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wiso's AW11 restoration to weekend fun/track car.

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wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Saturday, September 14, 2013 8:04 AM (permalink)
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Well this car has thus far been a drama. No updates for a while as I have been unable to work on it.
 
Got 1000km on the engine after it was rebuilt. then went to start it one day and just heard metal grinding. Pulled the sump apart to confirm the worst, the no.3 main bearing is totally stuffed, ground to the crapper, all the surface is flaking off. the rest are ok all be it slightly sctratched.
 
So out came the engine then that night i went to hospital with gall stones, so having that out for the past 4 weeks I have been on light duties so no engine work as stripping it down kinda requires heavy lifting, and twisting.
 
But starting to tinker again now. I picked up a spare 4age 3 rib for a replacement crank as that one seems to be off centre, hence the bearings going. so now gotta strip the engine down and clean it out, replace the crank pistons and rods with the smaller ones from the 3rib.
 
 
But today I did a little bit of dummy fitting, tried my quad throttle manifold I made on the spare engine, just to measure it up and see how it all fits, turns out gonna need to modify the airbox to make it fit on the 16v and in the engine bay.
 
For the past 6 months I have been slowly building a quad throttle manifold for a set of silver top quads I bought. using the stock silvertop manifold I cut this up, the filed the runners out as much as possible, cut the guts out of a t-vis plate, and bolted them together with JB-weld between them.
 
How my manifold started. cutting the silvertop one.

 
then how much needs to be ported

 
How the porting came up with the manifold glued together

 
My manifold Completed, just needs to have the JB-weld smoothed out with the dremel.

 
And today dummy fitted to the engine


 
and the modifications I need to do to the airbox to make it fit. it majority hits the alternator. and overall is too deep from the engine block, it will foul on the rear wall of the engine bay so I need to cut the depth off the box and weld a flat plate on it.

 
So now this will have to wait until Xmas when I go down to dads so i can modify the box. Ohh well engine will just have to go back together stock.

87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#31
wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Tuesday, January 07, 2014 7:18 AM (permalink)
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Well it has been a while since an update was put up. I was VERY VERY depressed for a while as the car was not going well, giving me heaps of dramas with oil pressure issues. After doing the first bearings i replaced the crank, new bearings cleaned her best I could, started her up and same thing, after a hundred KM's got the low oil pressure AGAIN. So I bit the bullet and paid an engine builder to do all the machining work on the engine. Save me wondering where I went wrong. So I got all the normal stuff done. 
 
Crank Linish, acid dip block, had to bore this block 0.020 oversize with new pistons, check deck, check head for valves seating, got the rotating assembly balenced. 
 
So once again got the block back in peices. Re assembled it and the car Only to find that once again after the first drive had Low oil pressure once been running for a while. Long story short by luck I remove the oil cap to check for oil then glanced over at the guage, the pressure went back up. I have a not right return valve in the intake manifold that stops the crankcase breathing so the pressure builds and stuffs my oil pressure. Not really happy as that meant the second engine was fine.
 
Anyway I have about 2300km on the engine as of now and its running very fine. So finally happy
 
all the Parts back all balanced

 
This engine has been twaeked, using blacktop rods and flywheel to save rotating mass weight

 

 
Decided to go for my Blue and Silver theme this time around

 
Just waiting on the piston rings to arrive, did as much as I could

 
and all finished


87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#32
wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Tuesday, January 07, 2014 7:23 AM (permalink)
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I put the car back togehter in the weekend before xmas 2013. 
 
Take 1 nicely modded rebuilt 4AGE 16V

 
and 1 Corolla C56 with MR2 Spyder Helical LSD with modified linkages to suit an AW11

 
Put them into a AW11 Hardtop with a sorted suspension setup

 
Throw some Nice brakes into the Mix

 
 
 
And hopefully you will end up with a car that goes as good as it looks.
 

87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#33

wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Tuesday, January 07, 2014 7:57 AM (permalink)
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I was doing some test driving around Sydney, making sure the engine was good. Went for a run through the Nasho with Tracey chasing.

 
At the new year i went down to my Dads place to sort out some niggly issues and give the car a good run to try and bed the engine in. the trip down I was leaking oil everywhere from the sump and dizzy seal, but it made the 900km journey.
 
While there I fitted up my new hurricance exhaust headers. modded the b-pipe to fit these. also reasled the sump again. last time I hope.

 
While there I painted the stock front bumper to match the colour. sanding the stock bars with 3 layers of paint is a prick to do.
 
I also did some finishing touches on the red one getting her ready to sell. So for the last time they are together I washed them and took some photos of my pair of twos.

 

 

 
Them having a quick kiss goodbye. HAHA

 
 

87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#34
wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Thursday, January 16, 2014 2:35 AM (permalink)
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well trying to sort out my quad throttle again, I picked up the manifold and found this, looks like the metal has tried to move and the JB weld stopped it, so she cracked. Let this be a lesson to people, it may not have stood upto engine vibration.
 

 
So i decided to cut the mountings an tubes off the front of the manifold, I smoothed the tubes into rounds I am going to now try to attached them to a manifold adapter with silicon hoses? I will have to wait and see how that comes up.
 

 
Ahh the **** you do when you are a tightarse.

87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#35
MR2QIK
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Re:wiso's AW11 restoration to weekend fun/track car. Thursday, January 16, 2014 3:18 AM (permalink)
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Sorry to hear about all the dramas with the motor but good to hear it's all back together & running now.

MR2QIK - "The Little Car That Could"



320rwkw @ 19psi (pump fuel, no giggle gas)
11.96 @ 116mph (with 228rwkw)
#36

wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Thursday, June 12, 2014 7:14 AM (permalink)
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well, its been a while since I last updated so here it goes. The engine has going along without much drama. been using alot of fuel up around the 11L/100km which is quite high for a 4age. So I have been forever stuffing around trying to find the cause of this.
 
I took the car out to Wakefeild park for its first time on the track. It went ok. felt massively underpowered. It developed a very strange lope in the idle after the first session, then after about 5 sessions my timing belt snapped :( . My awesome wife drove me a spare belt and tensioner down from Sydney so I can repair it and drive it home.
 

this is what happens when the springs get old, they look for an escape straight through the belt.

 
 
Then the following week got the car repaired so it was usable for our wedding day. Buffed here out the best I could.
 

 
 
 
 
 

87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#37
wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Thursday, June 12, 2014 7:23 AM (permalink)
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Since the car was no longer needed for anything major I decided it was time to continue my pet project and try putting those quad throttles on. I went a little over board though. As I am doing something rather differant with these. I am going to try and run them on the stock 4age bigport ecu with AFM. Si I have gone to tremendous effort to make sure the things still has a nice factory drivable idle. so I made and idle bypass screw similar to what the bigport throttle body has and plumbed it to each runner after the butterflies.
 



 
I also tweaked the stock ISCV for cold starts and mounted that underneath and tee'd into the bypass pipe. So I should theoretically have full idle control.

 
I had to route the fuel lines and wiring a little differant to stock, but should all work the same. had to change to a corolla FPR as they curl off to the side rather than straight down like the mr2 item.

 
This was the goal, but I could not get the blacktop airbox to seal reliably enough for use with the afm. So I have to go back to the drawing board and work something else out. It would have been great to use that though as it looks soo factory. You wouldn't really pick it
 


87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#38
MCT_MR2
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Re:wiso's AW11 restoration to weekend fun/track car. Thursday, June 12, 2014 10:29 AM (permalink)
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Nice update. Sorry to hear about you snapping the timing belt at the track. If it is any consolation, I had my timing belt tensioner bearing fail. Unlike you, my motor is no longer non interference and I have bent a few exhaust valves.

'88 MR2 4AGTE W/ EFR6258

224.6KW @ 20PSI

more to come......
#39
wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Thursday, June 12, 2014 10:29 PM (permalink)
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that sucks major. my last engine I built with these 8.1mm lift cams I used smallport pistons and that was an interference engine. thats why this time round I rebuilt with the stock bigport pistons. And lucky its all good. Even with the cams she does not touch, I would say its close though.

87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#40
MCT_MR2
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Re:wiso's AW11 restoration to weekend fun/track car. Friday, June 13, 2014 8:31 AM (permalink)
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Yeah, I have 9.3mm cams the are dialled in a bit aggressively with smallport gze pistons, so I wasnt very lucky at all.

'88 MR2 4AGTE W/ EFR6258

224.6KW @ 20PSI

more to come......
#41
Bot
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Re:wiso's AW11 restoration to weekend fun/track car. Wednesday, June 25, 2014 8:23 AM (permalink)
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did you ever dyno your set up? im just curious about the rwkw,  nice car btw,
#42
wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Wednesday, June 25, 2014 11:30 PM (permalink)
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nah, haven't dyno'd her. My old engine with these cams apart from that stock bigport got 74rwkw. I am not expecting much more than that. 
 
But I am not interested in chasing kw gains. since putting these on the car has so much more acceleration everywhere. its torque curve feels like its has been bolstered dramatically.

87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
#43
Carmikey
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Re:wiso's AW11 restoration to weekend fun/track car. Wednesday, June 25, 2014 11:36 PM (permalink)
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^^Wiso - great write up, reading thru you post, you state you used a Corolla C56 with MR2 Spyder Helical LSD with modified linkages to suit an AW11.   I too am looking at replacing my old AW11 NA gearbox with one I currently have from a AE93 Corolla Seca (4age smallport).
How did you go about modifing the box so the linkages are on the other side of the box?  It looks reasonably easy, yet some precision drilling looks to be in need.
 
 
#44
wiso
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Re:wiso's AW11 restoration to weekend fun/track car. Thursday, June 26, 2014 2:30 AM (permalink)
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You first need an AW11 C52 to get the linkage set off. this guy has the best write up. I  sort of followed his
 
http://www.padandwheels.com/mr2/blacktopproject/day13/c56.html
 
I didn't machine stuff like him, I just JB welded a peice of 27/28mm internal diameter pipe onto the casing after I drilled the hole

87' AW11 4AGE 
00' ZZW30 1ZZFE
01' ZZW30 1ZZFE Race car Edition
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