).jpg (60.71 KiB) Viewed 3532 times
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.
Attachments
IMG_0972 (2).JPG
IMG_0941 (2).JPG
Last edited by gticon on Tue Mar 31, 2020 6:54 pm, edited 1 time in total.
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 .
Attachments
IVYA2584 (2).JPG
WPXN8263 (2).JPG
20190320_111944_LI (2).jpg
20190226_133359 (2).jpg
20190226_141624 (2).jpg
IMG_0974 (2).JPG
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

finally slotted engine and box :D
Attachments
IMG_0990 (3).JPG
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

suzuki sport brakes with 276mm big disc
Attachments
IMG_1004 (2).JPG
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
Attachments
IMG_1007 (2)_LI.jpg
Last edited by gticon on Fri Apr 10, 2020 5:41 pm, edited 1 time in total.
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
Attachments
IMG_1006 (2)_LI.jpg
IMG_0976 (2)_LI.jpg
IMG_1011 (2)_LI.jpg
IMG_1009 (2)_LI.jpg
IMG_1005 (2).JPG
IMG_1006 (2).JPG
IMG_1013 (2).JPG
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
Attachments
IMG_1023 (2).JPG
IMG_1022 (2)_LI.jpg
IMG_1024 (2).JPG
bostssgt
Posts: 62
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,
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

thanks for that boosts sgt , when i found out about that extra mount , i decided to delete the suzitech engine steady .had to do mods to the bracket to fit it anyway.
if look closely you can see i used half of the suzitech steady on the mod bottom box mount , so i have a spare poly rubber.
with all 4 poly solid mounts now , i think im going to feel it.
Attachments
IMG_1024 (2).JPG
2016-07-08 10.59.36 (2).jpg
2016-07-08 10.59.36 (2).jpg (72.55 KiB) Viewed 4159 times
Last edited by gticon on Thu Apr 16, 2020 3:29 pm, edited 1 time in total.
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

fitted the drive shafts , coilovers and suzuki sport brakes :D
Attachments
IMG_E1027.JPG
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

fitted the 4 haltech high output coils with built -in ignitor to the suzitech shock tower brace .
also made a solid bracket up for the fuel pressure reg. and which bolts to the gearbox
Attachments
IMG_1067 (2).JPG
IMG_1066 (2).JPG
IMG_1047 (2).JPG
IMG_1051 (2).JPG
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

finally on its wheels
Attachments
IMG_1109 (5).JPG
Tassie_mk1
Posts: 2096
Joined: Wed Feb 22, 2006 5:19 pm
Location: Outback Tassie
Location: Launceston, Tasmania

Love you build man great work :)
Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

love you too ,thanks tassie, working on the intercooler piping at the moment ,then its back to wiring, shouldnt be to long now before it hits the dyno ,
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

been a little distracted on the build no.3, but back on track for my end of year deadline. #-o
finish the turbo ss pipe work , took for ever ,one weld at a time ,too and throw to the mig welder. had to mark the position for each weld , as the welder told me, a spot weld would ruin his work.
as you see on the photos not much clearance.
Attachments
IMG_0062 (2).JPG
IMG_0054 (3).JPG
IMG_0058 (2).JPG
IMG_0059 (2).JPG
IMG_0060_Moment (3).jpg
IMG_0056_Moment (2).jpg
IMG_0061 (2).JPG
IMG_1161 (2).JPG
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

replace the gti standard 50 amp with custom made brackets to suit the 110amp ford falcon BA alternator to handle the extra electronic components
Attachments
IMG_0081 (2).JPG
IMG_0083 (2).JPG
IMG_0086 (2).JPG
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

replaced the cable speedo drive for electronic speedo sensor from a SUZUKI ESTEEM 1.6L 1999-2001
Attachments
IMG_0087 (2).JPG
IMG_0089 (3).JPG
gticon
Posts: 409
Joined: Thu Apr 28, 2016 12:23 am
Location: adelaide

the electronic boost controller got its own box. fitted
Attachments
IMG_0097 (2).JPG
IMG_0110 (2).JPG
IMG_0108 (2).JPG
IMG_0111 (2).JPG
Post Reply