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 Ken's Cappo build (currently 1111 views) |
| ken_parsons |
| Posted on: Sunday, April 20th, 2014, 9:42:22pm |
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OK the summer is on the way so it's time to get started on the project. This is the car as acquired last year.
The car had been in storage for nine years. New battery, new fuel pump and fresh fuel and she started on the button.
Workshop space has been at a premium since I got the car so it's been tucked away in a lock up while I've been accumulating a few bits and bobs and deciding exactly what I am going to do with it. I am going with a full strip down rebuild so the first job is to turn this lot
Into a spit
Car brackets still to build but not a bad use of a rainy, boring Easter Sunday...
Folds flat for storage too. |
Last modified Monday, July 8th, 2019, 2:26:58pm by ken_parsons |
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| lord |
| Posted on: Monday, April 21st, 2014, 8:49:32am |
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| That's the best spit I've seen for a cappo mate! Fair play and it folds flat too |
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Reply: 1 - 38 |
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| ken_parsons |
| Posted on: Monday, May 12th, 2014, 11:15:14pm |
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Finally got around to doing the car brackets.
Still no space in the workshop so done a few small jobs to push things along.
Pulled out the interior to have a look at what I am up against. Not as bad as I thought it was going to be.
Someone has done some dodgy welding, just slapping patches on the outside and the floor has rotted away inside just leaving the patches.
I love the way the lazy bastards couldn't even be arsed to clean the soot off the inside where they burned the sealant 
Bottom of the bulkhead is not too bad.
Whilst the console is out I fitted a GReddy full auto turbo timer and Profec B spec II in place of the ashtray.
And a Toyoshima Craft carbon cubby box lid cover.
Looks good all together.
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Last modified Thursday, September 21st, 2017, 12:34:16am by ken_parsons |
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Reply: 2 - 38 |
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| lord |
| Posted on: Tuesday, May 13th, 2014, 12:33:19am |
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Hmmmmm some nice goodies!!
Where did one get them from ?
Looks like you aren't too bad in the floor but what's she like underneath the floor and where the floor meets the sill? |
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Reply: 3 - 38 |
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| ken_parsons |
| Posted on: Tuesday, May 13th, 2014, 8:50:43pm |
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Quoted from lord, posted Tuesday, May 13th, 2014, 12:33:19am at here |
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Hmmmmm some nice goodies!!
Where did one get them from ?
Looks like you aren't too bad in the floor but what's she like underneath the floor and where the floor meets the sill?
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Most of my goodies are eBay bargains. I take the attitude that if you look hard enough and long enough on eBay you'll get whatever you want for the price you want and more often than not, much less than you are willing to pay. You just have to be patient. For instance the Full Auto turbo timer was £30 and the Profec B spec II boost controller was £50. The Toyoshima craft carbon cover was part of a job lot of new Suzuki parts I paid £60 for that also included a load of genuine Cappo parts:- 2 sets of front brake pads, 2 rear wheel bearings, a window lift motor, JDM indicators and side repeaters, a couple of little bits of interior trim. Also pair of Cusco front shock top mounts. Plus a load of non Cappo goodies:- a Suzuki Sport carbon M series plug cover, a Suzuki Sport induction kit for a Swift, as well as a pile of SJ, Beleno and Cultus parts a lot of which I have re sold on eBay making a tidy profit and effectively getting all the Cappo bits for free..  |
Last modified Tuesday, May 13th, 2014, 9:00:12pm by ken_parsons |
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Reply: 4 - 38 |
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| ken_parsons |
| Posted on: Tuesday, May 13th, 2014, 8:58:21pm |
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Another little job done..
Paper template in place.
Dot punch through the template.
Onto the pillar drill.
and the finished article.
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Last modified Thursday, September 21st, 2017, 12:40:21am by ken_parsons |
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Reply: 5 - 38 |
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| lord |
| Posted on: Tuesday, May 13th, 2014, 10:05:18pm |
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wow fair play with the bits.. been there and done that with all mine.. well some. lol
as for the discs I have never seen someone make their own discs before. Those the rear? |
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| ken_parsons |
| Posted on: Tuesday, May 13th, 2014, 10:11:01pm |
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Fronts only cross drilled them not made them  |
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| lord |
| Posted on: Tuesday, May 13th, 2014, 10:17:14pm |
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you know what I mean.. lol
so what else you got planned for this bad boy?
You going to lease out the spit to cappuccino owners? |
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| nc30pete |
| Posted on: Wednesday, May 14th, 2014, 1:42:07am |
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| im jealous of your fabrication skills already !! I wish I did fabrication skills when i was younger ...... |
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Reply: 9 - 38 |
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| ken_parsons |
| Posted on: Friday, August 22nd, 2014, 8:52:10pm |
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So further delays in getting the car stripped and welded. The latest one being having to move workshops. Resigned to not getting the car on the road this side of Christmas now but still doing jobs. On the plus side the new workshop is great....
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Reply: 10 - 38 |
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| ken_parsons |
| Posted on: Friday, August 22nd, 2014, 9:02:20pm |
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On with the jobs then..
This is my nice new £10 off eBay intercooler core.
Nice compact size and double core so around three times the capalcity of the standard intercooler.
I mocked up the tanks in card to start with.
Only needs a yoghurt pot and some sticky back plastic and I should get my Blue Peter badge.
Transferred to metal.
Welded.
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Last modified Thursday, September 21st, 2017, 10:20:19pm by ken_parsons |
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| ken_parsons |
| Posted on: Friday, August 22nd, 2014, 9:42:07pm |
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The new intercooler is 60mm wider than the space between the rad and the front cross member with the A/C condenser removed so my intention was to remove the rad, extend the mounting brackets by 60mm, fit a slimline fan and slot it all back in there being plenty of space between the rad and the engine to accommodate this.
Things are never that straight forward, upon removing what appeared to be a nice good condition radiator that just needed the mount mod, a quick clean up and a coat of paint, I found these issues.
Oh well not too serious I'll just get our local radiator guys to rebuild it... £185 was the quote for the rebuild! A quick scan of the net and I found this for £53.
I know a few guys have fitted these as is but I couldn't help myself I had to modify it for a different look and more original hose runs.
So off with these bits.
Some more fabrication for Pete....
Fits on the original mounts and the "window" on the right houses a small oil cooler.
Painted with the oil cooler installed.
[IMGhttp://i.picorator.com/j5ojn.jpg][/IMG]
Close up of the oil cooler.
Baffle plate and fan fitted.
May modify this yet not sure there is enough air flow.
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Last modified Thursday, September 21st, 2017, 10:32:48pm by ken_parsons |
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Reply: 12 - 38 |
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| Andy |
| Posted on: Friday, August 22nd, 2014, 10:17:16pm |
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Official C.O.C Contributor
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Amazing stuff!  |
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 |
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Reply: 13 - 38 |
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| lord |
| Posted on: Saturday, August 23rd, 2014, 1:18:27pm |
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That's is deffo amazing.
Wish I had those skills man! Cappo is getting some love |
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Reply: 14 - 38 |
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| ken_parsons |
| Posted on: Wednesday, September 3rd, 2014, 12:18:09pm |
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Wheels done....
Before. Who said tyres only go flat at the bottom
Sand blasted. Local firm did them for £25 a wheel.
Painted.
Tyres fitted. Also have some nice titanium colour alloy wheel nuts.
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Last modified Thursday, September 21st, 2017, 10:37:47pm by ken_parsons |
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Reply: 15 - 38 |
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| ken_parsons |
| Posted on: Wednesday, September 3rd, 2014, 12:21:47pm |
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Painted some other bits whilst doing the wheels.
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Last modified Thursday, September 21st, 2017, 10:41:04pm by ken_parsons |
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Reply: 16 - 38 |
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| ken_parsons |
| Posted on: Wednesday, September 3rd, 2014, 12:34:41pm |
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But first a bit more fabricating.
Custom catch tank.
BOV adaptor plate.
Fitted to the outlet pipe, didn't get a pic before it was painted.
GReddy RZ BOV fitted.
Catch tank painted and assembled.
I know what you are thinking he's got that wrong, anything that goes in the top of that will just run out the bottom through the filter. I'm not quite that daft.....
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Last modified Thursday, September 21st, 2017, 10:50:04pm by ken_parsons |
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Reply: 17 - 38 |
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| lord |
| Posted on: Wednesday, September 3rd, 2014, 5:53:41pm |
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| You got some skills man. What colour was that and you put them on the car yet? |
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Reply: 18 - 38 |
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| ken_parsons |
| Posted on: Wednesday, September 3rd, 2014, 9:08:12pm |
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| It's Vauxhall Diamond Black light variant. The photos don't really do it justice it's a nice dark metallic gunmetal grey with a lot of blue in it. The fronts Wheels are on but it's hard to get a decent pic in the lock up and the scabby discs and calipers don't do them any favours. |
Last modified Wednesday, September 3rd, 2014, 10:32:52pm by ken_parsons |
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Reply: 19 - 38 |
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| ken_parsons |
| Posted on: Wednesday, September 3rd, 2014, 10:54:35pm |
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Fitted the bits on this evening. Need to get every thing in place so I can make up the intercooler pipes. Its also nice to get bits on the car even if they are all coming back off again. it's better for my motivation than a big pile of bits sitting in the workshop... It all looks a bit out of place the ratty engine bay but gives you a feel for where it's going when I get it all stripped out and rebuilt.
Rad slots in perfectly with good clearance all round even the standard expansion bottle stays in it's original location.
Ran out of time to fit the intercooler in, may do that tomorrow. |
Last modified Thursday, September 21st, 2017, 10:55:16pm by ken_parsons |
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Reply: 20 - 38 |
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| Ricou |
| Posted on: Thursday, September 4th, 2014, 5:47:58pm |
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Quoted from lord, posted Wednesday, September 3rd, 2014, 5:53:41pm at here |
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You got some skills man.
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I second that !
Well done mate |
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| ken_parsons |
| Posted on: Friday, October 3rd, 2014, 10:53:35pm |
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Another rack of shiny things..
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Last modified Thursday, September 21st, 2017, 10:58:21pm by ken_parsons |
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Reply: 22 - 38 |
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| ken_parsons |
| Posted on: Friday, October 3rd, 2014, 10:57:43pm |
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The Devil's in the details...
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Last modified Thursday, September 21st, 2017, 11:00:20pm by ken_parsons |
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| ken_parsons |
| Posted on: Friday, October 3rd, 2014, 11:01:30pm |
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From rust to glitz....
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Last modified Thursday, September 21st, 2017, 11:02:09pm by ken_parsons |
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| lord |
| Posted on: Saturday, October 4th, 2014, 1:19:44pm |
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Ken i'm loving what you're doing with this car...
I really do...
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Reply: 25 - 38 |
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| ken_parsons |
| Posted on: Saturday, October 4th, 2014, 9:17:39pm |
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Got the bits on the car today
Shiny tubes...
Must loose that rusty nut >
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Last modified Thursday, September 21st, 2017, 11:06:50pm by ken_parsons |
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| ken_parsons |
| Posted on: Saturday, October 4th, 2014, 9:24:39pm |
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Covered the battery box with DEI Reflect-A-Cool
It's a little blingy for my tastes but it doesn't look too out of place and it is there for a purpose. |
Last modified Thursday, September 21st, 2017, 11:08:24pm by ken_parsons |
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Reply: 27 - 38 |
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| ken_parsons |
| Posted on: Saturday, October 4th, 2014, 9:35:29pm |
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New induction pipe with carbon filter housing. It has a hose on the bottom that will run forward to a trumpet attached to the back of the bumper grille for cold air feed.
One of the mounting brackets for the original air box is just right for mounting the boost control solenoid valve, it all sits in quite nicely.
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Last modified Thursday, September 21st, 2017, 11:12:18pm by ken_parsons |
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Reply: 28 - 38 |
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| half-9 |
| Posted on: Sunday, November 2nd, 2014, 10:16:56am |
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| Some very good quality work going on here! |
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Reply: 29 - 38 |
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| ken_parsons |
| Posted on: Monday, November 24th, 2014, 9:17:48pm |
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Finally got the intercooler pipes done....
Mocking up
Welded up, painted and fitted
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Last modified Thursday, September 21st, 2017, 11:16:41pm by ken_parsons |
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Reply: 30 - 38 |
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| ken_parsons |
| Posted on: Wednesday, December 10th, 2014, 11:02:16pm |
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I'm guessing everyone is bored of pictures of painted pipework now so here is some electrical bits.
I'm planning a second phase to my build, after a year or so of being back on the road I'll carry out some proper engine mods. In the meantime I want to improve the performance a bit without going to the expense of an N1 or F100 etc.. Hence the induction and intercooler mods, the EBC and this conglomeration above.
I bought the jumper harness from Smart 51 and have added a few bits. The part with the white label on it is a speed converter chip, this moves the speed limiter from 140kmh to 140mph. The HKS FCD is obviously to remove the fuel cut so I can use the extra boost from the EBC. The yellow wire is just an unmodified speed signal for the turbo timer. The white wire going to the small plug with the brown earth wire is so I can read the lambda sensor output to the ECU. I can read the voltage from the lambda sensor with a multimeter set on the millivolt scale and see if the FCD is leaning out the AFR too much, if so, and it's quite likely it will, I can tweak it by adjusting a rising rate fuel pressure regulator. All for around 1/5 the price of an N1.... |
Last modified Thursday, September 21st, 2017, 11:20:31pm by ken_parsons |
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Reply: 31 - 38 |
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| Ricou |
| Posted on: Thursday, December 11th, 2014, 2:34:35am |
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About reading the stock Lambda sensor : I don't know if you'll get useful readings, even at mV scale.
Full boost AFR is between 11.5 and 10.5 on stock ECU, so that's way beyond the normal range of that narrow-band sensor.
If your idea doesn't work and If you can stretch your budget a bit, a wideband lambda sensor would be safer. But you probably already know that 
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| ken_parsons |
| Posted on: Thursday, December 11th, 2014, 12:32:36pm |
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Quoted from Ricou, posted Thursday, December 11th, 2014, 2:34:35am at here |
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About reading the stock Lambda sensor : I don't know if you'll get useful readings, even at mV scale.
Full boost AFR is between 11.5 and 10.5 on stock ECU, so that's way beyond the normal range of that narrow-band sensor.
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Are you sure about those AFR readings? 10.5 is massively rich. I would expect low 12s at the absolute richest.
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Last modified Thursday, December 11th, 2014, 1:49:02pm by ken_parsons |
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Reply: 33 - 38 |
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| ken_parsons |
| Posted on: Thursday, December 11th, 2014, 2:22:51pm |
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| Actually thinking about it low 12s wouldn't be the richest I would expect to see but certainly nothing as rich as 10.5. |
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| Ricou |
| Posted on: Thursday, December 11th, 2014, 3:12:03pm |
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Quoted from ken_parsons, posted Thursday, December 11th, 2014, 12:32:36pm at here |
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Are you sure about those AFR readings? 10.5 is massively rich. I would expect low 12s at the absolute richest.
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I am not 100% sure about those because we only checked once, and I was as surprised as you are now, but I think that's way stock ECU behaves.
It was before switching my mate's cappuccino from stock ECU to Adaptronic, we decided to have a little look at the AFR in various conditions. We installed a LC-1 o² sensor right after the catalyst and wrote down what we saw. We calibrated the LC-1 properly, and at idle AFR readings were really close to 14.7. Max boost was around 1.0 or 1.1b (using a bleed valve).
At max boost AFR went immediately to 11.5, then after a few seconds it changed to 10.5.
Maybe at stock boost (0.8b) it doesn't run as massively rich as that, but we didn't check.
As to whether it's useful or not to run that rich, the only way to know is to check exhaust gaz temp (EGT). I've got one installed but not wired yet, I'll have to work on that soon as I'll need it to try and adjust fueling on my Adaptronic.
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Last modified Thursday, December 11th, 2014, 3:16:21pm by Ricou |
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Reply: 35 - 38 |
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| ken_parsons |
| Posted on: Thursday, December 11th, 2014, 9:27:40pm |
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I wonder if you were getting boost spikes as you were using a bleed valve. I'm not sure if the Cappo ECU does it but quite a few stock ECUs give an extra dollop of fuel just before fuel cut to avoid detonation. Could explain the jump in the AFR.
I appreciate that the narrow band sensor won't read anything like that rich, the voltage flat lines at 1.0 volts so it won't see anything richer than about 12.5 but I'm only interested in seeing if it goes lean when the FCD modifies the MAP sensor signal to the ECU. I won't have a sophisticated method of controlling the AFR at this stage, I'll only be able to do it by fuel pressure. As long as I can keep it as close as possible to 1.0 volts on full boost I'll be happy.
When I do the proper engine mods I'll go wide band and junk all this crap for something sophisticated.
I'm not planning on running outrageous boost levels and have a good ear for detonation.. |
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Reply: 36 - 38 |
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| Ricou |
| Posted on: Thursday, December 11th, 2014, 11:27:34pm |
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Quoted from ken_parsons, posted Thursday, December 11th, 2014, 9:27:40pm at here |
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I wonder if you were getting boost spikes as you were using a bleed valve.
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As far as I know we weren't, but I can't remember the exact boost we were at.
We didn't go over 1.13b obviously because otherwise we would have felt the stock ECU's brutal boost cut.
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Quoted from ken_parsons, posted Thursday, December 11th, 2014, 9:27:40pm at here |
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I'm not planning on running outrageous boost levels and have a good ear for detonation..
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Good. I wouldn't go over 1.2b with that kind of system
As for detonation, I have a knock sensor attached to the block and I'm using it like a microphone to listen to engine noise. A while ago I was having various problems with my engine, and it was knocking at anything over 0.8b. I didn't detect it with my "naked ear" (not sure if this is the correct expression), only by listening to the knock sensor.
So what I'm saying is, be careful |
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| ken_parsons |
| Posted on: Friday, December 12th, 2014, 9:49:30pm |
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| Point taken. I think I'll build myself an audio knock detection system. My hearing isn't what it used to be.... |
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