Cottees' 1987 Sigma GN GSR Super Edition

[Cottees]

Since the building of the elbow isn't going as planned, I took a break from it today and made a start on the power steering.

The bracket mounted for the pump.


The Sigma now has handsfree.


The size difference between the manual and power steering columns. I may get another power steering one since the one I have at the moment has a loose ignition and broken steering lock.


Time to get the old manual steering box out.


Don't usually see this side of the brake master cylinder.


It has started to rust a little behind the steering box, so I'll give it a spray with anti-rust paint.


Cleaned up under where the box sits.


All but the steering column is now installed.

[Cottees]

New vs old pedals.


New pedals from a GSR now installed. It has a foot rest built in.

[Cottees]

I picked up a narrow KM132 today, thanks GB_BB4C!
If I can get all the parts together to bolt it straight in within 2 months, I'll install the transmission during my annual leave.

[Superscan811]

I picked up a narrow KM132 today, thanks GB_BB4C! If I can get all the parts together to bolt it straight in

Problem, it's a Narrow AND short gearbox..
The GN would normally be a long gearbox.

Cheers.

[Cottees]

Problem, it's a Narrow AND short gearbox..
The GN would normally be a long gearbox.

Not too much of a problem, I have a wide KM132 from a GK GSR. Should just be a matter of changing over extension housings.

[Cottees]

Gave taking off the extension housing a try, and failed. Not sure exactly how to take it off, so I took off the bottom plate to get a good look at the gears. The gears in it look to be pretty good. Rotated it around and checked it's teeth, and there is no visible sign of anything broken. It all shifts nicely, so it should co-operate when I finally get it into the Sigma. One thing I saw that I was concerned about, is that I thought that the manual transmission 'fluid' was meant to be a fluid, not thick like I found. Then again, it is the first time I have had a close look at a manual transmission.

[Cottees]

The power steering is all in and from limited testing, is working perfectly. It isn't registered at the moment, so I couldn't take it for a drive, but was able to drive it around the front yard at low speeds, and turning the wheel was effortless. Since the stock steering wheel was starting to come apart, I put the steering wheel from my GJ GSR into the GN.

[Cottees]

Success! I was going to try and pull more of the Transmission apart tomorrow (Tuesday), but got bored of waiting, so gave it another go. Everything on this side also looks good too.

[ISKA8]

she is getting there buds..

[Cottees]

This Sigma is all working again, just needs to be registered.

Thought I'd post a couple photos of the narrow vs wide yokes.

[Cottees]

Comparison between the long, short and short short extension housings.



got the pics of the trans that I don't have from here : http://www.cardomain.com/ride/758764/19 ... 200/page-2

[Cottees]

New Video : Pulling onto the NExy (Northern Expressway) doing 80, then accelerating to 100. This time I had the radio off so the engine note can be heard properly.

http://www.youtube.com/watch?v=D_3jaasxhR4

[cozer82]

you should film it ripping a burnout

[Cottees]

you should film it ripping a burnout

lol, na, it is still auto, and doesn't want to do burnouts.

This is a bit if a boring update, but the Sigma has just ticked over to 180,000kms. Almost didn't make it since I almost got side swiped by a mini bus earlier in the day.
http://www.youtube.com/watch?v=OIon_KfrEt4

[Cottees]

Having second thoughts of having the Magna TR engine and Starion JA suspension and parts in my car. Tried it today with them, and the car was slow, and slow to brake.

[Cottees]

I just got home to be welcomed by the latest piece that'll be going into the Sigma.


As a bonus, it was packed with a heap of Japanese newspaper from earlier this year.

[ISKA8]

I just got home to be welcomed by the latest piece that'll be going into the Sigma.


As a bonus, it was packed with a heap of Japanese newspaper from earlier this year.

nice thing to come home to..

[Cottees]

I am now in the process of planning out what exactly I am going to be doing with the SC14 I have just got. Before doing too much planning, I have been researching the SC itself, and how it operated when on it's original car. The SC14 I have got is a newer one off a Toyota Previa, or as we call them in Australia, Toyota Tarago. The engine it is off is a 2TZ-FZE. That is a 2.4L inline 4. So putting it on a 2.6L inline 4 isn't too much of a stretch. The earlier SC14s, which are pretty much the same spec as the later ones, were fitted to the 1G-GZE 2.0L inline 6 that was in the early Crowns, MarkII, Chaser, etc. Then there is the the SC12 which was on the 4A-GZE 1.6L inline 4 which was in the early Corollas and MR2s. Anyway, back to the SC I have. I wanted to find out how Toyota mounted this SC to the 2TZ-FZE to give me ideas on how I could mount it to my 4G54. It turns out that the SC is not attached to the 2TZ-FZE at all. In the Previa, the engine is on an almost 90 degree slant and sits near the middle of the car, and the SC is mounted to the front of the car and is driven off a accessory drive shaft that also drives the alternator, ac, etc. The same place I found that info also explains how the SC14 is meant to operate which will give me a good idea on how to set it up without killing it.

This is the PDF I got the info about the later SC14s:
http://ww2.justanswer.com/uploads/skyvi ... previa.pdf

Here is some info on how the SC12 on the 4A-GE works:
http://web.archive.org/web/199910131319 ... h/TCCS.htm

[Cottees]

I am going to take the Sigma off the road in a while to do some much needed work on it. Here is some sneak peek pics into a couple of things that I'll be changing. These aren't final plans, but ideas i have been playing with.

[Cottees]

Cottees' handy tip of the day: DO NOT use your finger to test for exhaust leaks.

This will happen other wise.


But I did take something positive out of it. There IS a leak in the manifold gasket, so I promptly bought one.


Hopefully that'll keep her going till I take her off the road to do some much needed repairs and improvements.

[Cottees]

So today I have the time to change the exhaust gasket on the Sigma. I know first hand (ha ha) that the exhaust is leaking, but when I went to take out the first nut for the manifold, I saw this :



Once that was all fixed up, I took out the gasket, and it had indeed blown where I suspected it had :

[A112H]

Hey cottees, whats the deal with the short little guy at your work, the one with the 80's man-perm? He seems like a bit of a twit.

[Cottees]

Hey cottees, whats the deal with the short little guy at your work, the one with the 80's man-perm? He seems like a bit of a twit.

LOL, he is a good bloke. I think that is his natural hair. When you are at my work, you are meant to check out my Sigma (and Lancer in a month or so), not the employees!

[A112H]

Some of the female employees are certainly worth checking out
I do usually have a nosey at the Sigma if I see it, I am looking forward to checking out the Lancer, looks good in the pics

[Cottees]

Some of the female employees are certainly worth checking out

Anyway, back on topic. I have updated my first post with the latest stuff, and also I have provided links to parts of the thread. Since it is around 17 pages long, it is a little hard to go through them all to try and find one part of my build.

[Astron Boy]

Good to see you've made a fair bit of progress on this.
Keep up the good work, be interesting to see your SC outcome now!

[Cottees]

Today I did some more towing with the Sigma. Maybe a little more than I should have done, but the GN passed with flying colours.

First was to move a GJ GSR. As soon as I knew I was going to be towing a Sigma with a Sigma, I had to do this:


GN + Trailer + GJ GSR would have been around 3,200kg total.

Then it was time to move a van. That ended up totalling 3,600kg.


The trips covered flat and hilly roads. On the flats, it was ok. Struggled a bit up hill, but did it without major problems. The only problems that were had were all when going down hill. Along the Southern Express Way, going down hill, doing 80-100km/h, the car started back firing pretty badly. The other problem was coming to a stop on Montague Road. It is on around a 5% grade, and the car started sliding down the hill while trying to stop. Ended up with smoke coming from the wheels and/or brakes. Even on that grade, it was able to hold all around 3,600kg with just the foot on the brake. Decided to put in the hand brake just incase.

I wont even mention how the GN slung shot the van into some letter boxes, while trying to free it from where it was being stored...

But all in all, the Sigma towed it just fine, and still runs afterwards.

[51gk]

It's not a problem, it's a feature! Auto accelerator! I will eventually move it somewhere more suitable.

haha nice thinking

[GC75]

keen to see what you do with the sc14 mate

[Billsy]

thats a good case of massive overloading and dangerous driving.
if a cop had seen you towing that you could have been up for one massive fine.