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Underbody braces, turbos and more!

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PostPosted: Sat May 19, 2012 12:23 pm 
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i was starting to think that honda had shipped him off to japan. :lol:

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1991 Blue Geo Metro Convertible highly modified 1.0L Turbo3 5 spd. - 1991 Red Geo Metro Convertible customized with a Twincam 5 spd. - 1992 White Suzuki Swift GT

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PostPosted: Mon May 21, 2012 11:31 pm 
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Nope, nothing like that! I won't bore you with the details, but suffice to say I just haven't worked on it much over the past year. Anyway, this summer it will be finished!!! At least that's what I've been telling everyone - for the past 3 years.

Once the car is rolling I will start working on an ITB + Turbo setup for it (I know what you're going say - that's stupid... turbos don't need ITB's... and ITB's are pointless on a 2-valve cyl head anyway... all I can say is I know it's stupid...)

Until then, I'll just run the stock TBI unit. Being as I am, I couldn't just throw that unit back on without cleaning it up...

This is what it looked like after teardown:
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And so I couldn't help but clean it up and port it out:
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Also, I opened a can of worms that likely should have stayed shut... eliminating all the unneeded wiring. Once you start to tear into it, the stock wiring layout is really silly, like this remote relay box to make room for the A/C fuse that they'd never thought of when they first made all the tooling for this car (and my car never even had AC... so I've moved the fan fuse back into the main box, and put the fan and horn relays into the AC relay spots - likely where they were planning on having them in the first place:
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So far I've got about 10 lbs of wiring and sundry other bits of harness, etc out of the car... I'll update soon with pics of more weight down efforts, some surprise rust problems, and the end (I hope) of the engine build until it's in the car


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PostPosted: Wed May 30, 2012 10:33 pm 
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Location: Columbus, OH
Okay... 3 areas to update:

1) Rust in the floor - I've got replacement panels and I'll be fabing up some replacement parts too:
passenger side
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drivers side
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This was an unwelcome discovery, but of course very common... at least I can fix it.

2) Engine - now just waiting to go in the car:
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Ported the entire intake - O/B throttle body. There are more pics of the engine in my gallery if you're interested.

3) Assembly of other components:
Fr Control arms + attachment forgings + Murr brace surplus from T3Ragtop
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Rebuilt shift linkage with new bushings
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Rebuilt steering rack, new driveshafts, new engine mounts (Superpro RR mount)
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New addco RR stabi, refinished 24mm Fr stabi, cleaned up intake
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New struts w/ new bearings, mounts, H&R springs, and new KYB bumpstops and boots
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Cleaned up coolant resevoir w/ new lid (old one was cracked)... okay these pictures are too detailed.
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New radiator w/ cleaned up shroud, fan, motor, etc
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Sorry about the volume of pics all at once. I said I was going to update!!


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PostPosted: Sat Jun 16, 2012 8:19 am 
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Location: Brainerd Minnesota
You, Sir, are truly an inspiration! :salute: Definitely brings things to a new level. :study: Excellent work! :thumbsup:

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.........I'll be back in a bit........
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Extreme Make Over....SnowFish Addiction

1991 Metro Xfi Sport, Crower XfiII Cam, .020 Over Balanced & Blue Printed, 3.79 final drive, WhiteLine Bushings Everywhere, 185/60R14's, TBI Bridge Delete, Edelbrock Air Cleaner.


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PostPosted: Sat Jun 16, 2012 10:34 am 
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yes indeed evan, the work is beautiful.

that will end up being the newest old car i've ever laid eyes on. :wink:

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1991 Blue Geo Metro Convertible highly modified 1.0L Turbo3 5 spd. - 1991 Red Geo Metro Convertible customized with a Twincam 5 spd. - 1992 White Suzuki Swift GT

My Turbo3 Project
My Cardomain Page -Ol' Blue
My YouTube Channel
My Photo Gallery
SAAB Sonett II


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PostPosted: Sun Jun 17, 2012 3:59 pm 
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Location: Palm Springs: Too hot from June to Oct.!
OK, now I've gone through it.
Actually, I only saw the one post where he showed the oil pan from you and that was about 2 years ago!

Thanks for the link.

He actually is 'Evan' on the forum....duh.

:oops: :oops: :oops:

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DIY Broken Bolt Removal: viewtopic.php?f=22&t=41042
DIY Clutch Adjustment: viewtopic.php?f=9&t=48281
DIY Wheel Bearings: viewtopic.php?f=2&t=29003
DIY Shocks: viewtopic.php?f=10&t=45483
DIY Wheel Align: viewtopic.php?f=2&t=42479
Once you get the cars dialed-in (compression, leaks, bearings, alignment, brakes) swap in new rubber and glass, you've got something which should last for years!


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PostPosted: Tue Jun 19, 2012 11:27 am 
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Location: Columbus, OH
Thanks for the comments everyone - hopefully I'll have more updates in the near future.

Once I'm finished fixing the front end rust, I'll be able finish painting the underside, and then reassembly can start!

Again, target is running this year.


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PostPosted: Wed Jun 20, 2012 9:07 pm 
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Evan wrote:
....target is running this year.


you told me that 2 years ago. :-P :lol:

that's okay, i've got time. i can wait if you can. :D

seriously, evan, the project is looking very, very nice. :wink:

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1991 Blue Geo Metro Convertible highly modified 1.0L Turbo3 5 spd. - 1991 Red Geo Metro Convertible customized with a Twincam 5 spd. - 1992 White Suzuki Swift GT

My Turbo3 Project
My Cardomain Page -Ol' Blue
My YouTube Channel
My Photo Gallery
SAAB Sonett II


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PostPosted: Thu Jul 26, 2012 5:33 pm 
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evan, check out the rust remediation products at eastwood company.

they have rust encapsulator and zinc rich phenolic internal frame sprays that are applied to internal cavities like in the frame horns and frame rails using an 18" teflon tube with a 180* brass spray head.

you push the tube in through a small hole, push the spray button while withdrawing the tube. the spray completely coats the inner areas. with the light rust you have, the rust encapsulator would convert the rust and coat it to keep condensation from causing any further problems.

it beats the heck out of rust eating the chassis from the inside. :twisted:

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1991 Blue Geo Metro Convertible highly modified 1.0L Turbo3 5 spd. - 1991 Red Geo Metro Convertible customized with a Twincam 5 spd. - 1992 White Suzuki Swift GT

My Turbo3 Project
My Cardomain Page -Ol' Blue
My YouTube Channel
My Photo Gallery
SAAB Sonett II


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PostPosted: Thu Aug 02, 2012 12:03 am 
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Location: Columbus, OH
Good info, Rich. Ill have to check it out.

Thanks!


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PostPosted: Mon Dec 10, 2012 6:20 pm 
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Location: Canada
Evan wrote:
Again, target is running this year.


'This year' I'm guessing I'll hear that again come January? So are we going to ice race this beast until it's so beat on that we demo derby it to death?

If you want a project to work on that will actually see the road I can give you my donor struts and you can order the koni inserts and mate them all up with new mounts and these springs I have.


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PostPosted: Mon May 20, 2013 11:24 pm 
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9 months since my last update... geeze.

Anyway, visited a friend in Georgia over the weekend - found the solution to my front end rust problem. This doner car was in great shape, except for where it had been hit and was poorly fixed. The entire underside was basically rust free... it hurt me more to do this than it's hurting you to look at the pics.

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Don't need any of that crap
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But I'll take that!
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What was left
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I was a fool to get rid of my Honda Fit - borrowing one for this trip reminded me what a great car it is. I'll have to get another.


Last edited by Evan on Sun Dec 01, 2013 12:09 am, edited 1 time in total.

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PostPosted: Sun May 26, 2013 9:17 pm 
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Location: Calico Rock Arkansas
Wow, very nice work, cant wait to see further progress :D


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PostPosted: Sat Nov 30, 2013 11:53 pm 
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Ok - I'm sure nobody was ever expecting another update on this one...

I've been tied up at work so much since the spring, that I've just recently had time to work on the car again.

Can you tell which parts came from Canada, and which from Georgia? Drilling out spotwelds isn't fun..
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Here's the doner cowl, the recipient, and one messy garage.
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Fits pretty good considering my car was made in Japan in 1992, and the doner was from CAMI, made in 1994. It took a little fitting to get everything lined up, and then I've bolted it in for the floor replacement fit-up. Once I have the floors welded in, I'll be welding everything else.
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And here's the passenger side floor cut and fitted
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And the welding in process - should get the passenger side finished tomorrow
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Also, I've got the garage setup to be heated all winter now, so progress should keep happening. Hopefully a lot quicker than in the past year...


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PostPosted: Sun Dec 01, 2013 12:59 am 
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man evan, that's a bunch of work. i'm happy to see your project is still ongoing.

your "rusty" parts are cleaner than the ones i was working with. :-P

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1991 Blue Geo Metro Convertible highly modified 1.0L Turbo3 5 spd. - 1991 Red Geo Metro Convertible customized with a Twincam 5 spd. - 1992 White Suzuki Swift GT

My Turbo3 Project
My Cardomain Page -Ol' Blue
My YouTube Channel
My Photo Gallery
SAAB Sonett II


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PostPosted: Sun Dec 01, 2013 11:53 am 
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WOW , great job :D

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at CAMI Automotive 2006 / 6 / 6


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PostPosted: Wed Jul 09, 2014 7:46 am 
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Location: Dalton, GA.
Whatever became of this project?


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PostPosted: Sat Aug 02, 2014 7:02 pm 
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jonathan180iq wrote:
Whatever became of this project?


Yes , We need to know !! :!:
All of your project workmanship is absolutely amazing :!:

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92 RAGTOP / SIGNED BY MR .SUZUKI
at CAMI Automotive 2006 / 6 / 6


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PostPosted: Sat Aug 02, 2014 10:18 pm 
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Thanks for the kind words and interest in my project folks!

The fact of the matter is that I haven't worked on the car since the fall.

I've been super busy at work, and I've also been working like mad to renovate our house - finishing the basement and adding a bathroom. I should be able to get back at the car in the fall.

I have no idea when the car will be finished... I had no plans for this thing to drag over almost 5 years & counting, but stuff happens.

Rest assured, it'll get done eventually!


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PostPosted: Sun Aug 03, 2014 8:55 pm 
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Evan wrote:
Thanks for the kind words and interest in my project folks!

The fact of the matter is that I haven't worked on the car since the fall.

I've been super busy at work, and I've also been working like mad to renovate our house - finishing the basement and adding a bathroom. I should be able to get back at the car in the fall.

I have no idea when the car will be finished... I had no plans for this thing to drag over almost 5 years & counting, but stuff happens.

Rest assured, it'll get done eventually!



I look forward to when you have time again to work on your project . :D
Your project is my favorite thread here at Team Swift :!:

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92 RAGTOP / SIGNED BY MR .SUZUKI
at CAMI Automotive 2006 / 6 / 6


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