Another quick update.
Started making Sh!tManifold v1.0 to get this show on the road.
 
Bought a $30 vice from Bunnings and taped some random bits of alloy to it to make it into a pipe crushing machine.

 
Bought some 3" aluminium tubing and crushed it over a 36mm pine plug to form the plenum chamber.

 
Brings it down to below the 45mm gap I have between the chopped 4AGZE manifold and the twinscrew unit.

 
A quick dummy fit shows it will do the job.

 
Quick dummy up of the intercooler placement and intake pipe paths.

 
Had a friend weld some plate to the chopped 4AGZE manifold. Each hole is for the cylinder runners and needs ported out to suit.

 
First port roughed out.

 
Few lumpy bits to smooth out.

 
It's nothing special, but it will work.

 
I'm working with minimal tools at the moment, just a rotary file bit in my dewalt drill

 
The plate welded to the manifold will be trimmed to size once the porting has been completed.

 
Then a section of the plenum will be removed to match the trimmed plate on the manifold.

 
Then the two halves will be welded together forming a sealed manifold/plenum.

 
Quick fitment to the motor to have a look.

 
Add the plenum.

 
Another angle.

 
Till next time...

It's a 10+year old 2 speed Dewalt that I picked up at a yard sale for $5. Battery was knackered and I have oodles of Lithium Polymer batteries laying around, so I converted it to run off them. Normally the battery is ziptied to the base of the drill to make it mobile, but I had just swapped batteries and hadn't put it back on :P

Playing with some other stuff over the weekend.
 
I picked up a dirty cheap M90 supercharger from a Ford Thunderbird which is in much nicer condition then the M90 from the L67 Commodore I picked up around xmas. It's got better mounting points, better ports and is a more compact unit. So I decided to play around with some potential fitments for the supercharger in the engine bay.
 
Mount it standing upright like the factory TRD unit. However not a lot of space to fit an sizable intercooler between the outlet and the intake.

 
Next up I tested it with the longer drive snout from the L67 M90 (TB one is just too short for this position).
There is plenty of space to build a laminova intercooler in the valley of the motor, however due to the position of the pulley directly above the engine mount, it will require a couple of idler and tensioner pullies.

 
Or it could even be mounted like this (factory Thunderbird orientation), this allows plenty of space for everything.

 
A quick dummy fit of some pipe work shows it is a good option.

 
During the weekend I helped B24 collect his 2GR from the engine builders and he offered me some spare 2GR valves to do some dummy fitting into the 1MZ heads I have sitting around. The 2GR valves are a honking big valve compared to the 1MZ.

1MZ-FE (without VVT-i)
Intake valve diameter: 34.0 mm
Exhaust valve diameter: 27.3 mm
Intake valve overall length: 95.50 mm
Exhaust valve overall length: 95.50 mm
Valve stem diameter: 5.5 mm
 
2GR-FE
Intake valve diameter: 38.0 mm
Exhaust valve diameter: 32.0 mm
Overall intake valve length: 105.85 mm
Overall exhaust valve length: 110.4 mm
Valve stem diameter: 5.5 mm
 
First think I noticed was, the two heads I have here are not a matched pair... One is a VVT head and one is not.

 

 
There is a noticeable difference in combustion chamber, valve guides and valve seats.
 


 
Plonking the valves in one head showed they were very close to touching, however they are unseated and would clear once fitted to the heads correctly. It would just be a case of ensuring the duration/overlap of the camshafts would not cause an interference.

 
Dropping them into the other head showed that due to the increased squish area, the valves will not sit without machining it back. However I reckon it can still be done.

 
One of these heads has had the intake ports ported out, so I thought I would show a quick comparison.

Stock porting, pretty rough and pretty average.

 
Ported head, cleaned up and looks the goods.

 
Gives me ideas for when I get around to porting some heads....

Finally bought myself a dremel on the weekend to clean up the ****ized rough job I did to form the first half of the 4AGZE intake. It took about 2 hours to run 80 and 120 grit sanding drums through the ports and it is now "good enough". The photos might look like the ports are rough, but they are smooth to touch, which is good enough for me.
 









 
Next step is to weld the plenum parts together and get it on the motor.

At least you've got some heads to practice on ;-)

Great updates, keep them coming!

5SGTE
Guess you've found where the sunroof water is drained to ;-)

I believe the rust forms due to leaf litter and dirt wedging between the body and guard.
The sunroof drains are probably just adding to it :P