precisegrak
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/02/21 16:45:51
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Doing a quick calculation on your compression ratio Keith. If you've got 8 :1 CR with a .051" head gasket....a .027" gasket will give you 8.43:1 if everything else remains the same.
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/03/07 08:05:22
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yes - correct it will be about 8.5:1..
I am about to remove the motor again .. It isn't going again, not sure if it's the computer or what but it dropped a cyl firstly then pretty much dropped 2 others shortly after. I removed the injectors and they are all fine, Fuel pressure is good. Two things I am very dubious about - the Wolf, and the LS2 coils. I bought the coils on eBay - brand new and only $20 each. I am wondering if they are seconds or if they didn't measure up to OEM specs. My wiring to them is good with correct ratings. The dwell set in the computer is correct too, but they just fail to excite me with the intensity of the spark.. it's not bright blue as I would expect. I also wonder if the reason so much timing had to be pulled to get the car to run was due to a weak spark???..
I'm not too fused actually - I need to remove the engine again armed with more knowledge and a page of to-do’s ...
My Kelford Cams arrived from NZ last week - I went for the 193T these have reduced overlap specifically for TC/SC apps, and in the vicinity of 266 deg. Also have some adjustable cam wheels on their way.. Once the head is off we will measure it to see how much can be shaved off with a safety margin to bring the comp up to 9:1 (maybe 9.2:1). I'm replacing the 440cc injectors with Bosch 750cc's These are the new ones that are incredible - can meter fuel very accurately and even though they are quite large for the AGZE will operate better than current 440 denso..
New head gasket and a very importing step I missed was laser alignment of the pulleys to the SC. I think they should be very close, but might as well do it all properly..
Upholsterer still has not started the interior – that’s 6 months he has had it for !!!! – I’s ok at the moment, but I better not get to a point where I have everything else finished and are just waiting for the interior…
I’ve also got 300mm Wilwoods on order from Fast Brakes in the USA – Will let you know how they fit, but are meant to just bolt up!. I’m using the Dynapro 4 Piston units as they have dust boots and are legal here.
Need to seel up all the entry and exits into the boot too as rain finds it way in !
That’s my update … Easter is not looking good – this project is really dragging out, but I want to get it right !
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Knightrous
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/03/07 09:22:45
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If your spending all this money, why play with a Wolf ECU, why not a Haltec or even a Motec if you've got the cash. Both brands have a great reputation, support and run some amazingly complex engines.
For your coil situation, have you considered the Coil on Plug units from a 1ZZFE motor? These are relatively cheap, super easy to control (no igniters required) and fit straight onto the 4AGE.
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/03/07 09:47:18
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I haven't really considered the 1ZZFE coils - Might see if I can find a cheap set to try.. Do they have an inbuilt ignighter (which is why I like the LS2) - Also Wolf recommended the LS2, and when working, are killer coils .. As for Motec/Haltec, I did look at them to start with and they were cost prohibitive.. I have been assured the Wolf will do the job and do it really well – Just need to get the motor sorted then will work on the final tune.
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Knightrous
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/03/07 12:39:41
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The 1ZZFE coils have internal ignitors. I picked up my set for my 4AGE 20V for $140 with plugs matching connectors. 
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MCT_MR2
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/03/09 09:49:27
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i would agree on the 1zzfe coilpacks, they are denso quality, have a strong spark, and don't break down. With a nice centre plate, they can also look close to factory. Good choice on the cams, i run some that are only mildly larger, and with the factory gze manifolds, i have only 8inch of vaccum. I'm assumig the bosch injectors are injector dynamics modified cng gas injectors. If so make sure youf tuner follows the injector scaling and dead times very carefully, as they are very low, and effect your injection timing and idle quality severely.
'88 MR2 4AGTE W/ EFR6258 224.6KW @ 20PSI more to come......
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/04/13 19:13:33
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Hi Everyone - It has been quite a while since my last update so apologies for that...
I've just returned from Japan - nothing to do with my AW11, but pretty cool anyway - You would not believe how many variants of Toyota exist up there!....
Since my last update there has been a lot of sole searching and head scratching.. I have pulled the motor and done an accurate comp calculation - would you believe 7.8:1 ... any wonder it was not performing!.... SO, back to the machine shop, fresh calculations and a plan .. more shaving than you would find on redtube... result comp is now calculated at 9.3:1 ... it should be very happy ...
Injectors are now 750cc Bosch jiggers ...
Cams are new Kelford items, specially made for forced induction .. not too agressive, but enough to be effective..
As the block/head are now closer together, I have installed HKS adjustable cam sprockets .. just to make sure they are performing as designed ..
I also discovered 2 LS2 coils were faulty ... the leads were incorrect too.. So I have replaced all the coils with MSD LS2s and the leads are MSD 8.5mm super race things ...
Actually - I bought a set of 8 coils, so have 4 spare - Anyone want to buy 4 MSD LS2's $125 each ?
Also, since the last post - My Wilwood kit has arrive from fastbrakes.com ... these are fantastic ! - Legal 300mm cross drilled and slotted rotors, 4 piston Dynapro calliper’s with dust boots (legal) 2 sets of pads, brackets, and dot approved (so adr approved) braided lines ..
Just bolted on ! - perfect!!!!!!
The car is booked to have the exhaust done this week - 3" stainless mandrel race setup - but legal!.. exhaust innovations in Capalaba Brisbane are exhaust artisans !
Turbosmart made a BOV for me - somewhat bigger than the pissy little thing I thought would do the job - $500 later and it's a sexy thing ... plumbed back so legal ...
We are booked on the Dyno on the 5th May ... My tuner expects big numbers now! - maybe too big!!!!!!!!!!....
PWR made a purge system for me so I can get the IC working properly - they are awesome ...
My expectations are > 300 at the rear wheels ... (KW) - I'll keep going till I get it but all indications are this will be easy .. hay might have the worlds first 400 – imagine how drivable that would be ...
Not sure I'm a bit silly, but I've just spent $2K on an amp and set of 6.5" speakers for it - Oh well it's cost me close to $40K so far so I have stopped counting .... I'm thinking I may have overcapitalised
I still have not had the upholstery done – I’m not in a hurry and they know that, but they have had it now for 8 months!!!!!! .. it’s a $5k job too…
Anyone want info Wilwoods, or the LS2’s let me know – BTW Brakes Landed in Aus were about $1000 … I got a couple of spare sets of pads too but have found they are available off the shelf at speedway spares in Brisbane. ..
I want to get the engine bak together this weekend – might even turn the key to see what it does..
AND … I will post more updates on this ridiculously over the top restoration!
Cheers
KD
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MCT_MR2
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/04/13 21:52:05
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with the numbers you have in mind now, it begs the question.... A: what are the intentions for the car and B: what is the most powerful vehicle you have driven?? I don't mean to offend in any way, but that is a lot of power for the adub chassis to deal with, the front lifts at high speed, the front torque mounts have been known to tear the chassis, and the integrity of the chassis will come in to question once you push past the 300rwkw mark. By your injector sizing, i'm guessing your attempting this on pump fuel...... All the best and i'm curious to see how you go. P.S. To put 400wkw in to perspective, that is 250kw per litre, which is equal in power per displacement as the auto salon 4 cylinder rwd record holder, who made 502.1rwkw from a 2litre.
post edited by MCT_MR2 - 2012/04/13 22:05:07
'88 MR2 4AGTE W/ EFR6258 224.6KW @ 20PSI more to come......
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Knightrous
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/04/14 01:21:05
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ozhummer Also, since the last post - My Wilwood kit has arrive from fastbrakes.com ... these are fantastic ! - Legal 300mm cross drilled and slotted rotors, 4 piston Dynapro calliper’s with dust boots (legal) 2 sets of pads, brackets, and dot approved (so adr approved) braided lines ..
Just bolted on ! - perfect!!!!!!
Anyone want info Wilwoods, or the LS2’s let me know – BTW Brakes Landed in Aus were about $1000 …
What is the weight of the Wilwood caliper and rotor together? I'm currently looking at putting the ST184 twin pot brakes + ZZE123 254X25 disc onto my AW11.... However once on the scales, they are looking to be 2-3kg heavier each corner, which has me having second thoughts on their effect to the cars handling and braking via extra unsprung weight. If the wilwood kit you have is close to the standard brake setup's weight, I might consider it as a better alternative.
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/04/14 11:31:00
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Wilwood calipers are about 1/4 the weight of the oem! The disks are a tad heavier, but for an extra 300 they can supply 2 piece alloy hats with steel rotors, these weight less than oem too. I went for the 300 mm solids, all up they would not weigh any more than the oem brakes!
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Knightrous
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/04/14 12:31:28
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If you have to remove the brakes for any reason, could you chuck them on the scales? Interested in the numbers :)
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MANDALAY
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/04/14 14:02:05
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The Turbosmart is an off the shelf unit how is it custom ?
I have the same unit
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MANDALAY
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/04/14 14:39:06
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Very nice build :) Looks familiar :) Can i offer a few observations you might want to consider. The idlers change them single row bearings will give up very quickly with a lot of play. Use the idlers of the 3SGE timing belt, double row. Personally i would of used an Autronic ECU . They are very good just that they dont have many fun bits like the MoTec but are really good for street tuning. What size is the PWR barrel, maybe a bit small. What is the water pump you have used. Suggest high flowing pump Johnson m90 Recommend COP's for sure With your gearing she probably will be around 16 psi max. If you get much more you have a restriction in what the engine can swallow. With a great flowing engine and the biggest Rotrex C38-91 max will be about 22 psi but it will have enormous power. You dont have VVTi so ild be careful in increasing the C/R especially without proper knock monitoring and control either with a separate unit ( Autronic, MoTec ) or an aftermarket one. BTW VVTi makes a world of difference 3 inch would be a bit too big unless its definitely over 250 RHKW. 2.5 might be better BTW i hope the clutch / gear box / drive shafts and more importantly the engine as its not forged is it ? that it can handle it. I think it will be very risky pushing over 240 RWPH Great to see another Rotrex !
post edited by MANDALAY - 2012/04/14 15:08:46
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ozhummer
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/05/07 09:00:48
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ALMOST FINISHED!!!!!!!!!!!!!!!!!!!!!!!!!! Car is back from tuners - Making ... hmm 'good' power! .. slightly exceeded expectations on pump fuel and running nice with a deep throaty lumpy idle, sounds like an old school muscle car. It's ready for the upholstery, and I think I will borrow necessary interior parts from my red car to get it registered. It has it’s blue plate with all required codes so no reason to hold off. I’ll drop it off this week. It’s looking awesome!!! But goes better! .. I have driven a lot of very powerful cars including my Group B Alfa twin turbo GTV6 with many hundreds of RWHP (ahh – many years ago that was..) .. I have a lot of WRX’s (including a rare STI 22B ) .. BUT – my MR2 is probably the quickest! – it’s ballistic. Task for today is pure finishing .. under body skins, side stripes and decals, when it’s done I will photograph it all and post some nice ones… I though the project would never be finished, but there is light at the end of the tunnel – ands it’s pretty bright… 
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dasic1
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Re:AW11 SC - Full Rebuild (and I mean full!)
2012/05/07 10:34:00
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post some pics of the 22b. I love them
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