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emo The story of our Carol a.k.a. 'spud'

08 Dec 2013 20:46 #20422

So a lot's happened since the last update... namely moving house, so we've lost the majority of bolts including a box containing all the bell housing bolts...
:angry:

Anyway

I've uploaded all our photos so far to the gallery:
kkitp.com/index.php/home/gallery/users-galleries/carol

Just before the move:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1228

Making the move:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1238

Cappo head, stripped and skimmed:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1241

Rebuilding the bottom end including new water pump and oil pump:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1242

http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1244

Painted the block, and started adding on a mix of Carol and Cappo parts:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1245

Jay did a 60mile 'round trip to get some genuine parts from the Suzuki dealer:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1246

http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1247

I cleaned up the sump and the cappo flywheel, then painted the sump:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1249
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1250
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1252

We discovered by chance that the flywheels are not the same, so I cleaned up Carol's flywheel and we fitted that one instead.

Jay began hunting the missing bolts while I cleaned up the cam covers:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1253


Then we discovered the Carol intake manifold does not fit the cappo head...
:unsure:

Carol uses an adapter plate, which I had assumed was to convert the cappo head to the carol inlet... thus meaning we could just remove the adapter. Not so at all...

Adapter:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1254

Carol inlet, the yellow denotes the water ports:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1255

The Cappo inlet, yellow again water ports, red part of the EGR system I think:
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1258

So looks like another challenge for us to work out...
:pinch:


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Last Edit: 24 Aug 2014 12:01 by wh1teleopard.

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08 Dec 2013 22:09 #20423

looking god so far Em :)

the clutch and flywheel on the cappo seem to be unique to the cappo, all the other F6As use the clutch and flywheel from the Alto Works - it's slightly smaller in diameter and has a different bolt pattern. I made that mistake when I first went to change mine.

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09 Dec 2013 06:20 #20424

Glad to see it's all coming together :)

Shame about the inlet mani :(

Unfortunately, as I've found with the Suzuki Kei, for some reason Suzuki made the same engine for lots of cars, but felt the need to change them all slightly so the parts are not interchangeable from other Suzuki's with same engine (>_<)

Is there any way of getting another adaptor plate made up?

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09 Dec 2013 12:54 #20426

although the inlet manifold on my AZ-1 and the Carol look the same from above they are obviously completely different, my inlet mounts straight onto the dohc head.
if you have the space, between the head and th bulkhead, the simplest option may be to use the cappo inlet and re-route the intercooler piping to feed from the other end of the engine.

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09 Dec 2013 18:18 #20427

Not enough room in the engine bay to re-route to other side of the bay. We will make a new adapter plate to replace the Carol one.
:)


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07 Jul 2014 21:38 #21950

So time for an update for you...

We moved house twice during the rebuild which added to the fun, we also had to clear out my Grandad's old garage and move all the non-carol parts to our new unit. Which did help us find a few bits, but we've lost a few in the moves too...

:pinch:

To overcome the problem with the inlet/head incompatibility we had to have a new plate made. Now when I say new plate, I mean a piece of art work.

Jamie's uncle Robert (uncle Bob) of Reeve Engineering spent months and a lot of brain power to come up with the final piece. 10,000 lines of CNC code for each side, 2 days to machine the piece. 1 amazing bit of engineering!

The plate not only allows us to mount it to the head, but allows us to mount the inlet manifold afterwards too. However the real masterpiece is the way the inlet ports go from the pear shape of the Carol inlet to the tri-lobe shape of the cappuccino head:





With the plate now finished after months of development, we were able to continue with the rebuild (the top half of the engine remained with Bob during the development of the plate).

I purchased Dazran's turbo from his F6A engine. Everything looked correct in the pictures, and it looked perfect when we collected it at Japfest. However, as we found out recently it's now a fancy paperweight (through no fault of Dazran I might add).

Not knowing what we know now about Suzuki's 90s engineering practices I set about swapping over the interchangeable parts with Carol's old turbo (which we had suspected of being no longer sealed).



Cleaning and painted as I went:



Jamie began wrapping the pipes in orange Samco hose wrap, not only because he likes wrapping pipes quite a lot now, but because as the pipes are over 23 years old the wrap should protect them further and it also adds further rigidity to them.



I realised at this stage that I had made an error with regards to the EGR. I had mistakenly thought we were using the Carol exhaust manifold when in fact we couldn't without another adapter plate. This meant we had to take the inlet adapter plate back to uncle Bob to be modified again to incorporate the EGR, which in the Carol runs externally alongside the head, whereas in the cappuccinos it's integrated into the head.

Bob very kindly and quickly modified the plate for us to incorporate the 90* hole that we had asked for.

Whilst waiting for the plate to return I decided to paint the cam cover:



We tested the new wheels to make sure they fit (they are the same size as the old wheels, but boy is there not a lot of room left inside that tiny 12" rim



The calipers were stripped and painted (yes I replaced the bleed screw that accidentally got painted too haha



We then began to build up the exhaust and turbo. This is where we discovered that although the flange looks identical the Suzuki Kei turbo is no where near close enough to line up, and even the cappuccino and Carol turbo flanges were 2mm different in 1 bolt centre!
:angry:

(From left to right, Suzuki Kei, Autozam Carol and the Suzuki Cappuccino turbos)


As you can see when you lay the gaskets on top of each other 3 of the 4 holes line up, 1 is just a few mm out... very frustrating



We then decided to turn our attention to the brakes again. Having previously discovered that the brake disc is sandwiched between the hub and the knuckle:



We eventually discovered that the only way to get the disc off was to press out the wheel bearings (yes 2):



Thankfully our local friendly ATS garage pressed out the 1 side for us so we could take it to Euro car parts who managed to match it up to a 1991 Suzuki Alto. They were the last 2 in the country (sorry Alto and Autozam owners).

We ordered them for next day pick-up and retired frustrated and annoyed at our lack of progress.



More cleaning took place as we waited for the discs to arrive and for the modification to the plate to be completed



My very kind friend Phil carefully pressed out the other wheel bearing and replaced the discs before pressing the bearings back in again.



We also discovered the lower arm and steering tie rod will not pass an MOT. They are too worn, so will need to be replaced... thankfully they seem quite common parts for a 1991 Suzuki Alto (with which carol seems to share her chassis). We also discovered that the spring has snapped in 2 places on the passenger side.
:pinch:

With the plate now finished we did a dry run to see what other issues we would encounter... nothing too surprising by now.



The Cam cover is sitting 17mm higher than it should due to the modified EGR pipe, so we'll have to modify that again. We had to chose the Cappuccino turbo in the end because the flange to the exhaust manifold is also different between Carol and Cappuccino...
:angry:

We also had to solve the problem of the water routing. This meant we needed more hose, everywhere that sold hose was closed for the weekend so we resided to doing a few little remaining jobs.

I made gaskets:



Jamie swapped out the studs in the head to accommodate the plate.



And that's pretty much where we are up to now. Still a lot of problems to overcome, but we've come this far. We've both sworn and fought with Carol, we will win this! We aren't giving up (though I finally understand now why basil fawlty attacked his car with a tree... I never got that until this weekend).

We will getting her running soon...


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Last Edit: 07 Jul 2014 22:11 by wh1teleopard.

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08 Jul 2014 19:33 #21956

I love the spud!


Unity of minds, unity of hearts, one sole sensation, no longer a coincidence, Overwhelming energy channelled, through universal language allows the personal legend to unfold......
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09 Jul 2014 17:23 #21967

u guys are doing a wicked job, gonna be good to see heron her road after all your work

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09 Jul 2014 20:59 #21971

Thanks Chris.

We were both getting a bit down about Carol. However looking at the pics of what she looked like after we dragged her out of that ditch has given us back our motivation to get her back on the road again, and in the best condition possible.


Author of The Ruins of Rytus Series
Sample, purchase or find out more at:
www.RuinsofRytus.com

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Last Edit: 09 Jul 2014 21:00 by wh1teleopard.

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09 Jul 2014 22:14 #21975

Carol has come along way since u got her out the ditch, and the feeling once she's driving will be worth all head ball ache your getting, will be one of those cars you can't sell as means to much to you both

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