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Ae86 booter rebuild
Well lawds
Just said I'd stick up this build thread of my mates 86 reg booter Ae86 that I am currently doing for him
firstly to start off the booter is by far one of the cleanest in the country, few on here can vouch for that
Initially bought it from Doofer on here back in 2009 and since then it has covered a whopping 4000 miles
It came with a low torque 4age that was in need of a little tlc so we got valves re seated head skimmed new valve seals and put a Trd metal head gasket on it but it was always a plan to put in a new plant once money was there
So the low torque 4age above is for sale too if anybody wants it
We had considered few options such as 20v, f20c, Sr20 and 4agze
But to keep it Toyota and narrow it down it had to be 20v or 4agze, some may remember i having a poll up here asking which ye would choose and as to why
Well it did help and it pushed us in the direction we wanted to go from day 1, and so it was 4agze 1600 supercharged
So the search began to buy a complete car with 4agze runnin gear, went to see quite a few including one dirt bag of a purple levin in cork
Anyhow we ended up buying a Corolla Ceres in Clare
The owner was bang on and had receipts and paperwork stacked mountain high for it
He had bought the engine from a half cut in maylasia and had it built by engine specialist in maylasia
He took us into house to show us a DVD of the complete engine build from start to finish
Summit I have never seen before by and engine builder
Even showed him setting torque wrench and tightening everything to Toyota spec even down to the nuts on the thermostat housing
With hardly any reason to drive the car as it only had 11k kilometres on it since fitted...we still did anyhow and it pulled well in every gear
So we brought it on
The owner gave us everything he ever had for car right down to the bottle of oil for the supercharger
He had receipts for 3.7k for buying engine and building engine and shipping of engine to Ireland, all of which I have to prove and I will upload pics of them later
So I drove it for a week or so just to make sure there was goin to be nothing wrong with it and to break it in gently as it had being parked for awhile
Good fun car to drive for a fwd, it is runnin 1 bar boost
And with that all done it was time to pull out the tools and start ripping them both
At this stage I would also like to mention if anyone would like a corolla Ceres rolling shell now is the time to contact me
Be funky rig to drop 2litre diesel into and cheap 1.6 tax
Anyhow back on topic
With there being some wiring issues I searched for ways to do it and got pointed in the direction of someone that would make me up a new loom
That man was Bryan Duggan, aka Jdm874agze off here
And I have to say the man is a legend, and extremely helpful always in the receiving end of phone for all my 600 questions ;)
Bryan made up a complete new loom from the 2 looms we gave him and he also made up a short harness to go from ecu to dash loom and also modified the mileage clocks so that the rev clock would read accurate
^^^ some man for 1 man
Next up while we were ripping around the dash area it was time to locate a new dash as old one was all cracked up top
So big thanks go out to the following 3 people who sold it>transported it and > collected it for me
So thanks to Doofer, Reilly and DarrenC on here for getting it all the way up from Wexford
Then I was in need for a intercooler and I got that from a man that can get ya anything from a Fmic to a crack whore............... Mr John Boost Hickey
So thanks to Mr Boost too for that, ps its all polished up now too so it like new
Also had previously bought a J-Blood Vented bonnet off a young chap local enough to us
So without further delay I will give ye a bit of spec and a teaser pic of what it stood like before
And I will update the thread with step by step photos of the build tomorrow evening
Now its no 2jz rig but will be a good fit road car
Spec
Fully built 4agze 1600 supercharged engine
Bigger crank pully lightweight
Smaller supercharger pulley
Metal head gasket
Magnacor Coilpack leads
Hks 4 branch manifold and downpipe
Hks de cat
Janspeed cat back
Hks mushroom air filter
Samco vacuum hoses
Samco intercooler pipes
We fitted 20v flywheel as it was lighter than low torque one
Also fitted brand new Exedy clutch kit too
Have ordered a Driftworks alloy rad off of Lorcan @ Drift2motorsport, cheapest around for alloy rad new
Few plans for the car which are
Alloy rad surround with twin fans
Alloy coolant bottle
Custom stainless intercooler piping
Custom stainless air intake pipe
Carbon aero catches
4 pot callipers front
Drilled and grooved brakes
Hydro handbrake
Change few bits with car setup too
Possibly changing wheels, currently has Ssr star sharks up front and Ssr mesh wheels rear
Car is going for a full respray next week
Plan to fit Coilovers to it soon but currently it sits and handles well with lowering springs and adjustable shocks
Bit of car spec
Cusco dash dodger cage
Cusco strut braces front and rear
Cusco anti roll bars front and rear
Full kit ( Origin ?? )
J-Blood vented bonnet
Ssr star sharks and ssr mesh wheels
2 way diff with 4:3 Cwp
Project Mu braided brake hoses
White line tail lights
Recaro drivers seat
Apexi boost gauge
Vacuum gauge
Apexi turbo timer
Deep dish steering wheel
Wide angle rear view mirror
Slight brown tint all round incl windscreen
I will leave ye be tonight with a Pic of how it sat before I got my hands on it
All opinions welcome
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Whilst i here, Anyone know of anyone that has samco elbows in stock????
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All that reading and only one miserable c**t of a picture. :)
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murray motorsport dublin, dont always have great stock though, im usually lazy and buy from demon tweeks, expensive but massive stocks
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At James ok
I will try upload another pic for u ;)
@raff
Murray Motorsport don't have them in stock and I emailed demon tweeks but I got no reply from them
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Ya joe sold that ages ago
Hav my eyes on summit tho that's locked up, just waitin on cash to free up
On topic related to this thread I will upload pics later.... But good news is it fired up tonight anyhow, tis runnin minty mint
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Ye are going to be picture less while reading this cause I done the writing first so I uploading the pics now and adding them as they uploaded
So put on yer reading glasses and slippers and sit back ;)
Here are sum pics of the donor car...corolla ceres,,, previos owner loved his choons :)
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1673.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1674.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1676.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1677.jpg[/IMG]
Right firstly I have to try remember the steps I took,so be patient with me
They ain't in any order some were done before others
I firstly cleaned down the engine bay with detergent and a pressure washer and then sanded it down and rubbed it down with scotch cloth and painted her all up, I am glad to say that's my first time ever spraying and I thinks it turned out quite well
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1684.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1685.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1690.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1691.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1759.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1766.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1767.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1770.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1752.jpg[/IMG]
Cocky fucker ain't I ;)....... Any over spray was cleaned down and loom was being stpipped down after this
With Bryan having the wiring loom done, i stepped up and done the rest, so with the altenator being on the passenger side now and previously being on drivers side I had to strip the loom crossing by slam panel and bring the wires across, but seeing as one was going out through valance I had to cut it and extend it
I had a shit load of tidying to do with the wires all around engine bay
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1888.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1887.jpg[/IMG]
So as above altenator is now on passenger side
Using the original 4agze altenator bracket leaves the altenator sitting close to the anti roll bar and with this ae86 having cusco anti roll bars they thicker so didn't help that situation
So we started out by shaving 5mm off the back of bracket to keep it closer to engine and away from the Ben of anti roll bar
And we had no choice but to cut a bit of the altenators skin off :)
This has no effect to altenator just appearance
But it now clears the anti roll bar
There was a few changes that had to be made
Flywheel was too tall so I used 20v flywheel and as I mentioned previously it was lighter so advantage was to us, and we used a exedy clutch kit
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1757.jpg[/IMG]
Water pipes were designed for fwd setup so I obviously had to change that to rwd
Amazingly it was like Toyota had designed it in a way that it could be changed using original parts by pulling out my mate (mr angle grinder)
Pics to show what it was like before hand and I used the original thermostat housing off of the fwd setup
Had to make brackets to hold thermostat housing in place
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1879.jpg[/IMG]
^^^Bracket made and as ya will see in pics below supercharger bracket had to be modified to allow engine mount to fit
[IMG]http://i980.photobucket.com/albums/a...IMG_1871-1.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...IMG_1872-1.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1873.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...IMG_1874-1.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1838.jpg[/IMG]
fairly tight and snug
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1863.jpg[/IMG]
[IMG]http://i980.photobucket.com/albums/a...r/IMG_1864.jpg[/IMG]
Next job on list was to change water neck on back of engine, and use the ones from low torque engine as it was narrower and we needed all the room we could get back there
Had to change the switches too to keep them matching the loom
Also relocated map sensor
From this area to below brake servo
Some may notice that I still running air con pump but that is just simply cause it has a twin pulley and I needed it to run power steering pump
Time to drop the petrol tank and fit the new fuel pump
So that was sorted in few min
With that job done I moved onto cleaning down the subframe and painting it up
Also cleaned down underneath of car and Shultz it
More info and pics to come
Thanks so far for taking time to look
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I must say its a Very well put together thread so far Skin.. Savage work goin in.. I'm happy and depressed about this all at the same time... On one hand Im delighted that my first twincam was passed in to the right hands and that its getting the right attention and not cut up or wrecked as a track car.. I loved it and definitely never should have sold it looking back.. And I'm depressed because I know il definitely never get it back now after trying for the last few years :)... Lyons will go before that goes now..
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stay tuned for the interesting pics now they uploaded jst now to photobucket so i goin to transfer them now,,, also the part about lyons going... ""That can be sorted for the right kinda money, i can even shoot him with his own gun if needed to make it look like he did it"" haha
a lot of dedicated time went into it and i glad to say its finished except for fitting front mount once the samco hoses arrive from demon tweeks in the uk and alloy rad from lorcan @ drift2.
its off for full paint job next week
let me know what ya think of the rest of the pics aarron
