Davros' Ke10 4age Project

[LittleRedSpirit]

Anyone who claims to have attention to detail should bow to Davros.

 

WOW.

 

Thats inspiring!!

[radrollaz]

Looking good Davro's, can't wait to see this thing all done. Keep up the good work :)

[Davros El Davros]

Thanks for the feedback guys, and thanks for the continued help LittleRedSpirit :)

 

I'm keen to talk to you more about some suspension/diff upgrades.

 

 

Mick - don't think that this car will go as hard as your beast, but hopefully will look just as neat!

 

 

I'm about to head over to my garage and drop the engine and gearbox in today...It's been a long time coming so I am a bit excited!

 

And of course there will be pics.

[PHATKE20S]

I don't see any pic's of the engine sitting in the car mate.....was there problems???

Looking forward to more pic's either way.

BTW I agree with LRS, attention to detail seems to be Davros' passion......

And i can only hope that my KE10 looks half as good as this one when it's done.

Edited October 19, 2008 by PHATKE20S

[Davros El Davros]

Well, never fear Dougy because it's all bolted in the engine bay right now!!

 

I started by prepping the engine, as it has been sitting on the stand for the last year or so.

 

Inserted the spigot bearing into the back of the crank, installed the manual flywheel with the proper long flywheel bolts I have had ordered for ages.

 

Aligned the clutch with LittleRedSpirit's super specialist T50 22 spline clutch aligning tool :yes:

 

 

Then I went to drop the engine in and took a look at the engine bay and cross member. Now this is the problem with having such a detailed engine -

 

It's like a domino effect. Once one part is polished, it makes the part next to it look like shite, so that part has to be polished as well, and it continues from there.

 

I was thinking that I could get away without re spraying the engine bay and cross member etc, but after seeing the engine sitting next to the car, I realised I didnt have much choice.

 

So I spent the best part of a day cleaning up the cross member and front chassis rails, and starting to rub back the engine bay.

 

I gave them a quick coat of primer. I am going to fit the engine first, then do all of the drilling and mod work in the engine bay to get everything in there,

 

and then once it's all running sweet I'll pull the engine back out and repaint the whole engine bay.

 

Can't help myself.

 

 

 

And now here is the sexy part.

 

 

Dummy fitted the engine first with no gearbox just to make sure the mounts I have had for over a year were right. Thank sweet baby jesus they were.

 

Then fitted the gearbox and backing plate, clutch etc and with the help of a mate dropped it in the car.

 

Was initially having issues with the gearbox hanging on the steering arm, but once I got under there and levered it over, it just dropped in fine.

 

 

And I am guessing this is where the real fun begins.

 

The engine sits in the engine bay really well, its pretty far back, but has just enough clearance for the small rear water outlet I have. Fitting the water outlet will be fun.

 

The bolts for the gearbox stays just clear the steering arm by about 3mm, and the gearbox sits in the trans-tunnel realy well, without rubbing anywhere.

 

I had to move the hole for the gear shift back by about 100mm, but will have plenty of clearance for the handbrake still.

 

The water pump and crank pulleys have plenty of clearance at the front to the radiator, and I will be able to use my triple core KE10 radiator if I wanted to, but I think I will go with a custom alloy radiator.

 

The 2 parts that will be a bit problematic are shown here:

 

 

The clutch slave cylinder is hitting the steering assembly, causing it to lose about 1.5 turns of steering lock on that side, so I am currently looking at off setting the clutch slave.

 

And in the engine bay, the intake plenum only just clears the brake master cylinder. I would ideally like to upgrade to a twin circuit master cylinder with remote booster,

 

but this may prove to be a bit more messing around than I thought.

 

 

But all in all its fits in there really well, and I can't wait to start work on getting everything hooked up....

 

Edited February 24, 2010 by Davros El Davros

[67Rolla-Ken]

This car looks amazing! I can't remember if I have asked already, but is it a 67? What are the first 3 numbers of the vin (after KE10)?

 

It would be great if we could get all these cars on the Rollaclub Database...

 

 

 

then I will know for sure if mine is the oldest one still registered :yes:

 

 

Edit: I checked out your profile webpage, very flash, I like!!

Edited October 19, 2008 by Dunadan

[beerhead]

Looking good there mate. Doesn't look too bad, should be easy enough to overcome. I'd head down the wreckers and look over all the toyota slave clyinders you can find. Hopefully there's one with the outlet in the better spot. Hows it look for clearance for the exhaust?

[Davros El Davros]

Hey Guys,

 

Dunadan - the VIN number of the little beast is: KE10178846

 

I have been meaning to get it on the database - I wanted to get the engine conversion done first.

 

Also cheers for the props on the website - that was a lot of work, and a lot of time I wanted to be spending on the car..

 

But I needed to get it all up and completed and get some work rolling through the door.

 

 

Beerhead - I have nutted out a solution for the clutch slave cylinder (I hope!).

 

I went to repco and got one with the bleed nipple in a different place, and then made up an offset bracket to step the slave cylinder and the strike plate off the clutch fork by about 30-50mm.

 

I will post up some pics as soon as I get back to the garage.

 

There looks to be a fair amount of room for the exhaust. By a fair amount I mean around 3-4 inches!

 

It will go pretty close to the slave cylinder, but I am looking to get the exhaust Ceramic Coated to reduce heat in the engine bay and hopefully this should be ok down there.

 

I have to rig up the hydraulic clutch system as soon as I get a spare weekend, and the time to take a trip out to All Brake and Clutch in Rocklea to get the correct thread fitting for my clutch master cylinder.

 

 

I am starting to wrap my head around the brake system. A few ideas in mind in regard to upgrading to a tandem master cylinder, with the super limited clearance I have, but nothing concrete as yet.

 

 

 

[cuzzo]

Is this going to be turboed?

 

Did you think about fitting a JDM bellhousing converting the slave to the inlet side?

[HIGH ROLLER]

All coming together i see Davros, nice work!

looks awesome with all the polished gear.

keep it up!

 

Mark

[67Rolla-Ken]

Hey Guys,

 

Dunadan - the VIN number of the little beast is: KE10178846

 

I have been meaning to get it on the database - I wanted to get the engine conversion done first.

 

Also cheers for the props on the website - that was a lot of work, and a lot of time I wanted to be spending on the car..

 

But I needed to get it all up and completed and get some work rolling through the door.

 

 

Beerhead - I have nutted out a solution for the clutch slave cylinder (I hope!).

 

I went to repco and got one with the bleed nipple in a different place, and then made up an offset bracket to step the slave cylinder and the strike plate off the clutch fork by about 30-50mm.

 

I will post up some pics as soon as I get back to the garage.

 

There looks to be a fair amount of room for the exhaust. By a fair amount I mean around 3-4 inches!

 

It will go pretty close to the slave cylinder, but I am looking to get the exhaust Ceramic Coated to reduce heat in the engine bay and hopefully this should be ok down there.

 

I have to rig up the hydraulic clutch system as soon as I get a spare weekend, and the time to take a trip out to All Brake and Clutch in Rocklea to get the correct thread fitting for my clutch master cylinder.

 

 

I am starting to wrap my head around the brake system. A few ideas in mind in regard to upgrading to a tandem master cylinder, with the super limited clearance I have, but nothing concrete as yet.

 

 

 

 

Damn.. I mean nice. I now no longer have the oldest running and registered Rolla I know off!

 

She is an amazing work of art, fitting for someone of your talents.

[Davros El Davros]

Hey Guys,

 

Thanks for the positive reinforcement.. |blink|

 

Cuzzo - no turbo planned at this stage - I want to get it all in and working and get a feel for the car with the 4AGE power then see where I want to take it.

 

I have thought of a JDM bellhousing, but I figured (maybe incorrectly?) that they were pretty hard to find, and I would like to try and utilise what I have got on hand at this stage.

 

But even with a JDM bellhousing unless the clutch slave is mounted higher on the JDM bellhousing compared to the ADM bellhousing I think it would still hit the streeting arm, but on the drivers side

 

rather than the passengers side?

[radrollaz]

Go all the way Davro's paint and polish everything. Motor looks great by the way :y:

[olskool]

This rolla is looking awesome. I know and feel your pain a lot with how you do something and then you find that it has caused a problem here or there and then you gotta fix that and this and the list goes on and on. I am still doing my 4AGE conversion to my KE55.

 

I must agree with every one else and say that your attention to detail is not to be missed.

 

Also I bet you are absolutely dying to get the beast on the road. Can't wait to see the little rolla driving. Not that I live in Queensland, but it will just be good to hear that it is finished.

[Jono]

looks great so far, but you will probably want it turboed after a few months. 4age conversions into early corollas are good but are just shy of the real wow factor IMHO.