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bugle
07-02-16, 10:30 PM
I bought this for $0. I call it "Woozy-oh", they are just the plates that it came with from new.
Never took a pic because it looked so shitty, so Google helped me out

http://starlyon.com/bugle/barina/googlebarina1.jpg
http://starlyon.com/bugle/barina/googlebarina2.jpg

bugle
07-02-16, 10:30 PM
Then I painted it and put some tyres that grip properly on it

http://starlyon.com/bugle/barina/BarinaPainted.jpg
http://starlyon.com/bugle/barina/BarinaPainted2.jpg
http://starlyon.com/bugle/barina/BeepBeep.jpg

Upgraded the horrible stock brakes

http://starlyon.com/bugle/barina/brakes/oldbrakes.jpg
http://starlyon.com/bugle/barina/brakes/newbrakes.jpg

Sloth
07-02-16, 10:39 PM
in for this.

bugle
07-02-16, 10:47 PM
Stock engine is pretty bad.
C14NZ 1.4 litre family 1 SOHC with toilet bowl injection - 44kw.

http://starlyon.com/bugle/barina/Engine/StockEngine.jpg

Got a X18XE1 engine. Family 1 1.8 litre DOHC. They're something like 90kw stock.

http://starlyon.com/bugle/barina/Engine/X18XE1.jpg

bugle
07-02-16, 10:47 PM
in for this.

Yeah finish yours too!

Roadsailing
07-02-16, 11:03 PM
they made a 2.4 litre version of that engine can't remember what it went in, maybe astra SRI. does the family 1 have the same bellhousing bolt pattern as the family 2?

bugle
07-02-16, 11:07 PM
Yeah Rodeos had it I think? Astra was 2.2.
Not sure about the bellhousing, but you can put a Family 2 engine and gearbox in a Barina which Sloth has done. It's just a bit heavier than a Family 1.

bugle
07-02-16, 11:16 PM
This is the plan for turbo

S14 T28 I got cheap ($37), only problem was that the arm that the wastegate actuator attaches to was bent a bit but I straightened it. Must've spooked the other bidders.
http://starlyon.com/bugle/barina/Engine/T28Turbo.jpg

Plan is to make a 2-1 turbo adapter off the bottom of the stock exhaust manifold.
http://starlyon.com/bugle/barina/Engine/ExhaustOutlet.jpg
http://starlyon.com/bugle/barina/Engine/x18xe1manifold2.JPG

Intercooler
http://starlyon.com/bugle/barina/Intercooler.jpg

Sloth
07-02-16, 11:24 PM
mines done, but i havent had time to run it. id run a 200sx tubular mani with a new flange. the stock cast fucker flows worse than a 1 inch u bend.

bugle
07-02-16, 11:31 PM
Stock intake manifold is pretty funky. Variable length intake runners type thing.

http://starlyon.com/bugle/barina/Engine/StockIntake.jpg

Felt like making something different, got the cheapest FWD style 4 cylinder plenum I could from Ebay to use as a base, it's for an early Evo 4g63.

http://starlyon.com/bugle/barina/Engine/X18XE1-2.jpg

Turns out I couldn't use the runners that came with it because they were too big, and port spacing is slightly different. I chopped the stock manifold off after the injector bosses, got some 50mm aluminium tube, crushed it to the right shape and welded it on. Then cut the plenum base plate in the middle to bring the ports closer together. The runners are angled a bit so that I don't have to cut it between every single runner.

http://starlyon.com/bugle/barina/manifold/intake1.jpg
http://starlyon.com/bugle/barina/manifold/intake2.jpg
http://starlyon.com/bugle/barina/manifold/WeldedRunners.jpg
http://starlyon.com/bugle/barina/manifold/WeldedRunners2.jpg

Next I grind the bellmouths into nice smooth things, but I need to finish my Piazza first.

bugle
07-02-16, 11:34 PM
mines done, but i havent had time to run it. id run a 200sx tubular mani with a new flange. the stock cast fucker flows worse than a 1 inch u bend.

The stock Z18XE manifold looks shit, but this one looks pretty smooth to me?

Lobster
11-02-16, 12:43 PM
Awesome!

milo
11-02-16, 01:20 PM
Loving this!!!

Lobster
11-02-16, 02:28 PM
Upgraded the horrible stock brakes

http://starlyon.com/bugle/barina/brakes/oldbrakes.jpg
http://starlyon.com/bugle/barina/brakes/newbrakes.jpg

Are they off something else or just vented versions?

bugle
11-02-16, 05:19 PM
They're Calibra/TR Astra/Daewoo Espero front brakes. SB Barina rotors are 236mm, these are 256mm and require atleast 14" rims. Caliper looks the same but it's different. Have TR Astra rear discs to go on too, but that's a bit more work involved.

Originals were so bad that they couldn't lock up with the new tyres, now I can lock them pretty easily.

MRMOPARMAN
11-02-16, 05:49 PM
Cool little project. Its interesting to see how interchangable euro gm stuff is. Will be a mad sleeper when done.

Sloth
12-03-16, 12:04 AM
im parting a gsi in a month or so. need any bits?

bugle
12-03-16, 09:06 AM
There are lots of gsi bits i'd want. But most of them would be too big to post, except maybe a later tacho dash with electronic speedo.

Sloth
12-03-16, 07:41 PM
dash and stuff is yours if you want. ill let you know nearer the time

crack
14-03-16, 02:07 PM
Great minds think alike! I'm doing the exact same thing with a cheap as 4g63 inlet mani atm.

Edit: your throttle body will just about fit inside the plenum opening lol

bugle
15-03-16, 12:00 PM
Sloth if there's any way to get side skirts and front seats to Sydney i'd be interested in those too.

Crack, yeah $150 can't go wrong. Bargain for a nice smoothly shaped plenum to chop up.
Except now I realised that the manifold interferes with the stock huge Bosch alternator. Going to have to convert it to a compact Denso type now.

Sloth
15-03-16, 04:07 PM
kubota tractors run a tiny alt that works. some rally guy in the uk told me.

Gammaboy
15-03-16, 05:10 PM
Same alternator is on 90's Suzuki swifts.

bugle
15-03-16, 08:52 PM
Yeah those look like the Denso ones. Used on every Toyota and Isuzu too.

Lobster
25-03-16, 06:26 PM
Is this finished yet?

bugle
26-03-16, 12:35 AM
Nah, but I lowered it with some king springs, fully sick.

Also got thicker swaybars from a gsi

bugle
28-03-16, 12:37 AM
I spent saturday working on this when I should have been fixing the Piazza, dammit.

New toy arrived on thursday, electric die grinder. Works really well.

http://starlyon.com/bugle/barina/turbo/grinder.jpg

Only used MIG for tacking shit. Final welding with TIG.

http://starlyon.com/bugle/barina/turbo/turboadapter1.jpg

http://starlyon.com/bugle/barina/turbo/turboadapter2.jpg

http://starlyon.com/bugle/barina/turbo/turboadapter4.jpg

Intake

http://starlyon.com/bugle/barina/manifold/intake3.jpg

bugle
28-03-16, 12:41 AM
Also the lowering

http://starlyon.com/bugle/barina/suspension/kingsprings.jpg

Lobster
28-03-16, 10:59 PM
Nah, but I lowered it with some king springs, fully sick.

Also got thicker swaybars from a gsi

Lows or Super Lows?

bugle
28-03-16, 11:34 PM
Lows, they don't do super lows for Barinas, not that I would've got them. It's low enough with these.

bugle
15-04-16, 03:49 PM
Started the TR Astra rear disc brake conversion, using a spare rear beam so I can swap it over quickly after it's ready, because the car is my semi-daily driver. Bonus is that the new one cost bugger all and included a thicker rear swaybar being from a GSi.

Made an alignment tool for the new stub axle mounts.

http://starlyon.com/bugle/barina/brakes/beam0.jpg

Modifying the plate mount to suit the different shape.

http://starlyon.com/bugle/barina/brakes/beam1.jpg

http://starlyon.com/bugle/barina/brakes/beam2.jpg

http://starlyon.com/bugle/barina/brakes/beam3.jpg

Got the tops of both welded, and one side of the left side, then I ran out of argon, dammit

http://starlyon.com/bugle/barina/brakes/beam4.jpg

bugle
20-05-16, 12:10 AM
Fully welded the things. Re-welded the handbrake guides on at an angle because the handbrake cable points up a bit now. Need to shorten the handbrake cable.

http://starlyon.com/bugle/barina/brakes/beam5.jpg

http://starlyon.com/bugle/barina/brakes/beam6.jpg

http://starlyon.com/bugle/barina/brakes/beam7.jpg

Painted the roof because I hadn't done it yet, and it had a few dents from some bogan walking over it. There was also a rust hole on the edge of one of the gutters which wasn't going to get any better so that spurred me on to do the whole job at once. Deleted the antenna too, because I can't remember the last time I listened to the radio.
Did it the same metallic grey as the bumpers just because I thought it might look ok. Painted the gutter strips the same colour will re-install them soon.

http://starlyon.com/bugle/barina/roof/Roof1.jpg

http://starlyon.com/bugle/barina/roof/Roof2.jpg

http://starlyon.com/bugle/barina/roof/Roof3.jpg

http://starlyon.com/bugle/barina/roof/Roof4.jpg

http://starlyon.com/bugle/barina/roof/Roof6.jpg

no13b_Coupe
20-05-16, 10:22 AM
Cool!

ALLMTR
20-05-16, 07:26 PM
I like!

milo
20-05-16, 09:56 PM
Are you going to get new plates? Those look out of place..

Sloth
20-05-16, 10:03 PM
reinforce the shock mounts on the beam, they have a habit of breaking off.

bugle
20-05-16, 11:17 PM
I also wanted some more practice with metallic. Going to try doing a whole car metallic blue next.

Sloth just welding it better should do?

I will probably get the plates remade in black or red at some point.

bugle
21-05-16, 09:45 PM
Done

http://starlyon.com/bugle/barina/brakes/beam8.jpg

http://starlyon.com/bugle/barina/brakes/beam9.jpg

bugle
12-07-16, 10:09 AM
I did a Skompa

http://starlyon.com/bugle/barina/blackbarina.jpg

Lobster
12-07-16, 11:24 AM
Gonna start all over again with a new car?

Gammaboy
12-07-16, 11:35 AM
Gonna start all over again with a new car?
Nah, he's going to build a panelvan out of them.

bugle
12-07-16, 11:36 AM
Nah bought it for some parts and to test fit the new engine, intercooler, do intercooler piping, wiring, ecu then transfer it all to the original one quickly.

bugle
12-07-16, 11:37 AM
Nah, he's going to build a panelvan out of them.

Damn, should've bought a Combo for parts!

bugle
12-07-16, 11:49 AM
In other news i'm likely taking the red one to Sydney Dragway tomorrow night to see how slow it is.

bugle
14-07-16, 12:26 AM
So that happened.

19.348@70.6mph
19.3@69.64mph
19.477@68.16mph
19.616@67.8mph

Did a 0.009s reaction on the 3rd run and won $100 for 3rd place in the reaction time competition.

Cusscuss's Supra ran a 12 and blew some kind of oil seal.

http://starlyon.com/bugle/barina/DragBarina.jpg

Sketchy
14-07-16, 08:57 AM
This is brilliant, I can't believe I'm enjoying a build thread on a barina. Excellent work as per usual.

Couple of tool related questions, what tig are you using and where did you pick up the electric die grinder? I want to port a few manifolds I have and my air compressor sucks dick.

no13b_Coupe
14-07-16, 11:37 AM
Mad

Jim
14-07-16, 12:19 PM
Haha
Cool build. Keen to see the engine swap.

bugle
14-07-16, 12:30 PM
This is brilliant, I can't believe I'm enjoying a build thread on a barina. Excellent work as per usual.

Couple of tool related questions, what tig are you using and where did you pick up the electric die grinder? I want to port a few manifolds I have and my air compressor sucks dick.

Thanks, funny people staring at me in traffic today with all the drag writing still on the car, I had added MCM stickers to the back window too. Do they think i'm Marty or something?

It's just a Chinese special "Super 200P" TIG, cost around $1000 on Ebay a few years ago, and so far have had no problems with it.

The grinder is this one http://www.ebay.com.au/itm/271201055537
It's pretty brutal if these carbide tools grab and bend though.

Gammaboy
14-07-16, 12:39 PM
The grinder is this one http://www.ebay.com.au/itm/271201055537
It's pretty brutal if these carbide tools grab and bend though.
How noisy is it?

bugle
14-07-16, 12:48 PM
Little bit less noisy than an angle grinder. It looks to be an angle grinder without the gears.

Gammaboy
14-07-16, 12:51 PM
Fixed speed?

bugle
14-07-16, 05:54 PM
Yeah, 27000rpm

bugle
15-07-16, 10:32 AM
So much squat
https://scontent.xx.fbcdn.net/v/t1.0-9/13669227_1239767032723260_6162726842464674536_n.jp g?oh=bab70f8e6a7eb624e11ab252b1f232c6&oe=58326C58

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpt1/v/t1.0-9/13654197_592437464250219_8604739957843091893_n.jpg ?oh=25508d7220f0dd23caaed5f2cd866b40&oe=5823F654&__gda__=1475515728_7dcab98aee6a56ac52be4605b2de2d4 2

krisr
15-07-16, 10:50 AM
Haha was it dead that night?

bugle
15-07-16, 11:05 AM
Yeah and it was going through pretty quickly, until the damn burnouts started.

F3ARED
20-07-16, 08:06 AM
:lol::lol::lol::lol::lol::lol::lol:

Fuck thats terribly slow. You going to put it on a diet first/try again or just move straight onto the power bits?

bugle
20-07-16, 09:40 AM
Nah not going to do any weight loss, just going to add more power. Hopefully the 1.8 on low boost will have triple the power of the 1.4. It only weighs 850kg stock.

bugle
03-08-16, 10:27 AM
This happened to the plenum, had to cut/shut it and trim it down so that the throttle body could fit between the cam belt cover and the strut tower. Made a new flange for 304 V8 throttle body

https://scontent.xx.fbcdn.net/v/t1.0-9/13680538_10153971433189263_4266227570193433546_n.j pg?oh=282ddb60b7fd199b35df9e9b5835df60&oe=5827F5E2

https://scontent.xx.fbcdn.net/v/t1.0-9/13681034_10153971433079263_509606990277506139_n.jp g?oh=78894664b3a3df7a4d15a00deb757d8f&oe=58279419

Sketchy
03-08-16, 12:15 PM
Awesome fab work as always. What settings are you using to MIG the alloy manifold?

Also, please incorporate a screamer sidepipe under the front bumper once the turbo is on.

Lobster
03-08-16, 12:33 PM
Lol. Flange.

bugle
03-08-16, 12:40 PM
Awesome fab work as always. What settings are you using to MIG the alloy manifold?

Also, please incorporate a screamer sidepipe under the front bumper once the turbo is on.

I'm using the TIG for it.
Also got an external wastegate for it because there's nowhere to put the internal gate actuator, so will have a screamer :)

dvs_5ltr
04-08-16, 12:12 PM
http://www.allcorsa.co.uk/forums/showthread.php/x18xe1-engine-conversion-11880.html#/topics/11880?_k=y43whl after seeing your work and reading this it's getting tempting to up the power in my little daily sb lol


Sent from my iPhone using Tapatalk

bugle
04-08-16, 01:25 PM
Yeah it's a worthwhile swap for any Barina even if just leaving it stock, since it's so easy, and cheap. I picked up the engine for $250

Lobster
19-10-16, 07:52 PM
Bump??

bugle
19-10-16, 10:27 PM
Nah still haven't finished the Piazza yet.. Soon maybe.

Lobster
26-12-16, 03:02 PM
So.... Now?

Sloth
26-12-16, 04:15 PM
lel

bugle
27-12-16, 01:36 PM
Yeah as soon as I can. Going on a holiday in a few weeks for a few weeks so I don't think much will happen before then.

Lobster
30-12-16, 06:21 PM
Leave Approved.

bugle
28-04-17, 12:54 AM
I'm trying to do more stuff on this.
The struts were worn out, so I got Koni yellows. Atleast when I try to do a skid now it spins the wheels smoothly instead of massive axle hopping, and it handles 100 times better.
http://starlyon.com/bugle/barina/suspension/KoniFront.jpg
http://starlyon.com/bugle/barina/suspension/KoniRear.jpg

bugle
28-04-17, 01:08 AM
Black Barina had a conversation with a sawzall

http://starlyon.com/bugle/barina/blackbarina/BlackBarinaChopped1.jpg
http://starlyon.com/bugle/barina/blackbarina/BlackBarinaChopped4.jpg
http://starlyon.com/bugle/barina/blackbarina/BlackBarinaChopped2.jpg
http://starlyon.com/bugle/barina/blackbarina/BlackBarinaChopped3.jpg

CA18escort
28-04-17, 01:13 AM
Gold, that is how you do weight reduction.

farmsci
28-04-17, 01:35 AM
Lol! Tell me there's a silly plan involving that one!

Sent from my E6853 using Tapatalk

Panda I give no fuck
28-04-17, 01:51 AM
Haha, that is going to need a phoneworthy. Awesome seeing some progress

InsaneAsylum
28-04-17, 10:29 AM
they came out of the factory like that
http://motordealersdirectory.com.au/vehicle_images/CDS/CDS1017/CDS1017_PYY824_5.jpg

bugle
28-04-17, 11:03 AM
Those Cabrios must've been so floppy. Even with a full shell if you jack it under the A pillar you can see the door gap changing and the latch no longer lines up.

No plans for the black one except to use some of the parts and to use it as a test fitment jig. It's just a front cut now.

Sketchy
04-05-17, 09:55 AM
So you're going to put some castor wheels under the back and do some epic FWD drift skids for our entertainment then?

bugle
05-05-17, 12:47 PM
So you're going to put some castor wheels under the back and do some epic FWD drift skids for our entertainment then?

Wish I had somewhere to do such fun stuff :(

bugle
01-07-17, 01:46 AM
I've actually done something!

I had a spare front nose cut bit which makes fitting an intercooler and radiator easy. The Barina radiator was too wide to allow for intercooler piping either side so I got a Astra radiator which is narrower but taller. Basically using it just for the core and i'm making new end tanks.

So here's the intercooler. 600x300x75 but had to cut one row of fins and a bar off the top, and weld some sharp bends to it. Only thing in the way with a non air conditioned barina is the outside air temp sensor and the horn. So i'll have to figure out somewhere for the horn to go to let out all the beep beeps.

http://starlyon.com/bugle/barina/turbo/BarinaIntercooler.jpg

Lobster
09-07-17, 10:56 PM
sweet

bugle
26-09-17, 12:17 AM
Got a chance to do some more turbo stuff. Removable section of wastegate dump is for quick screamer pipe swapping..

http://starlyon.com/bugle/barina/turbo/Turbo-1.jpg
http://starlyon.com/bugle/barina/turbo/Turbo-3.jpg

F3ARED
26-09-17, 08:51 AM
You are a sick, sick man Mr Armstrong...but i like it! How closely related to a Family II is the engine in terms of engine mounts? Would be hilarious in a Camira...

bugle
28-09-17, 12:13 PM
The engine mounts aren't the same but for a Camira you'd be better off with a Family II turbo engine like the Astra or Calibra engine. Camira with a full Calibra 4WD swap would be a cool sleeper!

Thought i'd stick with Family I to save a bit of weight and because of bolt in. Although the Family II conversion into a Barina (Corsa B) is common enough in Europe that you can buy engine mounts for it on ebay.

Lobster
04-10-17, 04:05 PM
Brake Update!

bugle
05-10-17, 10:41 PM
Yeah I finally installed the rear discs, pedal feels much better

http://starlyon.com/bugle/barina/suspension/Rearbeam/rear6.jpg

http://starlyon.com/bugle/barina/suspension/Rearbeam/rear7.jpg

http://starlyon.com/bugle/barina/suspension/Rearbeam/rear9.jpg

http://starlyon.com/bugle/barina/suspension/Rearbeam/rear10.jpg

Handbrake cable shortening :p
http://starlyon.com/bugle/barina/suspension/Rearbeam/rear11.jpg

http://starlyon.com/bugle/barina/suspension/Rearbeam/rear12.jpg

http://starlyon.com/bugle/barina/suspension/Rearbeam/rear13.jpg

Lobster
08-10-17, 09:42 AM
How far away do you reckon the turbo engine is?

bugle
08-10-17, 01:12 PM
I'll be unemployed after friday so will have a fair bit of free time and will try to finish this quick smart unless someone else gives me a job.

Sketchy
10-10-17, 02:01 PM
Nice. I love that the fab work is nicer than a large chunk of the proper nice cars on the forum (mine included :( ) That stainless turbo dump and screamer is workshop quality mint.

Bob Vegana.
20-10-17, 08:44 PM
Progress report?

I'm kinda keen to do one of these. Even though euro-GMs shit me up the wall, and the pedals are too close together.

Lobster
23-10-17, 09:59 AM
I'll be unemployed after friday so will have a fair bit of free time and will try to finish this quick smart unless someone else gives me a job.

That sucks.

http://starlyon.com/bugle/barina/suspension/Rearbeam/rear13.jpg[/

On another note. I didn't know you could buy momo brand tyres?

bugle
23-10-17, 09:42 PM
Yeah they're pretty good tyres, I think it was about $90 each fitted at St George tyres.
I've been doing a bit of stuff. Worst part about Euro GM stuff is the random mix between hex and torx bolts.

Made mounts for the smaller ex 4ZC1 Denso alternator.
Changed timing belt.
Got flywheel machined.
Started welding radiator and mounts then ran outta gas.
Made a custom banjo bolt for feeding turbo oil and can screw oil pressure switch into the head of it.
Bought a pipe bender and made oil feed hard line.
Made hose fittings for end of fuel rail.
Mounted fuel pressure reg.

Need to start assembling Megasquirt. Have a MS2 kit + boost control + 4x ignition coil drivers ready to go.
Turbo is too low to gravity drain to the sump so ordered a oil pump.

Will do a pic dump at some point.

bugle
25-10-17, 10:24 PM
Good news, I've been offered a job. More good news it starts in January so I have a holiday to concentrate on finishing this and hopefully make some good progress on the Piazza upgrade.

Lobster
26-10-17, 01:09 PM
Woo! a job. Congrats!

doink
07-11-17, 11:01 AM
Update?

bugle
07-11-17, 09:29 PM
Yeah today was the day I got the engine out. Got a VS Ecomoo to drive while this isn't working.

http://starlyon.com/bugle/barina/Engine/EngineIn.jpg

Nek minnit
http://starlyon.com/bugle/barina/Engine/EngineOut.jpg

Lobster
08-11-17, 10:51 AM
Sweet.

bugle
19-11-17, 10:18 AM
More pics

New Alternator mount
http://starlyon.com/bugle/barina/NewEngine/Alternator1.jpg
http://starlyon.com/bugle/barina/NewEngine/Alternator2.jpg

Had to adapt the Astra 5 rib pulley to the alt, with the correct offset
http://starlyon.com/bugle/barina/NewEngine/AlternatorPulley1.jpg
http://starlyon.com/bugle/barina/NewEngine/AlternatorPulley2.jpg

New water pump, seals, idlers, tensioner and belt
http://starlyon.com/bugle/barina/NewEngine/EngineFront.jpg
http://starlyon.com/bugle/barina/NewEngine/EngineFront2.jpg

Clutch, some heavy duty thing I got from the UK. "Kev-tek" clutch plate.
http://starlyon.com/bugle/barina/NewEngine/Flywheel.jpg
http://starlyon.com/bugle/barina/NewEngine/Clutch.jpg

Astra gearbox is slightly different where the rear mount attaches, has an extra mounting point between the two Barina mounting points which means the mount needs to be modified. Also had to swap in the Barinas cable clutch throwout fork, bearing and shaft. Astra has a hydraulic concentric slave setup.
http://starlyon.com/bugle/barina/NewEngine/Gearbox.jpg
http://starlyon.com/bugle/barina/NewEngine/GearboxMount1.jpg
http://starlyon.com/bugle/barina/NewEngine/GearboxMount3.jpg
http://starlyon.com/bugle/barina/NewEngine/GearboxMount2.jpg

bugle
19-11-17, 10:34 AM
Engine in

http://starlyon.com/bugle/barina/NewEngine/EngineIn1.jpg


Found out my measurements off the car weren't quite good enough and the throttle body was too close to the strut tower to fit a hose to it, so I had to cut off the flange and move it a bit.

http://starlyon.com/bugle/barina/NewEngine/Plenum1.jpg


Welded that up and welded a throttle cable mount. The VN moo cable had the same firewall/pedal end as the Barina one so that was easy.

http://starlyon.com/bugle/barina/NewEngine/Plenum2.jpg

Test fitting slim thermo fan, radiator, intercooler and turbo. The original fan is huge and doesn't allow any room for the turbo compressor outlet.

http://starlyon.com/bugle/barina/NewEngine/Plenum3.jpg


Might keep the chopped front bumper for the track. It's a 10 min job to change it. The original bumper only needs slight trimming to fit, not this extreme.

http://starlyon.com/bugle/barina/NewEngine/Intercooler1.jpg


Made an exhaust, 3 inch with a cheap varex style muffler. Still have to weld in a blocking patch at the turbo flange end, weld in O2 bung and have to change the tip for a straight pipe. For some reason the tip is 3" outer diameter but dual wall with 2.5" ID.

http://starlyon.com/bugle/barina/NewEngine/Exhaust1.jpg
http://starlyon.com/bugle/barina/NewEngine/Exhaust2.jpg
http://starlyon.com/bugle/barina/NewEngine/Exhaust3.jpg

crack
19-11-17, 12:15 PM
grass built stainless mandrel exhaust gets ultimate respect from me.

in retrospect, if you used the internal wastegate could you keep the main-turbo adapter thin enough to gravity oil drain?

second go at the inlet manifold is all too common when making custom parts haha.

bugle
19-11-17, 05:29 PM
I should've taken a photo of the makeshift hoist used for lifting the engine on to a trolley jack. Put a piece of wood across the chassis rails then a scissor jack on top of that with rope over it.

Nah i made the turbo adapter as thin as possible already. The two outlets on the manifold were too far apart to make it any closer.

I'm DJ!
19-11-17, 07:20 PM
This is beginning to come together. Well done.

Sketchy
21-11-17, 12:29 PM
Legit the most pimp exhaust ever seen on a Barina anywhere in the world.

As usual flabbergastingly good for a backyard job. Is your new job welding space shuttles or something?

Lobster
21-11-17, 01:48 PM
That engine looks pretty tough with the engine cover and inlet manifold together.

bugle
23-11-17, 11:07 AM
There are some pretty pimp Barinas in Europe though!
No I just work in IT like the rest of PF :)

Going to paint the manifold and all the piping wrinkle black. Hoping it will be pretty stock looking at first glance..

darwinschops
23-11-17, 02:02 PM
Awesome work man, will be an awesome little shopping trolley when done.

Bob Vegana.
17-12-17, 01:10 PM
Any updates, chief?

bugle
17-12-17, 11:02 PM
Have been working on it as much as I can but need to give nopics some attention too. Went on a holiday to NZ somewhere in there too.

Will post some pics but it's mainly just small shit that takes forever. Will post some pics soon.

Assembled the Megasquirt, made a circuit board that slots into the Megasquirt case which mounts the coil drivers and boost solenoid transistors. MS2 isn't originally setup to run coil on plug.
Have made a wiring harness starting from a multipoint injected Barina harness. Already had correct plugs for the TPS, idle stepper and coolant temp.
Sorted the turbo oil pump, made a little sump for the turbo and mounted the oil pump off the bottom of the gearbox, with it pumping oil up to the cam cover.
Made the intake piping, painted it wrinkle black and the plenum too.
Had to do a little modification of the heater pipe stuff.
Finished the exhaust, welded in O2 bung and pulled the inner wall out of the tip to make it properly 3".
Replaced the engine bay fuel lines with some new lines made up from steel. Originals are plastic and one had almost rubbed through at one point.

Other stuff
Replaced all bushes with Superpro polyurethane ones.
Had new whiteline steering rack bushes too, and a UK spec electric power steering rack which is the same externally so I can use it without power, just 2.7 turns lock to lock instead of something like 4 turns on the non power steering rack. So I swapped that in with new rack ends.

bugle
05-01-18, 11:53 PM
I've got it running, haven't driven it yet. Getting the Megasquirt set up took a bit of effort. Have it running wasted COP because I can't be bothered adding a cam input at the moment. The engine has a VR sensor on the cam as well as the crank so it can be done. Maybe in the future.
Also added tacho output circuit and boost control.

Still random bits to do, main fabrication thing left is some spacers for the swaybar because the turbo now occupies the spot where it went across the car.


Plenum

http://starlyon.com/bugle/barina/Engine/Plenum.jpg

Oil Feed off the pressure switch, still need to p clamp the line to the block

http://starlyon.com/bugle/barina/Engine/OilFeedBanjo.jpg
http://starlyon.com/bugle/barina/Engine/OilFeedBanjo2.jpg
http://starlyon.com/bugle/barina/Engine/OilFeedLine.jpg


Astra gearbox had nowhere to attach clutch cable, had to make this thing

http://starlyon.com/bugle/barina/Engine/ClutchCableMount.jpg
http://starlyon.com/bugle/barina/Engine/ClutchCableMount2.jpg


Radiator, this is a 32mm Astra core. Core is narrower than the Barina one which allows intercooler pipes to fit around the sides, it's slightly taller than the Barina one and the core is thicker. Using Barina lower radiator hose and Astra top one.

http://starlyon.com/bugle/barina/Engine/Radiator.jpg
http://starlyon.com/bugle/barina/Engine/Radiator2.jpg


Underneath showing turbo oil scavenge pump. It's hanging off the gearbox/engine mount. Had to get a one way valve to stop the oil running back into the turbo.
The lowest part is the sump plug, I don't know why they had to have it poking out the bottom like that.

http://starlyon.com/bugle/barina/Engine/EngineUnder.jpg
http://starlyon.com/bugle/barina/Engine/EngineUnder2.jpg
http://starlyon.com/bugle/barina/Engine/EngineUnder3.jpg


From above. Had to use an XC Barina coolant expansion tank due the original one not fitting with the new plenum. This also has a handy extra port in the top of it for turbo coolant return.
Will put wiring into conduit.

http://starlyon.com/bugle/barina/Engine/EngineTop.jpg
http://starlyon.com/bugle/barina/Engine/EngineTop2.jpg

Roadsailing
06-01-18, 06:41 AM
I've got it running, haven't driven it yet. Getting the Megasquirt set up took a bit of effort. Have it running wasted COP because I can't be bothered adding a cam input at the moment. The engine has a VR sensor on the cam as well as the crank so it can be done.

Just run wasted spark? Or is this going to red all the way to 11ty thousand?

bugle
06-01-18, 07:43 AM
Yeah it's wasted, but it has four individual coils so it seems a bit silly firing them twice as many times as they need to.

gtrboyy
06-01-18, 09:31 AM
Nice job on oil feed line!

Sump tanks for turbo seem to be the rage these days for the scavenge pumps.

bugle
06-01-18, 09:31 PM
Yeah the sump was pretty easy to make, unsure if it matters too much.

Made a short dose video


https://youtu.be/JeWaY5884s0

bugle
06-01-18, 09:52 PM
Also trimmed the original bumper to fit the intercooler. It's not too obvious, but then again it doesn't get as much direct air flow as I'd like.

http://starlyon.com/bugle/barina/Engine/Intercooler.jpg

BigJonWB
06-01-18, 11:35 PM
Sump plug would normally be a thin headed one with a female Torx hole in it. Tucks it up close to the sump.

Lobster
09-01-18, 10:28 AM
https://media.giphy.com/media/oiYnN3ba0YPkY/giphy.gif

WOU-SI-O!
WOU-SI-O!
WOU-SI-O!

bugle
15-01-18, 08:13 AM
I put it all together properly and took it for a drive on a base fuel & ignition map. It was stalling if the revs went too low, drove it for about 5km then pulled over to change something on the computer and it wouldn't start again so had to get rescued.
Ran fine while driving, just need to figure out why it won't start easily or run at low RPM. The MS2 is not liking the crank pickup signal 100% at idle RPM and while cranking. Maybe the sensor is dodgy as most problems people seem to have with VR sensors and MS2 is at high RPM.

Jim
16-01-18, 05:35 AM
Nice work! Awesome little car

krisr
16-01-18, 07:00 AM
What cable are you using for the vr pickup? Have you tuned the switch point and hysteresis pots on the VR input at all? R52 and R56 I think they were.

Sent from my SM-G930F using Tapatalk

bugle
16-01-18, 07:56 AM
It's a standard Barina shielded cable except I had to do a join to the Astra cable as it had a different plug. Astra cable was too short because the ECU is mounted to the intake manifold. I haven't adjusted those pots other than just setting them to full anti clockwise (I think) so i'll check them next.

no13b_Coupe
16-01-18, 09:28 AM
So you're bringing this to Geminats then ;)

bugle
16-01-18, 09:46 AM
So you're bringing this to Geminats then ;)

Maybe give this a go on the track if anyone drops out, will be surprised if I can get the Piazza going again by then.

krisr
16-01-18, 02:44 PM
Take a log and see if you're getting tooth errors causing sync issues. I've seen that cause stumbles and sometimes stalling which is usually noise or interference on the TachIn. See if this helps (from the docs):

"Optionally, when adjusting R56, you can measure the voltage at the "top" of R54. You'll need the board powered
up. Set your meter to volts, and connect the +ve probe to the top of R54 and the -ve probe to ground. Adjust
R56 to get around 2.5V on your meter."

If you're getting noise on the TachIn, this helps prevent the computer from thinking the noise is a tooth on the wheel and fucking up the trigger wheel signal. Keep in mind though, if it doesn't start, the air gap might be a bit too big between the sensor and the wheel so if you can't tighten the gap up
you might need to lower the voltage until you get a signal. If you have an analog meter or a scope you might be able to trace the peak voltage when cranking and set R65 about 0.5V below what you measure. Where does the shield get grounded? At the ECU end of the sensor end? (not both I hope).

HTH

krisr
16-01-18, 02:47 PM
Oh and if you're not running "Noise Filtering", try enabling it also. I usually enable it on all the cars I do. Distributor cars I'll also turn on Tach Period Rejection, but trigger wheels usually don't need it.

no13b_Coupe
16-01-18, 04:11 PM
Maybe give this a go on the track if anyone drops out, will be surprised if I can get the Piazza going again by then.

Yeah bring it to the cruise anyway. Piazza next year ;)

And yeah I'll drop you a line if that happens man.

bugle
18-01-18, 06:19 PM
I'll play with it on the weekend starting with logging. Started work last week so have limited time on it again, and the car is at my parent's house.
Have an analog meter and a scope if needed. The cable is only grounded at the ECU. Not sure if I can get the pickup any closer to the wheel, there's no adjustment as standard.

Many other non Isuzus going to the cruise Jonno?

no13b_Coupe
22-01-18, 10:08 AM
I'll play with it on the weekend starting with logging. Started work last week so have limited time on it again, and the car is at my parent's house.
Have an analog meter and a scope if needed. The cable is only grounded at the ECU. Not sure if I can get the pickup any closer to the wheel, there's no adjustment as standard.

Many other non Isuzus going to the cruise Jonno?

Yeah couple of datsuns. Probably a falcon or two a lame wrx.
Was talking to a fella up here who has a piazza as well. He's talking about bringing his MU down lol

bugle
27-01-18, 10:11 AM
Finally figured out what was wrong with the low rpm stalling. If I set the trigger to falling edge instead of rising edge it works perfectly. Have gone for a few test drives without a problem with it self tuning. Wastegate pressure with the lightest spring seems to be at 5psi (was supposed to be 7), added boost control to the MS2 so I can adjust that. I think the next spring up was 14psi which might be too much.

Feels pretty fast. Have never driven a fast FWD car before so torque steer is new to me.

Tidied up the wiring a bit.
http://starlyon.com/bugle/barina/Engine/EngineFinished.jpg

Sloth
27-01-18, 10:55 AM
i was thinking about this the other day. im about to sell mine. its done i just havent run it in anger. dirvorce means no toys.

hows the ms2 to set up etc?

awdmoke
27-01-18, 11:01 AM
That's way neater than factory. Nice work!

BLSTIC
28-01-18, 01:40 PM
If you're concerned about intercooler flow, post a few pics of the intercooler as fitted, the underside of the front bumper (looking up), the gap between the cooler and radiator, any gaps between them all and the body, etc. Enough to see any possible airflow path. I'm certain I could offer some advice to help with that.

My own car (A Suzuki Mighty Boy) had an engine swap and a front body kit that were poorly executed. It overheated in traffic, the fan operated until about 60km/h, and if you were overheating and then drove to 80km/h it took about a minute or two to come down to temp. With the application of some real estate sign and an old foam mattress (held on with zip ties) I dropped 80km/h cruise temps by about 5 degrees, any forward motion above about 10km/h didn't need the thermofans. If you were stopped at lights and it got hot enough for fans (which now took a while), it cooled down by the time you *got* to 80km/h, and generally solved all temperature problems. Air pressure across the radiator jumped by some 80% (meaning that airflow through it increased by around 40%). And I didn't even do it right. I could have got another 20-30% of airflow with another hours work, but it didn't need it.

I'm DJ!
28-01-18, 07:30 PM
Oh mighty boys are awesome kiwi bloke! Build thread? /It

This looks great man!

BLSTIC
28-01-18, 09:31 PM
Kiwi? Oh I mustn't have updated my info. I'm back in 'Straya now. No build thread, I didn't do the work and the car's gone.

Build thread on my 13's for $1300 all-motor AU though, I can do that.

InsaneAsylum
29-01-18, 08:27 AM
Finally figured out what was wrong with the low rpm stalling. If I set the trigger to falling edge instead of rising edge it works perfectly. Have gone for a few test drives without a problem with it self tuning. Wastegate pressure with the lightest spring seems to be at 5psi (was supposed to be 7), added boost control to the MS2 so I can adjust that. I think the next spring up was 14psi which might be too much.

Feels pretty fast. Have never driven a fast FWD car before so torque steer is new to me.

That looks bloody awesome, nice job.

It's not torque steer, it's activating the "surprise lane change" feature. It gets really funky in the wet :D

Guido
29-01-18, 09:42 AM
This is cool. Needs to be reshelled into a Combo van!

Bob Vegana.
29-01-18, 12:13 PM
*Cabrio.

Gammaboy
29-01-18, 12:18 PM
Pity we never got the Tigra.
https://parkers-images.bauersecure.com/gallery-image/pagefiles/190513/static-exterior/1752x1168/tigra6.jpg

Actually, looking at that pic, it's probably a good thing we didn't get it. Pity we didn't get the Puma.

turbo510
29-01-18, 07:19 PM
Pity we never got the Tigra.

But we got the later convertible Tigra so you can satisfy your desires
https://res.cloudinary.com/carsguide/image/private/t_cg_car_m/v1/car/0574/4263/2005_holden_tigra_used_5744263_1.jpg?version=15164 05743

no13b_Coupe
30-01-18, 10:19 AM
Apparently the HSV version is good?

bugle
30-01-18, 09:24 PM
i was thinking about this the other day. im about to sell mine. its done i just havent run it in anger. dirvorce means no toys.

hows the ms2 to set up etc?

Why no toys? Especially ones that aren't really worth any $.

MS2 is pretty easy to set up, having a distributor makes it simpler because it's not setup to run COP straight out of the box, but that's not hard to add.
But then again sometimes you run into a problem like what I had and it takes a bit of time to figure it out.



If you're concerned about intercooler flow, post a few pics of the intercooler as fitted, the underside of the front bumper (looking up), the gap between the cooler and radiator, any gaps between them all and the body, etc. Enough to see any possible airflow path. I'm certain I could offer some advice to help with that.

It doesn't have any overheating problems, just that about half the intercooler has no direct air flow, i'm sure it circulates up behind the bumper a bit. I don't think it matters much though after looking at the logs.

Did some tuning tonight, got it running 7psi and tuned decent through the whole power and cruise range up to redline and it's pretty damn fast.

Datalogs say the intake temp was 27 degrees on boost and ambient was maybe 1 degree lower than that, temps don't seem to rise at all with boost anyway. It only got up to 40 degrees with the car sitting idling.

bugle
30-01-18, 09:29 PM
Pity we never got the Tigra.

Actually, looking at that pic, it's probably a good thing we didn't get it. Pity we didn't get the Puma.

I don't mind the Tigra front stuck on a Corsa though
http://starlyon.com/bugle/barina/corsabtigra.jpg

bugle
30-01-18, 09:49 PM
How's this for no lag? This would be 2nd gear starting at 2600rpm up to 5500rpm with slight wheelspin

http://starlyon.com/bugle/barina/log.JPG

CussCuss
31-01-18, 07:51 AM
Was along for the ride when tuning last night. This is a stupid, ridiculous car and I love it. The in gear response is insane, accelerating to pass someone and you easily end up at twice the speed as intended. The thing makes boost free revving in neutral. Also makes all sorts of fknwhoosh noises, pretty much all the time because its instantly on boost.

The 1.8 N/A makes over twice the original HP, so at 7psi or so, would be about 3x the original barina power.

Will try to get some videos in daylight.

Gammaboy
31-01-18, 08:58 AM
I don't mind the Tigra front stuck on a Corsa though
http://starlyon.com/bugle/barina/corsabtigra.jpg

Yeah, that works!

bugle
31-01-18, 04:39 PM
Wonder how much power I'll need to run a 13. Rego says it weighs 820kg, I might've added around 50kg to it.

BLSTIC
31-01-18, 05:58 PM
http://www.torquestats.com/modified/index.php?pid=calculator&action=calculate_bhp_weight&drive=FWD&weight_bhp_selector=weight&weight_bhp_value=1000&time_selector=1%2F4+Mile+ET&time_value=13.9&submit=Calculate

According to that, which seems to be within acceptable errors for a Falcon (210hp, 1700kg, rwd, generates a 17.3 sec 1/4 mile,) you'll need around 210hp at the flywheel. So if we're talking metric wheel-killer wasps, about 110 of them

BLSTIC
31-01-18, 06:09 PM
It doesn't have any overheating problems, just that about half the intercooler has no direct air flow, i'm sure it circulates up behind the bumper a bit. I don't think it matters much though after looking at the logs.

Did some tuning tonight, got it running 7psi and tuned decent through the whole power and cruise range up to redline and it's pretty damn fast.

Datalogs say the intake temp was 27 degrees on boost and ambient was maybe 1 degree lower than that, temps don't seem to rise at all with boost anyway. It only got up to 40 degrees with the car sitting idling.

That seems suspiciously low, but the intercooler is fairly big and even with zero airflow a core that big and heavy can store an awful lot of heat before the cold side gets hot. Given the moderate boost level that could take a long time at WOT. Let me know if it heats up going up long hills or something.

bugle
01-02-18, 06:05 PM
I don't think there is a hill anywhere that I can get on it for long enough without exceeding the speed limit enough to lose my licence.

I think it can do more than 110kw at the wheels easily.

BLSTIC
01-02-18, 06:59 PM
Well, you've effectively build a lower boost, smaller, Astra turbo motor.

http://www.torquestats.com/index.php?car_id=605

2003 Astra turbo. 147kw, 1250kg. 15.17 @ 93mph

Astra turbo runs 12-13psi on a 2L engine, so unless your car holds on to its torque really well high in the rev range, you will have less power, but you weigh 400kg less.

T28 is apparently good for 250-260 odd hp at 15psi, so you shouldn't run out of turbo before you run out of conrod or cams

bugle
01-02-18, 08:21 PM
It's higher compression than the Astra Z20LET though. This runs 10.5:1 and the Astra is 8.8:1.
Probably helps with eliminating turbo lag and more low rpm power, but i'm going to be limited with how much boost I can run.

6000SUX
01-02-18, 08:35 PM
Mr Bugle...... I used to own an SB Barina GSI in the early 2000's that we used for recce in the Australian Rally Championship. I've long since sold the car BUT I still have a set of Murray Coote Proflex suspension from it. They've been sitting in my garage for a long time so they may need some attention but if you want them then they're yours. All you need to do is pay for the freight or arrange for it be transported to you. They are in Camp Hill, Brisbane. PM me if you're interested!

bugle
01-02-18, 09:31 PM
I'd buy that for a dollar!
Sent you a pm

BLSTIC
01-02-18, 11:00 PM
Water injection? Octane on demand

bugle
02-02-18, 07:12 PM
Yeah I could try that. Hadn't considered it before.
I'll probably end up with another engine and building it for more boost eventually..

dvs_5ltr
04-02-18, 12:40 PM
Hey mate just a quick question what drive shafts have you used


Sent from my iPhone using Tapatalk

bugle
04-02-18, 02:23 PM
I used the original shafts

Komdotkom
08-02-18, 04:22 PM
Mr Bugle...... I used to own an SB Barina GSI in the early 2000's that we used for recce in the Australian Rally Championship. I've long since sold the car BUT I still have a set of Murray Coote Proflex suspension from it. They've been sitting in my garage for a long time so they may need some attention but if you want them then they're yours. All you need to do is pay for the freight or arrange for it be transported to you. They are in Camp Hill, Brisbane. PM me if you're interested!

Fuck me, they must be the only set ever made! Great pickup for this thing.

6000SUX
12-02-18, 12:33 PM
I found them!

http://www.performanceforums.com/forums/attachment.php?attachmentid=104723&thumb=1&d=1518402497

bugle
13-02-18, 11:15 PM
Sweet thanks, let me know how much I owe you and where to send it!

6000SUX
20-02-18, 11:44 AM
Mr Bugle... check your pm's! I need a physical address for the courier!