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James' Daihatsu Cuore "SKD555"

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  • #76
    April 2019: So somewhat sadly we ran out of time to be able to get the manual swap done for the trackday. In saying that I thought it'd actually be fun to see what it would be like with the auto. Now that meant that two things needed to be done.

    Now my drive shafts have both been rooted for months, but I waited to replace them as they needed to come out for the manual swap anyway, but I didn't want that to maybe cause an issue on the track. So they needed to be replaced. Up she went.





    Wheels off.





    A hammer and punch plus some WD40 helped prep the main nuts.





    Trusty old dac popped the nut off like it was nothing.





    Before the shafts came out though, I drained the ATF. Now in the 5 years I've owned the car, this is something I've never done, for the same reasons as above. I've been meaning to for ages. I've had the oil for years. Yummy chocolate oil.





    Easy to see where they are split here.





    I popped the arms off the struts to make it easier to get the shafts out.





    Passenger side came out ok but the drivers side put up one hell of a fight.





    Passenger before and after.





    Drivers side.





    In they went.





    Time to refill the ATF.



    I couldn't find a funnel small enough for the hole. The only place open at 8PM was Bunnings. This was the best thing they could do for me... It'll do for the ATF.



    Once all that was sorted I got the car back down on the ground and began cycling the fluid. I went to use the brake and it completely went to the floor. Luckily I was quick on the handbrake but I was so confused what was the cause of this. Turns out, somehow when I was getting one of the shafts out the rear drivers side brake pad shook out and slid down slightly. Causing this to happen.





    Now at this point I would've been screwed for the trackday, but luckily this turd is still around.



    Grabbed all the pads off it and chucked them on. Much more life on them!



    Poor thing was filthy and needed a good clean too.





    Better.



    Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
    Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
    Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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    • #77
      April 2019: So here we are at the track day. It was so much fun I can't explain. This car is so inappropriate yet so perfect. Luddenham Raceway is the perfect kind of track for these little cars. I managed to get faster and faster throughout the day. It was all laughs. The car didn't have a single issue and took the abuse like a champ.

      Anyway. here's a bunch of pics from the day.















































      Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
      Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
      Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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      • #78
        April 2019: I'm happy to say there is an end to one chapter. The bloody parts car is finally out of my garage, thanks to my mate and his doggo!



        Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
        Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
        Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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        • #79
          July 2019: My journey with my Subaru wagon is about to end. A new owner is lined up and while I'm selling the car as is and heavily modified, the entire stereo system will be coming out and going into the Cuore, which is exciting cause its a pretty high end one.

          The car will be sold with no speakers or amp but I do need to swap the headunits around, the current one in the Cuore is actually from my Subaru. I hate it so much I can't explain.





          First thing though, I gotta pull the 'new' one out of the Subaru.





          With that sorted the old one in the Cuore could come out, I forgot how ghetto it was mounted, with two single din mounts.





          I'll have to look for a different solution.





          Quick test fir with the new headunit, the Sony is a little different as it just uses a single din to mount, I had to bend the tabs just to hold it in. It all has to come out anyway when the new speakers go in so it'll be fine for now.





          Despite both being Sony's the loom connector is different.





          I got an ISO adaptor on eBay so I could cut those off and make another one, again this is just for now, cause there will end up being three joins in it, which isn't preferred but it'll work fine for now. I''m going to repin the Daihatsu adaptor at a later point to have no joins.





          Joins done.





          Quick check in the car.





          Anoyyingly the sourround doesn't fit, I'll either have to modify or find another one to try.





          Lots of exciting times ahead for this, I'll be making a real effort to do it properly.



          Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
          Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
          Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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          • #80
            August 2019: So this one is going to be a big one, it's a very big thing to finally happen to this car. Manual swap time!

            I had everything prepared but I wanted to take the quick moment to give the box a little once over with some degreaser.





            Now that we're ready to get going, time to pop it in the air.





            Fluids were first on the list, coolant first.





            Oils and filter.





            As we're pulling the engine out with the crane, we need all the space we can get, so the front end can come off.





            The radiator could come out as one now.





            Hoses and exhaust.





            The lower bolts on the struts could come off the give the knuckle movement the make it easier to get the driveshaft out





            They're going to stay in the car but they just need to be popped out of the box.





            With everything on the engine side out, it was just about ready to pull. The loom needs to be sorted though, there are two ways to do it, disconnect everything from the engine, or what we did, remove the plug from the ECU and being the entire loom with the engine. This was a much much easier way we believe.





            On the crane, it went.





            Out it came.





            Good riddance.





            It could then come off the block for the last time.





            Converter and flexplate off.





            Looking at the rear main that was in the car, it was actually in really decent shape considering its never been replaced. I've got a new one though and it'd be stupid not to change now.





            With all the auto stuff now off, we can prep the engine for the manual box. I had the flywheel machined quite some time ago, it had the slightest amount of rust. A quick hit with some degreaser and a green sponge and it was good as new.





            New drive belts could then go on, again originals were in great shape but it had to be done.





            Manual specific spacer before the flywheel got thrown on with bolts torqued to spec.





            We didn't have the correct clutch alignment tool on hand to it took a little trial and error to get everything aligned in the end.





            Now this thing was a bastard, the old bearing came off no worries, we gave the shaft a quick clean.





            Quick grease.





            Must've taken almost an hour to get this little shit seated and clipped in correctly, we got there in the end.





            The manual box was no ready to go on for the last time.





            Starter motor is something that is different between auto and manual, you can especially hear it when you start the car, they sound very different. The wiring connectors are the same, however the loom length is routed differently as the starter is on the bell housing side rather than the block side like the auto one.





            Easily sorted.





            Before continuing we wanted to get the interior stripped of all the old auto stuff first. Starting with the pedal box.





            Engine is ready and waiting but when we went to go and throw the clutch cable in we noticed that for some strange reason there wasn’t a whole for it. It’s interesting to see they made two different firewalls for auto and manual.





            Luckily we had a bunch of Cuore’s around us to get an idea of the exact placement.





            Started with the bracket hole.





            Then the main hole for the cable, it needs to be bigger than the cable so the adjuster can be brought though, it needs to be fed from the interior.





            I could then bolt up the manual pedal box, I had to drop down the steering column to make it a little easier for it to pass through.





            Good time for the engine to go back in now.





            Struts back together after the shafts were pushed back in.





            Clutch cable and shifter linkage on.





            Time for fluids.

            Fresh Ryco Filter.





            Nulon 10W-40 and a fresh sump washer.





            Box got some Penrite 75W-85 Pro Gear





            Battery in.





            Got the shifter all buttoned up too.





            In.





            As we’ve retained the auto ECU, the car won’t let itself start without getting the inhibitor sorted. A quick check with a multimeter and look at the service manual.





            Derrick had a smart idea to cut the original connector off and wire it up instead.



            Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
            Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
            Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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            • #81
              The front end could then go back on.





              Coolant went in outside just in case.





              And it started up perfectly.





              At about 1.30am we were finished. All up it took about 14 hours but we got it done and I was able to drive home. What a transformation it has made. The car feels like it almost has double the power.



              Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
              Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
              Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

              Comment


              • #82
                September 2019: I've had a spare set of headlights lying around now, and a friend gave me a headlight restoration kit. I'm going to get my original set properly done and cleared when the car is painted.





                This is just a simple Mothers Kit





                The came up looking pretty great.





                Gave them a quick hit of wax too.





                Strangely, my driver's side was shocking and my passenger side was as new.





                Before and After.





                For a quick couple hours on a Sunday, I'm happy with the result.
                Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
                Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
                Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

                Comment


                • #83
                  October 2019: Been keen on doing this for some time, and with the Subaru leaving me, and injecting some cash back into my wallet it was time to do it, and do it properly. Copen brake upgrade.

                  Before anything could get happening I needed to head over to New Model Wreckers to grab myself a set of Daihatsu Copen calipers. They sold me everything as is whole on a hub. Not bad for 150. Also grabbed a second set for a mate.





                  Got them home, they looked pretty decent.





                  In the spirit of doing this properly, I decided to have them professionally rebuilt with genuine seals and rubbers, plus powder-coated in Oxytech Flame Red by a bloke in Sydney called On The Brakes. Glad I did, cause holy balls they come out amazing!





                  With no interest in using the original pads and rotors, I needed to upgrade those too. For disks, I went with DBA's T2's. They'll do perfectly for this application and look great.





                  Much better shape than the old stuff.





                  For pads I went for another thing I've been familiar with on other builds. Dixel, Type ES's in this application.





                  I truly believe this is the best bank for buck mod you can do to a car, braided brake lines. Hel as always.





                  Lastly, for fluid I went for some Motul Dot 3 & 4.





                  Before we get into this, these are such smol boi's its halarious.





                  Alrighty, in the air we go, wheels off.





                  The rotors seem to be original, they are thick with rust and have multiple cracks surrounding them.





                  Main part of the brake caliper could now be popped off.





                  Then the holders could come off.





                  Brake lines could then come off, also something that scares me, but flare nut spanners and a shitonne of WD40 help the anxiety.





                  With everything removed, I needed to prep the brakes. The hardware got a light coating of copper anti-seize





                  Lines went on the caliper side first as it'll be a little easier routing it.





                  Quickly through the disks side by side, the size difference is hilarious.





                  Not to mention that fact we're going from solid to vented.





                  Same deal with the factory calipers.





                  Anyway, back to it.





                  Mounting brackets could then be fitted.





                  Pads then went in.





                  Main part of the caliper could then go on.





                  Front lines in.





                  Always a pleasure working with satins clips.





                  Despite the fact I'm leaving the rear drums alone, for now, I still wanted to do the rear lines.









                  Nice difference.





                  Finally, everything is in. Before it can be dropped though we gotta bleed the system.





                  Far as I know, its never been done, and boy oh boy was it yuck.





                  Wheels could then go back on, got lucky with clearance that's for sure!





                  Got a few outside too, so happy.



                  Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
                  Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
                  Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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                  • #84
                    November 2019: With the brakes completely overpowering the tyres, which I knew would happen, it was rubber to be on the list next.

                    Being extremely limited on size options I ended up going with some Nankang NS2-R 165/55R14's. I wanted the 180's but they could only get 120 treadwear. Keen to see how long they last.





                    Mounting.





                    Big difference in width and sidewall.





                    They fit good and look pretty tough on the car.





                    The rear looks great but as the factory suspension is soft it rubbed really bad on any bump.





                    Luck would have it a friend was parting his Gino after an unfortunate event in traffic. Due to this, there was a set of ZerOne SSR coilovers with custom pillowball camber mounts up for grabs.





                    Up it went to chuck in.





                    Old stuff came out pretty easy.





                    Before and after of the front.





                    We had to ever so slightly notch the strut mount to get the camber tops to fit correctly.





                    Rear then went it.





                    Before we finished up for the night I chucked in a new front engine mount we noticed was completely rooted from when we did the manual conversion.





                    Gone.





                    New one is nice and fresh.





                    Out with the old, in with the new.





                    We got a couple of pics of the crew that evening too.



                    Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
                    Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
                    Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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                    • #85
                      Some awesome detail in the OP and a great read for the build log. I am getting some great ideas for my Cuore and are interested to see what you might do with the rear brakes.

                      Here is a pic of my unit which I am working on the make it more stable, have better braking and grip and be overall safer;
                      https://postimg.cc/sG1ZgfqN

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                      • #86
                        Originally posted by BoldEagle View Post
                        Some awesome detail in the OP and a great read for the build log. I am getting some great ideas for my Cuore and are interested to see what you might do with the rear brakes.

                        Here is a pic of my unit which I am working on the make it more stable, have better braking and grip and be overall safer;
                        https://postimg.cc/sG1ZgfqN
                        Thanks dude, sadly that link you posted, I can't access it. I've been thinking about the rear brakes. YRV or Sirion GTVI rear drums are bigger, so maybe at some point, I'll do them. Honestly, it is not that needed, the rear end is so light and they aren't really needed. If I were to do it, like the front I would go crazy with it and that gets expensive.
                        Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
                        Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
                        Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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                        • #87
                          January 2020: Supercheap Auto recently had a big sale on some things, like oil and such. So I took this opportunity to service the car. It's been less than my usual 5,000km, however, I've done three track days in the car so it's well overdue in my eyes.





                          Car was jacked up and drained quick smart.





                          Replaced the sump plug washer, ran out of copper ones but I had some ally ones lying around.





                          Filter replaced.





                          I thought it would be a good time to chuck some new plugs in too while I'm there.





                          The cover came off with ease.





                          Revealing the coil packs.





                          Am I doing it right?





                          Old plugs came out easy enough, they look ok for 4 years old.





                          New ones certainly look better.





                          And done.



                          Couple other things. I originally fitted a pod to the car ages ago, but it sounded like arse with the auto. I thought it'd be fun to chuck it on again to see if its better. It is! Will get a nicer one soon.



                          Now lastly, we noticed this when we did the manual swap. The bar that connects to each side of the k-frame was completely munted. Now it looks like it came from hitting something, hard! I tried to think back hard and I don't think it was me, but who knows. Either way I wanted it sorted.





                          Luckily I kept a spare, you can see how munted it got.





                          It needed a bit of work to get back in but eventually got it sorted.





                          I did notice that there is a bar that goes to one of the engine mounts. The bolt was finger tight, so I think some of the vibrations I've been noticing lately could've been coming from that.
                          Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
                          Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
                          Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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                          • #88
                            March 2020: Sometimes in life things happen and things come up, and despite being too good to be true, they aren't. This has happened to me a few times now. I think about something, look for something, lose interest after finding nothing. Then like clockwork, I give up, and the ultimate thing presents itself to me.

                            Firstly why? I've owned a lot of cars in the last 5 years while owning my blue Cuore. And I've been and driven so very very fast and more 'special' cars. But nothing puts a smile on my face like driving the Cuore. My friends always laughed at me, but I truly meant it when I said I would never sell it, and I wasn't planning to. There was something always in the back of my head though. Most of the work I've done on my car has been great. But particularly in the early days, a lot of the stuff I've done, I did for the first time.

                            Now is that enough justification to get a new car, not really. However, something pretty special popped up.

                            This popped up on my timeline on Facebook and I knew I had to have it. This is a 1-owner, 2002 Daihatsu Cuore in an unfaded red. It's manual with AC and has only 31,000km on the clock. Its been garaged it's entire life and has 18 years of service history. It's dead stock and is completely original.





                            Me with the original owner.





                            So what's the plan then, better believe its not staying stock. Some might think it's silly to modify this, but quite frankly it's my car and I want to. Also, I will be continuing this thread my journey is simply ongoing in a new chassis. Here's a little comparison of the two cars currently.





                            So a mate and I wasted absolutely no time getting this swapped over. We quickly took the car for those above pics to get a snapshot in stock form, but it was back to my new garage to get started. I won't go into insane detail of the mods as you've all mostly seen them.

                            We started off with the rear. Braided brake lines and coilovers in.





                            Front brakes.





                            Front coilovers.





                            Clear side indicators.





                            Wheels and tyres of course.





                            Lastly the seats, I didn't realise how dirty the GTVI seats were, I'll rent a cleaner soon and get that sorted.





                            Also gave the knob and handbrake a quick clean.









                            So happy already with how it looks. Quickly went out for some photos before we ran out of light.











                            So much more planned for this. Window tint is number 1 on the list to get done, its already booked for a week from now.
                            Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
                            Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
                            Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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                            • #89
                              March 2020: Had a great time at a friend's workshop fixing up a few of the little things on the car.





                              It started off easy with a quick service. Workshop tools are epic.





                              Filter and oil. Strangely, the car was heavily overfilled.





                              We popped it up to check a few things out, holy balls its clean under here.





                              The rear was a little low, so we quickly sorted that.

                              [



                              Handbrake adjustment and rear drum clean.





                              All wheels rebalanced and aligned.





                              Big issue I've had with the car is a hesitation on hard acceleration. I already knew this was likely the fact the car has been run on E10 its entire life. So we started with a good intake clean.









                              Much better.





                              Also thought it would be a good idea to get some injector cleaner in there.





                              Lenny also had a good look at the exhaust, in the spirit of doing everything properly. He's going to do up a custom 2" stainless Catback system. All mandrel bent and tig welded, but that'll be next week. Will likely do up an intake for a pod filter too.
                              Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
                              Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
                              Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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                              • #90
                                March 2020: Alrighty, been keen on doing this since getting the car. I honestly forgot how quiet these cars are stock. Despite having basically no sound deadening from stock the car feels like it is electric sometimes.

                                Finally though, its time for an exhaust. Now in the past on the blue car, I simply had the factory big muffler removed with a cheap hot dog resonator being added in its place. With a shiny tip of cause. As with the theme of the new car though, we're doing it properly this time though. So I popped over to Hunterstreet Automotive to get it done.





                                Let start by looking at how yuck the old system is.





























                                Time to rip it out, bit silly there isn't a good centre flange on the exhaust, nothing a bit of cutting cant fix.





                                We reused the stock flange off the headers so there won't be a need to use a flex joint.





                                For the pipe we decided to use 2 Inch, 409 stainless steel. All bends are mandrel and all joins will be tigged.





                                For the resonator, we used a quality and Australian built, Amron, 12x5 inch barrel muffler. This will give the car a deep note without to much rasp.





                                Let the work begin.

































                                The final product.

















                                Always great fun in the workshop on a weekend.





                                As per a fellow member's recommendation, we also swapped around my springs in the buckets.





                                Honestly, this makes complete sense.





                                Also, I quickly swapped over the head units between the two cars.





                                Happy to see it has a proper mounting kit already.





                                Better than my previous setup lol.





                                My fascia is a bit hacked, I'll look for another at some point.





                                Finishing up with some last pics.























                                Daily: '00 Daihatsu Cuore "Kelly" - Build Thread -
                                Project / Weekender: '05 Subaru Liberty 3.0R-B Wagon - Build Thread -
                                Motorcycle: '14 Triumph Street Triple 660 - Build Thread -

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