AW11 HKS Turbo System build

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

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.

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
 
 
 

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. 

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. 

Far out those rear wheels have moved a long way forwards.  IC look neat, nice and short.

yeah that looks neat and tidy setup like that man. good stuff. 

I know it's a bit soft but I was kind of keen to keep the a/c so that makes space at the front of the car very tight.
My current thinking is a large-ish radiator mounted flat above the gearbox with a blow through fan mounted underneath.
I have a supercharged engine cover to help fit all that in
I think I read somewhere that the air flow on adubs is from under the car, past the engine and out through the engine cover - given the shape of the car the area behind the rear window looks like it would be a low pressure area.
I would maybe need some sort of divider to separate the hot air from the turbo and manifold from the intercooler and radiator.
Actually, just had a thought - the Corolla I bought had a narrow but thick Koyorad radiator that took up just over half the width of the standard area. The turbo and wastegate sat in the empty space on the drivers side. If I could do a similar thing I could create a vacant space for the W2A heat exchanger.
Could maybe even use the radiator from the Corolla
Hmmm some serious conceptual thought is required......
Pete