Suzuki underdog build

[damagecontrol]

Awesome builds

[Pauluzz]

Disassembled and refurbished the cylinderhead of the G13B swift, had some help from my boy:







Had some stuff chromed and spruced up:


The headbolts were shot, so I got them replaced with new SGP ones. Also removed the vacuümdelay?? so my ignition-unit looks a bit sleeker.


Mounted an oilcatchcan:


And then, started the engine and found this:

http://youtu.be/wg8KPg8UUxc

Got it machined, need to put everything back together now.

[Pauluzz]

Got her up and running. Now making miles and making smiles. Also fixed the speedometer.



To do:
- allignment -> tomorrow
- finish front stabilizer
- rollcage need to be welded in
- install the audio
- deluxe wood floor in the trunk
- etc

[Pauluzz]

And then this happened https://www.youtube.com/watch?v=hdlRGQmdutQ

Had a short trip last saturday, drove 350km and then the knocking came. Pretty sure it's a connecting rod bearing. Also metallic flakes in the oil.

Bought the engine 3 years ago from a guy who said the engine was refurbished. Had to redo the cylinderhead 'cause of a leaking headgasket, but never took apart the crankcase. The cylinders looked fine by me.
So I think the seller did one of these three things:
- mounted a crooked crankshaft
- or mounted old bearings
- or he didn't tighten them enough

Anyway, back to the drawing board.

[Pauluzz]

First cilinder hit the head, as shown on this picture.


Lots of metallic in the oilsump:


Conrod bearing and damaged conrod


Damaged crankshaft, unrepairable:


How all the pistons look:


And how all the cylinders look:


Cleaning the gearbox:


Did some bead blasting on several external parts, gonna paint them black:


Cleaning the shit out of everything, all the debris needs to be gone. I’m using a big ass washingmachine and ultrasonic cleaner.

Why the engine got damaged? I will never no for shure, but I did found bead blasting debris inside the engine. The seller who I got the engine from, did some bead blasting on the cylinder head, wich of course ended up inside the whole engine.

While into this, I’m checking and testing everything I’ve bought from this imcompetent bastard. Wich lead to, a new alternator and starter. Bough new oversized pistons, the cylinderblock gets drilled and honed, still looking for a crankshaft wich will also get new bearings.

Sigh....

[Pauluzz]

Everything I've bought from that guy has gone to shit! Got my alternator and starter tested, yes they were shit too! So, new alternator and new starter.

Cleaned the sump, got rid of some rust and put a number of layers of black on it:


Disassembled the oil pump, cleaned it, cleaned it again and once more. Reassembled, new seal en gasket.


Bored the engineblock to 0.50mm oversize piston:


Honing engine block:


Cylinders are better then new now!:


Skimmed the engine surface:


Lots of new parts:


Everything ready for the crankshaft:




Still need to meassure the rods. And my crankshaft was unrepairable. Finding another one was a pain in the ass. Yesterday I found one I can use!

[DawsonLiri]

Back on the car again, ready for summer!








Meanwhile, I'm disassembling the cylinderhead of the MK1 because of a leaking headgasket.

My uncle had one of this, I never think in my life they look this cool!

Good luck for your project, that engine is a bit of underdog

[Pauluzz]

Measured the crankshaft and had it polished:






Measured the conrods and cleaned them up, before and after:


Mounted new pistonrings on the new pistons and mounted them with new piston pins on the conrods

[DutchieSaxo]

looking good, what kind of specs are you expecting from the engine when it's finished?

[Pauluzz]

I'm not going for extremes in horsepower, the car weighs 750kg and allready has wheelspin in 2nd gear. I'm shooting for 120bph and I will leave it there....

[Pauluzz]

Tuesday started to build things up again. Received the wrong mainbearings. Mounted the rods and pistons anyway.


Yesterday I received the right mainbearing, together with the conrodbearings and thrustbearrings:


Mounted the crankshaft and everything:


Oilpump, sealhousing and oil sump in it's place!




Disassembled the cylinderhead, cleaned it and cleaned it once more. Need to assemble it again. This saturday I want to finish building the engine and mounting it back in the car.

[rice4life]

I love that people like you are around on the forums to show us these uncommon platforms. I hope it inspires more people to want to build and save these cars.

Have you thought of shaving the head for an easy increase in compression to make a bit more horsepower and better gas mileage?

[Pauluzz]

..
Have you thought of shaving the head for an easy increase in compression to make a bit more horsepower and better gas mileage?

Head is shaved as well as the block itself

Yes everyone calls me crazy, but it just think it's cool to drive a car only 8 are left in this country in which mine is one-of-a-kind. I don't like driving a 12 in a dozen car.

[Knoopie]

Keep up the good work! Looking great..

Best grappig dat ik hier iemand tegen kom die ook uit Alkmaar komt! Ik zie je vast wel weer eens voorbij karren..

[Pauluzz]

Hhw om precies te zijn en er zijn er meer hier uit Alkmaar.