Thanks TerrA
Edited by Viper, 01 October 2010 - 07:47 AM.
Gemini Coupe Rebuild!!!
Started by
_Viper_
, Jan 07 2008 11:18 PM
203 replies to this topic
#176
_Viper_
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Posted 01 October 2010 - 07:47 AM
hah cheers josh where you in a Torana? if ya were in ya commo I woulda just mistaken you for every other commonwhore driver
Thanks TerrA
Thanks TerrA
#177
_Viper_
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Posted 04 October 2010 - 01:37 PM
Well yep BARDUP was seen to have sexual connotations and to be offensive but the new ones arrived today 
#178
_BAILLIE_
_BAILLIE_
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Posted 06 October 2010 - 11:16 PM
Could do with those flares being filled out properly tho.
Oh you mean like this???
Also hit the drags tonight and managed a new personal best.... from 13.8 to 13.3! all I changed was rear wheels and 3psi more boost (15psi)
FARK YEH!
That's exactly what i'm talking about, that looks nuts!
Now you just need the other half of your motor and you'll be set
Jokes mate, i love Gemmys and i still miss my old TD wagon. For a while i wanted to get the plates: HALF.V8
But that wouldn't have been right, it's less than half. Can't get a 3.2 litre V8. hehe.
They are mad fun with a four banger and they weigh next to nothing so don't need much work really.
Apparently even with V6s they twist the chassis.
#179
_Viper_
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Posted 10 October 2010 - 03:29 PM
Done a few small things not worth mentioning but I also sussed out my rear flares today and what needs to be done...
This is how it currently sits, Rides ok but scrubs at times and is quite high.
Now If I go over a large bump or if I tried to lower it it hits like this which is only up about 25mm
But as you can see I cut the guards out and I should have about 100mm to play with.
So took the springs out and dropped it down on the bump stops (well with the 17's it doesnt quite reach the bump stops is about 5mm off)
Anyway this is how the flares should be sitting which gives clearance all the way round even on bumpstops... Havnt decided yet if it would be better to start from scratch or to extend the current flares.
Then just out of curiosity I pulled the stands out and sat it on the ground, Me like...
Hopefully I can find a pro willing to do it for me, Im not so keen to do it myself as I dont think I would get the proportions right.
This is how it currently sits, Rides ok but scrubs at times and is quite high.
Now If I go over a large bump or if I tried to lower it it hits like this which is only up about 25mm
But as you can see I cut the guards out and I should have about 100mm to play with.
So took the springs out and dropped it down on the bump stops (well with the 17's it doesnt quite reach the bump stops is about 5mm off)
Anyway this is how the flares should be sitting which gives clearance all the way round even on bumpstops... Havnt decided yet if it would be better to start from scratch or to extend the current flares.
Then just out of curiosity I pulled the stands out and sat it on the ground, Me like...
Hopefully I can find a pro willing to do it for me, Im not so keen to do it myself as I dont think I would get the proportions right.
#180
Stinga
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Posted 10 October 2010 - 08:41 PM
would look awesome that low, and i like the new wheels too. good luck in getting the ride height sorted
#181
_Viper_
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Posted 31 October 2010 - 09:41 PM
Few Photos my mate took with is speccy Camera, Fish eye lens I think its called.
Thats me standing there btw.
Thats me standing there btw.
#182
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Posted 20 December 2010 - 11:24 PM
Well had my first attempt at racing on the weekend... I wasnt really that fast but had an awesome time! The tail end was very slippery. I had just re-fitted my adjustable rear swaybar and afterwards was pointed out I had it on the 2nd hardest setting when I thought it was on the 2nd softest (6 settings) oops But was a great day and im keen to get out on the track again.
Here's a couple of vids from one of the runs...
http://www.youtube.c...h?v=tpoSkM53o5g
http://www.youtube.c...h?v=XlPW3Ky55O4
Here's a couple of vids from one of the runs...
http://www.youtube.c...h?v=tpoSkM53o5g
http://www.youtube.c...h?v=XlPW3Ky55O4
#183
Potta
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Oh My, Don't you post alot
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Posted 24 December 2010 - 02:54 PM
Not much room to arc it up there but you did well for a first run.
#184
_Viper_
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Posted 08 March 2011 - 05:07 PM
Wow March already. Took the Gem to motorvation and had a great time But I blew the diff and the clutch at the same time :S
New Clutch Thanks to Neil
Had been collecting bits and peices and working out how im going to do it for awhile but figured it was time to get the Hilux diff conversion done. Is mentioned a couple pages earlier but since the Gemini have a Torque Tube and no upper trailing arms standard I had to design and make a new way to locate the diff from scratch.
This is the first main part of the conversion, Custom front crossmember which bolts to where the stock torque tube used to mount and it provides the mounting locations for the upper arms to the body.
Next were to make the custom arms, I got the parts from Mcdonalds Bro's, worked out the exact lengths and angles I needed them gave them to Embleton Engineering for him to bend and weld on the bush ends.
The black peice of wire near the top was my Dummy arm which I cut to length and bent to shape and what I told Embleton to make the arms as.
Sent the Hilux housing and my Gemini housing to Final drive for him to weld on the Gemini lower control arm mounts, shorten the diff and put Holden ends on so I can use my VN-VS commodore rear disc setup, also order Custom Moser Axles from Phil
I got the housing back and welded on the upper mounts
Then got the completed arms back from Embelton
Test Fit time:
Also picked up a Detroit Tru-Trac Center from Ebay, brand new still in the box for $500, cost me $300 to have it setup and fit to the front carrier with new bearings and everything
Got everything powdercoated
Now since I had everything stripped from the rear end and I didnt get a chance to when I painted the car I decided to strip the floor back to bare metal and paint it, nothing too flash just nice and neat, used a combination of wire wheel on the grinder and a little sandblaster I have.
Before:
Metal:
After:
Only did the back half of the car as ill do the rest when I pull the motor out next.
New tailshaft and Axles finally arrived
Stock Gemini 23 Spline vs Hilux 30 Spline
All done! Well almost goto finish fitting brakes
Went for first test drive not long ago, Was so nice to go around a round-a-bout and not have the locker jumping about... Everything felt normal, but the diff center was making a little bit of noise, mainly during part throttle... I dont know if these need to be run in? or whats the go, gonna speak to the guy who set up the center for me and see what he thinks. Have not tested the LSD fuctionality yet (done a skid) due to the noise and wanna make sure everything is right before I give it too much of a hard time.
New Clutch Thanks to Neil
Had been collecting bits and peices and working out how im going to do it for awhile but figured it was time to get the Hilux diff conversion done. Is mentioned a couple pages earlier but since the Gemini have a Torque Tube and no upper trailing arms standard I had to design and make a new way to locate the diff from scratch.
This is the first main part of the conversion, Custom front crossmember which bolts to where the stock torque tube used to mount and it provides the mounting locations for the upper arms to the body.
Next were to make the custom arms, I got the parts from Mcdonalds Bro's, worked out the exact lengths and angles I needed them gave them to Embleton Engineering for him to bend and weld on the bush ends.
The black peice of wire near the top was my Dummy arm which I cut to length and bent to shape and what I told Embleton to make the arms as.
Sent the Hilux housing and my Gemini housing to Final drive for him to weld on the Gemini lower control arm mounts, shorten the diff and put Holden ends on so I can use my VN-VS commodore rear disc setup, also order Custom Moser Axles from Phil
I got the housing back and welded on the upper mounts
Then got the completed arms back from Embelton
Test Fit time:
Also picked up a Detroit Tru-Trac Center from Ebay, brand new still in the box for $500, cost me $300 to have it setup and fit to the front carrier with new bearings and everything
Got everything powdercoated
Now since I had everything stripped from the rear end and I didnt get a chance to when I painted the car I decided to strip the floor back to bare metal and paint it, nothing too flash just nice and neat, used a combination of wire wheel on the grinder and a little sandblaster I have.
Before:
Metal:
After:
Only did the back half of the car as ill do the rest when I pull the motor out next.
New tailshaft and Axles finally arrived
Stock Gemini 23 Spline vs Hilux 30 Spline
All done! Well almost goto finish fitting brakes
Went for first test drive not long ago, Was so nice to go around a round-a-bout and not have the locker jumping about... Everything felt normal, but the diff center was making a little bit of noise, mainly during part throttle... I dont know if these need to be run in? or whats the go, gonna speak to the guy who set up the center for me and see what he thinks. Have not tested the LSD fuctionality yet (done a skid) due to the noise and wanna make sure everything is right before I give it too much of a hard time.
#185
_dirtbag_
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Posted 08 March 2011 - 05:16 PM
Looks cool mister!
You're lucky you don't live up here, there's no way you'd be able to run those top links up here legally. Not allowed to have bends in suspension components.
Great work though. Quality build!
You're lucky you don't live up here, there's no way you'd be able to run those top links up here legally. Not allowed to have bends in suspension components.
Great work though. Quality build!
#186
_Quagmire_
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Posted 08 March 2011 - 05:31 PM
Well yep BARDUP was seen to have sexual connotations and to be offensive but the new ones arrived today
hey clint
fix your fence m8t
#187
DanWA
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Posted 08 March 2011 - 05:50 PM
Yeah sadly that top arm conversion won't go anywhere near a pit inspection!!
But as usual, great quality work Clint! I've watched this car transform a crapload over the years.
I was going to go trutrac i just don't like the idea of 1 spinning up before the other locks
But as usual, great quality work Clint! I've watched this car transform a crapload over the years.
I was going to go trutrac i just don't like the idea of 1 spinning up before the other locks
#188
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Posted 08 March 2011 - 06:53 PM
the standard bottom arms are bent from factory. And I visited a Engineer before I did anything and showed him my plans and he has already approved it, told me to get it all sorted, bring the car in and he will sign it off. Even asked if he wanted me to add extra bracing around the bend but said nah its fine.
Have had varied opinions on the tru-trac, but most of the guys saying negative stuff had never actually driven with one... I'll let you know how it goes when I give it a proper workout.
Hah and actually half of my fence has blown over, waiting for insurance to get their ass in gear and fix it! lucky ive got good neighbors
Have had varied opinions on the tru-trac, but most of the guys saying negative stuff had never actually driven with one... I'll let you know how it goes when I give it a proper workout.
Hah and actually half of my fence has blown over, waiting for insurance to get their ass in gear and fix it! lucky ive got good neighbors
Edited by Viper, 08 March 2011 - 06:57 PM.
#189
_L32M20_
_L32M20_
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Posted 08 March 2011 - 08:05 PM
hey clint ,thats the best gemini ive ever seen! freakin awesome job mate.id kill for one like that. just sold my windowless td van .may as well have given it away .damn.
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#191
_Viper_
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Posted 08 March 2011 - 10:45 PM
Haha Cheers Jimmy, I dont think its the best gemini ever tho.
#192
_BAILLIE_
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Posted 08 March 2011 - 11:56 PM
Nice work mate.
Smashed the old gear to bits and then upgraded
Smashed the old gear to bits and then upgraded
#193
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Posted 18 April 2011 - 01:48 PM
Well well not much has happened at all since I been working away for last 6 weeks, In Dunsborough now so its just a little too far to come home for one day on the weekend. But came home on Sat and have a 10 day break 
Was greeted at the door by a big box containing these:
After alot of research for some decent shocks found there was nothing local that would suit, closest thing was Koni Yellow but could only get them for the rear and are only 1 way adjustable.
Anyway I found that the Kadett C in europe share the same shocks as us so I ordered a set of 28 point, 2 Way on the car adjustable Spax shocks from the UK and actually ended up a resonable price $700. considering a set of Koni reds (1 way adjustable and have to be removed from the car) are like $620 a set.
Now just goto sort out adjustable front and rear swaybars then hit some track days and get everything dialed in.
Was greeted at the door by a big box containing these:
After alot of research for some decent shocks found there was nothing local that would suit, closest thing was Koni Yellow but could only get them for the rear and are only 1 way adjustable.
Anyway I found that the Kadett C in europe share the same shocks as us so I ordered a set of 28 point, 2 Way on the car adjustable Spax shocks from the UK and actually ended up a resonable price $700. considering a set of Koni reds (1 way adjustable and have to be removed from the car) are like $620 a set.
Now just goto sort out adjustable front and rear swaybars then hit some track days and get everything dialed in.
#194
_stretchlc_
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Posted 18 April 2011 - 04:45 PM
Awesome Build Thread mate.......Love your car, and its evolution to what it is today I was looking at the picture attatched and thought that the Gemini next to yours looks brilliant with the silver grille and headlight surrounds.......really looks like a mini hatchback torana from the front!.....any ideas to follow suit with the front on yours???
Keep up the awesome work
Cheers stretch
Keep up the awesome work
Cheers stretch
#196
_BAILLIE_
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Posted 19 April 2011 - 09:55 PM
Done yet?Now just goto sort out adjustable front and rear swaybars then hit some track days and get everything dialed in.
#197
_Viper_
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Posted 19 April 2011 - 10:45 PM
haha by Sort out I mean track down where I can buy some, Well for the front anyway.... Ive got a adjustable one for the rear but doesnt fit with the Hilux diff. But been told suspension places can bend up custom ones easy enough.
Wouldnt be hard to paint the grill and surrounds grey... but not sure if it would be better. Might be worth swapping with Darren to have a looksie first
Wouldnt be hard to paint the grill and surrounds grey... but not sure if it would be better. Might be worth swapping with Darren to have a looksie first
#198
_Viper_
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Posted 24 May 2011 - 11:54 PM
Small update, working towards getting the car ready for engineering... I think its just about ready...
Since I had the diff shortened the handbrake cable brackets didnt fit anymore so had to fabricate some new ones. Also had to get the cable modified but got all that sorted and finished today.
I also bought a Tube flaring tool about a month ago as Brake lines etc was one thing I could not do myself... Untill now
Got it from Eastwoods in America for $200odd
Does nice bubble, Single and Double flares in various size tubes.
Made up the brake lines to suit the new diff, they polished up really easy too.
Couldnt get a photo with them fitted as was too dark.
But I think its pretty much ready now... Oh still need to setup my blow off valve as a plumb back and fix the last bit of rust in the car (boot floor)
Since I had the diff shortened the handbrake cable brackets didnt fit anymore so had to fabricate some new ones. Also had to get the cable modified but got all that sorted and finished today.
I also bought a Tube flaring tool about a month ago as Brake lines etc was one thing I could not do myself... Untill now
Got it from Eastwoods in America for $200odd
Does nice bubble, Single and Double flares in various size tubes.
Made up the brake lines to suit the new diff, they polished up really easy too.
Couldnt get a photo with them fitted as was too dark.
But I think its pretty much ready now... Oh still need to setup my blow off valve as a plumb back and fix the last bit of rust in the car (boot floor)
#199
_Viper_
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Posted 19 October 2011 - 04:30 PM
This is actually old stuff but I forgot to update it before:
Finished the brakes lines and handbrake cable.
Bulletproof Diff: Check
Bulletproof G/box: Check (well almost, not fitted yet)
Bulletproof motor: Nope
Anyway what Im trying to get at is I bought a New gearbox
Its the Big Supra 154 Box thats usually behind the 3.0L Turbo motors and apparently handle big horsepower. This one has had a Rodeo bellhousing modified and bolted on so it will fit behind a 4Z motor.
Gear rations seem nice too with a longer 1st and 2nd gear and Much longer 5th which will be great for cruising
First Gear: 3.250:1
Second Gear: 1.955:1
Third Gear: 1.310:1
Fourth Gear: 1.00:1
Fifth Gear: 0.753:1
TF-TG petrol 5 Speed
3.790:1 - 1
2.175:1 - 2
1.417:1 - 3
1.000:1 - 4
0.855:1 - 5
3.826:1 - R
I stripped down a E1 block I had and sent it to the machine shop a few months ago now. Still have not got it back but they should have it by my next break in a few weeks.
Block Machine Work
-Crack test block
-Sonic test block
-Line hone mains
-Grind/polish crank
-Face block
-Bore and Torque Plate Plateau Hone
-Balance Rotating assembly
Head Work
-Crack and Vac test
-Face head
-New valve guides
-3 Angle Valve seat grind
-Oversize Stainless valves
-Steel Rockers
-Custom Cam
-Port work
Engine Internals
-Stock Crank
-Spool Rods with ARP 2000 Rod bolts
-JE Forged Pistons 9:1 Compression
-MLS Head Gasket
-Head Studs
-Adjustable Cam gear
-Hi-Volume Oil pump
Fitted my new custom Starter switch
Speaks for itself really...
Finished the brakes lines and handbrake cable.
Bulletproof Diff: Check
Bulletproof G/box: Check (well almost, not fitted yet)
Bulletproof motor: Nope
Anyway what Im trying to get at is I bought a New gearbox
Its the Big Supra 154 Box thats usually behind the 3.0L Turbo motors and apparently handle big horsepower. This one has had a Rodeo bellhousing modified and bolted on so it will fit behind a 4Z motor.
Gear rations seem nice too with a longer 1st and 2nd gear and Much longer 5th which will be great for cruising
First Gear: 3.250:1
Second Gear: 1.955:1
Third Gear: 1.310:1
Fourth Gear: 1.00:1
Fifth Gear: 0.753:1
TF-TG petrol 5 Speed
3.790:1 - 1
2.175:1 - 2
1.417:1 - 3
1.000:1 - 4
0.855:1 - 5
3.826:1 - R
I stripped down a E1 block I had and sent it to the machine shop a few months ago now. Still have not got it back but they should have it by my next break in a few weeks.
Block Machine Work
-Crack test block
-Sonic test block
-Line hone mains
-Grind/polish crank
-Face block
-Bore and Torque Plate Plateau Hone
-Balance Rotating assembly
Head Work
-Crack and Vac test
-Face head
-New valve guides
-3 Angle Valve seat grind
-Oversize Stainless valves
-Steel Rockers
-Custom Cam
-Port work
Engine Internals
-Stock Crank
-Spool Rods with ARP 2000 Rod bolts
-JE Forged Pistons 9:1 Compression
-MLS Head Gasket
-Head Studs
-Adjustable Cam gear
-Hi-Volume Oil pump
Fitted my new custom Starter switch
Speaks for itself really...
#200
_Viper_
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Posted 28 November 2011 - 08:24 AM
Ok so ever since I fitted the hoppers kit the car pulls up really good but its had a spongy pedal. Spoke Neil / Dattoman and they bled it with there proper machine to make sure that wasn't the issue but was still the same so he told me to pull the master cylinder off the booster and check the pre-load which I did and was fine.
Checked for any slop in the pedals/linkages and that was fine
then checked to make sure the calipers were mounted centered and parallel with the discs.
I had to shave both the rear caliper cradles as they were not parallel. The front right was fine but the front left needed a shim on the bottom bolt to get it centered. So now all 4 Cradles/calipers are parallel...
Fingers crossed this fixes it! Other thing is the stock Gemini master cylinder has a brace from it to the shock tower area to stop the firewall from flexing when you press the pedal but the new master im using doesn't so ill fabricate a new one to suit as well.
But enough of the boring stuff, Since I had it apart I could finally paint my front calipers to match the rear.
And I also picked up my Supra R154 gearbox from S&G which I had them rebuild with some upgraded goodies inside.
Checked for any slop in the pedals/linkages and that was fine
then checked to make sure the calipers were mounted centered and parallel with the discs.
I had to shave both the rear caliper cradles as they were not parallel. The front right was fine but the front left needed a shim on the bottom bolt to get it centered. So now all 4 Cradles/calipers are parallel...
Fingers crossed this fixes it! Other thing is the stock Gemini master cylinder has a brace from it to the shock tower area to stop the firewall from flexing when you press the pedal but the new master im using doesn't so ill fabricate a new one to suit as well.
But enough of the boring stuff, Since I had it apart I could finally paint my front calipers to match the rear.
And I also picked up my Supra R154 gearbox from S&G which I had them rebuild with some upgraded goodies inside.
Edited by Viper, 28 November 2011 - 08:30 AM.
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