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 Post subject: Re: The Kadini coupe!
PostPosted: Sun May 03, 2020 7:01 pm 
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Location: Nudecastle
So what happened with the Aluminium blob? First I cut about 30mm off the end with the drop saw then squared it all up in the 4 jaw lathe.

ImageIMG_20200420_133540 by Justin Sherwood, on Flickr

I then bored a hole in one side, turned one end suitable for a 51mm hose, bored through the hose end, drilled some holes, and f*#cked about with the die grinder. This was the result, a new top hat for the throttle body.

ImageIMG_20200421_131352 by Justin Sherwood, on Flickr

ImageIMG_20200421_131408 by Justin Sherwood, on Flickr

ImageIMG_20200425_161258 by Justin Sherwood, on Flickr

It needs more work but that will be later.

I needed a small section of 51mm pipe so cut another section of Saab pipe, well I was about to and Kadyn wanted to do it.

ImageIMG_20200425_173101 by Justin Sherwood, on Flickr

I bought some aluminium tube bends to make up part of the intake plumbing then cut them up, drilled holes and beaded one end ready to weld together. I also took the sump off and cut another section out of it. Made up a patch to suit. The whole lot was sent out to get welded up.

ImageIMG_20200426_135454 by Justin Sherwood, on Flickr

ImageIMG_20200428_112153 by Justin Sherwood, on Flickr

Beaded one end of the pipe Kadyn cut.

ImageIMG_20200503_140058 by Justin Sherwood, on Flickr

I also bought an intercooler.

ImageIMG_20200426_141529 by Justin Sherwood, on Flickr

Then cut it up!

ImageIMG_20200428_112223 by Justin Sherwood, on Flickr

Shortened the mounts level with the end tanks.

ImageIMG_20200428_112211 by Justin Sherwood, on Flickr

Made up some fill pieces for the new engine mounts and welded it all together. Whats that saying? Oh yeah, “If you can't weld good, weld lots”. There's lots of weld in these!

ImageIMG_20200503_095530 by Justin Sherwood, on Flickr

The sump and pipe came back from the welder. I actually cleaned the sump in the sand balster this time.

ImageIMG_20200503_130347 by Justin Sherwood, on Flickr

ImageIMG_20200503_130411 by Justin Sherwood, on Flickr

Welded the new mounts on to the cross member and cleaned up a bit with the grinder.

ImageIMG_20200503_110047 by Justin Sherwood, on Flickr

ImageIMG_20200503_110102 by Justin Sherwood, on Flickr

ImageIMG_20200503_110124 by Justin Sherwood, on Flickr

ImageIMG_20200503_110132 by Justin Sherwood, on Flickr

ImageIMG_20200503_110147 by Justin Sherwood, on Flickr

Painted the cross member, refitted sump and then refitted cross member. Let the engine down on to its mounts and checked clearances. Fitted the Piazza rack and checked that too. Nothing is touching this time but technically some of it is still a bit close. If I need to I'll make up spacers under the rubber mounts.

ImageIMG_20200503_135126 by Justin Sherwood, on Flickr

ImageIMG_20200503_135139 by Justin Sherwood, on Flickr

ImageIMG_20200503_135202 by Justin Sherwood, on Flickr

ImageIMG_20200503_135241 by Justin Sherwood, on Flickr

ImageIMG_20200503_135920 by Justin Sherwood, on Flickr

Test fitted the intake and boost plumbing. The silicone joiner on the air flow meter just touches the bonnet. That can be massaged to fit so no biggy.

ImageIMG_20200503_140611 by Justin Sherwood, on Flickr

ImageIMG_20200503_142745 by Justin Sherwood, on Flickr

ImageIMG_20200503_142950 by Justin Sherwood, on Flickr

ImageIMG_20200503_143024 by Justin Sherwood, on Flickr

I don't know whats next, I'll figure that out later.

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 Post subject: Re: The Kadini coupe!
PostPosted: Mon May 04, 2020 9:42 am 
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Korean Jesus
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Posts: 2336
Location: Canberra. Where the Fast Geminis live
Such a good result man.

It's pretty rewarding putting the bonnet back on for clearance checks isn't it lol

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 Post subject: Re: The Kadini coupe!
PostPosted: Sat May 23, 2020 6:03 pm 
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Joined: Sat Aug 07, 2010 9:52 pm
Posts: 580
Location: Nudecastle
So what's next? Sometimes it seems bigger than Ben Hur but then I do one little job and then another. Soon there's things done.

I wanted to use these engine mount safety tabs.

ImageIMG_20200505_075452 by Justin Sherwood, on Flickr

So they got a trim and a test fitting.

ImageIMG_20200510_141757 by Justin Sherwood, on Flickr

ImageIMG_20200510_141813 by Justin Sherwood, on Flickr

Welded in a small bracket then put some nutserts in for the air box.

ImageIMG_20200510_141819 by Justin Sherwood, on Flickr

I started to cut bits of the front panel to install the intercooler and got the s*)ts with how it was all fitting. I ordered another intercooler and welded the bits back in.

ImageIMG_20200510_141834 by Justin Sherwood, on Flickr

Second intercooler turned up so then I cut this one up as well. Not as much this time.

ImageIMG_20200517_140033 by Justin Sherwood, on Flickr

ImageIMG_20200517_140055 by Justin Sherwood, on Flickr

Cut the front panel to suit. I wasn't keen on this as there is over $800 in front panel but it had to be done, maybe.

ImageIMG_20200517_140115 by Justin Sherwood, on Flickr

It's tight but slides in from the front.

ImageIMG_20200517_135942 by Justin Sherwood, on Flickr

This thing turned up from the land of COVID 19 f*&kers. It's a Honda something throttle cable/TPS doohickey. “Hey spell check actually accepts doohickey as a word”

ImageIMG_20200517_140130 by Justin Sherwood, on Flickr

Made an aluminium plate/bracket for it and mounted it next to the throttle body.

ImageIMG_20200520_154253 by Justin Sherwood, on Flickr

ImageIMG_20200520_154316 by Justin Sherwood, on Flickr

Bought this thing from a Hyundai Accent.

ImageIMG_20200517_140221 by Justin Sherwood, on Flickr

Made a bracket.

ImageIMG_20200520_153752 by Justin Sherwood, on Flickr

Nutserts and bolts in engine bay.

ImageIMG_20200521_151958 by Justin Sherwood, on Flickr

I grabbed one of my dashboards and cut bits off it. It came from the TC I bought to re-shell GEM77A. It isn't an immaculate dash so I didn't mind as much cutting it up but it already has the air vents on the ends. It was just a matter of trimming and test fitting until it bolted in around the Swift HVAC.

ImageIMG_20200517_151516 by Justin Sherwood, on Flickr

Next I'll make mountings for the HVAC and once it bolts in I'll make up the duct work to the vents. I still don't know if it'll work but you don't know till you try. I'll probably keep the electric actuators on it as I can see how drive them simply. This brings me to the next question, do I keep the AC a manual system or go full nerdy climate control?

I paid a visit to Pick N Payless and picked up this stuff.
A condenser from a Suzuki Ignis.

ImageIMG_20200523_124120 by Justin Sherwood, on Flickr

A plug/pigtail from a Honda for the TPS. The other things are light sensors for the XR6, the bloody things s*#t themselves in the summer heat.

ImageIMG_20200523_124113 by Justin Sherwood, on Flickr

I'll see how well the Ignis condenser, intercooler and radiator all fit together then make a mounting bracket for them.

Lastly I want to say something.
Everybody that builds something, and it seems to be common in the modified car scene, gets the odd smart arse making comment criticising their work saying things like you should have done it this way, it wont work properly or that looks s*#t! My build is no exception! A lot of the critics either have tons of money to do things differently, don't have all the facts and say s*#t without being informed or are plain and simply arseholes!
I just wish to inform these idiots that I am building this thing with next to no money, the tools I have at hand, and the parts available to me. It is not meant to be a super performance build but more of proving to myself that it can be done and be done the way I want it done.

Till next time.

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Last edited by gemsince88 on Sun May 31, 2020 6:03 pm, edited 1 time in total.

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 Post subject: Re: The Kadini coupe!
PostPosted: Fri May 29, 2020 11:01 am 
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Korean Jesus
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Joined: Tue Jul 25, 2006 5:28 pm
Posts: 2336
Location: Canberra. Where the Fast Geminis live
Mad

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 Post subject: Re: The Kadini coupe!
PostPosted: Sun May 31, 2020 9:23 am 
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Joined: Tue Apr 10, 2007 3:46 pm
Posts: 1874
Location: Brisbane
I enjoy your posts. Unfortunately you have to suffer citicism from the odd idiot when playing in the public realm.

I can only offer that most of the critics rarely finish anything themselves. If they really did the hard yards themselves, they would have a better understanding and respect for fellow enthusiasts.


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 Post subject: Re: The Kadini coupe!
PostPosted: Sun May 31, 2020 6:10 pm 
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Joined: Sat Aug 07, 2010 9:52 pm
Posts: 580
Location: Nudecastle
Thanks man.

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