Trigger

Yea I've tried "adjusting" the mixture screw

(the spring on the thread is almost compressed now)

I e-mail the dude who I brought the carb from and he suggested:

- checking the fuel pressure (not to be more than 3.5psi)

- and possibly fitting a return line to tank

so I checked fuel pressure from pump = 3psi (sweet)

and have re-fitted the factory fuel return line to tank

took it for a drive today but no real change...

still pumping out black fumes at idle and under secondaries

(and doing about 60km for $20 gas)

but no flat spots or missing

Looking at getting my carb (Weber 32/36) tunned - checked from around the Palmy area

any suggestions or better, recomendations would be GREAT!

or anyone who knows what they doing

not looking to spend hours and hundreds on a dyno tune...

it just seems to be running way too rich at the mo

(not sure what jets I've got)

cheers for any help,

Trigger

AARRGGHH, GDI!

(stay away)

SOHC '63, cant go wrong

Not sure "where" to put this?

but thought it would be good to have it here for anyone looking to do this swap/convertion in the future

and so no-one else will fall into the same problems I did...

When fitting a Sigma 5 speed gearbox into an Ex lancer there are x2 choices:

- cut a hole in the floor/tunnel (about 2inches) further back for the Sigma shifter to come up through

- or swap the Sigma extention housing with a L200 housing so the shifter is in the "factory" location

(meaning NO cutting needed)

All this is because the Sigma shifter (gear stick) sits further back than the Ex shifter, aswell as having

to cut a hole further back in the floor/tunnel you'll have to "trim" back the centre console trim

(if still using it) so it all lines up with the Sigma shifter

I went with swapping the extention housings over (rear half of gearbox) so no cutting required

and looks factory still

NOTE: Sigma and Ex have the SAME driveshaft uni (size and splines)

but the L200 is BIGGER and having more splines, (because the L200 has a bigger output shaft)

So I had to get a "custom" tailshft seal made up, with an outter diameter to fit into the L200 extention housing

and the internal diameter of the Sigma/Ex driveshaft uni to seal against it

For a month or so, I drove around with the Sigma box/L200 extention housing with constant OIL LEAKS!

I "thought" it was just the tailshft seal leaking, but after changing the seal x2 times, it turned out to be

the "internal bush" in the L200 extention housing which is BIGGER than the Sigma, leaving the driveshaft uni "flopping" around in the extention housing

(causing oil to get past and leak on to my garage floor)

Smaller (Sigma) tailshaft on the LEFT:

I compared a Sigma and L200 extention housing "side by side" to check for any differences,

to find the only difference between the them was the rear internal bush!

(note: the Sigma housing is on the RIGHT)

So It was a case of "working out" what parts I needed for it ALL to work...

- L200 shifter (to be in the factory location)

- Sigma extention housing (for the smaller internal bush, and NO oil leaks)

Difference between L200 (TOP) and Sigma shifter shafts:

LONGER = Sigma

Then just a case of using the L200 top plate/cover

(shorter of the two)

Complete Sigma box (with "some" L200 internals)

"Finally" got around to taking the gearbox out this weekend...

Had a couple of things to do to it while it was out:

- fix the oil leak

- removing L200 extention housing

- fit L200 parts to Sigma extention housing

- re-fit Sigma extention housing

- replace all gaskets/seals

- replace thrust bearing

- cut down shifter

Replaced the "nosiey" thrust bearing:

What I had to start with on Sat morning:

Sigma box with L200 extention housing (including leaking tailshaft)

Both the extention housings:

Spot the differnce... (Sigma on the RIGHT)

As you can see both housing "look" the same, except the L200 housing has a "bigger"

tailshaft (for its bigger driveshft uni) which is causing my oil leak

So I have to use the Sigma housing, but still want the shifter in the factory Ex postion

which the L200 did...

(Sigma shifter mounts about 2inches further back, need to cut a hole)

So after stripping down both housings, the only internal difference is the mount for

the shifter, on the shifter shaft

Sigma the "longer" of the two:

So all I did was swap the two shifters around (or could use the complete L200 shaft and shifter)

Then all I had to do was, re-use the L200 top plate/cover (same bolt pattern as Sigma)

L200 top plate/cover (TOP):

Oh yea and I "found" my missing speedo drive...

And swapped the Sigma shifter around with the orginal Ex shifter, to make it a bit lower

Sigma shifter:

Ex:

NOTE:

Put a notice up on "tech questions" about this box mod too...

viewtopic.php?f=2&t=20025

MINT looking car man!

um yeh what/ what

get some turbos.

deal

^ OK...?

Guy with the auction on Trade Me... http://www.trademe.co.nz/Browse/Listing ... =238096057

has finally got back to me with the price...

15x7 and 15x8 = $1300!!!

recokon these would be cooler (and CHEAPER)

http://www.trademe.co.nz/Browse/Listing ... =239090603

NO FUCKEN WAY!!!

what happened man... you ok?

^ Thats it!

Think I'll just save the $500-600 hundy on more wheels

and buy an angle grinder to remove 4inches out of my suspension!

Cheers again KPR

(have updated some more pics on my "build up" page too)

Mean!

Thanks for the photoshop "kpr"

guy has just answered my question on Trade Me, bot size/offsets

now just gotta get a price... then work out IF they are worth it

you can never have too many wheels!

liked it when it was on 14s, and have been thinking bot

getting some Sigma rims widened, but for $800-$900 (inc powder coating and tyres etc)

I thought I might have a look around and see what "mags" were out there...

Sigma rims:

RS-8s:

^ cheers for that man (good to know)

yea I can fully see them on the Ex, but not totally sold

I'm not a complete muppet when it comes to finding wheels

keep an eye on T.M, and ask about etc

(gotta be at least 14's to fit over brakes tho)

Wheels at the mo...

(16x7 16x8, SSR RS-8)

(needs to be lower)

Have been thinking about widened Sigma rims

^ yea these wheels always remind me of early Falcons...

could get something much better for that much

Like what...?

(In 4x114.3, 14-15inch, oldschool style)

Only seems to be these, Modgies or Hotwires...

crack up!

Yea dont know if colour coding them helps on his car

black centres and wider tho...

ogre had some on his EX for a bit. Looked yuck. Didnt suit them at all. Vote nah bro.

You mean like this...

I vote nah, and I also vote the EX looks epically hawt on the road, pretty darn sure it was yours I saw heading down Tremaine by the Cloverlea roundabout today.

could have been...

Yea thinking bot them for the Ex...

oldschool pic of yours looks very period correct, what you reckon bot them?

What you guys reckon of these...?

http://www.trademe.co.nz/Browse/Listing ... =238096057

Hello all,

I have just purchase a 1982 ex lancer and was wonder if the 1981 ex lancer Dash cluster will fit in (I know it will physically fit, but what I mean is will the plugs be the same, or is it impossible to get the sucker in)?

Pictures!

I want this...

In here...

Thanx,

Z-M-K

Yea man, can be swapped

Pretty sure it un-screws from the back of each cluster and comes off

I'm running 16x7 (front) on my Ex

with a +25mm offset and 195/45/16 tyre (using Starion front struts)

Any "higher" offset will bring the wheel closer to the strut

and anything lower than about +15 (for a 7in rim) will sit outside the factory gaurd

and will need mods to the gaurd to fit/clear

(so spacers, or different wheels)

Well its been awhile between posts... but for good reasons

my wife gave birth to our baby girl (so I ended up missing the swap meet...gutted)

but...

I've finally taken the Starmax out for a "drive" or two!

Not ALL 100% yet but SO GOOD to get out and drive it in this primo weather!

Have put the orginal 1200 Ex master cylinder and booster back in, but brakes still far from good...

just not pushing it too hard and giving myself a bit more time/room to slow down

(still only running it in anyway, and taking it easy)

Now some car pics...

(not from the garage or driveway for the 1st time!)

Views from "Pork Chop"...

From Mr Flatly's work...

been thinking about "more" wheels...

viewtopic.php?f=1&t=19916

- Have also found the speedo wasnt working?

- And the gearbox has an oil leak?

(always something aye)

Speedo:

After about 20mins of driving (the 1st drive) the speedo stopped?

So I pulled the speedo drive out, to find... there was NO drive sprocket?

disappeared? (see pic)

Cheers HEAPS to Cam (Ogre) for another speedo drive

(speedo all good now, just dont know "where" the other drive sprocket has gone?)

Gearbox:

Had a small leak coming from the tail shaft (about 5-6 drops on the ground)

so replaced the rear tail shaft seal (custom size, to fit L200 housing and Ex uni)

But went for "another" drive today and found its STILL leaking...?

Managed to get another L200 extention housing (thanks AGAIN Ogre)

to compare it with my orginal Sigma extention housing, (that I'm not using) and have noticed the rear "internal" bush

on the L200 housing is "BIGGER" and wont be sealing against the Ex uni (when it sits inside the housing)

Bit hard to see, but the Sigma housing is on the LEFT (smaller uni hole)

I'm using the L200 extention housing (Bigger of the two) and the Sigma AND Ex driveshaft uni's are the same size,

which is smaller than the L200, cant use an L200 uni because the splines are differnent between L200/Sigma,

so looks like I might need to get a bigger internal bush made up for the L200 housing to seal up against the Ex uni...

(make sence?)

Seems a few peole have swapped the Sigma extention housing with the L200,

to get the shifter coming up inthe same place as factory (in an Ex) but

have either put up with oil leaks or have done it "another" way without saying?

I hope to have found out a way of using the Sigma housing (ie complete Sigma box)

but still have the the shifter in the factory poistion and NOT having to cut a hole

V10 BMW (money no object)

http://forums.vwvortex.com/zerothread?id=4515333&page=1

un-real fab, top qualitly!

I've been a slack cunt and havent had a chance to get out to the shed and try anything yet...

But guess that happens when your wife gives birth a few weeks early!

maybe in a few weeks I'll get out there... ?

Ke36: at least your setup "was" working at some satge so hopefully it just needs a GOOD bleed

with some DOT 4-5 fluid? Be keen to hear how you get on...

sweet!

cheers for that man, I'll try a few things out on the weekend and see what happens,

but I'll let you know, and could be keen to take you up on your offer

cheers HEAPS for all the help and things to try out,

Lots of good info, unfortantly I probably wont be able to work on the car until the weekend...

Yea, was thinking could be something to do with the Sigma m.c being mis-matched with rest of the brakes?

I've re-fitted the standard 1200 m.c and booster now, so will try swapping the calipers over and see if that works,

at least then it'll be back to completely "standard" braking system again

Wondering if anyone else has changed there m.c on their Ex and what m.c they are now running?

(and still using drum rear end)

I didnt think it would make sence to use a Starion m.c, because they are disc rear

(at least Sigma is drum rear) simlar to Ex, but Starion calipers must be a bit bigger than Sigma/Ex?

I'll try find out ALL (Starion, Sigma, Ex) m.c and brake componnet sizes

and I'll try "adjusting" the push rod aswell