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Old 28th June 2009, 15:30   #31
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Thanks rmonie for your interest

The vehicle was throughly checked for corrosion points and integrity of chassis.
Weak points in chassis and body are identified and the chassis strengthening is also getting done.
Meanwhile the engine block and GB were sent to machine shop and the mating was done without using the adapter plate. The top two hole matched perfectly and two holes were drilled in the engine block to match the bottom studs.

As of now we are planting MGP clutch of maruti king.
Got plans for petroworks performance clutch plate in the second phase.

The work for extending the water outlet/inlet is in progress. I am confused on the material for tubing(i don't want to use long rubber tubes).
The OE water outlet is Al-alloy.So searching for Al-alloy tubes.

Decided to go for powersteering also ( I am forced by my friend to install PS)
So now searching for a Jimny's PS box

Current brain teasers.
How to get a speed signal input to the baleno ECM after the transplant?
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Old 28th June 2009, 19:03   #32
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Originally Posted by MexXxentric View Post
The vehicle was throughly checked for corrosion points and integrity of chassis.
Weak points in chassis and body are identified and the chassis strengthening is also getting done.
hi MexXxentric,
a 4x4 dragster .

nice mods (along with steady progress).
are you planning to do off roading with your MG 416W?

i want to know what will be done to chassis in strengthening process.
if possible share the cost for strengthening of chassis.

& best of luck
Nikhil
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Old 1st July 2009, 23:46   #33
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Originally Posted by jeepster View Post
hi MexXxentric,
a 4x4 dragster .

nice mods (along with steady progress).
are you planning to do off roading with your MG 416W?

i want to know what will be done to chassis in strengthening process.
if possible share the cost for strengthening of chassis.

& best of luck
Nikhil
Nikhil,
Thanks..
I am not a hard core offroader who takes his vehicle to mud every month.
But I will be doing off-roading once in a while, where ever my route demands.

4x4 Dragster??
I want a weekend pickup which is fun to drive & capable of taking rash driving through rough terrains.

Strengthening - means giving support pieces at required points and reinforcing the welded joints of all the mounting points in the ladder frame(engine, GB,transfer case & Suspension)so that the chassis can take new engine's additional power.

I will post the economic aspect of the project once I complete first phase.
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Old 7th July 2009, 00:10   #34
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Default Rust Proofing Options

Has any one tried zinc epoxy paint?
or Fiber coating?

What is the general procedure for rust proofing
What all options do we have in south India?
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Old 13th July 2009, 12:48   #35
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Default Non corrossive paint

Has any one tried zinc epoxy paint?
or Fiber coating?

Gents Zinc Epoxy is widely considered for high temp. service.
whereas Fiber Coating is Polyeurathane family Epoxy.

Any paint system you follow is having a limitations over application. you cant just simply use any thinner, primer and top coat over each other except specified.

In my view Go for Zink Epoxy for Engine bay coating, followed by Coal Tar Epoxy for underbody corrosion protection and for External Paint I suggest not to go with any Fiber / PU base as it is quite costly and definitely you will be often going for Offroading so vehicle will require frequent touchups.

Zinc and PU both are going to cost you.

Welcom to the world of Painting, Coating & Corrossion ressistance.
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Old 18th July 2009, 23:53   #36
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Default Power Steering Box

I was combing through scrap yard(UAE) got a nice deal on P.S box ( Koyo Japan Make for 50 DHS; approx 650 rupees)
The shop wallah assured that its RHS steering box. Experts, can you please confirm.
Attached Thumbnails
Project MG 416 W-dsc00654.jpg  

Project MG 416 W-dsc00657.jpg  

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Old 19th July 2009, 00:35   #37
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picked it up from Shj or Dxb?
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Old 19th July 2009, 01:01   #38
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@mexxxentric :

I am not an expert but this seems to be the same box that i have used in my power steering project . The only thing different is the pitman arm. here have a look at these pics. The third pic shows the mounted steering box. My mechanic said that in the particular steering box that I hadacquired, the length of the pitman arm was absolutely suited for my gypsy going into it without any modifications. Can you see if you can get one more box at dubai ? I will need it for my second gypsy. Did you also happen to come across a pump. Check out the pics of my koyo pump too and the finished assembly.

Could you also find out from your scrap wala regarding the vehicle from which your steering box came from ?

regards,
Abheek

P.S : your box seems to b in a better shape than my box.
If yours is a jimny box, then you shouldalso search for the mounting of this box and the mounting of the pump with the pump too.
Attached Thumbnails
Project MG 416 W-ps-box.jpg  

Project MG 416 W-ps-box2.jpg  

Project MG 416 W-ps-box3.jpg  

Project MG 416 W-ps-pump.jpg  

Project MG 416 W-ps-pump2.jpg  

Project MG 416 W-ps-pump-mounted-cistom-brackets.jpg  

Project MG 416 W-ps-pump-mounted-cistom-brackets2.jpg  

Project MG 416 W-pscompleted-assembly.jpg  


Last edited by abheekg : 19th July 2009 at 01:13.
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Old 19th July 2009, 10:16   #39
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Quote:
Originally Posted by Parm View Post
picked it up from Shj or Dxb?
SHJ, A shop near GK roundabout. exclusive for suzuki parts

Quote:
Originally Posted by abheekg View Post
@mexxxentric :

I am not an expert but this seems to be the same box that i have used in my power steering project . The only thing different is the pitman arm.

PITMAN ARM IS THE SAME NA? i feel so. I can see tat extra 'ear' on it both.


here have a look at these pics. The third pic shows the mounted steering bx. My mechanic said that in the particular steering box that I hadacquired, the length of the pitman arm was absolutely suited for my gypsy going into it without any modifications.

COOL, THATS HAPPY NEW FOR ME. thank you very much for the pictures.

Can you see if you can get one more box at dubai ? I will need it for my second gypsy. Did you also happen to come across a pump. Check out the pics of my koyo pump too and the finished assembly.
Could you also find out from your scrap wala regarding the vehicle from which your steering box came from ?

THE STEERING BOX BELONGS TO SUZUKI ESCUDO. EASILY AVAILABLE
THE ONLY ISSUE IS 'HOW TO GET IT TO INDIA' It weighs close to 10kg.
If there is a collective need, say 5 or 10 units, i can organize shipping( I don't know if someone is doing it as a business.If so they are the best to approach)

I have a P.S pump that came with Baleno engine along with mounting. need to check if it can feed this Koyo unit. else i will be getting original koyo pump also.


P.S : your box seems to b in a better shape than my box.
If yours is a jimny box, then you shouldalso search for the mounting of this box and the mounting of the pump with the pump too.
Does the steering box require a mounting? i thought that it was directly bolted to the chassis frame.
The scrap wallah told me that it might need a wedge type shim to adjust the angle.

another surprising fact. Suzuki Jimny's P.S box costs 250 Dhs. the only difference i could find was the Pitman arm,( z link type). I was in a mind set to fabricate the pitman arm when i took the item.
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Old 20th July 2009, 02:56   #40
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Quote:
Originally Posted by MexXxentric View Post
SHJ, A shop near GK roundabout. exclusive for suzuki parts
Great ! I'll send my contact this detail.

Quote:
Originally Posted by MexXxentric View Post
Does the steering box require a mounting? i thought that it was directly bolted to the chassis frame.
The scrap wallah told me that it might need a wedge type shim to adjust the angle.

box will require some holes to b drilled to the chassis and then on it wil b a bolt on job.

Quote:
Originally Posted by MexXxentric View Post
BOX BELONGS TO SUZUKI ESCUDO


.
You sure of this as the escudo came with a rack and pinion power steering. Can you recheck.
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Old 22nd July 2009, 13:11   #41
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Originally Posted by abheekg View Post
box will require some holes to b drilled to the chassis and then on it wil b a bolt on job.

I AM THE HAPPY MAN

You sure of this as the escudo came with a rack and pinion power steering. Can you recheck.
I asked for Jimny RHD's steering box and the guy(pakistani) came with a similar koyo box having a different pitman arm like in the picture and quoted 250Dhs
When we bargained on the price and told him about our requirement, he turned up with the box(which i bought) for 50Dhs, which he said to be from escudo. the price difference was due to availability issues.
As you said, escudo got R&P steering.I shall recheck.
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Old 22nd July 2009, 23:24   #42
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Quote:
Originally Posted by MexXxentric View Post
I asked for Jimny RHD's steering box and the guy(pakistani) came with a similar koyo box having a different pitman arm like in the picture and quoted 250Dhs
When we bargained on the price and told him about our requirement, he turned up with the box(which i bought) for 50Dhs, which he said to be from escudo. the price difference was due to availability issues.
As you said, escudo got R&P steering.I shall recheck.
Feel great for you.
In the ,meanwhile please do further enquiry regarding the availabilty of the escudo boxes and the escudo pumps too. I do have a requirement of 2-3 units and mayber for some more in the further coming months.
Please get back to me on pm regarding this. . Please feel free to comment and contribute.

I have posted a video report of post PS installation issues that I am facing here http://www.team-bhp.com/forum/modifi...ml#post1392981 (Power steering for Gypsy.)
Please feel free to comment and contribute.

Thanks.

Abheek
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Old 23rd July 2009, 16:46   #43
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Default Got the pump

Went to the scrap yard area again to get the PS pump.
This time, they really sensed that demand is high on my side. Naturally the price went up.
I had to part with my savings that was made on steering box.
300Dhs ( Rs. 4k approx.) for the pump with mountings alone.

But the pump is a bit different from Abheek's.
The scrap dealer assured that this pump is the one which feeds the Koyo box.

A CORRECTION - MY STEERING BOX IS FROM VITARA. NOT FROM ESCUDO.( this time he said so )

There is one lead(wire) starting from the pump(1st & 2nd pictures). what is this for? Any idea?

On the trip, I've located another shop which exports components to India.
Then happened to be out of stock as they shipped just 4000 P.S units to India the previous day.
P.M me for the shop's contact number.
Attached Thumbnails
Project MG 416 W-dsc00658.jpg  

Project MG 416 W-dsc00661.jpg  

Project MG 416 W-dsc00663.jpg  

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Old 23rd July 2009, 23:49   #44
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Hey even i am planing to install PS in my gypsy,any idea where i can get this unit in bangalore
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Old 24th July 2009, 03:40   #45
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Quote:
Originally Posted by MexXxentric View Post
Went to the scrap yard area again to get the PS pump.
This time, they really sensed that demand is high on my side. Naturally the price went up.
I had to part with my savings that was made on steering box.
300Dhs ( Rs. 4k approx.) for the pump with mountings alone.

But the pump is a bit different from Abheek's.
The scrap dealer assured that this pump is the one which feeds the Koyo box.
Why, what happened to the baleno pump ? why did u decide to use this new pump over the baleno pump ?

Quote:
Originally Posted by MexXxentric View Post
A CORRECTION - MY STEERING BOX IS FROM VITARA. NOT FROM ESCUDO.( this time he said so )
Ok. One confusion clears and the other begins :
From what I have studied, newer vitaras came with rack and pinion steering mechanisms while the older vitaras had such steering boxes.

It may mean that you may have ended up with the box of the old vitara and the pump of the new !!
Let me confirm this from my friends in maruti and I will update on the thread.

Quote:
Originally Posted by MexXxentric View Post

There is one lead(wire) starting from the pump(1st & 2nd pictures). what is this for? Any idea?


From what I have read about Ps mechanisms on various suzuki vehicles on the net, I feel that the steering gear box of newer vitaras consists of two sections: one including a cylinder
and the other a valve. Main components of the cylinder section
are a gear box, a rack and a tube and those of the valve section
are a valve case, a sleeve and a stub shaft. The sleeve is linked with
the pinion through a pin and the valve and stub shaft are integrated
into one unit. Then the pinion and the stub shaft are linked to each
other by means of the torsion bar.
Thus, when the stub shaft moves, the valve changes its position,
thereby switching the hydraulic passage from the pump to the cylinder
to help steering operation.
When turning the steering wheel feels heavy due to P/S fluid leakage
or for some other reason (i.e., when in the manual steering
mode), the stub shaft and pinion are in direct linkage and the force
is output directly through the pinion and rack.

As the discharge rate of the P/S pump increases in proportion to the
pump revolution speed, a flow control valve is added to control it so
that the optimum amount of fluid for steering operation is supplied
according to the engine speed (driving condition).

The pump that you have procured seems to come from a newer version of the vitara and the leads that you see may be the connections that give feedback to the ECM of vitara. This pump may be a part of the newer electro-hydraulic power steering systems that are found on many vehicles these days.
I will try to look up the manual of the vitara and update on the thread.


I am not an expert. But you never know.

Quote:
Originally Posted by MexXxentric View Post
On the trip, I've located another shop which exports components to India.
Then happened to be out of stock as they shipped just 4000 P.S units to India the previous day.
P.M me for the shop's contact number.
Thats great.
Could you enquire about the bulk price of a pump-box assembly too ?
Wud be great to have this info while bargaining with mayapuri guys.
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