Marks 2zz-ge Mk1 [Archive] - Woodsport Forum & The TB Archive

Paul Woods

21-05-2010, 18:28

This one is a another first in the UK, we have been building up to this one for quite a while planning it out, and promises to be a fantastic conversion, so here goes!

We started out by giving Mark his dream gearbox, a Corolla T-sport 6 speed unit, but then stripped it down and installed a Mk3 Mr2 LSD unit and also swapped in the 6th gear assembly from the Mk3 (better 6th gear ratio than the Corolla 6th).

The box was then converted for Mr2 use by making custom selector rods coming out the front end of the Corolla casing instead of the rear.

We broke the whole Corolla T-sport several weeks ago and ended up with this....

http://www.woodsport.org/forum/images/recovered/2010/05/242.jpg

Mark then sourced the aftermarket exhaust manifold because the Corolla one was just unworkable in the Mk1.

This is Marks engine bay with 4a-ge....

http://www.woodsport.org/forum/images/recovered/2010/05/243.jpg

And about an hour later it was on the floor...

http://www.woodsport.org/forum/images/recovered/2010/05/244.jpg

Nice empty engine bay...

http://www.woodsport.org/forum/images/recovered/2010/05/245.jpg

So LOTS to do, but i'm looking forward to this one, should retain the high revving nature of the stock engine without any weight penalty.

Aware

21-05-2010, 18:55

So LOTS to do, but i'm looking forward to this one

And you're not the only one...suscribed!! :cool:

A couple of q's though - 1) how is the ZZW 6th gear better, longer or shorter then the 'rolla one??

And even more obviously, how cheap is it to source a 2zz clip nowadays...<£1k yet??

Interesting that 'rolla and Celica engine-side mounts are different, wonder what else might pop up??...

Stoked, I am - it's SO about time someone did this swap('cos I'm bloody skint atm, and can't, lol :eusa_doh: )!!

:)

Paul Woods

21-05-2010, 18:59

The ZZW 6th is longer than the Corolla one, and a smashed up Celica or Corolla can be had for around a grand.

b4wrc

21-05-2010, 19:25

rexer200

21-05-2010, 19:26

Paul, my wife thinks I mad. I'm grinning like an idiot at a picture of my car's engine bay without a 4AGE :-)
I'm finally on the road to 2zz fun!
I want to say a big thank you for the work you've already put in on this. The same day I delivered the Corolla Paul stripped it and disposed of the rest. Also I know I've been a fussy bugger with the gearbox but Paul's managed to combine 2 gearboxes with consummate ease - a true pro!

It goes without saying, I can't wait for the next installment!

Paul Woods

21-05-2010, 19:45

This is THE one converesion I have been waiting to here about. What would be required to fit a 2zz with an Exige c64 box driveshafts etc. Also does anyone have any information about the option to stroke this engine out to nearly 2000cc?

Essentially this involves fitting a 1zz crank (and I guess flywheel) into the block, however which rods and pistons complete the build or are custom parts required?

Mark's the man to ask about that, he's done a phenominal amount of research into this swap. I would prefer to just Supercharge it myself using the Scion kit than take the bore out.

Mark i've thoroughly enjoyed the project so far, first time builds are what makes me get up in the morning, i love this shit! :) So no need to thank me.

I should add we have worked out a way for Marks car to also retain a supported driveshaft setup, that hasn't been done before anywhere, they all use Mk2NA unequal length shafts, so i had to build a custom shaft using part celica, part Mk2 and part Mk3 bits :)

Diesel Meister

21-05-2010, 20:57

Saw this today - will be right tasty when done! Forza Woodsplurt!

b4wrc

21-05-2010, 21:00

I am looking to build a mk1 as a tarmac rally car to use on single venue etc stage rallies, I want to contest the 2ltr class which is particularly well supported by other manufacturers notably mk1 and mk2 escorts sunbeams novas and astras. For this to work I need a well ballanced light car with a suitable engine. A turbo engine is out of the question because thart would put me in the same class as the Subaru and evo drivers not to mention full spec world rally cars and uprated mg6r4's all 4x4 and super expensive (think £100,000 plus just for the car without spares support etc).

The MSA have also tightened the rules regarding the modifications that can be made and now it is necessary to base the car on a production or lapsed production model, also the engine can only be increased in capacity by 25% (hense the 2000cc limit for a previously 1.6 car),

I belive that there is a driver in the north west with a mk1 that has a 4age engine fitted with a lotus exige box, this car also has several special suspension parts developed by a company called Trans auto sport (based in Preston at one time) These parts included rose jointed adgustable length track control arms and rear tie bars (anybody know who this is?)

Jiff Lemon

21-05-2010, 21:19

Trans Auto sport (TAS) were indeed based in preston - Used them a few times in long ago years. Think they went belly up a while ago.

There's plenty of people who still make stuff for MK1's. Check out TwosRus (http://www.twosrus.com/catalog/index.php?cPath=21_28) in the states. The exchange rate makes it quite feasible.

rexer200

21-05-2010, 21:29

This is THE one converesion I have been waiting to here about. What would be required to fit a 2zz with an Exige c64 box driveshafts etc.

With regards to the gearbox I decided that the UK MK3 MR2 6-speed box is not really suitable for this engine for 2 reasons.
1. With the standard 3.9 final drive at 8400rpms in 6th it'd do a theoretical 199mph!! The lower gears are also far too over-geared even with 15" wheels.
2. The first 3 ratios are not spaced close enough - it means even if the engine is taken to 8400rpm after each gear change the engine would fall below the 6100rpm high lift cam change over point. Resulting in a rather unrewarding experience.

What I have now, thanks to Pauls work, is a C64 close ratio box with the std. 4.5FD and close ratios but with a longer 6th. It means that it'll still do a theoretical 137mph in 5th and the 6th can be used as a motorway over-drive gear. This is the same spec box they fit in the US Exige / Matrix / Celica - however Paul also fitted the Mk3 MR2 torsen LSD for me.
With regards to the Exige driveshafts, this would give the supported setup however these I believe are longer than the Mk3 ones so only really worth it if you want an increased rear track - A guy on IMOC's done this but mounted to a 4AGE.

OlberJ

21-05-2010, 21:56

Paul Woods

25-05-2010, 18:06

The 2zz is now in the bay, with just one engine mount to make on the drivers side. I think i am going to make a bespoke mount that joins the old chassis mount onto the new 2zz bracket, that way it keeps everything reversable if mark ever feels the need to put a 4age back in :)

http://www.woodsport.org/forum/images/recovered/2010/05/260.jpg

http://www.woodsport.org/forum/images/recovered/2010/05/261.jpg

http://www.woodsport.org/forum/images/recovered/2010/05/262.jpg

The Corolla bracket is about 6" higher up than the Mk1 chassis mount.

http://www.woodsport.org/forum/images/recovered/2010/05/263.jpg

rexer200

25-05-2010, 20:26

That looks awesome in there! :-)
Could have been made by Toyota like that give or take 20 years!

Glad the Ebay exhaust manifold seems to clear ok too.

Diesel Meister

25-05-2010, 20:34

I can't wait to see a vid of this! ~8.5krpms will be mentaaaaaaal :thumbsup:

OlberJ

25-05-2010, 21:17

Very nice indeed! That's in on the 2zz gearbox mount? Handy!

What's the exhaust manifold clearance like, going to be alright or need re-worked?

OlberJ

25-05-2010, 21:22

Oh aye, and daft idea time.

Upside down Mk2 mount for the driver's side?

Paul Woods

25-05-2010, 21:44

It's hanging on the three mk1 gearbox mounts all of which fit the corolla box

nik

26-05-2010, 18:23

would you look at that!! nice fit in the bay by the looks of it..
another nutty mk1..great stuff..!

Paul Woods

26-05-2010, 18:59

I agree Nik, looks the part in a Mk1 bay for sure!

Today i sorted the drivers mount out, there were several ways to do it, we looked at making an adapter to go between an upside down Mk1 mount and the Corolla bracket but it was just going to be too long and have too much stress on it, so i wasn't happy with that idea. Instead we made extension plates that are welded onto the chassis mounts, this holds the Mk1 mount in the right place and after we filed out the holes a little the mount went on. The engine now sits perfectly level on all axis. I still have to seam seal and paint the mount but you get the idea. On the next 2zz build i'd probably cut the Mk1 mount off entirely and make the whole thing from scratch, we saved having to drop the engine out again doing it this way. The mount is also working the way it is supposed to (as it is on a 4age), which i like.

http://www.woodsport.org/forum/images/recovered/2010/05/264.jpg

Also the rad and heater pipe plumbing is done, nothing hard, just joining A to B...

http://www.woodsport.org/forum/images/recovered/2010/05/265.jpg

One of the major parts of this build is constructing all of the gearshift cable assembly.... basically nothing bolts up, do not believe all you read on the internet folks! So i am making the cable bracketry from scratch. This is done by selecting Neutral at the shift levers, and positioning the gearstick right in the centre of the gate and securing it there while the brackets are made. So far i have only managed to make the first parts that the cables clip into, i need to add a lot more support and brackets to this to stop them moving, at the moment they are not secured to anything other than the cables, but the cables themselves have a nice free run without any obstruction at all.

http://www.woodsport.org/forum/images/recovered/2010/05/266.jpg

Mark wants this conversion to be quiet, so induction kits and loud exhausts are out. I am making some pipework that runs from the throttle body to the Mk1 airbox, so it should all look very OEM as well...

http://www.woodsport.org/forum/images/recovered/2010/05/267.jpg

I have to make a section that fits where the yellow box is, for the Maf meter.

http://www.twobrutal.co.uk/forum/images/recovered/2010/05/167.jpg

By Friday everything should be done bar the exhaust and wiring.

Aware

26-05-2010, 19:24

Looking damned good(except plastic cover, lol)...from memory, MR2ZZ's swap(~2006) used a std AW11 engine mount(with removed studs), and an adaptor plate(~15mm thick) for 2ZZ side, with tubes welded down to meet the AW mount holes(from removed studs)... ;) :)
EDIT...took too long writing, nice alternative solution Paul!! :thumbsup:
Oh, Ollie, IIRR, manifold is fine, but downpipes need a sharper bend than in ZZW to clear rear chassis member nicely...then the rest is simples... :D
Yes, been looking at this for a while, yet I couldn't manage this job as fast as 'da man' Paul has...top work chap! :eusa_clap: :thumbsup:

Oh yes...supported shaft is SWNA inner, ZZW supported section, and AW spline end...correct?? Or complete fail?? :hidesbehi:
Which leaves...returnless fuel pump, and wiring...or also??...
EDIT2...interesting about gear cables, you're joining them to the ZZW box linkage, yes??

Paul Woods

26-05-2010, 19:30

Fail :) and on that front so did i, my hybrid supported shaft fits the diff end and hub end but it's 1" too long to work on this car, i'm still trying to find a solution but it looks like i might have to stick to the Mk2 NA shaft setup.

I would largely ignore all of the info out there about this swap, so far i have found about 10% of it useful, the rest is either totally wrong or missing large chunks of the details, so i am just working the problems out my own way and putting the details on TB which is the bible for such things.

Aware

26-05-2010, 19:37

Ooo...that IS a shame(only 1", too)...yet we all know you'll work something out... :thumbsup:

And agreed, too many cooks and all that...whereas you'll create a perfect template for others to follow...and we ALL love that! :cool:

OlberJ

26-05-2010, 20:19

If the Mk2 N/A shafts work, why can't you use the celica supported shafts? Problem with carrier on the block?

This does look a straight forward swap once you've got past the niggly bits, good work.

Garbe

26-05-2010, 20:43

Engine possibilities is widening, this will be one fun car.

Paul Woods

26-05-2010, 21:02

If the Mk2 N/A shafts work, why can't you use the celica supported shafts? Problem with carrier on the block?

This does look a straight forward swap once you've got past the niggly bits, good work.

Celica shafts are longer than mk2 na Olie , that's half of the problem. I'm going to have another bash at it though

BennyTheW

26-05-2010, 22:19

waiting with baited breath to see this one running, was thinking about this one for mine... (along with being 100% sure that i was doing every other conversion aswell mind!)

hmmmmm

26-05-2010, 22:42

Great progress mr Woods, and good luck with the gear selector calbes, that must be a pita! What bhp number are you expecting with the headers?

OlberJ

26-05-2010, 23:27

Celica shafts are longer than mk2 na Olie , that's half of the problem. I'm going to have another bash at it though

What about the Gen7 celica shafts, any shorter?

Paul Woods

27-05-2010, 07:04

No just as long mate, I've already had to use a combo of shaft parts from various models to get the shaft i have now, basically although a Mk1 hub spline has the same tooth count and diameter as a T-sport Corolla and a Mk3 Mr2, the shape of the spline ridges is different.... Toyota just changed the profile of them ever so slightly, so we can't use the original Corolla outer CV. I have tried various combos of outer CV joint, intermediate shaft, inner tripod joint and supported shaft and have found only one combo that fits together using bits from practically everything. It is a Mk2, Mk3, Celica hybrid shaft, but in doing that it is 1" too long.... the problem is in the outer shaft length, not the supported bit. Toyota also changed the spline type on the Mk3 and Corolla shaft CV spline too, so not all outer CV's will swap from the parts bin.... thought i'd explain the problem in a little more detail so you can see i really have thrown everything i have at it.

I will have another crack at it today.

rexer200

27-05-2010, 08:58

Again, great work Paul :-) Really good to see my car progressing in such a short space of time. I know it's not to everyone's tastes but I love the OEM airbox - hope it flows enough air?

FYI
The 91-94 Celica uses a supported shaft that is 20mm shorter that the (920mm total vs 940mm for post 94 Celica)

OlberJ

27-05-2010, 09:31

Paul Woods

27-05-2010, 18:12

Today saw the gear cable bracket assembly finished.... i basically gave up on all of the current information out there on the web at the moment and made my own.

http://www.woodsport.org/forum/images/recovered/2010/05/268.jpg

Here it is fitted with the clutch line bracket welded on...

http://www.woodsport.org/forum/images/recovered/2010/05/269.jpg

The gearchange works perfectly, nice and slick with no tight spots anywhere, and the beauty of this custom cable assembly means i haven't had to touch a single thing at the stick end, that is all stock. You will notice we have also polybushed the front torque mount, we did the rear one as well.

http://www.woodsport.org/forum/images/recovered/2010/05/270.jpg

I also made the Maf adapter...

http://www.woodsport.org/forum/images/recovered/2010/05/271.jpg

Here it is fitted with all intake plumbing finished...

http://www.woodsport.org/forum/images/recovered/2010/05/272.jpg

Also above the fuel pressure regulator is fitted, this allows the return style Mr2 system to have a working return, plus we can control the pressure.

An overview of the bay now, just wiring and exhaust to go... you will notice i have had to turn the battery 90*, space is tight but it all fits.

http://www.woodsport.org/forum/images/recovered/2010/05/273.jpg

snowtigger

27-05-2010, 19:12

so a fire up vid is imminent then mr paul "the magic man" woods.

Paul Woods

27-05-2010, 19:18

Shouldn't be long mate! Abracadabra, just like that...

http://s.bebo.com/app-image/9073325520/6454880385/PROFILE/i.quizzaz.com/img/q/u/08/05/02/Tommy_Cooper.jpg

dgh938peg

27-05-2010, 21:40

Very impressive PW - looks lovely indeed! :)

rexer200

27-05-2010, 22:24

The reason for asking Paul to do the 2ZZ transplant for me in the first place was that I wanted to maintain the character, ride and handling of the MK1 whilst giving it a bit more zing :-)
This is my road car after all so stuff like reliability, economy and quietness are also important. Seems like quite a long list I know but the great thing about this conversion is hopefully I'll get all of the above. Paul has done a great job and he's involved me in every step despite me feeding him some duff internet info.
Well done Paul, you've now also just added practicality to my list by keeping the battery in the engine bay, well chuffed with that :-)

rexer200

27-05-2010, 22:46

That'll be the pre-facelift 202 which is the tripod fitment, facelift 202 is the "ballache" 6 ball type.

Pretty sure you can't put the ballache cv joint onto a tripod shaft as the splines on there are different, had that issue with the supported shaft on the Mk1.6.

OK, so it needs to be a newer shaft then, what about a 97 Rav4? That's 908mm total

http://www.driveshaftstore.co.uk/index.php?prodid=66589

Here are some of the other Toyota shafts...

http://www.driveshaftstore.co.uk/index.php?search[partType]=DS&search[make]=Toyota&search[engine]=*&search[year]=*&search[side]=R&searchPart=&search[modelGroup]=*&searchMode.x=36&searchMode.y=9&searchMode=makeModelYear

Anything?? How long are Mk2 N/A shafts then?

Paul Woods

28-05-2010, 07:25

dgh938peg

28-05-2010, 08:21

The problem isn't so much shaft length, it's getting compatability

I think i have my new sig! :D

OlberJ

28-05-2010, 10:19

http://www.driveshaftstore.co.uk/index.php?prodid=66589

Here are some of the other Toyota shafts...

http://www.driveshaftstore.co.uk/index.php?search[partType]=DS&search[make]=Toyota&search[engine]=*&search[year]=*&search[side]=R&searchPart=&search[modelGroup]=*&searchMode.x=36&searchMode.y=9&searchMode=makeModelYear

Excellent find! Certainly beats Toyota's £522 for a new 1zz shaft.

rexer200

28-05-2010, 10:56

The problem isn't so much shaft length, it's getting compatability between splines for inner tripod fitment and outer CV fitting... with the correct outer hub spline as well. I will try again and see if i can get somewhere with it.

Thanks for the clarification Paul, I take it the 6th Gen Celica part of the shaft is currently in the middle? I spoke to a local place, Recoprop, and they gave me a quote of £80 to chop an inch from the existing shaft or £170 for a new middle section (although 4-6 week wait for this) of the correct length and ends.

rexer200

28-05-2010, 11:35

I just phoned Adrian Flux and the total increase in the yearly premium for all new mods declared - 2zz engine, 6-speed box, exhaust and fuel pressure reg is £46 !!!!!!!! well pleased with that. :-)
There are some advantages in being old!

snowtigger

28-05-2010, 12:56

I had a quote ages ago for a hyabusa thinking it would be thousands and it was only £300.

Paul Woods

28-05-2010, 19:26

Today saw the last of the plumbing completed, i fitted a Mk2 filler neck which has been T'd into the radiator pipe making this the highest point (vital).

http://www.woodsport.org/forum/images/recovered/2010/05/275.jpg

Here is the Mk1 expansion bottle back in its former home, now i had to remove the brake servo pipe and reroute the servo pipework so that left me with a rather nice pipe with brackets on it that lined up nicely with spare holes in the rear firewall, a perfect coolant overflow pipe.... how's that for recycling? Woodsport, helping save the environment lol.

http://www.woodsport.org/forum/images/recovered/2010/05/276.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2010/05/191.jpg

Just exhaust and wiring to go.

dgh938peg

28-05-2010, 23:01

I am really taking a dislike to the plastic cover now.. does it look better without?

rexer200

29-05-2010, 05:34

Because of the mr2's vented engine lid I reckon the plastic cover will do a good job of keeping the rain water off the coil packs. As mentioned before I would like the car to be as reliable as possible.

Paul Woods

29-05-2010, 07:42

Yes i agree, i think the cover is more function over form, there are a lot of electronic bits under that that need protecting, but i also think it would look more aesthetically pleasing without the cover (i like seeing the guts!)

snowtigger

29-05-2010, 11:49

It's nice to see the oily bits but it's even better when you spill oil on the cover when filling up, as it's so easy to wipe clean.

Pity you can't shave the lettering of and put it the right way round, and where would the woodsport logo go hmmm we need that in a lovely prominent position.

Paul Woods

01-06-2010, 17:58

Well after a bit of spaghetti juggling today she fired into life! Still no exhaust fitted so a video will come after i've done that, but it runs.

I had a few issues with missing power feeds from the ISCV and MAF sensor not to mention an immobiliser issue which threw a few surprises but nothing we couldn't overcome. I have had to make a Mk1 oil pressure sensor adapter to screw into the oil filter housing instead of the 2zz idiot light sensor and i have also had to make a water housing that fits inline on one of the rad pipes so we had somewhere to run the coolant temp sensor (for dash gauge).

So just the exhaust to sort and debugging (if any!)

Aware

01-06-2010, 18:32

Well after a bit of spaghetti juggling today she fired into life! Still no exhaust fitted so a video will come after i've done that, but it runs.

Ooo...fanfare time, methinks!! Top work chap!! :thumbsup: :eusa_drool: :praise2:

2zz idiot light sensor

My quote of the week, flawless... :laugh2::laugh2::laugh2:

rexer200

01-06-2010, 18:34

Wow! Fantastic work Paul :-)
Well done with sorting out all those wires and getting the gauges working too! Can't wait for the next instalment now, and start-up vid!

Paul Woods

01-06-2010, 18:40

Yeah the pinouts were only 90% relevant to your ECU, so we had to work the rest out, and i still have lambda wiring to do but i do love spaghetti problems. Hopefully get the exhaust sorted tomorrow!

Yep, oil idiot lights, you either have oil pressure or you don't..... great eh?

Aware

01-06-2010, 21:47

Tell me about it Paul...only yesterday did I have to advise my TRD sport M Celica-owning friend(no idiot, either) that oil pressure would be more important to monitor than his idea of...intake temp... :icon_redface: ...esp. given 2ZZ's propensity for pump/surge issues!! Odd that since SW20, not one performance Toyota has actually had an oil pressure gauge... :eusa_doh:

Ooo...O/T maybe, but has anyone ever calibrated AW 2ndry gauge readings(as Toyota so helpfully forgot to numerate them)?? Always wondered what min/max readings were on Oil p./Water temp... :shrug:

OlberJ

02-06-2010, 01:31

Does that mean you sorted the driveshaft conundrum too?

Paul Woods

02-06-2010, 07:07

I haven't got around to that yet Olie, still on the "to have a go at" list.

Aware i'm replacing all of my Mk1's Analogue gauges with digital readouts so i have an actual figure to tell me what's going on, needles are fine if you just want a rough idea, but an oil pressure light on it's own is just crazy, yet i know people who drive and top up their oil based on that light!

I'm not sure what the actual min/max figures are on Mk1 gauges.

nik

02-06-2010, 10:25

loving it..cant wait for the vid..

rexer200

03-06-2010, 17:55

Me too... almost 1500 views on this thread and I reckon half of those are me!!

Paul Woods

04-06-2010, 18:13

I took a video today of the engine running, this is on a Mk2 NA rear silencer and a merged downpipe that i forgot to take pics of! Anyway here it is, it is a very quiet engine indeed which mark really insisted on, the camera mic makes it sound a lot louder than it actually is, i promise you it's as quiet as OEM.

http://www.youtube.com/watch?v=B3LQ0eKiiso

snowtigger

04-06-2010, 18:54

That looks like factory fit that does, what a little cracker this has turned out to be, your repatoire is increasing on these builds mr woods sir.

Paul Woods

04-06-2010, 19:01

My what? lol

Diesel Meister

04-06-2010, 19:47

:icon_lol:

Genius.

rexer200

04-06-2010, 21:17

Paul you're a star!!
Superb work, I've just watched that video 5 times and its just how I wanted the transplant to be. I know the OEM intake and exhaust are probably not to everyone's tastes but the point is I expressed my wishes to Paul and he made it happen. His communication throughout the project has been faultless and the end result is a car that I can enjoy everyday with no downsides and about 70bhp more :D
Also, I don't know much about Durham but I know now I can't wait to go there!

Paul Woods

08-06-2010, 18:38

Pics of the Mk2 NA exhaust....

http://www.twobrutal.co.uk/forum/images/recovered/2010/06/27.jpg

The Y pipe merge i made...

http://www.twobrutal.co.uk/forum/images/recovered/2010/06/28.jpg

I noticed the rear firewall getting quite hot around the exhaust, and the ECU is on the other side of that wall, so i added a chequer plate shield around the exhaust, looks a bit industrial but this build is function over form.

http://www.twobrutal.co.uk/forum/images/recovered/2010/06/29.jpg

I also stuck a bit on the back of the ECU for good measure...

http://www.twobrutal.co.uk/forum/images/recovered/2010/06/30.jpg

I suppose i could move the ECU, but it is bolted in the stock Mk1 position and moving it is a pain in the ass.

During running up we have noticed some heatsoak issues at idle only, either the 2zz water pump is not up to the job on a Mk1 or we have a dodgy thermostat, so i've ordered a new stat and hopefully that will cure it.

Diesel Meister

09-06-2010, 16:12

Nice one Paul.

One thing that interests me with this build is any heat-soak issues. The 2GR geenrates quite a lot and so I'm thinking about how to retrim the trunk to suit (eg., thicker carpeting material with some reflective underlay on the firewall side maybe?). The interior of the car gets warm as well but nothing that isn't cured by turning on the fans, heh.

This is looking nice and stealthy - right up my street :thumbsup:

Moustachio

10-06-2010, 17:39

Dynamat? (Soundproofing and heat reflective). I've used it on my Mantas, and its good stuff.

Diesel Meister

10-06-2010, 18:06

aha - rings a bell. Thanks Moustachio :thumbsup:

also need some PlusGas on my rear links... but less thread derailment!

When is this being collected? We need more Brutal Mk1s OTR, especially after the recent export of a certain pink project.....

rexer200

28-06-2010, 15:59

I know this threads been a bit quiet recently but rest assured Paul has been working on my car in the background and giving me constant updates.
I now have holiday booked from work and myself and a friend are off to Durham to collect my 2ZZ Mk1 on Wednesday.
Can't wait for the drive home :-)

MartG

28-06-2010, 17:47

Just came across this, and thought it may be of interest to readers of this thread http://www.blitz-uk.co.uk/ProductItem-514.aspx . Expensive though

snowtigger

28-06-2010, 18:01

You may as well stick an na 2gr in there for that money.

Moustachio

01-07-2010, 09:27

How did it go... hope it all went well....?!?!?

I'm picking up mine tomorrow... tooned mk1's flying out of Woodsport atm!

snowtigger

01-07-2010, 10:16

Any news pics vids etc even a smoke signal?

rexer200

31-10-2010, 10:39

Just thought I’d write a long overdue update to his project.
We had a few initial problems which is to be expected with a project like this (1st in the country) but I’m very pleased to say that the bugs were ironed out about a month ago and now the car is exactly how I want it.
First problem was that the custom tubular exhaust manifold (designed for MK3 with 2zz transplant) I bought from Ebay in the states was way too thin and kept cracking. It was welded up in one place then it would just crack again in another place. In the end Paul sorted this for me at his own cost by cutting and shutting a MK3 manifold to suit and using the standard MK3 manifold to engine bracing. I’m very pleased to report there have be no further problems with this since.
Second problem was that there was a slight gear oil leak from the extended gear selector shaft. Again Paul managed to buy the correct seal from Toyota and this has been bonded on externally now making a oil tight seal. Throughout these problems and other very minor issues Paul has been outstanding with his customer service, always listening and rectifying the issues.
Anyway, how does it drive?…I decided early on that I wanted the closest ratios available in the gearbox (apart from 6th) with the torsen LSD and I’m very pleased I went for this setup. The traction on take off is great with both wheels digging into the tarmac. When the engine hits 6200rpm the second cam kicks in and the car just lets rip singing around to the 8500rpm cut out. Due to the close ratio box there is a momentary pause after the change to second gear then it hits 6200rpm cam change-over point and it takes off again. 3rd to 4th, 4th to 5th and 5th to 6th are all really close so from 2nd gear on the car never drops out of the high lift cam if all the revs are used. It is very addictive and amazingly fun. There is nothing better than taking it for a blast along known country roads on a quiet Sunday morning, with the engine on the high lift cam the noise is like a group A normally aspirated rally car 
The engine makes more power and torque at all points in the rev range than the standard 4AGE but it still retains and even enhances the high revving nature that makes the Mk1 MR2 so much fun in the first place. As Paul put it it’s like a Mk1 plus. Since this is my everyday car I also wanted it to cruise well on the motorway, be quiet and return decent mpg. I’m pleased to say due to the standard MK2 backbox, standard Mk1 intake and 6th gear it does indeed cruise more quietly than the standard Mk1 and returns about 40mpg at a steady 70 - 80mph. Handling wise due to the LSD this has improved immensely and in the wet I’m now able to hang the rear out around roundabouts and hold it there on the power in a lovely drift. The 2ZZ engine is very light being all alloy and is lighter than the original iron block 4AGE, this has cancelled out the weight of the extra (6th) gear and has maintained the great balance of the standard Mk1 MR2. Paul fitted a full set of poly bushes for me so next week I’ll have the car fully aligned to the TRD settings which should hopefully sharpen the initial turn in a little. Other than that I may experiment with drilling out the poly engine mounts slightly since at the moment there is a little too much vibration at tick-over due to the ridged nature of the mounts.
Overall though as you’ve probably guessed I’m delighted with this conversion… hats off to Paul at Woodsport for not only creating it but also the backup he’s given me since.

adamh

31-10-2010, 18:47

sounds awesome, it would be nice to see it how it moves if you manage to get it to a track take a cam. 40mpg is great also, the gearing pays.

Aware

31-10-2010, 22:13

That's really nice to hear after all this time...a conversion which doesn't change the characteristics of the NA, yet improves on the original in every area... :thumbsup:

As always, credit where credit's due...Paul, your efforts are second to none... :praise2:

Of course, should you get bored ever...there are plently of SC/turbo kits available...people are running over 400hp(on stock internals, too)... :eusa_whistle:

Oh, how did you get on with the rear control arm bushings - all sorted(LS400 ones)??

rexer200

01-11-2010, 06:03

Movies will follow shortly...

In the end I went for the twosrus adjustable rear toe arms. That way I get new ball joints too.

rexer200

01-11-2010, 10:38

Not sure if this video of the clocks will work, taken on my Nokia N97 (on private land) so it may require the right codec.

http://www.twobrutal.co.uk/forum/images/recovered/2010/11/1.jpg (http://s729.photobucket.com/albums/ww299/rexer200/2zz%20mk1%20mr2/?action=view&current=18072010023.mp4)

This was an early video with fuel pressure set to 52psi so probably running very rich as it should be 44-50psi. I will use my Innovate A/F meter soon to set the fuel pressure so I reckon this'll release a few more BHP.

As previously mentioned this is not a track car (I have a MK2 CRX track car) however I may take it to the Nurburgring soon to give it a bit of a test. If I do I'll be sure to get some video footage.

adamh

02-11-2010, 20:17

works fine in quicktime viewer etc. that motors! nice to see the needle up that end of the rev's

rexer200

01-01-2011, 22:19

I wanted to check power and A/F ratios so I got it rolling roaded the other day. Pleased to say that it A/F's were spot on despite guesstimate on FPR the 2ZZ ECU seems to have sorted it out. Peak power it made 156hp at the wheels which is about the book 190 at the fly. Above 6K there is a whistle believed to be the stock mk2 backbox being a bit restrictive, so possibly more to come in the future.

http://i729.photobucket.com/albums/ww299/rexer200/2zz%20mk1%20mr2/th_30122010067.jpg (http://s729.photobucket.com/albums/ww299/rexer200/2zz%20mk1%20mr2/?action=view&current=30122010067.mp4)

Aware

01-01-2011, 23:00

That's great news Mark... :thumbsup:

Do you know the I.D. of the manifold/downpipe at all?? Would help to calculate the required diameter of the backbox, if necessary... :icon_smile:

rexer200

02-01-2011, 05:45

Its using a cut and shut MK3 Roadster manifold at the moment. So it means that it looks a bit like this

http://www.twobrutal.co.uk/forum/images/recovered/2011/01/3.jpg

The insides of the pre-cats have been cut out though

Aware

02-01-2011, 10:55

Its using a cut and shut MK3 Roadster manifold at the moment. The insides of the pre-cats have been cut out though
Ah, I see...I'm not 100% offhand, yet I seem to remember the 1ZZ manifold being a smaller internal diameter than the 2ZZ(which of course, unfortunately, can't be used)...I'd expect this to be a problem at high rpms, over the SW20 'box(which is ~65mm ID, I think)... :eusa_think:

I wonder...could an Elise/Exige manifold be used?? Of course it would bolt up, the question is whether it's long enough to clear the rear crossmember...

Such a shame the PPE roadster 'header' is so expensive...that would fit fine... :icon_sad:

rexer200

02-01-2011, 18:10

I already checked the Elise / Exige manifold and unfortunately it looks the same as the Corolla / Celica one. i.e. it would hit the boot. I looked also at PPE header and the trouble with that 4 into 1 manifold is that it looks too long. I'm going to have a chat with Simpson race exhausts and see what they say about it. The main thing for me is that I want to keep the car as quite as possible and as yet I've not found an after market system as quite as an OEM one.

Aware

02-01-2011, 18:28

Ah, I see...other issue with the PPE is it's a 4-1, rather than 4-2...so great for power, yet not torque...
Interested to hear what Simpson say then!! Oh, on noise, the best(quietest) aftermarket system for AWs has always been the HKS 'Silent Power'/'Legal' systems...only 2db up on OEM... :thumbsup:
Unfortunately, they're very expensive, and 'only' mild steel...yet they have a great sound(one of the best on a 4A engine, period)!!

Oh btw, pm'd you on Mk1club chap!! :icon_smile:

rexer200

23-06-2011, 20:49

A quick update to this project. The body was starting to look a little scruffy around the edges so I gave it to the Dickersons to work their magic. Nearly ready for me to collect, just the screen to go in, bumper and trim and a fresh MOT to go! Finished off with some classic BBS RZ's :-)
http://www.twobrutal.co.uk/forum/images/recovered/2011/06/329.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2011/06/330.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2011/06/331.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2011/06/332.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2011/06/333.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2011/06/334.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2011/06/335.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2011/06/336.jpg

Gary.H

26-06-2011, 12:45

Did you upgrade the oil pump (CircuitWorx) Paul ? (known weakness on these engines so I read). Accusump oil accumulator and Moroso baffled oil pan could be options too I guess ?
esp. given 2ZZ's propensity for pump/surge issues!! Odd that since SW20, not one performance Toyota has actually had an oil pressure gauge... :eusa_doh:

More power, no (?) weight penalty over the 4AGE, higher revving engine :thumbsup:

Goldy

26-06-2011, 13:45

There's a guy on the kent car club forums who's building his own 4 into 2 into 1 manifold, Here's the link :

http://www.kentcarclub.co.uk/forums/viewtopic.php?f=6&t=683

rexer200

27-06-2011, 11:41

That looks very good! I wonder if he can make me one?
One thing though the standard manifold has some hefty bracing to the block that way the stresses go through the flexi in the system and not the manifold itself. Having had my first tubular manifold crack I'd recommend he adds some bracing

Paul Woods

27-06-2011, 18:42

+1 on the bracing, of uttmost importance.

rexer200

02-07-2011, 15:50

Bodywork is finished! Maybe nows the time to supercharge it?

http://www.twobrutal.co.uk/forum/images/recovered/2011/07/6.jpg
http://i729.photobucket.com/albums/ww299/rexer200/02072011340.jpg

OlberJ

02-07-2011, 16:15

Lovely example.

That's brought bang up to date, everywhere. Excellent.

Jiff Lemon

02-07-2011, 17:36

looks bloody lovely! Enjoy the sun whilst you can, then get it garaged for winter!

Paul Woods

02-07-2011, 18:18

Looking very nice indeed Mark :thumbsup:

cdwood2010

02-07-2011, 18:47

Looking awesome!

And is that a Lotus over the road there!?

Nice cars in your manor clearly!

Chris.

Sent from my spackytard 'spell it how you like" iPhone

rexer200

02-07-2011, 21:54

looks bloody lovely! Enjoy the sun whilst you can, then get it garaged for winter!

I've now got a little Toyota Aygo thats running on LPG as my daily driver. Don't laugh 20 quid takes me 300 miles, it also means I can keep the miles off the MR2 and keep it in the garage in bad weather.

rexer200

02-07-2011, 21:56

And is that a Lotus over the road there!?

Yup, its been sat in that same place for about 7 years now! Wish the guy would do something with it.

rexer200

27-12-2013, 10:54

I wanted to update this build thread as it’s now been over 2 years since I wrote anything!

Since this was the first 2zz mk1 to be built in the UK I was always aware that there would be some teething issues as we entered into unchartered territory. Thankfully I chose Woodsport for the conversion as the support that Paul has given me throughout has been second to none. Despite my conversion now being almost 3 years and 15,000 miles old Paul has continued to support me and in November this year I took my car back to him for a check over and to fix some issues that were outstanding. Paul did not of course have to do this but I was so glad he did and this just confirms what a top bloke Paul is and what a great company Woodsport is.

Since the initial build my car used a re-drilled Corolla gearbox case with an additional selector rod welded on and exiting out the front as at the time this was the only known solution. Since then on Pauls conversions it was found that a Celica case can be used as the selector shaft exits out the front as standard. Due to this better option Paul agreed to strip the gearbox out and replace the case with a Celica one keeping the whole gearbox it as standard and as reliable as possible.

Second issue was the exhaust, this has always been a problem mainly down to the short pipework as there is not much room with the exhaust exiting out the back of the 2zz. I’ve had to get it re-welded several times and a new flexi and I found it would be welded in one place then split in another. Anyway Paul again came to the rescue and has now created a full stainless steel downpipe and system which uses a modified Magnex back box. To help with the stresses on the system there is now an 8” flexi so hopefully now it will be reliable. I used to have a standard Mk2 back box which felt strangled but now with the new Magnex system the car sings at the top end. I’ve yet to get it back to a rolling road but the previous result showed flat bhp from 7000 onwards and I’m now expecting a noticeable climb in power. The exhaust also bizarrely used to whistle but now that has gone too.

http://www.twobrutal.co.uk/forum/images/recovered/2013/12/250.jpg (http://s729.photobucket.com/user/rexer200/media/2zz%20mk1%20mr2/photo2_zps4cac2ffb.jpg.html)
http://www.twobrutal.co.uk/forum/images/recovered/2013/12/251.jpg (http://s729.photobucket.com/user/rexer200/media/2zz%20mk1%20mr2/photo1_zps2e772a21.jpg.html)
http://www.twobrutal.co.uk/forum/images/recovered/2013/12/252.jpg (http://s729.photobucket.com/user/rexer200/media/2zz%20mk1%20mr2/photo3_zps3242225d.jpg.html)

Other odds and ends that Paul sorted was connecting the engine fan and fitting the Corolla cold start-up air-pump relays to fool the ECU into think it’s there. Paul now does this mod to all his 2zz conversions. Lastly stuff that was nothing to do with the conversion but Paul still did because he’s just like that was the front bottom ball joint and rear brake calliper to compliment the WMS 4-pot front setup..
Many, many thanks to Paul and Woodsport, I’m now a step closer to my perfect mk1.
Paul is a complete star for sorting all of the above ‘Under Warranty’ despite my car being converted back in 2011 !