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 Post subject: SOBIL's Rally Car
PostPosted: Mon Sep 09, 2013 11:04 am 
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Location: StAlbans Vic
SOBIL's rally car Started February 2009

Model: Suzuki Swift MK1 GTI (SA413)
VIN#: AA33S101669

Known Previous Owners:

Will Arden (GTI4DR)
(Snapper) ???

History:

I believe Will (GTI4DR) bought the car off Snapper with a blown motor and had the the intention of building up a turbo mk1. As you can see hisbuild thread, it never got finished. He parted it out and i first ended up buying some of the running gear out of it and shortly after acquired the rolling shell when nobody else was interested.

It sat in my driveway for a good year until I decided i would build a rally car in 2009 and sent it off to fabraications in Braeside, VIC. See Pics here

It then sat around for a few more years until in 2011 I pulled the motor out of the road car and got it ready to compete in autocross.

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File comment: ready for motor
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File comment: in autox trim
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The shake down went well so I went and had it painted for the 2012 season which started well until I put it on its lid.

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I switched to a holden nova/corolla for the rest of the season and parked the GTI until June this year.

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 09, 2013 12:25 pm 
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Because i simply had too many cars in the driveway and had to get rid of some, I got the front of a 4dr barina cut and shut onto the GTI so i could finally clear the driveway of the holden.

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File comment: at JAK motorworks getting painted after a rail replacement.
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McQueen Motorsport helped me out with seat mounts

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File comment: seat rails
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I then began putting it together in true rally trim.

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Something I always wanted to do was a SA310 headlight conversion lights and as the GTI lights couldn't fit the Barina front panel, I went about the making adaptor plates for the older style lights. This was pretty straight forward but required the bumper and mounts to be cut back because the lights on the 310 sit back a full 45mm compared to the GTI.

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File comment: light mounted on bracket
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I finally built put my KONI struts together. (see what i think of them later on)

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File comment: DIY KONI CUTASTRUT before rally
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and put some mudflaps on it and entered the Mt Porepunkah Rallysprint.


Attachments:
File comment: Looked pretty good.
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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 09, 2013 1:35 pm 
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Mt Porepunkah was great as my first rally. As the only car in class A I can claim a class win :P but better yet, I may did pretty well for my grade finishing on par with some of my autocross competitors that usually do better than me.

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File comment: John Doutch always gets a good shot.
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A nasty pothole proved too much for the koni's. Luckily the sway bar held the spring in place long enough for us to make it into service where the trusty Ultra Performance shocks and factory springs went back in and we finished the rally on them.

Attachment:
File comment: Koni's just not up to big potholes
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So i can say my first ever rally went well and the list of repairs is coming together for the next event.

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 09, 2013 4:58 pm 
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Nice work, the SA310 lights aren't my thing, but I love seeing a MK1 out there racing and showing up "better" cars all the same =D>

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 09, 2013 6:27 pm 
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Well done Simon =D>

Persistence pays and your dedication is to be commended. Lesser mortals would have just given up and not bothered to get back on the horse for another shot at it.
I'm not against the early SA front and think it's actually neater than the later model 86-88 front - bonus is that if you have to replace the headlights, they're much less expensive and you're not restricted to the Suzuki units. Once again you appear to have done the job properly.
Keep up the good work - I envy your ability to get on with the job. Good luck with your rallying :wink:


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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 09, 2013 7:54 pm 
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Thanks guys,

The headlight choice was heavily based on the fact that its soo hard to find top notch GTI lights and 6x4 lights will always be obtainable.

The strut thing is a real downer as it seems I'm going need to drop some SERIOUS dollars on struts.

DMS or MCA seem like the obvious choices, but with not much change from $4000 i'm keen to hear any other ideas. Anybody?

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 09, 2013 8:29 pm 
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Not a fan of the headlights either but understand the availability of parts.

Koni's and twin tube shocks in general are not great on gravel but the swift specced koni sport is pretty crap, I would use the ep82 koni because it at least has low pressure gas so will help prevent cavitation, also has external rebound adjustment.

Ideally you want monotubes with stiffer lowspeed damping and then a regressive rate to soften up under the big hits (high speed damping)

I would talk to Tim/Gibbo and see if he has his old Proflex... the problem with our cars is the strut is so short there is nothing in the Bilstein catalog that fits without being modified.
The wrx strut is not too far off, body is about 20mm longer but they do have great strut travel to body ratio, you just need to run LOTS of droop, ie a couple of keeper springs on top of your progressive spring.

What happened to the koni?, did it leak or rip out?

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 09, 2013 10:41 pm 
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Thanks dattman,

I did about 15km flat out after the big hit, so forensics on the shock is a bit hard to tell. It is stuffed to the point I can't even begin to guess what failed first. It looked a bit like a inner tube component exploded and I'm guessing bound up and then ripped the guts apart. the sway bar was the only thing stopping the thing from separating.

Definitely will look if the Subaru stuff will work. Buying second hand gear seems like a bit of a worry. A mate bought some cheap S/H DMS and ended up replacing just about every component at it's next service. False economy?

Do you know someone who has tried the mating up Subaru stuff?

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Tue Sep 10, 2013 6:09 pm 
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What sort of bracing have you got underneath for the control arms? reason I ask is that it's very flimsy under there and that allows the wheel to be pushed forward and back, in and out as well as the intended up and down, this equates to a huge amount of side loading on the shock.

There are many problems with using the swift koni, because it's designed to go inside an existing strut its a very narrow diameter which means small oil volume, being a twin tube and then encased in another strut means it's not good at shedding heat.
Also there is dead space in the insert which means they lower the rebound stop on the piston rod to get the same travel for a shorter body, this means less piston rod inside the shock body at any given point which means it's weaker when handling side loading.

Attachment:
Koni bits.jpg
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Here you can see the difference, at full extension the subaru one has very little rod left inside the shock body, would be very weak but since the subaru springs are very progressive they actually run about half the travel as droop.

One of the guys on TS ran Subaru struts on his mk2 swift rally car for a while but I'm not convinced he had the car setup very well, if you can find some 2nd hand wrx Bilsteins it would be worth playing with them to see if you can get a good ride height and the correct amount of travel and droop, then I'd get them serviced and revalved to suit once you're sure they will work.

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 23, 2013 12:24 pm 
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Thought you all might like a look at the new bash plate and the under body of the car.


Attachment:
File comment: ready to race
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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 23, 2013 12:55 pm 
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Thanks for the look at the bash plate but you didn't need to go to all that effort to show us :shock:

what's the damage?

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 23, 2013 1:04 pm 
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i haven't string lined it yet, but at first glance it all looks superficial and should beat out ok.

The wife has imposed that I'm not allowed to touch it until I build a garage to work in. (Aint she just terrible... :D )

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 23, 2013 1:07 pm 
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Seriously? Again??? Have you calculated your $ to SS km ratio for the last couple of years?
While my first love is gravel you have highlighted why I stick to Tarmac, that seriously sucks mate, glad you're ok by the looks of it.

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 23, 2013 1:14 pm 
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SOBIL wrote:
i haven't string lined it yet, but at first glance it all looks superficial and should beat out ok.

The wife has imposed that I'm not allowed to touch it until I build a garage to work in. (Aint she just terrible... :D )


Geez she's a tough task master :wink: too bad you'll have build one nice and tall to fit a hoist just in case :wink:

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 23, 2013 7:12 pm 
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the car has done approximately 300km. and i have spent.....

cage- 2500
paint and repairs 2000
donor car for front end and misc parts 300
order from menace motorsport (mudflaps intercom belts etc) 1500
suspension and brakes $500
misc $1000

expected cost outlay to fix. <$1000

going to do it again. :D WORTH EVERY CENT!!!

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 23, 2013 7:35 pm 
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NOT AGAIN!!!!?!?!?!?! ARE YOU SERIOUS..
I think its time for a new co-driver for better directions lol..

Hope it all goes well for u..


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 Post subject: Re: SOBIL's Rally Car
PostPosted: Mon Sep 23, 2013 9:01 pm 
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SOBIL wrote:
the car has done approximately 300km. and i have spent.....

cage- 2500
paint and repairs 2000
donor car for front end and misc parts 300
order from menace motorsport (mudflaps intercom belts etc) 1500
suspension and brakes $500
misc $1000

expected cost outlay to fix. <$1000

going to do it again. :D WORTH EVERY CENT!!!

Approx 9k and not counting entry fees, fuel and tyres it costs about $30 for every km :shock:

I love your enthusiasm =D> may it long continue!

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 Post subject: Re: SOBIL's Rally Car
PostPosted: Tue Feb 11, 2014 8:08 am 
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Attachment:
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Well I put an entry in for the first round of the club rally series. under vehicle i left the rego and logbook TBA. but the plan is to get this thing back together in 2 weeks. Starting today. :S if it doesn't look good by the end of the week I'll settle for the autocross car.

Mechanically the car sounds ok but the injectors are firing properly. I'm suspecting the water in the ECU did it's damage. Fortunately I have a full spare loom.

So anyway I put a few hours on it last night and it's coming along well.

Attachment:
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 Post subject: Re: SOBIL's Rally Car
PostPosted: Tue Feb 11, 2014 7:31 pm 
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wow dude nice work! I saw the first pic and thought oh crap but those few hours work are looking good. I hev no doubt you will have it done in time.


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 Post subject: Re: SOBIL's Rally Car
PostPosted: Wed Feb 19, 2014 11:58 pm 
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evilhighway wrote:
wow dude nice work! I saw the first pic and thought oh crap but those few hours work are looking good. I hev no doubt you will have it done in time.



Thanks, for the vote of confidence. And the prep materials ;) from SCA

im running a bit behind schedule, i was hoping to have it painted by now but instead have just finished filling. Its also hardly showroom quality, but still, considering what it was and what it is im happy.

The new headlights came in too which i think look great

Yes, a few days behind but still on track for scrutiny next wednesday. Testing might be cut short though.


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