ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, October 31, 2011 2:38 AM
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Progress Report …
I have to admit when I first started this project I thought it would be up and running by now. It is taking a whole lot longer than I first thought.. I have to admit, I do have a bit of a tendency to over-engineer things (pretty evident) .. Currently all the interior is at the upholsters, no rush for this for me as it will be the last thing that goes back in. I have had no end of trouble with the painter – Just can’t seem to get him to actually turn up to look at the car and settle on a day! .. may need to explore other options…
The engine is just about finished – I have rebuilt the alternator, air cond compressor and just finished the dizzy (actually it’s just a cam angle sensor now). Throttle cable has been custom made, and I have done all the brackets for it . I have also installed the LS2 coil packs and made custom leads for them. Just need to find somewhere that does the plugs ..
I have just discovered that my second set of extractors also have a crack! – so now I have to get someone to fabricate a set for me. I am very reluctant to do this as from what I understand it’s pretty hard to find a better exhaust manifold than the OEM one ? – if anyone has any ideas please let me know.
Intercooler heat exchanger is all mounted up too and I have been able to fabricate in brackets for the battery.. I was thinking I was going to need to relocate the battery, but not the case luckily!..
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jdmr288
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, October 31, 2011 8:49 AM
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Now THAT'S an engine! I don't think Toyota could have made it look that good from the factory. Props on the time invested in this!
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gear2
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Re:AW11 SC - Full Rebuild (and I mean full!)
Tuesday, November 01, 2011 7:05 AM
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Do you have any photos of how you did the Intercooler heat exchanger mounting? Im just about to do the same thing and couldn't draft up a neat way that didn't require me moving the battery to the funk. Also like your use to the tablet to read your manuals...
post edited by gear2 - Tuesday, November 01, 2011 7:09 AM
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
Tuesday, November 01, 2011 7:16 AM
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Will take some pics of that this afternoon
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, November 21, 2011 0:25 PM
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UPDATE:
I have spent the past few weekends fitting the engine and fabricating the intake piping. After fitting the new clutch and gearbox I discovered my original intake design was not going to fit and also it fouled the speedo cable. The IC barrel did not fit at all.. Although I didn’t want to alter the fundamental layout, I have been forced to relocate the IC barrel into the boot and although it does reduce the boot space by a small amount I have worked out a method of making it a show piece – wait for final photos as it should look really cool!...
Anyway – Everything else fits nicely including the super charger, all with excellent clearances.. And it looks great!!!!!!!...
I have made a special 3 strap extension for my engine crane, and a castered trolley that the motor fits perfectly onto – long and short I can drop the engine and gearbox is about 15 minutes! ..
The car has been totally rust proofed in every cavity and the entire underside has been coated with rubberised body deadening.
I also made a trolley for the body to sit on – this has casters and bolts to the suspension points on the chassis so I can move the body about. This was the best way to allow it to go to paint.
On Sunday it was loaded onto a flatbed and taken to paint (finally)…It will be there for about 3 weeks and should coincide nicely with the completion of the upholstery.
I will now spend the next few weeks putting together all the wiring looms – these will be completely new for the entire car! – I don’t trust 25 year old wiring and oxidised connectors.. Thank goodness for Lithia Toyota in Oregon USA for their massive assistance in sourcing new parts for me. They managed to source for me a brand new exhaust manifold (yes – brand new OEM!), all the engine bay, boot warning plates/stickers (brand new again). Plus so many other parts.. Also need to thank Bruce from Oldmac Toyota Cleveland – he has been great too sourcing parts from japan (although the USA seems to have most things still hanging about)…
I think there is light at the end of the tunnel…J
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MR2QIK
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, November 21, 2011 1:02 AM
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Gorgeous! Will keep an eye on this thread.
MR2QIK - "The Little Car That Could"  320rwkw @ 19psi (pump fuel, no giggle gas) 11.96 @ 116mph (with 228rwkw)
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dennis the menace
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, November 21, 2011 1:39 AM
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Gob smacked!! This has to be the most awesome 4AGZE AW I have seen in, well, ever!
And big thumbs up for the use of the Rotrex - the Skelta made a huge step forward when we moved to this unit. How is your clearance for replacing the SC belt? I've recently worked on an SC14 equipped AAW that required the supercharger to be unbolted before the belt could be changed . . .
Can't wait to see this baby on the road, Keith!
Past-President, MR2 Owners Club Qld "There is a fine line between hobby and obsession."
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, November 21, 2011 1:54 AM
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Rotrex is a beautiful fit !!!!! - Took a lot of design work and trial and error, but I nailed it and the clearence is excellent. Wont be any issue changing belts, or even the pulley if necessary....
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RdS
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, November 21, 2011 3:23 AM
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seriously good work here. really impressed. :D
cant wait to see it painted.
you need to take more pics though! so much work happening, and so much GOOD work, and i just want to see! :)
anyway, keep it up. :)
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, November 21, 2011 9:01 AM
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Ok.. What do you guys want photos of??? I'm about to start rebuilding the air cond units.. That may be interesting ?
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just_ace
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Re:AW11 SC - Full Rebuild (and I mean full!)
Monday, November 21, 2011 10:27 AM
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photos of.......EVERYTHING!!!!!
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
Tuesday, December 06, 2011 12:33 AM
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Just a quick update - Working on many things but the one I want to share is the recon of the aircond and vents system. Really, this is one of those jobs that everyone could/should do. It's cheap in parts and the results will blow you away (ha!)
The photos are a mix of before and after - basically the vents system is split into 3 units, a blower unit with the main fan - this also controls recirculation. That leads into the air cond cooler (if fitted), and the final is the heater and diverter. The diverter is full of flaps that open and close to direct air to the desired vent system. One issue is these diverter flaps are covered with foam for sealing and in 20 yo cars this has turned into powder!... no sealing and a stink through the system. Also, the air cond cooler and heater both are finned arrangements (like radiators) - they collect crap overtime and become less and less effective -and stink too!... I took these both out and using both compressed air and careful use of high pressure water cleaned these to as good as new. All the rusty brackets were sand blasted and painted with rust proofing zinc paint. The diverters were all cleaned of all residue foam, rust, dirt etc and new high density foam applied. All sealing edges have been re-foamed with the correct size sealing foam. I carefully inspected all PCB's for dry joints and resolders all the headers for the wiring. On wiring, I replaced some wiring and re-loomed it all. All relays were replaced with OEM newbie’s...
Finally, all moving parts were greased with graphite grease and re assembled. End result is an Air cond/Vent system that is as good as if not better than new! ... AND - you all could do this in a weekend!....(but remember you will be de-gassing your air cond so take that into account).
Currently I'm wiring up the engine to the Ecu - ( BTW: LS2 Coil packs f'kn send you across the room when you energise them and discharge through your finger!!!) -As the car has gone to the paint shop I have the garage floor to layout all the wiring for the entire car, then replacing and testing will occur - should be able to test everything!!!....
Oh and just spent another motza on stereo gear! - watch out for a full Alpine RX Reference series system with dual subs (yep in an AW11) and over 2000 W of RMS POWER! - fun fun....
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
Tuesday, December 06, 2011 12:40 AM
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here are a couple more photos - my painting prowess on the intake, LS2 coils, and half way through the rest of the ECU wiring (not as bad or disorganised as it looks)...
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Doctor
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Re:AW11 SC - Full Rebuild (and I mean full!)
Tuesday, December 06, 2011 12:56 AM
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Looking good Keith.
The before photos are scary though.
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
Tuesday, December 06, 2011 1:01 PM
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when can I watch you do yours ???
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