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 Post subject: TG Gemini EFI Turbo 202 for the strip
PostPosted: Wed Mar 11, 2009 11:57 am 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
I hope you guys don't mind me putting my Gem up, i'm a NSW fellow but Antus told me i should post it up (cause i was bored at work) :roll:

For a long time i have pondered building a purpose built car for doing burnouts and having some fun on the 1/4 mile.

At one stage i was going to go ahead with it in the LH Torana but plans changed and im now driving it on a daily basis, plus its heavier than other options out there so then i thought LC/LJ would be the go and as far as weight goes with a good engine bay they would have been the best option, but they are few and far between with alot of $$$ on the price tags so i pretty much gave up on that and turned to the faithful Gemini.

In my opinion the only problem with the Gemini was the badge on the motor :) so to resolve that issue i figured why not throw a 202 in there, so yeah started collecting parts slowly and doing some research on models and options etc. Decided that TE TF TG would be the models i wanted mainly because i like the look of that shape and also because of some of the standard features of them.

Eventually stumbled across this on ebay and ended up hauling it home for a grand total of $100

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most of the body is reasonable and the paint aswell, its just the doors and guards that have rust in them, and some in the floors aswell, nothing i can't sort out!

so i set about removing all the crap from it i didn't want which included most of the interior and dash and alot of stuff from the engine bay like heater and stuff like that.

originally i was going to beef up the salisbury diff in it and go with that but the more i looked into it the more issues i found with the strength of them and parts availability etc so i made the decision to scrap the stock diff and cut down a commodore borg warner for it, which would mean commodore brakes, axles and rims would bolt straight on and the diff with a decent full spool and axles should be fairly unbreakable for my application.

SO ... the only problem with this is that the gemini only has lower control arms and uses a torque tube off the front of the diff centre that connects to the floor about 1 mtr infront of the diff and this is used as the upper control arm to stop the diff twisting etc .... so to resolve this issue i had to fit some type of upper control arm that would work on the commodore diff and from everything i've seen people try etc the best solution i found was to use commodore upper arms and just hack into the floor and make mounts for them, which is not a problem for me as the car isn't going to be registered anyways.

here you can see the commodore mount is in place on the diff (just sitting there) to work out the best angle and where it would fit in the diff hump etc.

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and here we have a working end result (obviously not strengthened or finished)

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and this is the other view, mounts are tack welded onto the diff and the they are actually holding the weight of the car and all looks dandy!

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so that was that pretty much sorted out (albiet not finished :)) so i decided while i had the axles out of the diff i would chuck a commodore brake and axle in there to see where it all sat so i could work out if i needed to change diff length etc and this is pretty much the wheels i plan to run atleast at first.

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there was about 1 inch clearance on the inside and outside of the guard with this wheel, and i think it was a 195 size tyre so that worked out perfectly.

so while i was at all this i have been browsing around the web to find a steering wheel for it as i never got one with the car so i figured i'd go straight to the wheel i plan to use in the long run and not stuff around with stock wheels till then ... eventually i settled on a speedway type wheel with a quick release hub, this will require the steering column to be machined a bit and then the fitting thats in the back of the quick release hub gets welded to it.

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all going to plan i will be getting this done tonight or tomorrow night then hopefully i'll be back in action. Also the crash pad is optional but i thought i'd leave it for safety purposes!

also on my order was an rci 30 ltr fuel cell....

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also in the picture you can see there is a fuel pump and filter there, this is a pro comp pump capable of 140 GPH and 14psi, and it can handle methanol. Once its done I'll have 1/2 inch line from the tank to the engine bay where it goes into a pro comp pressure regulator which will keep the pressure at a carby friendly 4-5psi and from there goes to a 5/16 inch line to the carby which is a 465 holley.

other than that the plan is to fit a 202 which i have in the shed along with a trimatic, this will be initially run as it is on pump fuel (makes approx 120hp at the wheels) and once everything is sorted and i've got a handle on it then i'll be working out what i need to do as far as cam size etc and then swapping cams and upping the compression to run it on methanol.

i'm not 100% decided on brakes yet but im thinking commodore rear drums and something like vt twin piston front discs will be the go.

your probably getting the idea that this is a bit of a slap together cheap job, which it is because the whole idea is to get some racing experience without spending too much, but on the same token im not going to skimp on safety, theres going to be a full racing harness and roll cage go in it aswell and hense the commodore brakes to pull it all up!

so hopefully if everything goes to plan it will be a nice light little pocket rocket that i can have plenty of fun punting down the track.

hopefully in the next few weeks i'll be able to start work on getting the engine in the bay, i'll keep you posted.

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No matter what the question is, the answer is always more horsepower!!


Last edited by Gem202 on Tue Jul 29, 2014 2:39 pm, edited 2 times in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 11:58 am 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
well i finally got a chance to get on my mates lathe and turned down the end of the column and the sleeve etc and shes all done!!

have to turn the shaft down to approx 1/2inch then the sleeve will fit over it nicely and then turn down the outside of the sleeve to suit the quick release hub ... also i plan to use the lathe to remove the steering lock bit as i wont be needing it and its a bit bent etc.

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all finished, took longer to do it all than i had expected but hey its done now :) i hope the bearing in that boss doesn't crap itself as i'll probably have to cut something off to get to it!!

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back in the car ready to rock and roll!

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with the steering wheel installed .... i think the crash pad makes it look less trendy so i might remove it till i need it :)

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i don't really know where it sits compared to the stock wheel but it should work well :) i can now move the car around without needing vice grips! Next item for the cabin will have to be a seat i reckon :)

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Last edited by Gem202 on Tue Jul 29, 2014 2:40 pm, edited 1 time in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 11:59 am 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
now that my shed is all completed i have finally gotten a chance to make a start on the fitting of the motor into the gem

so pretty much, shes sitting in there fairly much in the location i want it to go

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so this shows roughly the extent of the mods i've done to fit the engine as far back as i can which is for a few reasons

1 i wanted it back for better weight distribution
2 i want to be able to easily fit a radiator in there and all that sorta stuff
3 the engine mounts line up nearly perfectly

.... so i still need to get a gearbox in there and see how that sits and how it fits in the tunnel etc but short of any major hassles thats where i'm gonna put it. I also have a transmission tunnel cut out of a vr commodore and one from an lh torana if i need them.

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as you can see theres not alot of room here and what there is, is from me removing the tunnel and bashing the sides out with a hammer :)

hopefully i'll get the gearbox in the next week or so and i'll be able to make some more progress ... in the mean time i'm going to start making some bits for the engine mounts!

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No matter what the question is, the answer is always more horsepower!!


Last edited by Gem202 on Tue Jul 29, 2014 2:41 pm, edited 1 time in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 12:00 pm 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
well there has been a good amount of progress on this beast, firstly i have a gearbox in there and have been able to work out how everything will fit etc .....

i have completed the engine mounts and i am working on the gearbox.

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also after lots of thought and time lying under the car i have decided apon a set of chassis rails to use for mounting of the gearbox and also because they will provide added strength to the car which in this application is going to be a good thing!

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as you can see it ties into the lower control arm mounting point and runs through the floor up to the main support that goes from the sill in and around to be the chassis rails in the engine bay.

the floor will also be fully welded to the rail where it has been cut for the rail to fit through it.

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once the two of these are installed i will be able to run a pipe from side to side and support the gearbox from it, i'm hoping it will also be handy as part of a tailshaft loop later on.

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Last edited by Gem202 on Tue Jul 29, 2014 2:43 pm, edited 1 time in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 12:00 pm 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
Well its all in and holding the gearbox now!! stoked!

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still only tack welded in and this is to allow me to remove the rails later on so i can get to the extra holes i need to drill aswell as welding in captive nuts on the inside of the rails and then welding the plates back into them where the holes are.

i've been able to do a bit more work on the floor aswell, most of it is now gone to clear the exhaust etc

i've sorta stopped work on the car now so i can focus on using the engine in it to get VN injection running (which is to go on the torana) once thats done i'll be back into the gem!

this is what i've done to the floor to remove enough to allow everthing to fit :)

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plenty of room for the efi and exhaust to clear in this department!

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Last edited by Gem202 on Tue Jul 29, 2014 2:44 pm, edited 1 time in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 12:00 pm 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
Well i finished with this engine for the EFI conversion and i have since made a bit of progress and a few changes.

first change was to ditch the trimatic in favour of a powerglide as i had talked to a few people at the drags with holden 6's and they said that the powerglide in stock form can handle about 500hp whereas a full house trimatic would be lucky to even handle that much.

so in went the powerglide after a quick removal of the pan to check the internal condition and to put a different shifter linkage in it for the B&M.

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plan is to run the car with the box as is to make sure it all works ok, once that is confirmed then i will pull the box and reco/shift kit it.

once it was in i was then able to start welding in the transmission tunnel and fitting the B&M Pro Rachet.

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tunnel is out of my wrecked LH Torana i kept it thinking it would be handly for a conversion one day and i guess i was right :)

also while i was at it i remove the chassis rail kit and finished drilling holes and welding captive nuts into it then painted it all up and put it back in the car. its now fully welded in at both ends and i have started stitching it onto the floor pans that it runs past.

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i have also sourced some thermo fans that fit perfect on the torana radiator and i have also mounted an electric water pump and removed the mechanical water pump pulley and blades so the electric water pump is the only thing that controls the water flow and this can be switched on and off by the driver. plan is to use the fans and pump while in the staging lanes and then switch them off for the 1/4 run to save load on the engine.

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this will also mean i can get the engine up to temperature quicker but also means i'll need to keep a good eye on the gauge!

i have also started working on the pulley system for the blower. at this stage i have found a serpentine pulley that with some minor machining has been mated to the front of the 202 balancer, i have then modified the alternator brackets to allow the fitment of a commodore alternator which already has the right pulley on it aswell as being able to product about 80amps! plenty more than i should ever need in this car.
Image

the belt ratio with this pulley size combined with the blower pulley size should mean the blower is spinning at 2.04 times the speed of the crank and this works out to be roughly 11000-11500rpm at the engines redline and the blower is rated to 12000rpm so it should be perfect!

i have just yesterday finish off the mounts for the fuel tank and have run a fuel line up the side of the car to a fitting in the engine bay where the pressure regulator will be attached. I have yet to mount it as i am not sure where the best spot will be till i get everything on the engine. will hopefully get some pics of the tank soon.

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Last edited by Gem202 on Tue Jul 29, 2014 2:46 pm, edited 1 time in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 12:01 pm 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
well i haven't done alot on this thing over the last few months but this is what i have done.

got the fuel cell fully mounted up, all i need now is some insulation to go between the straps and the tank

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i've also run the fuel line from the pump up the inside of the car to the firewall and put a fitting through the firewall into the engine bay.

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on the other side it will connect to the pressure regulator!

also on the weekend i got off my ass and finally did something about the hole in the floor (well one anyways)

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i think i'll try and get the other floor pan sorted next, then it'll look a bit more complete!

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No matter what the question is, the answer is always more horsepower!!


Last edited by Gem202 on Tue Jul 29, 2014 2:47 pm, edited 1 time in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 12:01 pm 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
where do i start ... well i guess a quick update, as you would have seen back almost half a year or more i had fitted commodore upper control arms to the diff and suitably modified the floor to allow for it. i'm sure i also mentioned that i plan to use a commodore borg warner diff in it.

so this is what was pulled from the car...

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so i put the stock salisbury diff in my diff jig and set about taking measurments and degrees and stuff like that...

i then got rid of the weak part of the diff :)

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so the next step was to cut the ends off a borg warner housing to fit into the gap!

so below you can see the borg warner centre is in there and there are tubes inside the housing where its been cut for extra strength and to ensure correct alignment. i then put a degree device on the front shaft and make sure the centre is pointing up at the same angle as the original diff was. This is not super critical because i plan to make some adjustable upper control arms down the track anyways for fine tuning.

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so i then plug welded the inner tubes in place then welded the entire way around the diff where it was cut... and this is the finished product ... i still have to weld the upper control arm brackets back on but i ran out of time tonight!

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so next step will be to fit the diff back into the car and then i can cut down a commodore tailshaft to the right length, tack it together then take it to a tailshaft specialist to get a custom one made up.

also i have some measuring to do of the housing to work out the lengths i need for the axles as i am getting billet custom length items made with commodore stud pattern etc....

while i've been doing all this i've been doing some shopping and i have purchased a full spool for it ... its a 31 spline unit to suit the borg warner.

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so i'm hoping with all this stuff sorted out i should have a pretty bullet proof diff (well for a supercharged 6 anyways :))

i'm also scouring ebay looking for a suitable diff gear set ... i am thinking something like 3.5, 3.7 or 3.9 will be the go .. either way theres HEAPS of options in the borg warner range so i should be right!

thats pretty much it for the moment. Once i get the diff back in i'll post some pics aswell as the tailshaft etc. Hopefully axles will be getting ordered sometime around christmas maybe Jan ...

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Last edited by Gem202 on Tue Jul 29, 2014 2:49 pm, edited 1 time in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 12:02 pm 
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Joined: Wed Mar 11, 2009 11:10 am
Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
well aside from axles and some bearings and seals the diff is done!!

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one borg warner gemini diff :)

i also made up a temporary tailshaft from an old commodore two piece unit cut and re-joined just to get the length worked out etc and as i have no handbrake in the car i can use the gearbox to stop the car moving! (well once i get my axles anyways.)

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below are just a few more pics of things, tailshaft pinion angle worked out pretty well with the stock gemini angle so that made life easier!

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once i get the billet axles it comes out for a full rebuild, new bearings and seals and a paint job then i will hopefully not have to touch it for quite some time :).

i was hoping i could leave the handbrake mechanism in the floor but the yoke wouldn't go into the gearbox without removing it so thats pretty much decided for me that i wont be having a handbrake in this car :)

so now i have to make a plate to go in place of where the handbrake section was that i cut out :)

at the moment i have been working on the brakes a bit aswell as just removed the motor and gearbox so i can finish off all the welding up and mods to the firewall etc.

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Last edited by Gem202 on Tue Jul 29, 2014 2:51 pm, edited 1 time in total.

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 Post subject: Re: TG Gemini with 202 for the strip
PostPosted: Wed Mar 11, 2009 12:02 pm 
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Posts: 248
Location: Tenambit, NSW
Car(s): TG Gemini, Holden Cruze SRi
well in the mean time while i'm saving for axles i have been busy finishing off the new floors/trans tunnel and firewall mods to fit around the 202.

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as you can see its not a show car finish and its not even symetrical, but basically its what i needed to do to fit the 202 and powerglide in so yeah, and the drivers side i wanted to keep as much leg room as i could as it was small enough to start off with :)

for those that don't know why the passenger side of the engine bay has a bigger area cut out its because the 202 has the exhaust on the passenger side and it didn't really matter if i did it this way cause it makes it fit in easy as and doesn't effect the passenger ... i haven't even ground down the welds or anything, but it will be plenty good enough with a coat of paint for what i want it for cause after all this is a go car not a show car!!

you can also just see in the bottom of the picture i have welded the engine mount to the chassis rail.... i figured i might aswell as it will give the car more strength and really if i ever had to swap the crossmember it is an easy task to cut it off.

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so the floors and firewall are all done now, i have some small tidy ups to do in a few spots, like where i cut the handbrake mechanism out of it then once i finish them i will be fully welding the chassis rails into the floor (theres alot of gaps in them at the moment)

also i've finished the fuel tank now, i got some felt with sticky backing to put on the straps that hold the tank down and also on the floor where it meets the tank and also painted up the straps.

i've also been doing some work on my Torana (which i drive daily) and it looks like the 202 in it will be coming out not to far down the track and a ecotec v6 will be going into it so i'm thinking that i will probably use the torana 202 in the gemini as it makes about 20hp more than the engine i had for it.... so i'm thinking i'll leave the bitza 202 in the gemini for the moment to get it all up and running then once its all happy i will probably do a run or two in it and then put the good motor in.

the 202 in the torana is running fuel injection with a programable computer so im thinking i MAY use it in the gemini aswell, im just not sure, i was going to use a carby but efi would be good!!..... lots of options in the computer i can use on the strip!

also picked up my kirkey race seat yesterday, its pretty kewl, i am in the process of making the mounts for it so i will post some more pics up once its in ... hopefully that will happen this weekend!

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Last edited by Gem202 on Tue Jul 29, 2014 2:52 pm, edited 1 time in total.

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