awd conversion, help? Options

[Rook]

Hey guys. I'm definitely interested in doing an awd conversion within the next 6 months. I wanna make it a straight up gt4 conversion. I know its alot of work. As far as I've read on my parts list is:

3sgte engine
e154f transmission
gt4 driveline
rear differential
rear cradle
driveshafts
gt4 fuel tank

i know theres gonna be fabrication needed but im not sure how much. I'm not exactly sure how the cradle would go in but I'm sure its supposed to be welded up somehow. So far my favorite thread has been czwalga's rally car...difference though is that i'm going with the 3sgte and i'm wanting an awesome street car not an awesome rally car. lol. but definitely kudos czwalga . But yeah anyway i know i do have a long way to go. I just wanted help with this cus i know its alot. I've heard alot of guys getting it done under $10k. I would be willing to go a little over if i have to since im not a fabricator or a welder. . any input would be awesome.

[richee3]

I would personally buy one of the GT4 half cuts that has the whole floor/rear diff etc. with it and use it as a template to emulate. Take measurements, emulate mounts, everything. Be sure to start a thread, and good luck

[rave2n]

I got the trannie if you need it. Fresh off my 3sgte.

[mandrek]

i seen that you refernced the car but indeed this is a great thread to look over,as well as this. two great builds.. but honestly IMO, if you are ready to invest that much, i would try to find one that is already state side, or try to import one.. they are alot cheaper over seas, and you could always do the "kit car" registration..

[czwalga]

i seen that you refernced the car but indeed this is a great thread to look over,as well as this. two great builds.. but honestly IMO, if you are ready to invest that much, i would try to find one that is already state side, or try to import one.. they are alot cheaper over seas, and you could always do the "kit car" registration..

Importing a GT4 is not nearly as easy as you say. Also talking just strictly AWD setup, none of the rally stuff, I have probably $2k or less into it. All AWD parts including trans was ~1200, FIA fuel cell setup was 400, but that's only cause its required for what I do you can do it much cheaper, Misc. steel 100 bucks maybe. Weld wire/gas, minor expenses.



FYI to OP the gt4 gas tank does not fit unless you swap the entire back half of the shell. The GT4 floor/frame rails sits much higher. It is a lot of work though if you pay someone to do it it could get very pricey.

[mandrek]

i seen that you refernced the car but indeed this is a great thread to look over,as well as this. two great builds.. but honestly IMO, if you are ready to invest that much, i would try to find one that is already state side, or try to import one.. they are alot cheaper over seas, and you could always do the "kit car" registration..

Importing a GT4 is not nearly as easy as you say. Also talking just strictly AWD setup, none of the rally stuff, I have probably $2k or less into it. All AWD parts including trans was ~1200, FIA fuel cell setup was 400, but that's only cause its required for what I do you can do it much cheaper, Misc. steel 100 bucks maybe. Weld wire/gas, minor expenses.



FYI to OP the gt4 gas tank does not fit unless you swap the entire back half of the shell. The GT4 floor/frame rails sits much higher. It is a lot of work though if you pay someone to do it it could get very pricey.

true on the fab part, but also, you did all the work yourself, (and quite well i might add!!!) i was simply pointing out that since he was not going to do the fab work him self, the importaion option may be an easyer way of getting what he wanted concidering his already substantial budget. a bit more and he could get what he wanted w/o much mechanical work into it.. this of course is with hiim shopping around agood bit.. on the other hand most "shops" would charge an arm and a leg to do the swap proper and right. and then there is the fact that few (if any) shops would want to take on that kind of project with out alot of paper work reliesing them of any kind of liability for work done. so the chance of it being done "right" by a shop. is slim.. unless he was able to find a member here that would "do it for him for a cost" and that would be ok with any kind of fallow up work there after.. but again.. a big hasle..

but i agree the best way is the get the parts and do it your self....

for some it is easyer to cut through the red tape than to cut through the metal..

[czwalga]

Yep you're right a lot of places wont even touch it. If you dont do the work yourself it could end up being very costly.


I still dont think theres a way to legally import a car in the USA without paying for like 3 more and getting them to pass the crash tests etc costly lots and lots of money. You can do it illegally and probably get away with it if you're smart about it.

[Rook]

all good points. However all i'd really have trouble with is the fab. Your right czwalga i would probably do a fuel cell instead. But i can take care of the mechanical myself. lol. wat i'm not sure about is that rear end. how do the struts location differ from the usdm version? you have to cut stuff out and replace with the gt4 rear and weld up?

[czwalga]

all good points. However all i'd really have trouble with is the fab. Your right czwalga i would probably do a fuel cell instead. But i can take care of the mechanical myself. lol. wat i'm not sure about is that rear end. how do the struts location differ from the usdm version? you have to cut stuff out and replace with the gt4 rear and weld up?

Well the thing you're kinda missing is that it's all fab, no real mechanical. You have to do the mechanical stuff in conjuction with all the fab work.

Start by installing the transmission, then there's 4 driveshaft mounts. Align those so that the angle of the ds is within .5-2 degrees of the outputshaft on the tranny. Then make mounts for the ds get those welded in. You'll most likely have to remove the carpet otherwise youll probably catch it on fire.

Once you have those mounts done you have a new reference point. Then there's a CV joint, this is to account for the fact that the rear subframe needs to sit higher than a straight line out of the transmission. However, the angle of the subframe should have the same slight angle as the last long section of the driveshaft. This is so the U joint at the differential is within .5-2 degrees


I spent a few hours just aligning the rear subframe on blocks before i started fabbing mounts. I'm sure you can get away with doing a ****tier job, i've seen others keep the rear subframe in a straight line and it sits way lower than it should, this causes the axles to much more angle than it should. (With full weight on the suspension the axles should be around perpendicular with the differential +- a little) In my opinion its wrong, but hey it functions so who am i to judge. But mine has survived 6 rally days of complete abuse and haven't had any problems.


Aside from installing the transmission and towing to a shop everything else is fab and custom work. Installing the parts in an already compelted car is like 1/50th of the actual time it takes to do it.


If you're serious about doing it, my suggestion is buy a welder with gas, practice, take lots of time and dont half ass it. Unless you find a shop that does custom work most wont touch a project like this. Also shops that would do something liek this will charge you big bucks.

This post has been edited by czwalga: Dec 24, 2011 - 5:03 PM