My GE Sigma Build

[78Sigma]

Hi,

this is my build for my GE Sigma, i got it completely factory right down to the AM/FM radio, it has a 4g32 with a 4 speed but plans are to get a 4g63 and 5 speed in over the next few weeks

When i got is


the following weekend

[78Sigma]

Last night i started to redo the rear brakes,mainly because the cylinders were seized and did no braking at all. But got in there and went to start pulling it apart and sure enough the parts i got were wrong

I also noticed that there is no return line from the motor to the tank so have to get one before i start the swap. but there was a fitting coming off the tank. can someone please confirm this can be used.

this is the fitting on the tank it had a blanking cap on it

[78Sigma]

New fuel return line in and ready for the 2L, i got 5 meters thinking id have heaps left over but after all the twists and curves under the car there was only about 1.5 meters left. I also got the correct bits for the rear brakes so that's tonight's job.

[78Sigma]

so While waiting for my clutch to arrive i have been doing a few little things like i now have rear seat belts and have tinted the inner headlights yellow, they will be crap but they look good.

[Scorpma82]

Congrats on the swift progress of your car....coming along nicely

I'd be making those oil line a bit more discreet tho by running the lines behind the bumper bar...... (thats just me being paranoid of people vandalising the car tho)

[78Sigma]

Thanks, there not hooked up at the moment but once I get the 2.0L in I'll get it sorted. I didn't want to make it suit the 4g32 and then have to change it again.

[Taz]

Why run them behind the bumper?
Classic Japanese muscle look, look far better in front than behind ;)
I'll be doing this with the lc once the new engine goes in...

[Scorpma82]

Pretty much from what I said previously..... Paranoid that some moron would vandalise/steal the lines and cooler.....or get damaged by an oblivious passer by etc

[jvflash]

Classic Japanese Muscle??? The car was designed, built and exported from Australia.
Team of Australians went to Japan with their mock ups, and some of that team still work at MMAL. But that's as close as you get.
As for Australian Muscle Cars, I'm not sure Sigma rates a mention.

[Taz]

Didn't say the car was Japanese muscle, just said that gives it the look and personally I like the style. Obviously everyone's different and others don't like it, was just expressing my opinion

[Scorpma82]

Classic Japanese Muscle??? The car was designed, built and exported from Australia.
Team of Australians went to Japan with their mock ups, and some of that team still work at MMAL. But that's as close as you get.
As for Australian Muscle Cars, I'm not sure Sigma rates a mention.

Depends on ur definiton of "muscle"
The only real reason why the Sigma isn't deemed as a muscle car (that i can tell) is that there was no N/A hi-po, limited run version of the car....and it has no racing pedigree..(where every muscle car had the chance to actually "flex it muscles")

But all the elements are there......late 70's styling, lots of chrome, big cube motor, plenty of torque, manual and auto options, rear wheel drive...ability to develop the car to your own specs

[78Sigma]

Clutch arrived today just went with a Exedy standard clutch but with the silver Japanese cover.

Also got a little carried away with the spray paint but owell got plenty of bits to change it later if it looks crap.

And got a set of extractors on the way super happy I didn't really want to use the factory manifold as it had a couple of cracks welded.

Just a few more little things done so it looks better like replace the old ripped gear boot with a nice new leather one with white stitching I'll get some pictures tomorrow in the light.

[Scorpma82]

What did ya paint up

[78Sigma]

Rocker cover, the base of the distributor, thermostat housing and water pump pully I painted them with vht anodized base coat, basically silver with a flake to it.

[Scorpma82]

Looks good....... Nothing wrong with going crazy with paint

[jvflash]

Love the passion, and great job by the way. For all those who want to have a go at my comment, then great I like your opinions, I don't think anyone here has a deliberately negative opinion. Also realise I like following all projects and appreciate that your car is your car, style it, build it, as you want it.

78Sigma - keep up the effort man, next time I'm in NZ I look forward to seeing it cruising.

[78Sigma]

Thanks

Sorry for all the photos but i think visuals are the best way to explain. anyway i needed to change the tail housing on the gearbox as the one i had sat the shifter too far back and had a quick look on how to do it and haughty id show how i did it.

i took off the shifter (8 bolts) and undone the bolts on the side (the centering things) be careful as there are springs in there, then undone the bolts holding on the tail housing, knocked out the pin and then maneuver the selector shaft and hey presto shes off. I haven't put it on the other box yet apparently can be a pain.

Take this off




Take out bolt in the side and where you can see the hole is where the pin came out of


This is the pin

[Taz]

When you put the engine back in make sure to take the rocker off the motor or that chain will take a few chunks of that nice new paint with it. Seen it happen a million times with friends cars.

[78Sigma]

Will do thanks for that.

Last night I got the gearbox back together and yes it can be frustrating but when a mate turns up it makes things easier.

I also got the old engine and gearbox out and put the clutch on the 4g63.

Also I found out her name the other night when I removed the back seat it had a name under it "Wendy" not my preference but I'm not going to change it.

Before


During


After


Her name

[78Sigma]

IT'S ALIVE

I got home on Friday night after work and got the motor out, then Saturday bolted gearbox to motor and dropped it in, all bolted up to factory 4g32 mounts and there was extra bolt holes in tunnel as the gearbox mount sits back but all mounts were there. Just got to figure out the wiring for the alternator and weld exhaust to the extractors and then go for a drive

[78Sigma]

Also if you are changing the tail housing on the gearbox it is worth noting there are to output shaft sizes and that in turn means there is 2 different seal sizes. The one I used was a 89 ute tail housing on a 83 gearbox so I needed a seal with a od of 52mm and a id of 32mm but I didn't know that until it was too late and I had gearbox fluid down my driveway but owell these things happen.

[78Sigma]

Hey guys

Haven't done alot to the car now that the 4g63 is in but just wanted people to know if you do the swap you will need a longer speedo cable, today I went to pick a part (self help wreckers yard) and got one out of a 93 L200 2.6L 4g52 and works a treat. Just another thing no one tells you lol. Just need to do the reverse lights as the one in the box is missing the wires.

[78Sigma]

got some lowering springs yesterday, i went with cobra as i have had them in the past and always had a nice ride (softer than king springs). it has dropped it about 30-40mm both front and rear and loving it, however all springs have become un-captive and need to get shorter ones. My question is has anyone had this same problem and if so what shocks did you use? Its kind of hard to take the old ones out and take them to a local bnt or repco as it is my daily.

[Sigmaproject]

Is that the factory twin horn setup ??? They are freaking huge. Stick a couple of later horns in behind the radiator support and make the under bonnet area much less cluttered.

[Sigmaproject]

got some lowering springs yesterday, i went with cobra as i have had them in the past and always had a nice ride (softer than king springs). it has dropped it about 30-40mm both front and rear and loving it, however all springs have become un-captive and need to get shorter ones. My question is has anyone had this same problem and if so what shocks did you use? Its kind of hard to take the old ones out and take them to a local bnt or repco as it is my daily.

Mid 80's Nissan Skyline/Pintara strut inserts have 30mm less piston stroke than a sigma insert. The body is also shorter and will require a spacer to be dropped inside the Sigma strut body. (around 40mm from memory). The 30mm less travel may save your bacon at the front. These measurements are for the struts on my GN wagon ..

[78Sigma]

i dont think they are factory, a old boy had it before me and he did some cool stuff like the horns and kill switch. i like them

ill have a look and see if i can find online sizes for the GE

[78Sigma]

Not much been happening except little things like i am on my 3rd alternator and second gearbox lol.

Also i fount Hiace rear shocks are shorter and work then R31 front shocks with a spacer work a treat.

But i just picked up a 4g54 and gearbox last night and was thinking about putting it into the sigma but now i think i will pull out the 4G63T that i put into the ute and put the 4G54 back in its place then tidy up the 4G63T and put that into the sigma, it's not going to be a big job as everything has been set up for rwd all ready so all i need to do it "massage" the firewall to allow the cas to not rub, wire it in, put a fuel pump in it, make an exhaust and plumb intercooler piping... so kind of a big job but the motor is done lol.

Next question is what have people used for a better diff? mine is ok at the moment but when not if but when it breaks i want to upgrade without too much hassle.

[78Sigma]

I have managed to score a set of starion strut/hub assembly and on my shelf at home have a set of new rotors and rebuilt calipers so looks like i am putting in a starion front end .......... if i ever get time to start lol

Also i have started to buy little goodies to make this better looking (and fingers crossed performing). I picked up a evo 3 head cheap, a evo 6 manifold and got a 70mm evo 9 throttle body, also on the shelf is a "HKS" fuel rail that i will put my 510cc injectors into and then it should be a good base to start from.

On a recent trip to auckland i picked up a rev counter cluster, light dimmer switch and the chrome door lock surrounds from a 1978 GSL Sigma now i can finally get rid of the tacho that is taking up space in the center console.

[78Sigma]

Not much of an update but i picked up a chin spoiler the other night so then decided to mock up how it would look on the car, and it didn't turn out too bad. i am still yet to make up metal tabs to secure it on, i don't want to drill extra holes into the body but then again i don't think i will take it off so drilling holes may not be such a big deal.

[78Sigma]

Small update

i have decided i want to drive this for another summer so the DOHC Turbo swap i on the back burner, however i took the car for a drive and then couldn't stop, eventually when i stopped i popped the bonnet and sure enough the master cylinder was empty so out with the old and in with the new and while it was out it was a good time to take out the booster and give it a paint because it was flaking off due to leaking fluid



also i picked up a roof rack but it needed some work and after 3 hours of using a wire brush it doesn't look too bad but i need to make some mounting brackets and paint it