2010/08/01 08:52:22
GUN METAL
The inside of the donk looked mal treated and hows the rust !, was it in the salt water for a while ?????????

anyway looks like you have it looking good now 1

Also i love the LEDs in the steering column i have had that issue for ages......GREAT FIX !!!! :)

while i think of it from the gearbox thread why not just use the equal length driveshafts, i have the AE101 in mine with said EL driveshafts.............unless you can just use all the C52 stuff ???

keep up the great work, oh and i loved the prices how bout adding in the mates rates labout and all the gearbox stuff, maybe run a page and keep it updated with the costs, sounds like youve spend around 12 allready ......spend baby SPEND !

When you have it the way you want it it will nearly be as fast as an elise and cost less that a 1/4 of the price......i am guessing
2010/08/01 20:14:09
AdrianS
Yes, the half-cut had seen some salt water, but none made it into the engine or gearbox, although the both the idler pulleys (alt and a/c) were shocking. I had the starter and alternator checked by an auto-elec; the alternator was ok, but the starter needed some cleaning up. I think it's got wet in the container ?

I don't think I can re-use the ae111 driveshafts, as the cv joints are f'ed. Having said that, I'll see how it looks when the c52 is out of the mr2, and I have them side-by-side.
I'm trying to do as much as possible before taking the aw off the road, so the actual swap can be done fast. I can't do the gearbox mount or exhaust yet, but I have the engine wired up; all I need to do is the clutch/flywheel, and finish replacing the gearbox seals.

The problem with borrowing a mate's workshop is that I have to fit in around him; I can work on the drivetrain any time, but I can't have a dead mr2 on the floor for more than a few days.

Anyway, I hope to do the swap in 1-2 weeks time. Yippee!

Cost:
When it's all done, I might add up the costs (or maybe not). It's the 6 speed box that makes it costly; you could get a blacktop on its own for a lot less, but then you need the sensors/ecu etc. I want a factory look and stock toyota ecu (for now).
I think I'm up to about $6-7k so far, with nothing much left to spend.
(Until the bodywork gets done).
My guess is that I will have spent about $15k (including the car itself) all up, but that includes new suspension, exhaust, 20v engine, 6-speed box, lsd, and minor bodywork.
A lot of money for a 22 year old car, but it will be unique, and I love driving it, even with the current 16v. Not quite an elise (about 200 kg too heavy, and 30 hp short), but still a fun toy.

As I may have mentioned earlier, I had custom springs wound for it, as I wanted to keep the ride height standard. I do a fair bit of country driving, including the occasional dirt road, and need the ground clearance.
2010/08/01 20:28:53
AdrianS
Gearchange graphs
I have been playing with my spreadsheets, looking at gear ratios.
The power curves are approximate, as they are taken off the net, but I don't care about the actual power figures, just the shape of the curve.
Note : the force curve is the torque curve translated to force (thrust) at the wheels in the specified gear.

Blacktop / c160
I created this using a blacktop dyno chart I found on the net, from an AE111. Nasty dip at 4500 RPM.




Here the same chart using Toyota's claimed (flywheel) figures : interesting how the dip at 4500 RPM is almost gone, and the much stronger top end.

2010/05/02 01:46:23
AdrianS
Got the clutch, p/plate and flywheel back today! Flywheel skimmed, std. exedy clutch kit for the AE111 BZR. Looks quite good.
I hope to bolt the tranny to the engine on saturday, fit alternator, a/c etc, and check belt lengths. I can use the std. alternator belt, but the a/c belt I have is designed to also run the power steering pump, which I've removed. I'll cut it to fit, and use that to find a replacement.
Finally some progress!
2010/03/25 23:54:42
AdrianS
Update - entire driveline bolted up ready to install, still waiting on time / workshop for installation. Got another rally on this w/end, so the Fiat got priority (again).

Note - Exedy supplied the wrong throwout clutch bearing (twice!). The correct bearing is listed by them as being for a "supercharged corolla".
I now have the right bearing, and the Exedy part number for next time.

ps Looks like I'm back in the Dyno business!
2010/03/26 02:08:21
evl_132
Fiat hey! Sounds interesting... I've got an old 132gls 1800 that's been in my family for ages, love that car.

Good news on getting everything ready for the conversion, im sure the end result will be more than rewarding. Whos going to do the install if you don't mind me asking? Need to update this with some new pics!

Whats the go in regards to dyno business? Sounds even more interesting.
2010/03/26 14:05:23
AdrianS
quote:
Originally posted by evl_132

Fiat hey! Sounds interesting... I've got an old 132gls 1800 that's been in my family for ages, love that car.


The Fiat is a 1965? 1500 twincam. We are running selected historic events - the Alpine was a blast; this weekend is a shakedown for the Old BP rally in May.

quote:
Good news on getting everything ready for the conversion, im sure the end result will be more than rewarding. Whos going to do the install if you don't mind me asking? Need to update this with some new pics!


The install is being done by myself and the guy I navigate for (it's his Fiat). He has decades of experience building rally cars, including some serious kit.
Many more pics when we get it in (shift linkage cables, water hoses, my planned cold air intake, etc.)

quote:
Whats the go in regards to dyno business? Sounds even more interesting.


I have worked as a programmer for Dyno Dynamics on several occasions over the years (decades), and am about to start some part-time work for them again. I can't say too much about the specifics, but I worked on their first 4wd dyno, along with many other interesting projects in the past : go-kart dyno, emissions testing systems, Toyota's durability test cell at Altona, among others.

I could bore you to death on atmospheric correction factors, SAE standards, and the limits of dyno accuracy. As a programmer, coding to control 100's of kW is much more fun than shifting numbers around in a database.

ps One of the reasons I have a soft spot for the 4AGE is that I've seen them run for tens of hours on the dyno at 7500 RPM WOT, exhaust glowing red/yellow. The heat soak and cooling requirements for an engine dyno get interesting too, after the first few hours at WOT.
2010/04/24 23:03:40
AdrianS
Much progress !!


Engine lifter :




Workmanship for a tool we will probably never re-use :




Tool for holding hub to remove driveshaft nuts :




And now we have a second drivetrain on the floor :

2010/04/24 23:20:47
Knightrous
Interesting exhaust there on that old 4A... Doesn't look stock...
2010/04/24 23:23:27
AdrianS
ctd...

Stripped the engine bay of all plumbing - we'll re-run that when the engine is in.


Finished off the gearbox and cable mount today.

The c52 gearbox mounting plate has been re-worked to fit the c160 casing, while still using the stock aw11 rubber mount.

To mount the pivot for the selector, we first re-drilled and tapped the small threaded hole on the box in front of the selector shaft, and fitted a threaded insert. A mount was made which bolts to the insert, and snakes around to pick up a threaded hole on the other side of the casing. The mount has to curve to clear the speedo sender, and was shimmed to the correct height. The original c52 pivot bracket (with some modification to clear a bolt head) bolts to threaded holes in the new mount.




Also highlighted the timing marks as best I could :




Made up a remote mount so I can run a low oil pressure light, along with the gauge : no pics yet.

Monday is bolt-in day!!!!
<< ..34.. >> - Powered by APG vNext Trial
© 2025 APG vNext Trial Version 5.5

Use My Existing Forum Account

Use My Social Media Account