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DaewooOfDeath
DaewooOfDeath SuperDork
4/25/15 12:31 a.m.

It's been nearly a year since the demise of the Daewoo of Death. Granted, that car had sentimental value out the ass, it was faster than it had any right to be and the track days were hilarious, but I should not let nostalgia cloud the facts. Almost every Daewoo part on the Daewoo of Death needed to be upgraded if I was to move forward.

That had started out relatively cheap. I could junkyard source stuff like larger rotors and spare body parts. The cheapness of the parts also made me completely remorseless about chopping stuff up and fabricating body panels out of discarded central air conditioning units. However, I was running out of low hanging fruit.

The Daewoo family of engines had oil control and heat management problems that were going to take many moneys to fix. I was actually getting ready to swap in a Hyundai beta drive train, which would have been an enormous PIA but probably better than Daewoo E-tech turd polishing. My brakes were turning blue after the last track day and there was no obvious upgrade path. Best of all, lateral grip was getting high enough that chassis rigidity was becoming a major issue.

In other words $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

But now I have something better. Behold, Rocinante, the 2002 Hyundai Avante Deluxe.

I've christened her Rocinante in honor of Don Quixote's horse. Like the great knight of Lamancha's fine steed, my Rocinante is unlikely to inspire awe in the passerby. Further, like the legendary battle charger of yore, my car is awkward, past its prime and soon to be engaged in tasks far beyond its capabilities. Last, but by far most important, like the biological Rocinante, my Rocinante shall charge headfirst into many excellent and droll adventures.

She's got a 1.5L alpha DOHC engine with 104 hp and a 5 speed stick. It's immediately obvious that a 104 hp Hyundai makes a lot more power than the original 1.5L, 106 hp Daewoo engine. Gearing is similar, weight is similar and this Avante is vastly faster than the Daewoo was before the 2.0L motorswap.

The suspension is four wheel struts. Due to the sub-optimal geometry up front, I probably can't lower Rocinante at all, which is okay because it's pretty low as is and Korea is REALLY bumpy. The brakes are all discs, the unibody is miles stiffer than the Nubira and most of the rust is confined to dangerous places like control arms. I'm excited to begin!

RexSeven
RexSeven UberDork
4/25/15 1:31 a.m.

Good job, man! That's the Hyundai Elantra in the US, correct? My sister had a 2002 2.0L, and it was a fine commuter until crankwalk reared its ugly head at about 90k miles. I've heard many of the go-fast bits from the Tiburon/Tuscani are either a direct swap or can be adapted to fit (like aftermarket LSDs, though that may only apply to the 2.0L). Will this be another school project?

petegossett
petegossett GRM+ Memberand PowerDork
4/26/15 5:10 a.m.

And a generic cone filter will really wake up that engine.

Woody
Woody GRM+ Memberand MegaDork
4/26/15 7:00 a.m.

In reply to DaewooOfDeath:

I can't seem to find the appropriate thread, but I'd like to nominate you for that "Which GRM'er would you like to hear about on a podcast" deal.

DaewooOfDeath
DaewooOfDeath Dork
4/27/15 12:09 a.m.
RexSeven wrote: Good job, man! That's the Hyundai Elantra in the US, correct? My sister had a 2002 2.0L, and it was a fine commuter until crankwalk reared its ugly head at about 90k miles. I've heard many of the go-fast bits from the Tiburon/Tuscani are either a direct swap or can be adapted to fit (like aftermarket LSDs, though that may only apply to the 2.0L). Will this be another school project?

Thank you sir!

Just me on this project, though I've got something pretty awesome cooking with a college. You'll hear about it first if it comes to fruition.

Yeah, Avante is a KDM Elantra. I've basically got an Accent twin cam engine, which isn't as good as the 2.0, but it does take 100 lbs off the nose.

It's almost identical to a 2g Tiburon under the skin.

DaewooOfDeath
DaewooOfDeath Dork
4/27/15 12:10 a.m.
Woody wrote: In reply to DaewooOfDeath: I can't seem to find the appropriate thread, but I'd like to nominate you for that "Which GRM'er would you like to hear about on a podcast" deal.

I'm honored.

:)

DaewooOfDeath
DaewooOfDeath SuperDork
4/27/15 10:02 a.m.

First movement on the project.

I went down to my friends' race shop this weekend and fixed a horrifying problem, fiddled with my $50 turbo and completely failed to upgrade the brakes. Brace yourselves, there are windmills aplenty just ahead!

So, is this, like, a problem or something?

Or, you know, how about this?

Not visible in these pictures is the rust hole (trench?) circling about 260 degrees of the left ball joint or the bushings that looked sort of like used kitty litter.

I did find something interesting when we were all under the lift, though.

See that groovy little cast iron piece? The one that rotates inside the rubber bushing? It turns out that shimming under that mount raises the roll center and dials out some anti-squat. I'm gonna try just that in a month or two after I install my (planned but not yet purchased) coil overs.

In other news, I am officially old. For the first time in my life, I paid actual, real money in order to make my vehicle quieter. It was not long ago, back before the ravages of time sapped my spirit and rendered me a desiccated fogey, that I would have embraced a rusty exhaust as a "free racing pipes." In my lamentations, I prostrated myself before SWMBO, who empathized by remarking that "I prefer elderly Ben and anyway, you've been balding since you were 24, so it can't really get much worse."

Since the racing shop actually had tools, I consoled myself by disassembling my $50, junkyard, Kia Carnival-sourced turbocharger. I was expecting I'd have to rebuild it, seeing as it was the same price as a nice surf and turf for a berkeleying turbo. However, upon pulling it apart, the condition seems remarkably solid. The shaft rotates freely, the oil seals are in good condition and both the impeller and turbine, aside from some minor grime, look brand new. Shibby.

By the way, if anybody speaks IHI, I'm curious as to what this signifies.

People whose engineering knowledge surpasses even my journalism degree convinced me, after only a few hours' discussion and no more than half a dozen veiled threats, that I should not attempt to radically engineer this turbo with a die grinder and TIG welder. Once more crestfallen, I soothed myself by cleaning up some crappy casting on the impeller inlet, eliminating two humps near the flange and lightly porting the wastegate.

I cleverly didn't take any useful before pictures, but here's the after. I knocked down a ridge shrouding the flapper and opened the side nearest the opening up a few millimeters.

Here's the exhaust inlet before.

And after.

Lastly, I got to sit down with the guys and draw up plans for the next stage of aero development on this 400 hp, turbo beta powered Tuscani (gen 2 Tiburon in the US).

Want to touch the lady ...

Swank Force One
Swank Force One MegaDork
4/27/15 10:06 a.m.

Babby turbo!!!!

DaewooOfDeath
DaewooOfDeath Dork
4/27/15 10:10 a.m.

Also, my awesome Tiburon aluminum calipers, Sonata rotors and stock hubs jumble won't fit under my 15 inch wheels.

So yeah, wheel shopping time.

DaewooOfDeath
DaewooOfDeath Dork
4/27/15 10:16 a.m.
Swank Force One wrote: Babby turbo!!!!

It's not the size of the boat ...

gamby
gamby UltimaDork
4/27/15 11:39 p.m.

OMFG those control arms

DaewooOfDeath
DaewooOfDeath SuperDork
4/27/15 11:58 p.m.

I concur. Apparently it was a recall item. More than a couple broke in half, according to the interwebz.

mndsm
mndsm MegaDork
4/28/15 12:00 a.m.

I keep reading this as the accidental Hyundai. Like I accidentally a car.

DaewooOfDeath
DaewooOfDeath Dork
4/30/15 1:55 a.m.

Assemble, oh masters of taste and subtle practitioners of fine art.

Since the Tuscani (2g Tiburon) brake upgrade won't fit inside the stock 15s, I need to upgrade to at least 16 inch rims.

I want to make my car as sleeper as possible, which means I'd prefer to stick with OEM wheels. There seem to be four common styles I can poach that will fit. Which do you prefer?

16 inch Magnus wheels.

16 inch Tosca wheels.

17 inch Tosca wheels.

16 inch Sonata wheels.

petegossett
petegossett GRM+ Memberand PowerDork
4/30/15 5:32 a.m.

Option-1

Stealthtercel
Stealthtercel Dork
4/30/15 6:27 a.m.

For my money (all $.02 of it), Option 3 is the best choice for "sleeper."

DeadSkunk
DeadSkunk UltraDork
4/30/15 7:09 a.m.

Door #3 !!

RossD
RossD PowerDork
4/30/15 7:15 a.m.

The lightest of the 16" wheels. (Cheaper tires than 17s)

pinchvalve
pinchvalve GRM+ Memberand MegaDork
4/30/15 7:21 a.m.

"problems that were going to take many moneys to fix."

I love that line.

Bobzilla
Bobzilla UltimaDork
4/30/15 7:45 a.m.

http://i2.photobucket.com/albums/y17/bobnjenmiller/Cartoday004copy.jpg

Those were my favorite wheels on the Elantra. IIRC, they were the 2002-2004 Sonata V6 LX wheels.

AS for the lower control arms, there was a recall in the US for those. Mine rusted out around 140k miles and 8 Indiana winters.

The cheap/easy suspension/brake set up is to use 2002 Sonata V6 Rotors (11"), Tiburon calipers and Hawk HPS Tiburon pads, Tiburon KYB struts and H&R springs, Tib 19mm rear sway bar and poly bushings for front and rear sway bars. The rear calipers/pads are the same as the Tib so just pick your choice of pads. Car does things a cheap Korean econobox should never be able to do!

As much as I love the Forte SX with the big block, I do miss this car. Rust forced the move after 10 and a half happy years!

DaewooOfDeath
DaewooOfDeath Dork
4/30/15 8:27 a.m.

Yeah, I'm all about that particular brake swap. I have all the parts sitting at the race team shop in Gumi, just waiting for wheels. I've never seen the 16's you have a picture of in Korea. They might be a US only thing.

As for the suspension, I was very happy with my no-bars, high roll-center setup on the Daewoo and want to use it again. There are about 8 Tiburon race cars outside getting parted out or upgraded and I can pick the coilovers I want for not that much money. I'm thinking right now I'll go 9/7 kg/mm with a Tiburon rear bar and no bar up front for the street and then swap to a 9/12 kg/mm no bars setup for the track.

BTW, since you miss your Elantra, you might enjoy these dudes I saw floating around at the Korea International Circuit.

More stuff here: http://bengarrido.com/more-photos-from-the-yeongam-race-weekend-courtesy-of-chris-marsh/

http://bengarrido.com/photos-from-the-yeongam-race-weekend/

Bobzilla
Bobzilla UltimaDork
4/30/15 5:33 p.m.

I'm curious what these cars weigh there. Mine, on a diet was still 2880lbs empty. 1/4 tank of fuel, 15lb 16x7 wheels, lighter exhaust, no spare/tools, etc. I'd dropped about 65lbs from the car over stock and it was still damn near 2900 before I put my fat butt in!

DaewooOfDeath
DaewooOfDeath SuperDork
4/30/15 5:49 p.m.
Bobzilla wrote: I'm curious what these cars weigh there. Mine, on a diet was still 2880lbs empty. 1/4 tank of fuel, 15lb 16x7 wheels, lighter exhaust, no spare/tools, etc. I'd dropped about 65lbs from the car over stock and it was still damn near 2900 before I put my fat butt in!

2700 ish. Alphas are lighter than betas. ;)

DaewooOfDeath
DaewooOfDeath Dork
5/4/15 12:43 a.m.

Sorry, misunderstood you Bob.

The minimum class weight for the Elantras is 1150 kg. All of those cars are right on the limit.

DaewooOfDeath
DaewooOfDeath SuperDork
12/2/15 1:04 a.m.

Finally! Action on Rocinante!

I finally got my coilovers and dropped those babies on. Also got some wheels. It turns out all those Daewoo and Chevy wheels wouldn't fit and the Sonata wheels are about as common as unicorn feathers. So yeah, I venture once more unto the land of used aftermarket wheels and got a set of NOT AT ALL SLEEPER WHEELS.

Hooray for mission creap!

Those are Tien coilovers with 10kg front and 12kg rear springs. I'm running everything at max ride height so as to not ruin the suspension geometry. Man, the car handles WAY better now.

If you want to read my much more long-winded writeup, it's here. http://bengarrido.com/2015/12/02/rocinante-gets-sharper-teeth/

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