I had been obsessing over the best way to give my N/A A-Dub a power up - 3SGTE, 2ZZ, 3SGE, Turbo 4AGE, 20V, cammed Bigport, anyway it was getting ridiculous so I bought an old HKS turbo kit for the 4AGE - so now I am locked into a turboed 4AGE
I think the parts may originally have been part of the HKS Twincharger kit for the 4AGZE.
The kit came with

• A small Garrett T3 with a HKS turbine housing - seems to be in good shape but i will probably get it rebuilt before I use it

• HKS hi mount turbo manifold

 

• Cast dump pipe and O2 sensor

 

• An modified AFM that has been lock wired

• A weird ass "peninsula per4mance" intercooler

• A sketchy looking injector manifold with 3 extra injectors that looks like it bolts on to a GZE inlet

 
The plan at this point is to use the turbo, manifold and dump pipe and ditch the rest.
I was concerned that a high mount turbo would fit in but after a test fit last weekend it looks like there will be enough room - I will need to move a couple of hoses and add some heat shielding but I expected that. I will probably need to change the angle of one of the shifter cables as well. 

 
I am going with a W2A intercooler and got one of these
 
It fits in really well and was only $180.00
 
I also got a brand new Bosch starter motor for a GZE off Amazon for $200 (arrived in 4 days!) so I can move the starter away from the turbo and onto the inlet side. The original starter still fit but was really close to the turbo.
So there is still a bunch of stuff I need to track down as funds allowed.

• An ECU - thinking Megasquirt DIY PNP
• Coil on plug ignition set up
• Bigger injectors -7MGTE should do it
• Some GZE pistons - I want to get some new 8.9:1 pistons from the late GZE but may go with some used 8.0:1 to start with to get things going then do a full engine build later
• Blow off valve - looking for a early HKS one to match the rest of the kit
• Wanted to use a small port head and inlet manifold but may also wait till later

As much as would like to get it all done straight away budget and family mean it is going to take a while. I am also not looking for mega power - if I get 200-250 hp I will be happy - although I want the build to be solid enough that I can give it a hiding at a track day without any issues.
Let me know if you see any pitfalls in my plans.
Pete

how did you go with this?  updates....

Slow progress I am afraid.
I am chasing down the bits I need for the motor side.
I want a small port head and n/a inlet manifold and I am going to use smallport GZE pistons.
Corolla Spares have a small port GZE short motor with a spun bearing that I will take a look at this week to see how bad the damage is - it may be a good option.
I am also modifying a sump at the moment by adding 20mm to the depth, adding some baffles and extending the pick up. Kind of like this
http://hardtechlife.com/4age-deep-baffled-oil-pan/
I really do not want spin a bearing and drop a rod like I did at the 2015 track day.
Then I need to chase down a suitable computer.
I have also decided to have a go at the North Shore Sporting Car Club twilight super sprints that start in October and the entry fees, memberships and Cams license is burning up more of my limited budget.
Definitely a long term project but I will update when something noteworthy happens
Pete.

Small port gze pistons can still be bought brand new for quite a good price.
It wouldn't be hard to find a smallport head and inlet manifold on gumtree.
That's what i did with my current build and just used my old bigport block etc.

Good suggestion - I actually had already requested a quote off Amayama this morning. They have them listed for about $48.00 for 0.5 oversize - will be a bit extra with freight but still cheap for a decent piston.
I think I will skip the engine with a spun bearing - the crank is likely to be stuffed and possibly the block too.
Over the weekend I got into the sump mods. Looking at the standard sump it is no surprise these engines suffer oil starvation on right handers. The gaps around the stock baffle are so big they do nothing to stop hot oil ending up at the flywheel end of the engine.
 
First up I sliced the bottom off the sump.
 
Then I made up some small plates out of some 1.5mm steel I had lying around to fill in the gaps at the corners of the factory baffle. It took a bit of time to get them to fit closely to the sides of the sump and then used a big 5mm monel rivet to hold them in place.

 
Then I used a drift to tap down the gap at the back of the baffle

So now the space for the oil to bypass the baffle is almost zero.
 

I reckon the oil will still be able to return to the sump through the slot further forward on the baffle and the main oil pick up hole.
When I add 20mm extra to the depth of the sump I will also need to extend the pickup by the same amount. I will cut the last 20mm off another oil pick up and add it to this one.
All i need to do now is see if I can remember how to tig weld so I can put it all back together.
Pete
 
 
 

Did you ever have a project that just kind of escalated?
Over the weekend I bought a damaged AE93 Corolla SX - the previous owner had spent a fortune building the ultimate sleeper and fitted it with...
A rebuilt smallport GZE all reciepted with new stock pistons, HKS valve springs, all the ARP hardware and cam tech cams
Fidanza cam gears
Haltech PS1000 tuned for e85
575cc Bosch Xspurt injectors
Garret gt2871r on a custom manifold with separate turbo smart wastegate.
3 inch exhaust with remote Xforce varex muffler
Massive front mount completely concealed behind the grille
LSD e58 rebuilt with receipts
A heavy duty Jim Berry clutch
A spare 2 week old Tilton/MRP twin plate race clutch and flywheel that was too aggressive for street.
Dyno sheet for 228kw atw
BC Racing coil overs
The car was a nice and clean SX hatch until it was rear ended hard by a speeding p plater.

I haven't got any pics yet because I haven't been home in daylight - will get some up on the weekend.

Plan is to use the engine, gearbox, Haltech in the adub and sell the rest. The turbo set up won't fit unfortunately but I am keen to use the HKS set up I already have anyway. I reckon after selling the rolling shell, turbo set up and the Bigport/C52 out of my car I should come out about even. At least that's how I have sold it the financial controller anyway.

There is still plenty to do making it all fit and work in the adub but picking up the wreck has kicked the project along quite a few steps.

Pete

sounds like a bit of love went into that rolla!  
 
i was kind of hoping you were going to use the lot and sell what you had.. i would of been keen on that hks manifold.. hahahaaa
 
gt2871r is what i am running on my twincharger. 

Way too much love probably.
I thought about trying to squeeze in the full set up but the HKS manifold keeps everything so neat and tidy and compact.
And being old school HKS it is kind of cool too.
The guys who built the Corolla did an awesome job to get the turbo, wastegate and big intercooler hidden away without any evidence from outside the car but the plumbing is still a bit of a nightmare with the pipes into the intercooler having to wrap in and around the dump pipe.
I like a clean and neat engine bay - ratty wiring and spaghetti junction plumbing doesn't do it for me.
I am tempted to try to make the GT2871r fit - it spins so nice compared to the old HKS/Garrett turbo.
What sort of boost are you running on your set up?
Pete

28psi. but it's in dire need of a proper tune.   i plan on doing some changes soon which involves changing over one of my intercoolers cores to a different one and probably mounting it in the boot and bringing the turbo up from the generic position to over the gearbox. 
then i'll drive it up to the city (720k's away) and get it tuned properly and see what it can do. 

28 psi is serious stuff.
Moving the turbo to a rear mount is interesting - the twin-charge set up will allow you to go to a free flowing high volume manifold like the WRC guys. You can avoid the lag this set would normally get with the supercharger instead of the weapons grade anti-lag the guys with unlimited budgets can use. You wont have room to fit the manifold below but that's the idea.

Had a big day in the garage removing all the good bits from the Corolla wreck. There was some fairly dodgy stuff lifting the front of the car high enough to clear the motor using only a trolley jack and pieces of wood but got it done with all limbs intact

I had a some trouble with the driveshafts because there is an extra bit of unthreaded material at the end of the shaft that means a standard 32mm socket can't reach the nut (see pic). Tried to buy a deep 32mm at Autobarn/Repco/Mitre 10 but no go. I ended taking off the whole upright however I still need to get the shaft out of the hub so Ican get the car back on it's wheels.

Anyway the engine is out and couldn't resist doing a quick mock up with the HKS set up.
  

There is a little messing around with plumbing but I am really happy with how neat it all fits together.
Mounts for the W2A will also be pretty straight forward.
I still need to work out a solution for the W2A heat exchanger though.
Pete