Twinky's Old Fart [Now Super Dooper Charged]

[Twinky]

Okie Dokie! Long time no progress! With the arrival of my daughter on the 21st Nov I've been a very busy dad taking care of the little fluid factory.

Not helping the issue is the fact that we seem to have a nocturnal baby that sleeps all day and poops all night. After a couple of weeks she settled herself into a routine

and now it time for daddy's turn to play with his toys! Jeez..... never thought I'd be calling myself a dad.... Funny how things change.

 

Anyhow, my mate recently bough an MY05 STI along with my brother purchasing a track 93 R32 GTST with custom fluff. This seemed to give me the motivation

to finally get that supercharger on and join in on the boosting. So I got back to the drawing board, welded up some mountings and got the supercharger in place

on the dummy motor. One thing that I had been meaning to do for a while was to actually calculate what kind of boost I would be looking at with the standard pulley attached to the motor and supercharger. Good thing that I did because I calculated that I would be getting -2psi. Somehow I doubt my engine would have liked that too much.

So about an hour and a half at u steal it I managed to find a ribbed belt pulley with an acceptable pulley ratio from an Audi V6. So mow I'm looking at 4.2psi with

a pulley ratio of about 1.94. I could bump it up to 2.53 but that would be hitting the limits on safe supercharger speed.

 

So, today I'm going off to John at KEMotorsport to pick up some flanges and other boost related paraphernalia. I would suggest checking out his website!

 

http://www.keicarshop.com/

 

He is located in Port Adelaide SA. Also don't call him if you have no actual interest i.e DREAMERS!

 

So progress is slow and steady, pics up when there is something worthwhile taking a photo of.

Edited January 12, 2012 by Twinky

[SLO-030]

Congrats on daughter mate!

 

Good to hear things are moving along nicely.

[Twinky]

Finally got my arse up and went to the wreckers to go treasure hunting. Good thing I did too!

I went down to the Gillman yard to have a look at what it's like, not really that impressive.

All the bogans are kept out of the sun inside the massive shed and all the imports are outside in the sweltering heat.

All of the KE3/5 series if just shithouse there, smashed, rusted, ripped as people don't give a ʞ©$ɟ about anyone else wanting anything from the car.

Anyway, I did manage to find some decent speaker door pods, they even have provisions for tweeters!

So I pinched some average door cards which have had the cardboard ripped/split and I'll use that material to re-trim the material on the pods to match the door cards.

 

I also took a trip up to Elizabeth and managed to find what in my opinion is, the better dash out of the KE series. And it only have one small crack!

I was at the yard before and saw it there but it had a heap of bits missing, only by chance did I spot that someone else had already ripped apart the

dash and hid the components in three different Corollas. Maybe he was trying to do what I wanted to do? Who knows, I'm just happy that he didn't take the

rip it to shit approach in getting the dash apart.

 

The spoils of war!

 

It's a dash out of the 2 door KE30 sedan, a corolla that I barely see around Adelaide. Plenty of coups but barely any of these.

So I'll be cleaning it up and I'll fix/hide the crack and give it a lick of paint.

 

A question for anyone who knows, What is the best vinyl paint to use? I want something that will not scratch off. If there is nothing good out there

I'll just clean it up and polish it as best as I can.

 

Woot!

[Oh-KE]

I have had good results with VHT vinyl spray. Still going strong on my door cards etc.. No scratching or fading so far..

 

Also if you are looking for the toyota sign that goes in the rectangular gap in that dash I think I might have one you can have.

 

Cheers

 

Chris

[Twinky]

I have used VHT before and I did like the engine enamel so I'll give the vinyl spray a go then.

Hopefully the colour looks ok.

 

I thought that gap was for the radio and the other way for the ash tray.

If you do have one that fits in the gap I'd definitely like it, what you want for it?

Northern or southern suburbs?

[Oh-KE]

This piece ive got is about 138mm by 57mm, has toyota on it and in good condition. So maybe measure your gap to see if that sounds right. You can have it for 10 bucks if you want it.. or some beer! I'm down south but not too far, at seacliff. Pm me for more details, cheers.

Edited January 28, 2012 by Oh-KE

[Twinky]

Sorry mate I've changed my mind. I realise that I'll need that cut out for instrumentation.

After going through a few build threads I got some inspiration to re upholster the boot and fuel tank cover.

 

So materials check!

 

9mm ply

Black fabric, any choice is fine!

Underlay (only if your fabric is thin like mine)(synthetic wadding is quite cheap so I would advise it).

Father in laws staple gun + staples.

Half a brain (a quarter will do)

Paper for stencil or original cards.

 

After stencilling out and cutting out with a jigsaw you are ready for fabric application!

 

Lay the fabric down first and place your new card over the fabric. Cut around with enough space to curl around all sides.

 

curl over one side only and staple to the card. Then flip it over with top side facing up.

What you will be doing now is pulling on the underlay and stapling it down.

 

Stretch it out with each staple added untill you get to the edge.

 

Then pull it around the edges and staple away!

 

Underlay done!

 

Then magic happens!

 

No not really there is no magic.

Staple one side down, pull taught to the opposite side making sure there are no creases.

Then do the sides the same way. Don't pull too tight otherwise you will weaken the fabric.

For those who use carpet material you don't have to worry about this.

I chose not to use carpet because the colours offered weren't white right and I didn't want to run around for hours

finding the right stuff. Plus I like the look of a flat colour.

 

More Voodoo!

 

Simple, cheap and effective!

Sorry about the quality of the pics, had to use my phone as the cameras batteries were flat.

 

Now that your work is done, pour yourself a scotch and coke and chill out.

 

http://www.youtube.com/watch?v=qjC-hznTwMA

Edited January 29, 2012 by Twinky

[Twinky]

Now on to those speaker pods!

 

I ripped off the vinyl from the cardboard and was left with this.

 

So after about 30 mins with a razor blade and some scizzors.

 

Now I'll Try to see if the original door cards can be manipulated into shape to fit over the pods.

[ae824ate]

Interesting taste in music, but good! Great work on the rolla bloke, keep it up!

[Twinky]

Interesting taste in music, but good!

 

Yeah I listen to anything and everything, depends on the mood at the time.

I love to just chill out to this type.

 

Anyhows, The re-trim worked ok. The shape was quite hard to dorm to but a bit of heat gun work and stretch works fine.

It'll come up a treat when the speakers are fixed in.

[Twinky]

Better piccies!

 

 

And another grille I might try on for looks

 

I like this other camera! Makes my car look shiney!

[Twinky]

I couldn't help myself, I wasn't going to put the new dash in until I fixed the crack in the centre but it was just sitting there looking sad.

So I cooked dinner early and set off to work! Wasn't the easiest thing to do, took me about 4 hours all up. The original dash is such

a pain to get out. Then I found out that I had to swap over the air con control cables as they were slightly different. The bolt holes

to mount the dash were also about 5mm off, nothing a bit of light manipulation couldn't fix. It sits nice and tight, no rattles

and looks amazing I must say. I definitely do prefer the new dash over the old. I just have to make some blanking plates to go over the

holes left over and mount the AFR meter, Comms cable and start switch.

 

[Twinky]

More stuff! Only by chance did I see that U-pull it at Gillman was having a special sale on Saturday.

The special was that you pay $55 entry fee but any parts that you could carry with your two hands were free.

I saw some innovative ways of carrying gearboxes that day.. Anyway, I was after two Honda prelude seats that

I saw earlier that week. Failing that I spotted some good condition Celica seats in case the Honda seats were taken.

When I got there the Honda drivers seat was gone and both Celica seats were pillaged. It had occurred to me that I had

just pretty much wasted $55. So I began scouring the un-organised jap section to see if I could find any good interior bits.

I came across a KE30 with a good condition centre console, as in it was in a condition better than mine because it did have a crack in it

but it was all in one piece. In further travels I found another KE30 tucked away in the corner out of sight and it had a perfect condition

centre console! woot! Still not worth the $55 that I spent though. Luckily I walked across a Hyundai coupé FX and it had great condition seats in it!

Score!

 

So I struggled them back to my car which was close to 1km away from the point of where I picked the seats up to my car door. My arms are very sore today.

The rails on the seats were slightly wider than the corollas so I couldn't just weld the rails onto the supports. I ended up cutting off the entire bottom

support from the corolla seat and welding it onto the bottom of the coupé seats. The welding part was easy but cutting off the entire bottom bit was a pain in the arse.

I went through 4 disks. So after all the welding I cleaned it all up, brushed all the slag/oxidisation off and painted over so that it wouldn't rust.

Vacuumed the seats and bolted straight in! Soooooo much more comfy.... So next will be to do the passengers side and get some seat covers so it doesn't look sus.

 

Edited February 5, 2012 by Twinky

[Twinky]

For some reason I have quite a bit of motivation recently. I spent another few hours of cutting, grinding, welding, measuring and got the passengers seat finished.

 

 

The more that I do to the car the more I start to really like it. Next is to neaten up the dash ie get the start switch, AFR meter and comms connector fitted and sealed off.

 

So, I have really ratty carpet and have been wanting to change it for some time now. So that is next on the shopping list. Along with that I have never liked the look of the bare handbrake

so I'll start looking around to see if any other cars handbrake console will fit nicely over the corollas one and custom fit it on.

 

Also on a happier note I have re mounted the supercharger with gilmer drive pulleys. The new ratios seem to make it scream! My neighbours even heard the thing winding up.

I'll take some pics and a vid when I neaten it all up. Then will come the task of making some induction piping, should be rather interesting considering there is stuff all space to do so.

Edited February 7, 2012 by Twinky

[Twinky]

Well. It has definitely been a while since my last update but for good reasons. For the past months I've been quite busy being a dad

and all the things that come with it. The unfortunate part of that is of course time and money as the missus has only returned to part time work

which means I can't splurge out on things as much.

 

The little one.

 

 

Recently the bubs has been sleeping great giving dad more time to stuff around in the shed. No joke the little one sleeps through the angle grinder.

So I finally cut up and welded some inlet pipes from the manifold to the charger and from the charger to the throttle. I'm no pro welder so it took a few tries

to get them right with no pin holes. The good thing about mig welders is that there is no crap left behind after a weld, so it is a lot easier to weld air tight.

So after about 15 hours worth of work here we are!

 

 

Aligning the pulleys is such a pain in the arse, they are slightly off and it rubs on the crank pulley. Fortunately it isn't hard up against something, it's only a slight rub

so I can't even see any damage/heat/warping. I'll monitor it for a while and see if it does degrade the belt.

 

Started up first crank and happily idled and revved. Unfortunately the pulley ratios are not quite what they need to be and I only see a peak of 3psi.

It stays constant at 2psi though all gears at what sneaking up to 3 at higher rpm. So it's not a dramatically noticeable difference in power.

I've still got a bit of tuning to fuel wise, not that it isn't getting enough but the map isn't as smooth as I would like it to be especially below 2000rpm.

 

Overall I'm quite happy that the thing is running and quite well at that, I would just like about 3 more psi and it should be great.

John from KEmotorsport has kindly offered a hand to help at tuning the thing on road. He's been great help so far and has

fixed a few issues with my car already. He's definitely a top bloke and happily helps out people that want to take the time to listen

and try things themselves.

 

You should keep an eye out on his web page as he is developing a fuel injection kit that is bolt onto the original k series carby manifold.

It's similar to the Ford single injector type set up. He is also designing a new rocker cover for K-series engines too!

 

So my next task is to find a bigger pulley and get my pulley ratio to about 2:1. I've talked to John and he seems willing to make a bigger

crank pulley (140mm gilmer). Failing that I'll make up something from a V belt setup but I would hate to get rid of the gilmer pulleys!