#
It is currently Sat Nov 22, 2014 2:06 am


Post a new topicPost a reply Page 2 of 2   [ 28 posts ]
Go to page Previous  1, 2
Author Message
 Post subject:
PostPosted: Mon Nov 08, 2010 2:13 am 
User avatar

Joined: Sat Aug 29, 2009 12:23 am
Posts: 53
Location: New Zealand
8/11/10 - Super Update Time! Part I

So I haven't done a decent update for ages. Been very busy at work and I normally get home mentally fatigued and with no energy to focus my attentions on the elephant.
But I have slowly being doing work on the the silly car, so I know that counts for something :lol:
Plus I have been buying lots of stuff, and you all know how that can be very enjoyable as well!

In this update (which will most likely be multi-part due to the amount of photos) I'm going to cover all the little things that I have done, purchases and any misc. stuff.
Oh and if my boss is reading this, sorry boss. Need to do focus on work life balance :)

Engine

So I'd thought I'd just start from the start and get everything up.

Engine received (note: this was back in June 2008)
Image

Putting onto the stand
Image

Strip down
Image
Image

ST205 TB
Image
Image

More strip down
Image

Initial clean up of all the grease and dirt build up on the engine.
Image

W2A
Image
Image
Image

#$%^&* I bent the water pipe (sigh) So obviously this was of great concern for me. Not too many st205 engines are broken down, so finding a replacement was going to be a bitch.
I actually found the gen3 3sge had a similar pipe according to the EPC, and luckily I found one up at pick a part and got it for $10.
But recently when putting the engine back together, I've found that there are issues. More on this later.
Image

Bought a chinese special. 3" dump pipe with support bracket. This is obviously going to change with the holset, but I will still use temporarily while I run the CT20B/CT26R2
Image

Ugh..
Image

Okay, so after many months of waiting for a 3sge gen3 to come up to pick a part, the patience was rewarded with a 1996 celica and I was able to grab the oil pan, baffle and oil pick up to replace my dented baffle and lower pan.

If you remember, I posted this:
Image

Well, after spending 8 hours up at the scrap yard, I finally got my replacement baffle and lower pan. I only took removing the ancillaries, engine from the bay, getting the auto box off, rounding an allen head bolt between the block and the box and rushing to the hardware store to get some vice grips and finally prising the oily parts away from the block, I had what I wanted.

Here is the comparison between the old bent baffle and the replacement. Some may say it wouldn't have affected performance or it could be bent back, but I'm too pedantic for that :(
Image

As you can see, there is a slight deflection in the baffle. Enough for me to wait nearly a year for something to come up!
Image

New oil pump to install
Image

Engine gasket kit (thanks always to Mark @ Manawatu Toyota for the prompt parts delivery and great service :) )
Image

Decided to clean all surfaces between cam cover and head of old gasket crap. Cam's came out for some reason as well :lol:
Image

Replaced crank seals as well
Image

All back together and sealed up :)
Image

A little extra sealant was applied. No biggy though.
Image

So this 3sge water pipe. Sigh. Good intentions, but as you can see, there are differences. Another difference was that the water pipe to oil cooler inlet/outlet (whatever) was shorter than the st205 one. Estimate for a new pipe was expensive to say the least. But I went to Howat engineering this past weekend, and the engineer said that since the pipe wasn't creased and no hole, then flow would be impeded minimally. Yay! No having to pay $$ for mistakes!
Image

Decided to see what the differences between the throttle body diameters were.
Image
Image

Side by side comparison. The ST205 TB on the left doesn't have the inlet piece on it. St215 TB has the inlet piece as part of the TB body.
Image

Purchase time. A powerful gt4 was being broken/sold on as the owner had decided to move in a different direction.
I was able to purchase a pile of things off him. Intercooler setup, including inlet pipe with tial bov mount, bar/tube intercooler, other intercooler piping; 3" dump pipe with WG pipe; 3" mid pipe with flexi; Carlos Sainz/RC bonnet - the bonnet was the most important thing for me. Rare as hen's teeth in NZ.
Image

Image

This is the engine as it stands at the mo. I won't lie. It's been over 2 years since the engine was stripped back and I've been trying to figure out how to put it all back together. I'm just glad Ii bagged and tagged all the stuff that came off! Getting there though :)
Image

So ends this part of the update.

Oh - there is also an Audi A3 turbo block/head in my garage that my sister broke a cam on. I should either dump it or strip it down and see what can be salvaged. Prob just get rid of it tbh. Taking up too much room!


Top
 Profile  
 
 Post subject:
PostPosted: Mon Nov 08, 2010 2:13 am 
User avatar

Joined: Sat Aug 29, 2009 12:23 am
Posts: 53
Location: New Zealand
8/11/10 - Super Update Time! Part II

Before anyone says anything, yes I do start have a lot of little mini projects going on at the same time. If I didn't then just doing the same thing would be quite boring :lol:

Body:

Carlos Sainz/RC bonnet :D
I'll take a mould before painting. Gotta go lightweight or at least have a replacement in those times of need!
I did plan on asking someone if I could take a mould of their bonnet, but that would have meant flying around NZ, shipping the mould back to Wellington and that was if I absolutely couldn't find a bonnet. Glad Ii have something local I can work off now haha.
Image

Driveline: June 2010

Drive shaft doesn't look in too bad condition
Image

Bottom of the car is also in good condition. Minimal signs of any rust or corrosion. Lucky me
Image

Sometimes my friends give me a hand every now and again. Scoob came over in the STI and was poking around under the rear of the car helping me remove the rear driveline.
Bit of plumbers crack there hahahaha :lol:
Image

So after unbolting the rear subframe and lowering on the jack, the elephant is coming apart slowly.
Image
Image

Bit rusty, though I've seen worse. I like the small collection of stones on top of the diff. Found similar on the subframe itself which I'm currently cleaning.
Image

Overall, rubbers aren't in bad condition. Undecided whether I'll replace. I'm sure it's going to cost me in parts from Japan. Won't be going solid bushings. I like some comfort.
Image

Diff cushion is cracked. Will have to cut out and re-poly.
Image

So one of the long suspension arms is bent (no pic yet). I saw a trace of rust under the paint. Better inspect.
Image

Err.. will clean up that mess :)
Image

New front and rear bearings for hub conversions for brake upgrade :D
Image

New ball joints from Mark @ Manawatu Toyota again ( I see a trend here :D )
Image

Electrics: April 2010

Starter motor was begging attention - looks so dirty! So I decided to take it apart and inspect and start cleaning.
Image
Image
Image

Brushes are fine
Image

Cleaned up the crap on the armature
Image

More inspection - this time the solenoid.
Image
Image
Image

Hmmm... new toy ;) Link G3 LEM with 55psi MAP sensor internal :D Thanks Matt D
Image
Image


Top
 Profile  
 
 Post subject:
PostPosted: Mon Nov 08, 2010 3:32 am 
User avatar

Joined: Sat Aug 29, 2009 12:23 am
Posts: 53
Location: New Zealand
8/11/10 - Super Update Time! Part III

My AC removal: Found these pics from 2006 :lol:

So the AC was shot. I already had plans to mount a sub in the dash based on my experiments:
Image

Let's get this #$%^ out! AC gas was already gone, and I didn't really want the extra crap in the bay. Also, at the time, I needed to fit larger batteries for my audio.
Image
Image

Was an interesting experience finding out how the lines snaked through the bay. This was before I had the BGB's and EPC to guide me.
Image

Wow- garage was kind of empty hahaha
Image

Hmm.. that was it? Oh well.. in the bin in went :D
Image

Engine Bay February - October:

So this is where I left a previous update..
Image

So the aim here was to clean up all the road grime and built up crap around the bay and in the guard areas. Seriously, it was the worst job cleaning up all this.
Ideally, it would have been easier media blasting, but hey, it's me and there is always a reason why I do things the way I do.

February
In this case, I didn't want to remove the old underseal in the guards. a) it's a messy job b) what do I gain from something that I won't see? c) i won't have to reapply underseal, though I am going over with a plastic liner material to ensure that there is more than adequate protection.
Image

Found a little bit of rust where the suspension was in contact with the body. Will clean up before liner application.
Image

The build up, while under flash, was actually quite bad. I initially thought that some areas were painted black. How wrong I was. The black on the tow hook is actually dirt!
Image

Cleaned up.
Image

Amazingly white under here.
Image
Image

One of the things I wanted to do was delete holes and major depressions in the bay.
Commonly, hotrodders will delete the firewall and smooth out the bay. For me, this was not a focus.

The main reason is that I've been to many car shows and I smoothed out engine bay is actually rather boring.
Who wants to see an engine sitting in a shiny box? Not I! The contours and shapes within a bay give more character and actually interesting.

Then again.. deletion of the engine loom hole, AC pipe and heater pipe holes time hehe :D

3 holes to delete
Image

studs sticking out.. need to get rid of those! Angle grinder time..
Image

goneburgers
Image

not too bad. Reasonably clean job.
Image

so i had to get to the firewall. I store a bunch of shite in the cabin most of the time.. whats that down the back?
Image

Why there are some cusco front and rear strut braces. Brand new, but will be stripped of the blue. I have my colour codes firmly in mind with white as the primary colour and red/black accents.
Image

Great.. a bit of room to work in now.
Image

First things first.. clean up the replacement metal. Jonno had already used this panel for his widebody kit.
Image

I cleaned up the glue and other crap then grabbed the paint stripping disc to get some clean metal.
Image

Voila :)
Image

Double skinned firewll. Plan is to weld from the interior side so that nothing is protruding on the engine bay side.
Image

Time to make some templates.
Image
Image

3 templates made.
Image

Added a weld buffer for me to push the metal up against the back of engine bay metal of the firewall.
Image

Cut and traced.
Image

Interior shot, fit's like a charm
Image

Some gear that was borrowed. Mask for Jonno, mask for me. I really need to learn how to weld. This is a TIG welder I can borrow after all lol.
Image

Welded up. Jonno used rods, but ideally we would have got the auto feed mig, but that was in use building a garage haha.
Image

Oops.. drop plastic got burnt up with all the sparks haha.
Image

Little mess under the plastic. Not too bad and the concrete pad is still protected to this day after a couple of years living under plastic.
Image

Grabbed some new plastic and duct tape and did the fix it job - easy peasy
Image

Oh - Speed Source solid engine brace mounts. Fancy! Decided that I would play and see how they fit.
Image

Not bad.. but oh no.. what do I see? A dent in the metal member running across :( More on this later..
Image

Considering I didn't remove the gearbox and engine orginially, I actually had no idea how the brace fitted. Oh well, worked it out :)
Image

fibrglass infused filler. Strong, but a bitch to sand. Note, the left hand side of the pic. The weld areas for the centre brace on the interior side had depressions. They were filled up and smoothed out.
That was the extent of the smoothing on the firewall.
Image

after all the seam sealer was removed, smoothing done with filler (not on any seams mind you..) and some spray putty to check smoothness, this is a high shot of the bay - 12 March 2010
Image

Thought I'd get fancy with the merge function in photoshop. Saved me from manually merging the photos in Adobe Fireworks. Yes, ASI radiator on the back.
Image

Etch primed ready for seam sealing.
Image

Another fun photo merge
Image

This is an example of how I did the seam sealing. I carefully taped and cut around the seams and then applied the sealer. Then I removed the tape and smoothed out with my fingers before the sealer skinned.
I used wax and grease remover to keep the sealer flexible while smoothing out.
Image

Nish came around and watched me for a couple of hours. I made him tape up some bits..
Image

And this is the bay as it currently stands. Due to the method I used, it took quite a while to get the seam sealer done. Tape, seal, remove tape, smooth. Repeat over and over and over.. many hours and cramped fingers, but its all worth it :D
Image


Top
 Profile  
 
 Post subject:
PostPosted: Mon Nov 08, 2010 4:01 am 
User avatar

Joined: Sat Aug 29, 2009 12:23 am
Posts: 53
Location: New Zealand
8/11/10 - Super Update Time! Part III

Transmission stuff

Rermember the gear leaver mechanism?
Image
Image

And no, I didn't leave them in the vinegar for 3 months :P

Come February 2010..
After a couple of days, the levers were removed from the vinegar. I then cleaned them up, started sanding and polishing. Probably one of the few things I'll polish myself as it took bloody ages!
Image

Main mounting plate was quite rusted if you remember.
Image

Just some other bits and bobs that went into the vinegar. A-arm washers, starter motor bolts, metal washer mount thingys
Image

rusted vs vinegar dipped.
Image

As you can see, the vinegar left a film from the zinc coating on the metal.
Image

both gen1 and gen 2 mounting plates were dipped.
Image

The rust build up.. no one likes rust.
Image

small amount of rust on the gen 1 mounting plate.
Image

I put under some water and the film wiped away :D I still went over with a plastic scrubbing pad to get rid of the deep rust that was still present.
Image
Image

Etch primed - April 2010
Image

7 November 2010. Actually got around to finishing these up. Etch priming protected them so no issues there. Some zinc paint tarts them up some :)
Image

Thought I better take some pictures today. This the gear lever mechanism. Sugar cube had minimal wear on it.
Image
Image

Ii had my clutch plate machined by Hutt City Engine Reconditioners. Cheap and its machined, not lathed :D
Image

RPM HD clutch..
Image
Image

Couldn't be bothered to open the box, but the HD plate is in there :)
Image

Speed Source stainless braided clutch hose
Image


Right - midnight.. and i need to get up in 6 hours for work.
I'll update another little bit tomorrow, radiator fitment fun :(

Hope you all enjoy

Cheers
Dave


Top
 Profile  
 
 Post subject:
PostPosted: Mon Nov 08, 2010 11:19 pm 

Joined: Mon Jun 09, 2008 11:07 pm
Posts: 174
Looks great dude!.. love it :D


Top
 Profile  
 
 Post subject:
PostPosted: Wed Nov 24, 2010 3:57 pm 

Joined: Mon Jan 04, 2010 3:33 pm
Posts: 13
Location: UK
Damn, was getting excited that there was a partially new Toyota here, I do have a soft spot for the Gen5's.

Just.. Your bandwidth has exeeded. Though page 1 with the yellow track Celica, I also got as excited as you!


Top
 Profile  
 
 Post subject:
PostPosted: Wed Nov 24, 2010 10:03 pm 
User avatar

Joined: Sat Aug 29, 2009 12:23 am
Posts: 53
Location: New Zealand
yeah - sorry about the bandwidth issue. Am hoping to move to a dedicated server space, but just don't have the time to do so at the moment.


Top
 Profile  
 
 Post subject:
PostPosted: Mon Jan 24, 2011 2:22 am 
User avatar

Joined: Sat Aug 29, 2009 12:23 am
Posts: 53
Location: New Zealand
I'll be changing various photo filenames as I'm currently building a blog so if you don't see the photos, don't worry, all will be well soon.

In the interim before I find the time to do the next update (lots of stuff done over the new year :D ) here's a fun video

Image

_________________
The White Elephant


Top
 Profile  
 
Display posts from previous:  Sort by  
Post a new topicPost a reply Page 2 of 2   [ 28 posts ]
Go to page Previous  1, 2


Who is online

Users browsing this forum: No registered users and 2 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  


Powered by phpBB © 2000, 2002, 2005, 2007 phpBB Group
610nm Style by Daniel St. Jules of Gamexe.net