|
|
 Author |
 Nick's cappo project (Espresso conversion!) (currently 3739 views) |
| clemdobain |
| Posted on: Saturday, March 29th, 2014, 6:38:56pm |
  |
|
|
This is my first cappo project. Bought from Ebay and transported to Northern Ireland where it will have most major welding and body work carried out (my dads garage), then off to Edinburgh for engine work and various other bits and pieces and to live (where I am based). As you can see in the photos there's a fair bit of work to be done but done it shall be!!
Will update photos as we go! Oh and sorry for the lack of descriptions with the photos, there were just too many to label everytime i update the album! I will do my best to describe what i've done in between posts!
|
Last modified Tuesday, September 9th, 2014, 8:53:51am by clemdobain |
|
 Logged |
|
|
|
|
| clemdobain |
| Posted on: Saturday, March 29th, 2014, 6:44:29pm |
|
|
|
CLICK TO PLAY VIDEO
Floor pan drivers side ( with initial section cut away to see extent of chassis leg rust)
 |
Last modified Saturday, March 29th, 2014, 6:45:12pm by clemdobain |
|
| Logged |
|
|
 |
Reply: 1 - 86 |
|
|
| fuzz573 |
| Posted on: Saturday, March 29th, 2014, 7:49:18pm |
|
|
|
Great start, loving your plans for this, I live about 20 minutes from Edinburgh, give me a pm if you fancy meeting up once the weather is better. There is a few of us nearby now with plans for modded cappos. Are you planning on attending any of the scottish shows?
Cheers
Donna |
|
| Logged |
|
|
|
Reply: 2 - 86 |
|
|
| clemdobain |
| Posted on: Saturday, March 29th, 2014, 8:57:13pm |
|
|
|
Thanks Dona. Great to know there's a few more Cappo'ites in Scotland! I'll definitely be up for a a meet and will be at the shows for sure! (Hopefully in the cappo) =) Are there any coming up this summer?
|
|
| Logged |
|
|
|
Reply: 3 - 86 |
|
|
| clemdobain |
| Posted on: Saturday, March 29th, 2014, 8:58:53pm |
|
|
|
Drivers side cut out and prepped for welding this afternoon (My dad couldnt wait to get stuck in!)
 |
|
| Logged |
|
|
|
Reply: 4 - 86 |
|
|
| clemdobain |
| Posted on: Saturday, March 29th, 2014, 9:00:31pm |
|
|
|
Kurust is being applied to any areas that aren't bad enough to need cut out or welded (before anti rust top coat) This section is still to get cut out also....
 |
Last modified Saturday, March 29th, 2014, 9:02:15pm by clemdobain |
|
| Logged |
|
|
|
Reply: 5 - 86 |
|
|
| fuzz573 |
| Posted on: Sunday, March 30th, 2014, 7:46:59am |
|
|
|
“ |
Quoted from clemdobain, posted Saturday, March 29th, 2014, 8:57:13pm at here |
” |
Thanks Dona. Great to know there's a few more Cappo'ites in Scotland! I'll definitely be up for a a meet and will be at the shows for sure! (Hopefully in the cappo) =) Are there any coming up this summer?
|
|
There is the scottish car show at ingilston, jap show at knockhill, jap shows at Crail quarter mile track and various jap type ones at driftland in lochgelly, I will try and pm you some dates for them.
Loving the quick work, can't wait to see the next stage  |
|
| Logged |
|
|
|
Reply: 6 - 86 |
|
|
| clemdobain |
| Posted on: Sunday, March 30th, 2014, 11:10:11am |
|
|
|
|
| Logged |
|
|
|
Reply: 7 - 86 |
|
|
| clemdobain |
| Posted on: Thursday, April 3rd, 2014, 5:20:54pm |
|
|
|
More updates of areas cut, prepped and welded
|
Last modified Thursday, April 3rd, 2014, 5:33:28pm by clemdobain |
|
| Logged |
|
|
|
Reply: 8 - 86 |
|
|
| Avar |
| Posted on: Thursday, April 3rd, 2014, 6:30:44pm |
|
|
|
| Lots of good stuff done but one question have you run out of gas on your welder? |
|
| Logged |
|
|
|
Reply: 9 - 86 |
|
|
| clemdobain |
| Posted on: Monday, April 7th, 2014, 11:52:44am |
|
|
|
| We've been through a couple of bottles already actually so in some areas it was running low while welding. What makes you ask? |
|
| Logged |
|
|
|
Reply: 10 - 86 |
|
|
| clemdobain |
| Posted on: Monday, April 7th, 2014, 12:16:11pm |
|
|
|
Another update with 99% of welding complete
|
|
| Logged |
|
|
|
Reply: 11 - 86 |
|
|
| clemdobain |
| Posted on: Monday, April 7th, 2014, 12:27:28pm |
|
|
|
So work carried out so far is:
Cut, patched and welded full length of offside floor along with both sides rear bulkhead behind seats.
Cut, patched and repaired both sides of front and rear sill ends
Cut, patched and repaired near side outer sill
Several repairs to rear chassis legs inner and outer
All repairs primed and coated with anti rust treatment
Fuel filter and feeder hoses replaced
Also new fuel filter (with hoses) fitted as it was rusting and leaking! Not a good idea welding next to a leaking fuel filter FYI haha!
Sorry for the huge number of photos with no descriptions there were just far too many to label as i uploaded them!
So that's near enough all of the welding complete, now going to give her a proper wire brush rub down underneath and get a damn good coating of under seal and wax oil also.
Following that i'll be giving her a good service with new plugs, oil + filter and a decent air filter of some sort! Still needing to source a rear shock (that hasnt leaked all over itself) If anyone has one lying around please let me know!
|
Last modified Monday, April 7th, 2014, 12:35:53pm by clemdobain |
|
| Logged |
|
|
|
Reply: 12 - 86 |
|
|
| Andy |
| Posted on: Monday, April 7th, 2014, 8:29:36pm |
|
|
Official C.O.C Contributor
Gender:  Male
Posts: 23604
Posts Per Day: 3.48 |
|
And the number plate has changed too!  |
Drop me a PM if you would like to be added to the ClubCappo Member Map. More details can be found here.
We now have an official Facebook group as well as a page! See here |
|
| Logged |
|
|
 |
Reply: 13 - 86 |
|
|
| clemdobain |
| Posted on: Monday, April 7th, 2014, 8:59:14pm |
|
|
|
| Haha yes!! I knew I'd forgotten something! (The newest parts on the car) haha! |
|
| Logged |
|
|
|
Reply: 14 - 86 |
|
|
| senna847 |
| Posted on: Monday, April 7th, 2014, 10:57:03pm |
|
|
|
Hi buddy good to see the work going in to keep a cracking wee car going. I've recently bought a cappuccino with similar levels of welding needing done to it. I'm in Dunfermline so hopefully I'll see you at the Scottish events this year.
|
|
| Logged |
|
|
|
Reply: 15 - 86 |
|
|
| ishigakisensei |
| Posted on: Tuesday, April 8th, 2014, 5:32:34am |
|
|
Big Member
Posts: 141
Posts Per Day: 0.08 |
|
| Just curious, Japan is also an island country as is the UK. So, why do you guys have constant rust problems but we in Japan do not? |
|
| Logged |
|
|
| |
Reply: 16 - 86 |
|
|
| paolo |
| Posted on: Tuesday, April 8th, 2014, 8:01:44am |
|
|
|
“ |
Quoted from ishigakisensei, posted Tuesday, April 8th, 2014, 5:32:34am at here |
” |
Just curious, Japan is also an island country as is the UK. So, why do you guys have constant rust problems but we in Japan do not?
|
|
Probably due to the large about of salt based grit we throw on our roads every winter to keep the ice away!
|
|
| Logged |
|
|
|
Reply: 17 - 86 |
|
|
| clemdobain |
| Posted on: Tuesday, April 8th, 2014, 8:18:40am |
|
|
|
| Awesome buddy, glad to hear there's another cappo in Scotland! If I can help at all just let me know!! I'll look forward to getting out for a blast once we're both on the road! I seem to have got off a bit lighter with this cappo as someone has kindly used underseal at some point in the past. Scared to think what it would be like if it was totally untreated! |
Last modified Tuesday, April 8th, 2014, 8:21:27am by clemdobain |
|
| Logged |
|
|
|
Reply: 18 - 86 |
|
|
| Avar |
| Posted on: Tuesday, April 8th, 2014, 10:14:57am |
|
|
|
“ |
Quoted from paolo, posted Tuesday, April 8th, 2014, 8:01:44am at here |
” |
Probably due to the large about of salt based grit we throw on our roads every winter to keep the ice away!
|
|
I think there's something up with our climate too. I dunno what its like in Japan but if I leave a sheet of non oiled mild steel outside for a night (summer or winter) I will find it starting to rust the next morning. When I repaired the last car, spot welding the sills I forgot to zinc the spots one night, the next day they needed some serious grinding to clean up 
|
|
| Logged |
|
|
|
Reply: 19 - 86 |
|
|
| clemdobain |
| Posted on: Tuesday, April 8th, 2014, 5:25:58pm |
|
|
|
My Dad it out for a wee nip round the block this afternoon to test everything. Clutch bite is a little high so might need some attention. Does anyone know if the clutch cable can be adjusted on the Cappuccino or is it hydraulic? Also reported some light "clunking" form the diff area so i'll be ordering some poly diff mounts asap! Brakes also CR&P as would be expected from sitting in storage for 4 years. They will be my first main job to sort I think. Just stuck on 6 months tax today so that's it sorted for the summer months! =)
We also discovered another rust hole just beside the of side front subframe mount area and jacking point. All welded up now and repaired, pics to follow |
|
| Logged |
|
|
|
Reply: 20 - 86 |
|
|
| clemdobain |
| Posted on: Tuesday, April 8th, 2014, 5:31:14pm |
|
|
|
As mentioned above, repair pics to follow
 |
|
| Logged |
|
|
|
Reply: 21 - 86 |
|
|
| Ricou |
| Posted on: Tuesday, April 8th, 2014, 5:58:21pm |
|
|
Maximum Member
Posts: 1110
Posts Per Day: 0.65 |
|
Congrats on all the work done ! Always nice to see a Cappuccino being saved
The clutch cable can be adjusted from under the car (driver side of the gearbox), it's very easy to do, no need for tools. |
|
| Logged |
|
|
| |
Reply: 22 - 86 |
|
|
| Avar |
| Posted on: Tuesday, April 8th, 2014, 6:32:49pm |
|
|
|
Yep looks good, a good fast job, well done.
Re the noise from the rear, first give the exhaust rubbers a check, if its been sitting for a while the bushes aren't getting abuse but the mounts are always under stress and they're a fraction of the cost of suspension bush set.
While your setting the clutch cable up I'd check the pedal adjustment for brake and clutch too, easy enough job to do. |
|
| Logged |
|
|
|
Reply: 23 - 86 |
|
|
| Avar |
| Posted on: Tuesday, April 8th, 2014, 6:36:09pm |
|
|
|
“ |
Quoted from clemdobain, posted Monday, April 7th, 2014, 11:52:44am at here |
” |
We've been through a couple of bottles already actually so in some areas it was running low while welding. What makes you ask?
|
|
Just noticed you'd replied, only asked cause I could see a lot of cratered spot welds which usually indicates low or no shielding. |
|
| Logged |
|
|
|
Reply: 24 - 86 |
|
|
| clemdobain |
| Posted on: Thursday, April 17th, 2014, 6:18:30pm |
|
|
|
Well I finally got so see her in person! Got my first drive in her, polished up and looking good!
Definite clunking around the rear diff during gear changes when you put the power down so im guessing diff mounts? Also got the front calipers freed up and "floating again" which made a big improvement to the stopping power. Discs seem to be cleaning up ok after being in storage for 4 years!
I've fitted a lovely cone air filter and have done the "dump valve mod" of removing and blocking off the return line from the ABV which by the way sounds AMAZING. I've had a few turbo'd cars in my time with various branded dump valves and this sounds right up there with the best ive ever heard!! AND ITS FREE!!!
Engine is running very well, boost seems to come on smoothly and at quite a low rpm which is nice! (Air filter has definitely allowed the engine to rev more freely and the spooling noise has really got louder which I LOVE!
Needs a good service and plenty more attention to clean up the body work and still need to replace the rear shock which is really affecting handling since its leaked its oil out. Also the high level mid brake light isnt working and the door switches (for interior light) are being temperamental!
Here are a few snaps while out for a blast with my brother in law (driving my dads MG Midget)
 |
Last modified Thursday, April 17th, 2014, 6:27:02pm by clemdobain |
|
| Logged |
|
|
|
Reply: 25 - 86 |
|
|
| clemdobain |
| Posted on: Wednesday, July 9th, 2014, 8:53:50am |
|
|
|
| JUST PASSED MOT TODAY!!!! Yeeoooooooooo!! Should be in for a lick' o paint (black) this week then bringing it over to Edinburgh next weekend! Exciting times! |
|
| Logged |
|
|
|
Reply: 26 - 86 |
|
|
| Youichi |
| Posted on: Wednesday, July 9th, 2014, 10:37:00am |
|
|
Big Member
Posts: 257
Posts Per Day: 0.15 |
|
“ |
Quoted from clemdobain, posted Thursday, April 17th, 2014, 6:18:30pm at here |
” |
<SNIP>
Also the high level mid brake light isnt working and the door switches (for interior light) are being temperamental!
|
|
The high level brake light were disabled by Suzuki when they were imported, as the DVLA said they were a distraction to other road users.... 
I bought an aftermarket brake light of fleabay, and stripped the LED board out of it, and put it into the Suzuki light. Suzuki left the loom attachment in the boot (on the right hand side).
See this thread:- http://www.clubcappo.co.uk/board/Blah/Blah.cgi?,b=Technical,v=display,m=1153745382,s=
The door switches can be easily removed, and cleaned up with a wirebrush/wheel.
|
|
| Logged |
|
|
| |
Reply: 27 - 86 |
|
|
| clemdobain |
| Posted on: Wednesday, July 9th, 2014, 11:23:29am |
|
|
|
| Thanks Youichi, I'll give the switches a good clean and I'm sure that'll sort it out. The brake light will be another addition to the to do list =) |
|
| Logged |
|
|
|
Reply: 28 - 86 |
|
|
| clemdobain |
| Posted on: Friday, July 11th, 2014, 11:13:58am |
|
|
|
And so the painting begins!!
Sanded down and masked....
 |
|
| Logged |
|
|
|
Reply: 29 - 86 |
|
|
| clemdobain |
| Posted on: Friday, July 11th, 2014, 11:15:00am |
|
|
|
white undercoat (mainly for me to decide if I wanted to keep it white or go for black!)
 |
|
| Logged |
|
|
|
Reply: 30 - 86 |
|
|
| clemdobain |
| Posted on: Friday, July 11th, 2014, 11:16:43am |
|
|
|
First coat! Looking lovely! A few tiny blemishes have been caught, anything missed will be sorted after the main coats are applied.
(And yes that white line on the bonnet is a light overhead not a bizzare go faster stripe!)
 |
Last modified Friday, July 11th, 2014, 11:18:05am by clemdobain |
|
| Logged |
|
|
|
Reply: 31 - 86 |
|
|
| clemdobain |
| Posted on: Friday, July 11th, 2014, 12:53:50pm |
|
|
|
|
| Logged |
|
|
|
Reply: 32 - 86 |
|
|
| Andy |
| Posted on: Friday, July 11th, 2014, 6:14:55pm |
|
|
Official C.O.C Contributor
Gender: Male
Posts: 23604
Posts Per Day: 3.48 |
|
How quick! Top job  |
Drop me a PM if you would like to be added to the ClubCappo Member Map. More details can be found here.
We now have an official Facebook group as well as a page! See here |
|
| Logged |
|
|
| |
Reply: 33 - 86 |
|
|
| clemdobain |
| Posted on: Tuesday, July 15th, 2014, 1:36:02pm |
|
|
|
How about this!
 |
|
| Logged |
|
|
|
Reply: 34 - 86 |
|
|
| clemdobain |
| Posted on: Tuesday, July 15th, 2014, 1:58:13pm |
|
|
|
| Not sure if I want to keep the stripe up the side or not yet..... we had it sitting in the garage so thought it was worth a try =) |
|
| Logged |
|
|
|
Reply: 35 - 86 |
|
|
| Cappo_Ash |
| Posted on: Friday, March 20th, 2015, 10:17:15pm |
|
|
|
| Labour of love......good work.... |
|
| Logged |
|
|
|
Reply: 36 - 86 |
|
|
| clemdobain |
| Posted on: Monday, March 23rd, 2015, 9:48:07am |
|
|
|
So after a lot of deliberation and epic courier fails the project has been renamed Nick's Cappo to Espresso conversion! I started with the intended fitment of this....
But after lots of F'ing and blinding and some sheared cat-turbo bolts I decided enough was enough and removed the whole turbo and manifold...
And just as well I did as a quick inspection of the turbo's exhaust housing exposed this beauty of a crack!!
Obviously caused by years of bad turbo care or lack of a turbo timer! Pretty amazing considering the turbo held boost well!
|
Last modified Monday, March 23rd, 2015, 11:16:10am by clemdobain |
|
| Logged |
|
|
|
Reply: 37 - 86 |
|
|
| clemdobain |
| Posted on: Monday, March 23rd, 2015, 10:10:21am |
|
|
|
Theeennnn this happened....
I am now the proud owner of a CT9 Turbo kit previously put together and set up by a member of CC, Nigel or "Bainsey" then purchased by nc3pete (who never actually fitted it) and then passed to me!
The kit consists of:
Toyota Starlet CT9a turbo with modified oil and water piping
N2 ECU
Starlet 295cc injectors
Custom fabricated stainless exhaust manifold
Custom fabricated decat downpipe
Modified Nissan Skyline R33 intercooler and piping
Magnecor HT leads
Nige had the kit set up on a dyno and had the A/F ratio's checked while upping the boost. You can read his full right up of the fabrication, install and set up here: http://www.clubcappo.co.uk/board/Blah/Blah.cgi?b=Technical,v=display,m=1202894797,s=0
He managed around 110hp at the flywheel and 83 to the wheels with what seemed to be a very poorly engine at .85bar boost. Therefore 125hp ish should be easily achievable with a fresher engine and more boost!
Heres a lovely comparison...
I don't have any pics of the kit as a whole as I was WAAAY too excited to start fitting it when it arrived!
Manifold:
Downpipe decat:
Small vs large injectors:
N2!!:
Modified engine mount to make room for oil feed/return pipes:
Very tight squeeze!!:
Also pulled out the aircon which wasn't working which has saved a fair bit of weight!
Had a proper battle fitting the oil feed with the turbo in situ but it was the only way possible! All in with lovely braided water piping also.
(I had some spare):
 |
Last modified Monday, March 23rd, 2015, 10:29:29am by clemdobain |
|
| Logged |
|
|
|
Reply: 38 - 86 |
|
|
| clemdobain |
| Posted on: Monday, March 23rd, 2015, 10:27:27am |
|
|
|
Had my first test drive in her with a blast to Knockhill circuit for a car show with my buddy and HOLY SH*T THIS THING IS FAST!! I had the boost set to .8 bar (manual boost controller and gauge fitted) and lets just say my mate couldnt keep up with me in his WRX impreza running around 230hp!! There isn't a lot happening before 4k rpm but after that the sound, power and torque are absolutely unbelievable!! The best part is it will carry the power right up to the rev limiter (which is raised with the N2) and once I change gear it brings me straight back on boost perfectly!!
Starting and idleing is nice and smooth and she is running up to temperature and holding it nicely after cleaning out the radiator and fitting the new thermostat.
Next thing is the rear end refresh as im getting big clunks from the diff when changing gears... |
Last modified Wednesday, August 26th, 2015, 1:10:24pm by clemdobain |
|
| Logged |
|
|
|
Reply: 39 - 86 |
|
|
|
Cappuccino Owners Club › Gallery › Cappo Related Album › Nick's cappo project (Espresso conversion!) (Moderators: )
Locked Board