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Post by DoItSidewayz on Jun 16, 2005 7:40:15 GMT -5
Lightened Flywheel = 12 lbs (stock was 22)
Custom Strengthened Pressure Plate = 1200 Lbs (stock was 600)
Custom Kevlar Clutch Disc
You almost need 2 feet on the clutch, but man does it hook up.
a brand new stock clutch would not hold boost in any gear.
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Jun 18, 2005 0:37:42 GMT -5
I have not lightened my flywheel that much, to prevent stalling and to keep up heat absorbtion properties. But I have changed the pressure plate to a stiffer one as well. Iam using a stock clutch disk now, and in 4wd, it did not slip even when I tried 14 Psi! I had the surfaces machined well, and the clutch pedal is much softer than what it used to be now, as i have heat hardened the previous one with use . No more cursing in traffic for me now, at first it felt like the clutch cable had snapped, it is that soft . How did you adopt a Kevlar Clutch? From which car was it originally intended for?
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Post by DoItSidewayz on Jun 21, 2005 15:58:20 GMT -5
It was custom made. I took them an old core, and they installed a Kevlar friction surface.
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Post by baron on Jul 4, 2005 7:00:33 GMT -5
any idea on cost for the new clutch/pressure plate? i know you all deal with the $$$ but it could give me an idea to calculate
Dan
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Post by DoItSidewayz on Jul 4, 2005 15:36:00 GMT -5
was around $300 Canadian Dollars
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Jul 9, 2005 7:47:39 GMT -5
Unfortunately, my #3 rod bearing did not take the power, and now I have a bad rattle there. I need to disassemble the engine, and put new bearings in. I had replaced them 1000km ago, and it seems the standard bearings can not take more than 12 Psi , even with lowered comression. I am now looking for a stronger replacement. If I can not find one, I 'll install OEM again, and keep both boost and revs down. So much for high boost with the EDM engine...
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Jul 10, 2005 8:46:17 GMT -5
Hey sidewayz, happy birthday BTW...
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Jul 12, 2005 15:43:52 GMT -5
OK, I opened up the block, and it was NOT the bearings. #3 piston melted. The other pistons are allright, and this one seems the mixture was lean. this one has the thermostat on the intake manifold, so I suspect the mixture was not healthy there. It is very stange that #1 cylinder showed rich, and #3 was lean! Meanwhile, I have looked at the Subaru Van pistons and they have a dish at the center. I checked, and assebled the block with them, adn they are a good fit. The parts list shows the piston ring numbers the same. So they go in, lowering the compression to around 8.3:1 now. I also took advice, and now I have an EXEDY clutch disk! It was a bit hard to find, but it turns they manufacture one for Justy, and it goes in. Will take a week to reassemble my block and put it in. New headgasket and piston rings everytime I open up is a real PITA. but my dear Justy will come out fine I guess. ..
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PL
Posts: 9
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Post by PL on Jul 12, 2005 22:20:53 GMT -5
Hi Subieguy here is my little .02 cents....
Melted piston results from too much knock
Knock results from running too lean
Since Justy engines don't have knock sensors, unlike most modern cars, you should consider investing in a Widband O2 sensor that can also record so you can better fine tune your fuel curve....
Do you have an EGT gauge (exhaust gaz temperature) this could be a very very good indicator that you are going lean and might save you an overhaul....
Good luck, keep us up to date, im going to check a Justy tomorrrow night, 2-door 4wd injected white 700CAD $.....
later,
PL
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Post by DoItSidewayz on Jul 12, 2005 23:50:34 GMT -5
Exedy clutch disc is a simple piece to find....they made the stock one...Exedy/Daikin is the same company...
Now....you need to remember that the only thing that adds stress to the bearings is RPM. Boost will have no affect at all on the bearings.
my bet is you were running way lean....my stock fuel injectors run out of steam at around 4 psi of boost (go to 100% duty cycle). there's no way the factory carb can give you enough fuel for 1 bar.
Also...people get WAY too hung up on compression ratio. The only reason people reduce compression when turboing is to decrease the likely hood of knock/detonation. The only reason you get knock is if your timing is too far off, or you have too much heat/lean. If you have proper Air/Fuel ratios, and are not knocking, you could basically run unlimited compression, and unlimited boost.. Assuming ofcourse you don't blow the head off the thing.
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Jul 13, 2005 4:03:52 GMT -5
It was not easy for me to find the Exedy clutch. All I could find were some aftermaerket crappy discs. So I am happy I found one here in Ankara. So, now with the lessons learned, I am lowering the RPM,s as with the turbo, the engine can not take that much power above 6500 or so... I used to run 9000's without the turbo for more than 3 years daily, without a single problem. But it is a whole different subject when turbo gets in... For advance, I used to have +13 degrees before, and I reduced down to 7 when I put the turbo in. But I guess I need to find a way to decrease dynamic advance (both centrifugal and vacuum). A boost retard seems logical here right? One problem I had is, when I opened up the head, #1 cylinder had soot and showed overrich, while #3 was greyish, and had severely detonated. I guess this is mainly due to the manifold design, which incorporates the thermostat on the #3 runner, along with the fan switch. So , now I will perhaps go the "MegaSquirt" route with fuel injection, or just keep the boost down, revs down and continue with the carb setup. I was already building the MS box for a Ciciv project, but it may end up in my Justy. Or I might lok for another carburetor, perhaps from a 1.8 subaru? Thanks for the suggestions, will let you know how it goes.
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Jul 27, 2005 1:47:54 GMT -5
New Pic: New Van e10 pistons installed, lessons learned. (Hopefully)
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Post by baron on Aug 2, 2005 3:04:37 GMT -5
im loving the justy SubieGuy!
justy88carb, are you in the UK?! i am and i dont like citroens much. i have also been after a bike carb conversion for at least a year now, but like others dont know what to do with the manifold, please could you inform us what you had done with this so we can sort out what is required for the modification!!
cheers, Dan
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Aug 2, 2005 14:45:33 GMT -5
Thank you! I too had thought of cutting the manifold, plug up water pathways, and weld on runners to each carb. But getting the length equal would be a real hard thing to do, and the stock manifold is really hard to duplicate. I too would appreciate a "photo essay" on how this has been done. I know the World Speed record holder guys at subaru America have done it, but no details are available.
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Post by baron on Aug 3, 2005 6:25:49 GMT -5
i was wondering how far up the waterways go on the manifold? i cant remember what it exactly looks like but could it be done by chopping off the ends and welding new pipes onto it to an equal length? or could it be done by making a new manifold to bolt onto the current manifold? it might involve alot poking through the bonnet and excess metal before the cylinder head, but it could be done that way i suppose? it might save having the same length pipes too? otherwise im gonna aim for the 'plug the waterways' and have 3 inlet pipes to a bank of carbs. ive read its easier to make up a manifold to suit the bank of carbs rather than make new linkages to fit the manifold and set up. but they are talking about 4 cylinder conversions where you can split them into pairs as well... i was thinking for a carb donor i will look at a Triumph daytona speed triple. im guessing here but i think it is actually a 3 cylinder motor. i have to do some research on it i think!! its that or find a single cylinder 1000cc bike or something and just slap that on! ...a chance would be a fine thing
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Aug 4, 2005 5:39:59 GMT -5
Making a new manifold to bolt on the current would not work, as the stock manifold is a 3to1 cast design. You need individual runners of equal length, and cutting the original at a point, then welding on pipes with flanges, and then making up water passages with aluminum pipes... It clearly is a lot of work... I would guess matching the manifold flange with water passages and manufacturing a housing for the thermostat would be really hard to do. Finding a carb is the easy part. Older units from 1200cc bikes, Mikuni single carbs and all carbs from Triumph triples would do fine. Even if you have a four cylinder setup, you can easily remove one from the linkage,and bolt that on. Then, you need to calibrate all three carbs simultaneously and synchronize...
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Post by baron on Aug 4, 2005 7:38:16 GMT -5
the calibration im not even going to try!! theres a couple of guys over here that have the nack with them and its one of their specialities. i just need to work out/ find out if the manifold thing is going to mess up my plans or cost me hundreds of pounds to pay for, or even worse both!!
when i get some time here i think i will scan the article on them in on the computer and put it on the web to link to, its what gave me the buzz and something to aim for when i realised someone can actually do it.
it does seem alot of hassle though, but the results would be mega!!!
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Oct 19, 2005 8:36:52 GMT -5
I have now installed new WRX seats! It took some fiddling to get them to fit, especially as the original seats have one side higher than the other in mounts. They sit slightly higher than the old seats, and are much more comfortable. I am in Turkmenistan now, so I will post pictures when I get back to my car.
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Post by maltajusty on Oct 23, 2005 23:54:16 GMT -5
Congratulations for the excellent work that you have done. I intend to upgrade the carb and go for an Alfa Romeo down draft type of carb. I have a question about the upgraded coil, what brand did you use and can you give me further detail on this item.
Thanks and keep up the good work. Ray
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SubieGuy
The guy who put a boxer in a Justy. :)
Posts: 191
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Post by SubieGuy on Oct 31, 2005 8:24:40 GMT -5
Congratulations for the excellent work that you have done. I intend to upgrade the carb and go for an Alfa Romeo down draft type of carb. I have a question about the upgraded coil, what brand did you use and can you give me further detail on this item. Thanks and keep up the good work. Ray Thank you Maltajusty. I need to change the carb as well. Still I need to find a R5turbo or a similar factory turbocharged carburetor. Finding is the hard part in my country, implementing is easy. For the coil, I picked one from Demon Tweeks Catalog, along with the resistor box, and installed that in place of the original coil. It really is easy to install. I used to have many burned points in the ignition. Along with new condensers, I just adjust the original points, and they work fine.
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