Ae86 4Agte........all The Gear, No Idea.

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Thought Id share my creation that has been ongoing for a great many years now.

My background I have been a light vehicle mechanic for almost 10 years and have now moved into the mining industry.

 

The car

 

engine:

4agze 7 rib bigport from ae92, complete rebuild by me.

ARP headstuds

ARP main studs

ARP rod bolts

ARP flywheel bolts

balanced bottom end

honed and new acl rings

decked block and head

tunnel bored with 10thou oversized acl bearings

OEM head gasket

Acid dipped head

three angle valve cut

new valve guides

OEM gasket and seal kit

RC Racing 440cc injectors

Modified fuel rail to suit speedflow fittings

Modified OEM sump to increase capacity and windage flaps

Cusco catch can

HKS cam gears

Microtech LT10s

SQ Engineering COP plate

1zz coils

Trust oil cooler and remote oil filter including thermostat control

T3 underdrive water pump pulley

TRD oil filter

TRD thermostat

TRD radiator cap

52mm alloy radiator

Silicone radiator hoses

 

Drivetrain:

JDM t50

TRD short shifter

extreme 4 puk clutch

T series disc diff

TRD 2 way with 4.3 gears (Kouki diff, large axles)

 

Suspension front:

AE86 strut converted to coilover by AJPS

AJPS 7kg springs

HTS102 front inserts

Cusco camber top

Cusco lower control arms Formula link

Cusco castor rods

Cusco cross brace

Cusco 23mm swaybar

AJPS RCA

AJPS lock spacer

AJPS rack bushes

Powersteering arms

New rack ends and boots supplied by AJPS

 

rear:

4.5kg rear springs

HTS102 adjustable shocks

Cusco on car adjustable panhard rod

AJPS traction brackets

complete rebushing

 

Brakes:

FC3s rx7 calipers

unknown brand adaptor

AJPS braided brake lines

AJPS S13 rear rotor conversion, 258mm rotors.

S13 booster and BM44 master cylinder.

 

interior:

stripped plastics and carpet

Bride fixed back seat "HKS edition"

Bride recliner passenger seat

autometer tacho

autometer boost

autometer oil pressure

autometer oil temp

autometer coolant temp

 

wheels

R: 15 x 8.5 -22 Work Equip 03

F: 15 x 8.0 -4 Superlites

 

I'm just going to copy various things from my other build thread to show some progress of the vehicle.

[slide86]

- cleaned up and got my front end parts sorted

- got some discs from AJPS for my brakes, test fitted them, all sweet.

 

 

here are some pics of my painting skills.....or lack there of:

 

the starting product, i had them bead blasted by a guy at work:

 

 

 

 

then i went and got some killrust primer and 2 cans of matt black.....then applied said paint:

 

 

after a few coats of the kill rust (only 2) i started to apply the colour.

 

 

 

 

[slide86]

went down the hardware store and got some paint and a wire brush to tidy some things up.

 

ended up removing the entire xmember, rack, castor rods and swaybar.....all in preparation to fit the cusco stuff.

 

 

then i proceeded to give the rack a clean up, it wasnt too bad, but a clean and a lick of paint wouldnt hurt.

 

 

whilst the rack is out, i put new rack ends on it. looks like someone had fitted one new one not long before i bought it, it was still pretty tight.....but my AJPS items are much better. just need to get my lock spacer from work and then it will be all tight and nice.

 

i also got a bit excited while i was doing the front end and decided it would be a good idea to give the front end a quick coat of paint before fitting the cooler and bumper.

it will also make the cusco front end look better by having the lower part of the rad support nice and fresh. so:

 

 

 

 

 

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fitted the rear end stuff today

 

 

actually didnt fit the RCA's cause they didnt fit.....but oh well.

 

as you can see, it looks good. notice how my panhard rod is almost totally horizontal.....thoughts.

springs are totally captive at full droop with the HTS shocks. they are 4.5kg springs for those that are interested. here is a photo of the springs that came out compared to the new ones....

 

 

 

fitted my cusco engine mounts and gearbox mount too. was REALLY disappointed with how the gearbox mount fitted. i had to modify it with a hammer ALOT to make it fit......not a happy camper.

 

 

also fitted my kouki parkers....just something small, but makes me happy. they also came with the looms, so that was a bonus.

 

 

LOTS more happening tomorrow, i have some motivation, better not let it go to waste :worried:

[slide86]

Parts were coming in thick and fast:

 

 

 

 

 

 

 

And the things thats going to turn the tyres:

 

 

 

too cold to go out to the shed, so i just paint now........anything not bolted down....and some stuff that is!

 

30 mins turned these:

 

into these:

 

its not the best job out, but it looks a bit neater.

 

just a misc pic of my seat for happy fun times

 

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Took the head off today to ensure things are all good on the inside.......they are :thumbup:

 

switched the headgasket from the HKS item to the stock toyota one.....the comp is already low enough enough on this engine, i don't need large amounts of metal between the head and block making it worse.

 

here is a comparison between the two: HKS

 

 

And stock toyota:

 

 

So anyways, head is all bolted on and cams re-installed. Just have to go to work and borrow the mini torque wrench to tighten the cam caps and then that all is done.

 

then i got to fitting these things:

 

 

 

here is the comparison between the RWD and FWD water necks.

 

 

I'm pleased to say I'm running a FULL RWD cooling setup now, so nice and neat. Also good that you can still get the parts and gaskets new......

 

 

This is the clutch ill be using:

 

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Couple of random shots of the car outside, getting ready to have it towed to my new place:

 

 

 

So tow truck delivered car. All is good.........apart from tierod that came out of lock spacer.....so LH wheel was floating about. Fixed that.

 

Sussed out the rust.......there is definitely some there, but I'm not worried about that at the moment, it will be fixed once car is running.

 

here are a few nicer pics now cars has a better home:

 

 

 

 

 

[slide86]

parts pieces. Cusco swaybar

 

 

Cusco Formula link front suspension:

 

 

Got alot of time off at the moment, mine is shut because the pit is full of water from the QLD floods/rain.

 

What else have i got to do but try and get something happening on this.

 

A while a go i managed to win an auction on yahoo for a single HTS102f cartridge that i desperately needed as i was using a temporary TRD blue in the front. I set about removing the strut so i could do the swap:

 

 

I was lucky, the shock looks brand new, i don't even think it has been fitted to a car before!

 

While i had the strut out, i knew it was a good opportunity to get that piece of sexual goodness Formula link kit in the car. Was very easy to do and including the new swaybar installation (23mm Cusco item) , only took about 45 mins:

 

 

 

Its so very very pretty!

 

Ever since ive had the car, its not had a working handbrake, i put this down the the genius who cut the front cable before i got the car. So i jumped on toyodiy.com and sourced a new front cable, and some new retainers to hold the rear cables to the body:

 

 

Unfortunately i have left the other cables at my other house, ill have to collect them during the week.

 

In an effort to continue with the OEM products, i purchased two complete cam belt kits. One for this car and one for my daily AE93 seca. After replacing the belt, pulley, tensioner spring and bolt on the Seca, i set about doing the same on this engine. Although it is a 'new' engine, it only had a generic belt on it, and i wasnt happy with that or the fact the pulley wasnt new.

 

 

I am in the process of painting the cam gears because they look a bit old a crusty. I have smarted them up with a paint scheme that seems to be the way to go these days.......pics to come soon!

 

Tomorrow ill spend a good deal more time and have something else to show i guess.

[slide86]

Not much of an update, I'm in QLD at the moment, at work. Whilst i was home, I got a few deliveries. Well actually my partner goes to the post office for me ALL THE TIME to collect Jesse Streeter parcels:

 

 

I did get a second recliner seat to match my drivers, it needs a wash tho:

 

 

And some little service parts i needed to finish the cooling system.......and something to filter the oil too:

 

 

Waiting for another parcel that will have my sideskirts (OEM) in there and whatever else i decide to buy inbetween ;)

 

Refitted struts and wheels to move. I am quite surprised as to the lack of poke with my custom hubs on there. Essentially the front specs are now 15 x 8 -14, I think the Cusco LCA is slightly shorter when not extended.

 

While I had the car in the carport I tackled something that has been bugging me for ages, the body loom that runs around the front of the car was going behind the rad support, thus putting it inbetween the radiator and the rad support. I could never get the radiator to sit hard against the support. So i unplugged the harness from the passneger footwell and fed it through so I could re position it on the FRONT of the rad support.

 

To do this I had to remove all the lights and brackets:

 

 

Once that was all done, I moked up all the various cooling components that will fill the front end:

 

 

And just a mock up of how it will look, bonnet needs painting and so does front bar (and a lip):

 

 

For several years I was sure that a Kouki bar and lip was the way to go, but I have done a 180 and I'm liking the Zenki bar and a OEM Zenki lip will complete what I'm after.

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Nothing exciting.......

 

 

 

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Oh Huws home from work for a week, its time to update with more useless shit he has purchased:

 

HKS cam gears:

 

Brand new OEM Zenki lip. I bought a bumper that is in MUCH MUCH better condition than mine, and it came with indicator housings which I also needed:

 

 

Also got some sideskirts which I thought would be OEM, but they arent made of the same plastic material, I think they are copies......BOOOOOOO:

 

 

Got this modified sump to increase the oil capacity a bit. Has surge flaps in it, a turbo drain and oil temp fitting in it. Just needs a clean up:

 

 

Lastly, a seat rail for that Bride recliner that I unpacked last time I was home:

 

 

I have a SQ Engineering COP plate coming, going to run this setup instead of the poo Bosch coils and leads I was going to use. will be MUCH neater and less of a headache.

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Finally got back home and was able to spend some time down the shed. Started fitting some of the stuff I have accumulated. I got these 16v rocker covers off ebay, I needed them because i am going to install a SQ coil on plug setup and you can't use the supercharged rocker covers. Corolla shed life:

 

 

OEM cam belt, HKS gears, rocker covers and COP plate installed:

 

 

Next up I got the TRD thermostat in there and fitted the RWD neck onto the thermostat housing:

 

 

I thought id tackle the rear brakes, AJPS s13 upgrade. This stuff has never been apart before so I thought it would bring fun times:

 

 

After removing that ol busted shit, and some serious bashing and swearing I finally got this bastard out:

 

 

Rinse and repeat for the other side. Now.......it was about this time I thought "Hmmm I have no idea what diff centre is in this thing," plus I really wanted to know what ratio is in it. Considering the axles are out, its only a few more nuts and bolts and the centre will fall out. So i ripped the centre out and boy was I happy I did!!!!!!!

 

TRD 2 WAY and 4.3 ratio Yeeeeeooooowwwww:

 

 

Now I'm left with this till I get new bearings on the axles:

 

[slide86]

Spent 10 hours in the shed while I had some time off work, and got almost nothing achieved. The more I looked at things the more compounding jobs I found. Have come to the realisation that with my current work roster, this will be 6 months away from being driven. But anyways..........

 

Went to see an IPRA champion of the world and autosport and picked up this stuff, have no idea what any of it is but apparently it will get fuel from one end of the car to the other:

 

 

Got one of those new tanks from the states, gave it a clean up and a few coats of paint:

 

 

 

I purchased a new OEM efi pump bracket to sit the pump in. I was surprised that these were available and not really that expensive. I have modified this one by cutting the original threaded fitting off the fuel feed line and fitting a 5/16 to -6 fitting so I can fit the fuel line onto it. The pump also fits almost perfectly too, with only minor adjustment to the lower bracket to get the pump inlet to sit in there. I think it works well:

 

 

Something thats always bugged me is the rear end and how the springs are compressed just to get the shocks on the diff. I also noticed that the ride high was about an inch higher than i wanted. So with that in mind, you know what comes next:

 

 

I have removed 1 coil off these. The difference in the heights is almost exactly 20mm. The springs are still captive in the car, but there is not as much preload on them now when the shocks are fitted up. Have yet to put it on the ground to see the ride height.

While I was in the rear, I started to put some stuff back together. The diff centre, axles, brake caliper brackets and braided lines were all fitted up. Just need the correct calipers and discs and we are set.

 

Diff was refitted with new OEM gaskets care of this cheap kit:

 

 

Braided line set sourced from AJPS.

 

 

Brakes will be finished when I get home and so will the fuel setup.

[ryanjayx]

So bummed that I came into this before it was finished, lol. You're doing excellent work. Can't wait to see more!

[slide86]

Nothing new. Gave rear calipers a quick look with some new seals and dust boots.

 

 

 

 

 

Also fitted this gear up, hopefully the clutch works as it should now. Once again www.ajps.com.au supplied at an amazing price. Literally saved me over $100.......

 

 

 

Also fitted the S13 booster and master, was a bit tight but will do a good job. Need to source another RHF brake line and make a new one to join master to rear brake line. No pics at the minute.

 

Fitted up those calipers, discs and pads:

 

 

 

Got some new pins and clips for the handbrake cables:

 

 

The ongoing saga to findout what brakes I had on the car when I got it has come up again, here is the difference between an s13 rotor and the rotor removed from the car, there is only a bees dick in it. They must be larger than the OEM 230mm ones:

 

 

I was always going to need something to make these brakes work, and what with the upgraded fronts, I wanted a master that I knew I could rely on. After a few minutes on ebay I found what I was after, the booster and master from an s13. A BM44 15/16 master will work well, and the booster bolts into an AE86 chassis.

 

 

Note the new clutch master, it has a new slave too with an AJPS braided clutch line. How about the state of that bulkhead, will be fixed once the engine comes out again.

 

Next thing is to finally get the ECU wired up and ready to go, I dug out my electrical tools and started on making the harness:

 

 

I have decided to make the injector loom seperate, incase I change injectors and need new plugs later down the track. I just need to source new plugs and I can finish this part up: