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Are you sure the axle nut was tightened adequately? From a quick google search it looks like it should be 180ft*lbs
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Bingo! That's exactly what happened. The Geo hub spline is too long, and if put all the way into the spindle, the splines poke out so that even if the axle nut were tightened all the way down, it wouldn't be hugging the bearing, it would just be at it's dead end. When I replaced the bearing the first time I forgot to add my small stack of washers to the back of the bearing. I made sure to do that this time, and tighten the snot out of it with a big breaker bar. I'm very sure I got at least 180 ft lbs on that sucker; I pulled it
real hard. I've been driving it around with no sign of bearing failure again.
I've been eliminating minor annoyances like rattling sounds from the muffler and doors. I added a killswitch, successfully employing the coil driver wire method (divert it to a normally closed switch on the shifter knob). Works like a charm, did not use a relay. For safety it might be a good idea though.
Problem of the day is that no matter what gear I'm in, but especially second gear when accelerating away from a stop, at a little over 2k RPM, I get hesitation/jerking sputters. Someone told me to try changing the spark plug gap, as he'd had a similar problem whose remedy was spark plug gap widening. This sounds feasible, as I added singh grooves and the dynamics in the cylinders is definitely gonna be different than OEM. Thoughts? I still haven't gone through and checked all the solderless connections I made, but this problem really does not behave like a faulty wire... it reliably happens every time at that RPM when throttle is applied, no matter how fast or slow acceleration is, no matter if the car is turning or not. On a related note, I don't think my timing is quiiiite right yet either, as in higher speeds/rpms, I'm getting more vibration than I think I should. This could be a 3 cyl thing, but I know what a metro is supposed to feel like. Takes a pretty long time to start up from cold too - often needs a little throttle help to start up, but then won't stay running at idle until I get a solid minute of driving in.
I appreciate everyone's help and insight with this project. Feels great to finally start driving it around and not having to stop and fix something catastrophic every time I take it out for a ride. I'm figuring a lot of this stuff out for myself as I go, but it's nice to get input and document it here. I'm probably going to move a bunch of the content I've made to crxfi.com, which I purchased a while ago. In due time, folks. In due time.
