Thought you guys may like to see my project. Most of this is copied from another forum so its a bit messy.
She's a bit of a mess on outside with lots of surface rust but no major rust issues luckily. Had been in a barn for 10 years or so so it was kept dry.
Interior is super mint though!
The engine is pretty damn tired and only manages about 55mph, the spare is even worse I've been told.
I'd love to see a G200W with ITBS, would be pretty interesting
Was hoping for better progress this week, but got a decent start on it anyway.
Built the bottom end today with some new bearings etc and painted it up. Didn't like the orange though so went and got some red to suit the new colour scheme
What I found in the sump, with lots of other bits
Stock ports compared to a few hours on the die grinder. Still got shit loads to go.
4.8kg Fidanza flywheel.
In red with a few more bits
As far as I got done this weekend.
I should have the rest of the bits to make the intake next week, the flanges need a hour or so with the die grinder to match them too.
Engine is a 2 liter 8v DOHC from an Isuzu Piazza
Took the engine, loom and a few bits out of the bay today then degreased and water blasted all ready for paneling.
Took the guards off on Sunday and did a bit of work. Had to use the easy-outs on about 8 out of 12 door hinge screws
Not too bad, mostly surface rust but will have to grind back and see.
Other side wasn't so great, so I'm borrowing a mates mig.
Bit of a boring update but it all has to be done
So I cracked into the ole' girl this weekend.
So I started off by stripping the surface rust in the engine bay, when I found this :doubt: (lame pics cause it was dark)
All set for some POR15 Metal Ready and then a prime, minus the rust hole. I also welded up all the un-used holes and will smooth them off later.
Don't have any Metal Ready though.. So I moved onto something a bit less boring.
First up I chopped up the original Bellett (G150) timing plate, as you can see at the bottom/sides it has nuts to take the G150 engine mounts where the Piazza one is different (Piazza mounts from the middle of the block, Bellett = front mount) The G150 plate fouls the sump aswell, so I went choppy choppy.
Then I decided to start on the manifold. After a while of die grinding I sat the plates onto the head.
Carbide bits ftw, although rough.. they are fast. Finished off with stone, will then hit it with 150g paper when its all done to smooth it right off.
Tapped some holes. Sweet new wharehouse angle grinder. $17.99
Tacked the throttle body plates together at the right spacing to make cutting/welding the manifold in the right spot easier
Mocked up in the engine bay in the right spot to get the angle for the runners.
Cut the angle on a runner, getting a template for more port matching. I will need to cut the rest so I can get it all spaced up right etc before grinding though. I had gotten sick of die grinding by this stage lol.
Finally the original mock up I did that gave me some inspiration and a shot I though was kinda cool
Fixed rusty sill, still waiting on por15 so no changes to body yet.
Didn't know if they'd suit but I took the plunge anyway and got them. (equip 03 knock-offs) Will mount with 165/45/15s if I can get them. Offset is perfect on rear, has about 5mm clearance to the guard
POR15 metal ready'd (gives a zinc coating) then etch primed, few bits to bog tomorrow and lots of sanding to get it smooth ready for paint. Unfortunately the paint didn't turn up but I've got the rust to fix up in the lower shock towers to keep me busy.
Bugger all progress this week, have been doing a little panel work and have welded up chassis rails/shock towers. Forgot to get pics so I'll put one up of the cam cover instead.
Went and lent on it and smudged it so hopefully I can find another can of wrinkle paint. Repco probably won't get more in for years. The brushed letters came up alright I thought
Fixed up chassis rail/shock tower rust, using my mates gasless mig
Seemed to do the trick after a bit of trial though. I also soaked it all in por15 for the whole week making sure I got it as best I could and thick coats of primer in behind it all to hopefully stop it for a few years to come.
Due to working on the new daily driver (TE Gemini) and consumption of alcohol, there has been a rather large lack of motivation to work on the Bellett. But, I've made an effort this week now that the Gem's engine is away at the machinist.
I bolted on the original Bellett mounts to the twin cam. The drivers side fits on sweet, the passenger side mounting holes are about 10mm further back on the twin cam and as you will see from the photo is sitting on the wrong side of the timing plate and 10mm too far back for the crossmember bracket.
Passenger. I also needed to chop the G150 alternator bracket part off as it fouls the timing case on the twin cam.
Just a few misc pics of it all mocked up. Needed to set this all up so I can make sure the throttles won't foul on anything.
Engine isn't actually built, just the bottom end. The head is just sat on there to get clearance problems sorted.
Pretty good day today. Little better at welding but still not good enough, manifold is in its final position and half welded up.
Here's my little jig from yesterday, making life far easier.
Few pics of the almost finished setup on the engine. Ignore the trumpet spacing, they're not on properly.
Got some old bike's exhaust off my mate and found some factory Toyota extractors laying around, so I decided to chop them up and make a template for my exhaust.
Quickly cut out a piece of thick sheet metal for a dummy flange, cut the bolt holes and marked the port spacing. I then proceeded to cut, tack, cut, tack, cut tack.. you get the idea. Just using an arc welder and random pipes as its only a template so its ugly as, but saves wasting decent pipe.
Thinking about just getting the pipes bent up as one solid piece so I only have to weld them at the flange and collector, perhaps in polished stainless, depending on price.
The shock towers on this make it hard to make them equal length without being ugly. I might have a look at just dropping then straight down from the head, but that's no fun!
I got these measurements. With a guess of 150hp (probably a bit optimistic)
35mm primary pipe diameter
800-850mm long primary pipes
55mm collector size (I'll just use 57mm)
330mm long collector