Adjust headlamps beam

My projector lights beam is nonsense. With the beam adjusted like that, I cannot see the road at night at all, because only 5 meters in front of me are illuminated.

Look. nonsense. I decided to fix this annoying problem.

Firstly, remove the eyes. There are a few sites teaching you how to remove the eyes, so I will not go through it.

Once you have the eyes removed, use any normal hairdryer to heat up the glue sealing the lamp together. This could take about 10 mins to open up each side. The projector light (crystal ball thingy) is on the left, remove the screws that are holding it to the casing.

Then, remove the 3 screws on the projector light itself to separate the different “layers”.

AHHHHH! This is the culprit. Donno which donkey fellow went designed the light to look like this. Find a way to cut it straight. I used a sheet metal cutter for this.

 

Testing the modified beam out….

Kaotim SIAP!!! =D

Moved!

Hi tharr, I have changed the address from “donkeypowder” to “keretabapakau”, since it suits the car theme more. :)

Enjois!

200km/h speedometer

I feel that the standard 260 kph speedometer of my putra to be too optimistic, and the speedometer face is so childish looking. So I was looking to change it. This is a base spec speedometer.

Being extremely budget on this one, I managed to find one for RM10 from a nice guy from the lowyat forums. The meter that I got had a broken temp and fuel gauge, but not like I was going to use it anyway.

ROGOLLL!

The guy said that the odometer was not working, and I could see the mileage was 500k+ because of this…So I reset the mileage to match with mine. Taking it out is quite simple as all you need is to pull one end out. However you have to put the numbers back in a certain way otherwise the numbers won’t be aligned in a straight line. This will take some trial and error.

Meanwhile, I also cleaned the numbers to make them shiney and whiney.

Cleaned one on the right, dirty one on the left.

Also, do NOT lose this tiny bearing. Otherwise your speedo will be damn stupid. It is supposedto go into the white hole in the middle of the blue circle in the pic.

Now, to test the speedo whether it’s working or not. I used a drill with the bit turned the other way around to spin the thingy.

But then I found my speedometer cable, so I used that instead.

Top speed >=D

Swapping the 1.3 speedometer onto the 1.8 one was quite simple. The back of the two meters are slighty different, but it won’t be a problem. No need for mods to it at all.

Done! Notice the childish font and background of the old speedometer. =)

100km later, still running fine!

Replacing foam speaker surround

The speakers on anodder car were getting yucky. The foam has TOTALLY disintegrated. Here’s what it looks like together with one that I already fixed.

Look at it, so disgraceful. =/

Luckily, you can get it fixed for reallyreally cheap. =) I bought 2 foam speaker surrounds from pasar road, RM3 each.

Here’s what it looks like, the graceful foam.

scrape out the extra crapppp with a ruler or something…

Apply glue to the sides, PVA glue works just fine, no need to use the special “speaker glue” as the effects are more or less the same.

Glue when wet is whitish, but when it dries its almsot unnoticable.

Fixed speakers! =D

DIY oil catch tank

After cleaning my intake manifold, I didn't want it to get dirty again so quickly knowing how much a pain in the ass it will be. So, I made a DIY oil catch tank for it. Borrowing the ideas from KHguan’s DIY, I made my own one, but without the intake side as the air is a vacuum, having no oil vapors what.so.EVERRRRRRRR!

Browsing around car accessory shops you can find oil catch tanks to be in the RM80-120 range, 60 for a cheapo one. I got my proton saga petrol filter for RM4 instead.

=D

Other misc parts to buy is a hose clip and some gas hose(usually transparent with weaving but i bought the ones in black cause they look neater.) The top hole in the petrol filter goes into the intake manifold, and the bottom one the valve cover.

Next, choose a spot in your engine bay to mount the tank. I chose this place near the firewall again, so that its not that messy and I won’t have to use cable ties or whatsoever.

Drilling a hole is easy. So, I drilled one in the hose clip to fit the nut. After that, adjust the hose clip to fit the petrol filter, tight but not too tight.

Here’s the thingy mounted in my engine bay. Hopefully the hardware store uncker didn’t con me and the pipes can withstand the heat. The connection at the valve cover was abit loose too, so I added another tiny hose clip to it to prevent it popping out. The filter can either be drained out or changed(only RM4 maaaa! =P) once it gets full. Which will take a few thousand kms I guess.

There we have a decent looking and cheap oil catch tank.

More responsive throttle pedal

My throttle cable has a very squishy feeling when pressing it lightly. Not a problem for most cars, but its very annoying on my car especially on uphill jams. Because my throttle cable is squishy, if i press down on it a lil’ bit, no response from the engine. Press a little more, the engine revs till about 3k. Either I engage clutch at 3k rpm or keep stalling. Which is very embarrassing. =/

I took pics only after i modified it, I put some ABS glue in the place highlighted in blue(can get a can at any hardware shop for around 6 ringgit, used to glue ABS pipes together, when it hardens it turns into ABS plastic.

Originally the place was hollow, so the rubber had some space to squish together. Like i said, the problem only occurred in my car, not a very common problem, this.

The red part is the firewall, green is the accelerator pedal. No screws required to remove the cable, everythign is held together by clippy clips.

This is where the cable connects from inside the engine bay,

Bore-ing and cleaning the intake manifold pt. 2

So, continuing from part 1, making the gasket for the intake manifold. You can use those normal gasket papers available from any car parts shop that sells it. Its quite cheap and it does the job quite well, less than rm10 can get you one BIG sheet of paper. making gaskets are very easy, just trace and cut. =) This is the end product.

Next day, fixing the whole car back together… Manifold and gasket goes in first,

Manifold is in, now connecting all the wires and plugs.

See how rusty my brakes are, haven’t driven the donkey for a few weeks already.

…. and it’s all done! Will be making a DIY oil catch tank to prevent the manifold from getting dirty so fast again.

Bore-ing and cleaning the intake manifold

So one night for no reason at all again, I went to check on my throttle body. I noticed it was kinda different from the normal throttle body sizes form google.

SO I TOOK IT OUT. >:D

and

It was 60mm, from the 4G92 mivec/ 4g63 Evo III engine… What a jolly delightful surprise. =)

Only problem was, the intake manifold hole was too small for it. (54mm)

Soooooo, it was time to take it out for some boring/cleaning. Be sure to label all the pipes and whatever nonsense you are removing, otherwise, when you fakap, you fakap bad like mad.

Letting out all the fuel in the fuel rail…Some of the petrol leaked out, this was all that i managed to catch.

Well, shouldnt put it to waste, right? =)

…And here is the car with the intake manifold taken out. Didnt take very long, about 2-3 hours to remove it, and this is the first time i am trying.

Parts all kept in my bedroom to prevent getting thrown away by my mom.

Next, boring the manifold. Since I didnt have a proper filing bit, I just used a grinder bit with a drill. This was a goddam slow and boring process. =/

But I managed to bore it. quite satisfied with the new size of the intake hole. 58/59mm, leaving it roughly 1mm smaller than the throttle body as i was afraid that i might overbore the manifold.

Now, for the cleaning process. T’was a good decision to remove the whole intake manifold as compared to just boring it on the car itself, as it was all… black.

I asked one random workshop how much it would cost if i sent it to them for cleaning,

RM40.

Nah, I’d rather do it myself. Bought thinner for about 18 bucks, and one of those brushes for toilet bowls for 2 bucks. Make sure the brush is not plastic cause most plastic reacts with thinner, and I doubt that melted plastic in my intake would be very fancy at all. Open up the brush and make it straight, from its bendy shape. Also, cut off a little portion of it and connect it to a wire. There you have your very own 2 pipe cleaners! ;D

I only used like 2/3 of the can of thinner to wash the intake, so for about 20 bucks, you can get it washed yourself, and still have like 1 liter of thinner left for your amusement. How cheap is that. So after cleaning, the manifold naturally will be dirty. I used some engine degreaser to wash it, available at pasar road for rm18 a gallon, will last you for a long long time. If you don’t wanna buy that though, you can still use thinner to wash the outside too. I had enough thinner on my hands for a day though.

See how clean it is now?!?!?!?!??!?! =D