View Full Version : my mk1.5 swap
spent most of yesterday stripping & plating my knuckles on various parts of me engine.. i got the cam belt back on earlier , fanks. thought i may aswell post a pic of yesterdays assembly efforts.. just standard block and head colours really, had to do it, when i got it, was covered in a funny powder substance, so ive had to wash the engine off and strip and clean it so the powder residue has gone.. jesus.. i wont be stripping it again.... now if i could remember what go's where id be doing alrite #-o
http://www.adamhutchison.co.uk/graphics/painted1.jpg
http://www.adamhutchison.co.uk/graphics/painted2.jpg
ive done all of the engine and all the other parts.. jus not all back together yet, waiting for big ends ,..then i'll weld it all together for good :lol:
what a distinct mass of wires..i'll be lucky not to blow it up when i turn it on
MegatronUK
07-08-2005, 18:50
Adam, what did you paint that with?
I've got a couple of spray cans of halfords hi-temp aluminium paint that I'm thinking of using.. hoping to get the same look as that!
Gary Symons
07-08-2005, 18:56
ooohh shiney inlet manifold, looks good :D A job I stiil have to do, I know what you mean about the mass of wires and pipes :shock: I took loads of photos of my engine when i stripped the bits off. Hopefully will help me get it all back together.
the block and black parts.. high temp black, halfords, lovely matt black it is. and the ally parts.. smoothrite silver, smooth hammerite, sticks to ally well and gives a gloss finish, but avoid it on high temp bits it go's a tinge of yellow!. the silver high temp is a matt finish. cost me 10 quid for 2 tins. cant say fairer than that :)
Paul Woods
07-08-2005, 19:14
dont worry about the pipes and wires chaps,the schematics are still hardwired in my brain from when i did the swap,when you need to know where something goes or went just ask.....adam that looks the dogs mate.
dont worry about the pipes and wires chaps,the schematics are still hardwired in my brain from when i did the swap,when you need to know where something goes or went just ask.....adam that looks the dogs mate.
i'm gonna need it, i seem to have about 30 loose pipes that werent there before :? i took pics so i should fair o.k, got the turbo to put back on at some stage.. anyone got one of them rings that clamps the turbo to elbow? i trashed the bolt on mine (seized then angle grind off :twisted: ) trying to strip the turbo from elbow..
ooo.. remember asking about that shaft support bearing on the drive shaft to block .. its 27 quid. pick that up next week from mr.t, the factors dont do them, neither bearing distributors.
looking real nice adam i got all my new clamps from rs thier the monster wide things think they were about ?4 a pair and look and perform real well
looking real nice adam i got all my new clamps from rs thier the monster wide things think they were about ?4 a pair and look and perform real well
hiya mate.. i know you know what i mean, i think!.. im lookin for this fella.. the big bertha thats joined with a captive thread & nut.. a big 'C' hinged in the middle.. 3-4 inches in diamater, did u get that from RS? or u mean the jubilees?..
http://www.adamhutchison.co.uk/graphics/17clamp.jpg
ah sorry adam thaught you meant the jubilees i know what type your after tho and ive seen them somewhare and all diferent sizes ill have a think
MegatronUK
08-08-2005, 08:14
Adam, I may have one of those from the couple of CT26's and CT26A's I've got. I'll check tonight for you.
cool .... fair trade for 2" pipe if you have one that isnt bieng used :D i have standard rev1 ct26
ah sorry adam thaught you meant the jubilees i know what type your after tho and ive seen them somewhare and all diferent sizes ill have a think
jubilees, recap!.. yes.. im having some of those too.. very wide,v nice..
http://www.twobrutal.co.uk/forum/images/recovered/2005/08/11.jpg
more blood and guts.. and nearly finished :D few parts to fit on yet, then theres ic piping and the rest of the post fabr'c stuff, spent the past couple re-fitting the turbo, new big ends put in, yes they were oiled!..dosent show. new clutch & g-box re-fitted.. quite some parts n pipes left still..where does it all go :shock: ..yards of it :lol:
http://www.adamhutchison.co.uk/graphics/12t.jpg
http://www.adamhutchison.co.uk/graphics/7t.jpg
http://www.adamhutchison.co.uk/graphics/8t.jpg
http://www.adamhutchison.co.uk/graphics/9t.jpg
http://www.adamhutchison.co.uk/graphics/11t.jpg
http://www.adamhutchison.co.uk/graphics/6t.jpg
http://www.adamhutchison.co.uk/graphics/15t.jpg
a few short days left before i begin the install, i can stop banging my head against the wall now :D
MegatronUK
25-08-2005, 23:39
Bah, ya posh git... all that fancy looking kit! :P
Gary Symons
25-08-2005, 23:49
Bah, ya posh git... all that fancy looking kit! :P
Yeah, its so annoying when someone else makes an effort, means you have to try that bit harder to impress.
looking good 8)
my god adam wtf that is sooo clean , just wondering are you an obsesive compulsive :wink: :lol:
nice mate real nice keep up the good work i can see me taking my engine back out now to do that lot
obsessive compulsive?.....does that mean im in the gang? 8-[
that chain looks awful dont it?.. have to spray that for the next shots :lol:
my car is now in the 'workshop' just about preped everything... i start on tuesday have a week off to do it .. few simple questions.. well.. a tin of worms really..
what should i remove from the bay fuel filters, vacuum swithes.. bits..?
i have a rough order of events..
remove engine, + other parts(?)
remove mk1 d/shafts + outers from whats left etc.
fit new celica outer cv's + t/bo shafts
remove fuel tank/pump, fit new pump, re-fit tank.
stick engine in bay
line up mounts
tack
remove engine
snap off... drill 10mm higher
put back
seam, clean.
spray bay
waxoyl bay
fit engine
right then.. please critic anything you did which ive missed/would be an idea to do before i fit engine/during.. much appreciated
i have 5 days in workshop, then im out on me ear :shock:
Joshstix
28-08-2005, 02:23
remove engine, + other parts(?)
You'll need to remove the overflow bottle and radiator flexible hoses in the bay. You also have to cut off the two side engine mounts and the battery tray.
It took me quite some time to cut those off. Mostly because a good original AW11 in Australia is worth about $9000, unlike the bargains you guys in the UK and US seem to be able to pick up.
yep just take the lot out and start from there
Paul Woods
28-08-2005, 07:17
adam only one thing id suggest on your list....when you say fit engine and tack mounts in,then remove engine,snap them off and drill 10mm higher up.....i wouldnt do it this way as you will lose the position slitghtly.
The best way is to get the engine in its perfect location up/dpwn,front/back,left/right then tack one side of each mount at a time.....so for instance tack the left side rear plate first,mark the mount bolt with paint and push it through the mount from behind so it marks the plate.....then you can snap the plate off,drill it 10mm higher up....now do the same for the front plate on the left side and then refit both plates tacking them,you can now jack the left side (gearbox) by 10mm and push the bolt right through the mount.
Repeat this for the right side.....doing it this way ensures your bolt goes through both plates properly otherwise if you remove the engine and then start tacking plates in the bolt holes may not line up properly=nightmare!
You may find an alternative way to do it,theres no set way to go about it but i found this way easiest when doing my swap and when mounting megatrons engine.....good luck mate.
MegatronUK
28-08-2005, 08:10
Yep, the mounts went on exactly and the bolts ran through smoothly after Pauls method above.
copy that.. when the engine is fitted, does it sit on a slight camber, not as much as the celica.. but a wee bit for top clearence?.. or am i imagining things .. does it fit in with ample clearence square?..
joshstix, you should pop over and introduce yourself you guys have very nice looking celicas over there. and an aus 3sgte powered mk1.. are there any more in aus?
Paul Woods
28-08-2005, 12:03
adam it will naturally hang (with no torque mounts) well forward so the inlet manifold sticks up in the air,you need to jack the exhaust downpipe up to level it off....an idea of where it needs to be is by getting the tops of the engine mounts level and also the supported output shaft should be somewhere in level with the rear crossmember if viewed from behind the car.
cool, just one more thing, that liquid plastic stuff from RS.. do you rate it for encasing the mounts in?.. i searched the whole site while you was away..and RS could i find it?.. could i...
:D
Paul Woods
28-08-2005, 16:55
yes its crackin stuff,i only used it to fill the torque mounts with as the side mounts only carry the engine weight and are more or less solid filled anyway....the RS number you need is 199-1395 mate
ta :D .. one thing im left with..(theres always more :? ).. what have people done with there alternator mount and tensioning it?.. i have the celica top mount bracket.. i guess i'll make a tensioner bearing up and attatch it 'somewhere' to the block etc..
Paul Woods
29-08-2005, 18:03
had a look today mate and i dont have THAT bracket,the bracket i did have that i mistook it for was the one directly opposite it on the throttle body and secures it to the rocker cover...so sorry matey cant help this time! easy to make though.
As for tensioning the alt,i used a mk1 4a-ge alt arm...bolted it to a convenient hole under the alt bracket and stuck a nut and bolt through the slotted bit..i think i needed to space it with washers that i later tack welded to the arm but its not rocketry.....if you are extra clever you will incorporate an adjusting threaded bar....sadly im not that clever! :lol:
here we go then.. engine work started :D i tore through like a man possesed.. its been a 6 month wait, i needed to :twisted: ..( cautiously).
day started draining the blood from her veins .. removed the fuel tank undercover, removed the fuelling lines, coolant, loom, drive shafts dislocated, torque mounts out, chain on, other mounts off. and away she went :D not a personal best.. which stands at 7 hour out and in. but it took me a whole day on my own. handy things forklifts :) the day ended man handling the d/s driveshaft with an angle grinder when it got in the way of pulling her clear.. ..for once i didnt need the damn thing , good therapy :D
http://www.adamhutchison.co.uk/graphics/2s.jpg
http://www.adamhutchison.co.uk/graphics/3s.jpg
http://www.adamhutchison.co.uk/graphics/4s.jpg
http://www.adamhutchison.co.uk/graphics/5s.jpg
http://www.adamhutchison.co.uk/graphics/6s.jpg
http://www.adamhutchison.co.uk/graphics/7s.jpg
few questions.. these pipes.. i never saw that many before.. all coolant pipes.. do we use them all? have you tucked them behind the new heatshields? i'm looking to strip all the crap out of the bay t'mrow, and p'haps have time to get the fuel tank down and pump changed.
lodgeman
30-08-2005, 22:33
love the hi-tec axle stands :lol:
hi adam, get them out of the way mate hang onto them for now but get them out of the way and drop the tank before that engine goes anywhare near it believe me i ended up taking mine back out to do the job :evil:
heres what mine looked like
http://www.twobrutal.co.uk/forum/images/recovered/2005/08/21.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2005/08/22.jpg
i took out the fuel filter aswell but make as much space as you can!!
its up on palets at front aswell.. should make the pump change a little bit more palletable :lol:
quality shots, thankyou. will print them off for reference, and sort it tommorow. fuel filter out aswell then..blimey.
Paul Woods
31-08-2005, 07:27
yes agreed,strip out everything...you want the bay as bare as possible,only the fusebox need stay.Your new heatshield will stop where the coolant pipes exit so no probs there.
Wow all that wonderful level space :shock:
That engine of yours in your other pics looks a showpiece :)
I'm just hopeless at cosmetics, feel so ashamed :cry:
Adam have you fitted your supported shaft into your box yet? If not can you do some measurements for me?
David Sleith
31-08-2005, 17:45
Can you leave the existing sound deadening on the firewall or does it need to come out and get replaced with a heat shield? Mine is still in but I'm worried its too near the exhaust and turbo.
My engine is in and sitting on its two main mounts and rear mount. The front mount is split so just bought a replacement from Ebay. Bit of delicate engineering with a two pound hammer to the rear boot wall.
The mounts have been one of the easiest parts of the job so far and its great to get the welder cranked up for some some serious heat instead of piddling about with panels and still burning holes in them.
MegatronUK
31-08-2005, 17:51
Can you leave the existing sound deadening on the firewall or does it need to come out and get replaced with a heat shield? Mine is still in but I'm worried its too near the exhaust and turbo.
Yep the insulation on the firewall can be left if you've got the mounts just right. I've left mine on, refitted the mk2 manifold heat-shield and my dad has also fabricated an ally heat shield to go in front of that on the firewall (paranoid?!). There's still clearance at the closest point on the turbo housing to the ally heat shield.
Taking out a section of the rear bulkhead definitely helps with clearance - it doesn't seem like much, but it gives much more breathing space.
Wow all that wonderful level space :shock:
That engine of yours in your other pics looks a showpiece :)
I'm just hopeless at cosmetics, feel so ashamed :cry:
Adam have you fitted your supported shaft into your box yet? If not can you do some measurements for me?
output supported shaft not fitted yet, (still to change bearing over), no problems to get a measurent now, let me know what you need.
reference the rear boot wall chop..pauls style.. i'll be doing that, id like more clearence at the front turbo side and access to the rear of engine if needed, i can then fit all the heatshields in the world to keep my paranoid a** cool *quote :lol:
todays ..
stripped the bay of 'debris' , removed fuel tank.. jeez, no chance of doing that with any engine in, cheers podge. I had to fit my st205 pump which is smaller than both 4age and mr2 3sgte pump..
quick techy bit..
the st205pump does fit, just have to pull the pump down to the bottom face of the carrier, and move the rubber feed pipe accordingly. The pumps rubber foot (4age foot).. needed chopping a bit to fit the bottom profile of the st205 pump, easily done. some plastic cable ties to hold the bottom from walking outwards, looped through a hole in the carrier.
The standard 4age pump uses bolt terminals, the st205 is hard wired with a plastic plug(arrowed in the pic), i simply chopped the wires, soldered together the positive/negative respectively, and used some heat shrink sleeving to ensure the bare wires didnt chafe on the carrier, and the positive didnt earth on the carrier at anytime. if i didnt sleeve the soldered joints.. and the positive arked on the carrier (earthed) when in use.. it would blow the tank up :!:
i rubbed some rust bubbley patches off the tank (not many).. and painted it with some good old hammerite. i also sprayed the area where the fuel tank sits in, and the underbody of the motor with some waxoyl.. great little pump gun sprays.. recommended.
http://www.adamhutchison.co.uk/graphics/bayempty.jpg
http://www.adamhutchison.co.uk/graphics/tankout.jpg
http://www.adamhutchison.co.uk/graphics/st205pump1.jpg
http://www.adamhutchison.co.uk/graphics/st205pump2.jpg
http://www.adamhutchison.co.uk/graphics/fueltank.jpg
my wheels have come back from the welders too :D i need to machine the excess ally lumps off the back face first, then they go back to have the spacers/spigot combos stitch welded on.
http://www.adamhutchison.co.uk/graphics/azevweld.jpg
tommorow i plan to fit the new st185 outer cv's, grind off old mounts and battery tray, and ready it for the mock fit for the first side mounts fabrication, which i guess i might get half way into.
nice one adam comming on well mate
today saw my new CV joints not-fitting from parts in a box. basically, they sent me standard mk1 CV joints somehow, which fit into the mk1 hubs, but the female side is too small for the turbo shaft, same number of splines, but too small to fit the turbo shaft.
after a lengthy discussion on my application with parts in a box previous to ordering these i'm not sure how they could have sent me the wrong ones.. never mind.
The part number ordered was OJ-0220, the part number parts in a box said i now needed was:
OJ-0220/30
this is for turbo input hole and mk1 output shaft.. so we shall see!.
after some negotiation, i should [-o< have some tommorow, delivered free courtesy of parts in a box, thankyou. The new part number has also been placed on the 'trader or traitor' section.
After running about like a headless chicken for a while i decided to turn my attentions to grinding the mounts off which i was going to do anyway.. it took half a day to get them things off.. all i can say is..prepare yourself for taking the old mounts off it's one evil job :cry:
still... i got fed well.. (half an mr2 in grinding dust) , and the bath got a new coat of paint..black. I rang 'the hof' for some advice on the CV joints, cheers :drink:
im waiting for the shafts to arrive now so i'll start chopping the front & rear parts of the old mounts needed for the torque mounts tommorow.
http://www.adamhutchison.co.uk/graphics/rightmountbare.jpg
http://www.adamhutchison.co.uk/graphics/leftmountbare.jpg
EDIT: where i sanded the panels.. go all the way up the sides aswell, to seam the back of the mounts in, i had to re sand more off, where the green lines are.
David Sleith
01-09-2005, 20:54
You going for the fastest MK1.5 build. Another week off on holiday and you would have it finished!
drive shafts arrived this morning at 11am, correct part numbers. Those guys at part in a box really do provide a grand service.
I readied the engine for putting it in, few things to be stripped off etc. it took quite a while to get her in and lined up just so, she still needs a nudge up on the cam side of the engine, and a nudge forward & twist back!, and the d/shaft travel through hub face needs equalling. i'm hoping to get it lined perfect early on, and then welding side mounts & torque mounts before removing for bay painting.
http://www.adamhutchison.co.uk/graphics/8s.jpg
http://www.adamhutchison.co.uk/graphics/9s.jpg
http://www.adamhutchison.co.uk/graphics/10s.jpg
http://www.adamhutchison.co.uk/graphics/11s.jpg
http://www.adamhutchison.co.uk/graphics/12s.jpg
http://www.adamhutchison.co.uk/graphics/13s.jpg
p.s.. inbetween the drive shaft & gearbox, shouldnt there be a thin metal cap like a dish with six holes in it?.. to stop the grease coming out the driveshaft?.. if so, i must have put them somewhere, cant remember taking them out?.. i dont want to buy a spare set! :D
if someone can agree that there should be an end cap that fits on the end of the drive shaft before it mates to g/box.. then i must have some as the engine came complete with d/shafts attatched and i dismantled them..
:?:
lodgeman
03-09-2005, 00:02
looking good 8) and i see you painted the chain then :lol:
i'm not sad am i? its a different chain :wink:
ive got at least 4-5 tins paint left too.. :lol:
No dish on mine! The grease from the inner joint spreads into the matching cup in the outer end of the supported shaft on the RH side and the stub sticking out of the diff on the LH side. Either that or I've lost my dishes too :? :lol:
if its the drivers side one there isnt a cap and dont push it around to much as the tulip will come apart and bearings everywhare i remember paul gave me that advice and what happend "ill just push that a bit" 2 hours later i got it all back together :oops:
cheers, thats the news i wanted to hear, i know im absent minded sometimes about parts, thousand of bits laying around.. was pretty well sure i didnt take any caps off.
tulips?.. what them things with 6 balls and a slotted cage?..that if you put back in the wrong way it seizes? they were sent to test us werent they :roll: grrrr.
hands up who stole me front torque mount when i wasnt lookin? *cough*
lodgeman
03-09-2005, 22:04
wasnt there someone looking for one :lol: :lol: perhaps he's spirited it away :twisted:
lined her up a bit better this morning, clamped the mounts with g-clamp to tack a side at a time & plates square to the mount faces etc, paint blobbed & drilled higher. same with drivers side. once drilled, i re-lined the mounts as best as poss paying attention to hole centres on mount plate and mount. a good bud welder of mine seamed up the bottoms on both sides, and we then lifted the engine up that 10mm further and pushed the mount bolts through.had to use longer 12mm bolts as i used quarter plate for my mounts. the bolts needed to be 15-20mm longer. i'll cut them down another time. the engine was then hung on its side mounts. manifold was jacked up and then i made the rear torque mount to fit. I've got about 45mil clearence between turbo heat shield and bulkhead, plenty of room for a further ally heatshield etc.
The rear torque mount is sorted, the engine is now out again (pain in the aris that was 2nd time round).. and tommorow i'll seam the rest of the mounts up.. and weld extra support plates across the top (quarter plate again).. once all seamed and stron, i'm going to paint the bay.
TB blunder of the week :oops: front torque mount gone awol, or p'haps somebody overlooked it, cant get the staff these days.
the other 3 mounts are good & pretty much done, and sort the front torque mount as soon as i get one :oops:
good news is i found a use for the toyota jack.
http://www.adamhutchison.co.uk/graphics/14s.jpg
http://www.adamhutchison.co.uk/graphics/15s.jpg
http://www.adamhutchison.co.uk/graphics/16s.jpg
http://www.adamhutchison.co.uk/graphics/17s.jpg
the d/shaft spacing isnt perfect i got 10mm more on one side, what i will say is it all becomes alot to keep track of when spacing everything and welding and jimmying the engine about, keep on your toes.
I'll find out if it bottoms out when i drive about, altho im sure my uprated suspension , bump stops and other bits will help no end, and the shafts wont get the chance.
well then ..she's in. bug*er doing that again soon.
im short 1 front turbo torque mount.. just the rubber mount itself, i have the bracket, no problem to fabricate at a later date. i've also yet to fit the d/side d/shaft.. i'll pop out the strut bottom another time.
Lost 1 part.. the frilly gasket thing that seats on the d/shaft end, have to get one from mrT. its been quite a task getting it in, there's only me here....but i had some good lifting equipment about which helped no end, and pallets!.. which were great to sit the car up on, made the job a bit less stressful, although i was running round like a loon for most of the week. i'm looking forward to plumbing it all in now, still a way off, but she's home :D
http://www.adamhutchison.co.uk/graphics/18s.jpg
http://www.adamhutchison.co.uk/graphics/19s.jpg
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http://www.adamhutchison.co.uk/graphics/33s.jpg
http://www.adamhutchison.co.uk/graphics/34s.jpg
bloody hell adam you made short work of that lot mate :shock: :D
keep it going its coming on real well!!!!!
short work?.. :shock: i was at it 8-8 since tuesday with a help..i printed pauls manual off, sorted :wink: , it was a tough slog.. i know what you guys have been thru now :lol: pain mongers.
i tell ya.. it feels like ive been hit by a train this morning.
MegatronUK
05-09-2005, 18:27
Well done mate! :D
Some cracking progress images there, I also see you've got a good amount of space in front of that turbo... hopefully we'll not lose any UK mk1.5's to fire! :shock:
yup, plenty of room for a extra heatshield. lots of work left.. at my leisure now (phew).
i called mrT for a front torque mount today, just for the rubber mount piece... ?72 ... still what has to be has to be, so i ordered it, got home, someone offered one for 20 quid off the imoc.. :cry:
front engine mount arrived, part number pictured!.
having gotten this far, ii found my engine was sitting just 5mm to the right of the front torque mount .. i guess thats allright after all that lining up. the front torque mount i welded to accomodate that, with a little bias on the mount. heres the mount.
I also managed to fit my downpipe this evening, that was a task, i ended up turning a nut down so it would fit on the thread without fouling on the pipe.. one of the underneath fixing holes on the downpipe was very close to the pipe surface. eventually got it on and tightened up after 2 hours.
ive only to put in a gear box oil seal / gasket / dust cover, and put the drivers side d/shaft back in, thats all the main fabrication work sorted. then she's coming back to the garage to continue work.
http://www.adamhutchison.co.uk/graphics/35s.jpg
http://www.adamhutchison.co.uk/graphics/36s.jpg
http://www.adamhutchison.co.uk/graphics/downpipe1s.jpg
http://www.adamhutchison.co.uk/graphics/downpipe2s.jpg
some more work, not much.. just chipping away. fitted the new gear box oil seal, cheers lodge & JB. I had to pivot the hub out to get the drive shaft in.. as most prolly do. I then re-sealed my sump with black silicon (couldnt find my sump sealer!).. and dropped her back on the floor, front engine mount also fitted. bolted a few other bits on. first time she's been on the floor :shock: with both driveshafts in.. they look pretty horizontal to me :) , all's well.
stuff to do next:
make cardboard template for heatshield (tin bashers will guillotine sheet)
fit alternator on top mount & fab adjustable jockey pulley for belt.
make turbo - ic /bov pipe 'bracket'
mount header / overflow tank
re-machine bolt pattern into wheels
http://www.adamhutchison.co.uk/graphics/37s.jpg
http://www.adamhutchison.co.uk/graphics/43s.jpg[/img]
Driftin_AW
18-09-2005, 00:17
excellent work adam, didn't realise this thread was full of your progress!
it's much better doing things like this full-time rather than during your spare time on weekends etc
looks like you should be driving it in no time!
if i could do it in my fulltime id have it done sooner. dont know why people get the impression im flyin with it?.. i took a week off work to get the engine mounted and pump change, was well prepared for it, even so.. still managed to order the wrong drivehshafts, theyd been sitting in my workshop for 2 months :lol: ..and i was missing a front torque mount.. things get overlooked,.. if i could do it again i'd write a checklist before i installed...thick as sh*te :D
me..im just chipping away with a few hours in my spare time here and there. i hope she'll be a starter in about 4 weeks...
battery relocation,
supra TT IC mount / fan & s/steel piping
boot floor scoop for IC
turbo to IC pipe bracket (fab)
panel for inlet manifold boot hole
header tank
water pipes
bulkhead heatshield
selector cables
throttle cable
wiring & pnuematic plumming :shock:
wheels to machine / powder coat or spray
brakes to fit
suspension to rebuild..koni
full bushing kit
turbo arb to fit
all round drop links
tons of work mate! that lot'l keep me quiet
lodgeman
18-09-2005, 15:27
dont forget the exhaust :P
i was going to run it wihtout one :D
been keeping a look out.. waiting for a turbo dual 3/3.5 inch exit, cheap. arent we all.
started fitting the engine around august ehhem 2005 [SIZE=2] not that long ago .. i got side tracked with a few 'small' spots of bodywork and other stuff as you do.
i rewired her over xmas, plumbed her in this gone week, am now just finishing off in the bay at long last, 5 small jobs left till turney key time. thats an afm bracket, some straight lengths of ic pipe to cut, a small mod on the throttle body which is to angle the inlet plenum 90 degress via curve to the left, and a heatshield to cut and fit. once that lots done, i'll be having the two bits of exhaust mid pipe tig welded together the week after this coming which are allready made just not joined [SIZE=2]:thumbsup:
http://www.adamhutchison.co.uk/graphics/engineplumbed1.jpg
Marksman
20-01-2007, 22:22
Very very nice, and with some individual design and build features too. TB-ism at it's finest Adam, credit to the club mate, well done.
Owen.
Cripey! I thought you were just here to make parts for everyone else on here. :hidesbehi
That looks like a top notch install you've done there Adam. As i don't know very much about the car, i.e nothing, what's the lowdown on it all?
Marksman
20-01-2007, 22:40
Toyota.
MR2.
Big engine.
Go fast.
Hope that helps,
Owen.
As always Owen, as always. lol
about bloody time too ad ive been waiting almost two years to hear this beastie run all the best with her podge:thumbsup:
lodgeman
21-01-2007, 01:44
Cripey! I thought you were just here to make parts for everyone else on here. :hidesbehi
That looks like a top notch install you've done there Adam. As i don't know very much about the car, i.e nothing, what's the lowdown on it all?
dont get him started! he'll never get it finished!!!!! has some special cams and shit in it :rofl: something like 3 million rwhp and a 0-60 of oh my goddddddddddddddddddddddddddddddddddddd!! and with all the engineering will probably be twice the weight of a normal mk1 ( was gonna put mk2 !! lol lol ) i think i have personally put about half a ton of new metal on it!!! mind you it had lost three quartes of a ton with rust!!
Paul Woods
21-01-2007, 09:16
first time ive seen the engine bay on this one,thats looking very neat indeed,some special touches going on there,everytime i look i see another bit of detail,special!
dont get him started! he'll never get it finished!!!!! has some special cams and shit in it :rofl: something like 3 million rwhp and a 0-60 of oh my goddddddddddddddddddddddddddddddddddddd!! and with all the engineering will probably be twice the weight of a normal mk1 ( was gonna put mk2 !! lol lol ) i think i have personally put about half a ton of new metal on it!!! mind you it had lost three quartes of a ton with rust!!
thanks al, you did scare the rust off and eat the local sausage roll shop outa business lol .. true it has alot of new metal, not worried though as we have 300kilo head start over the mk2's or there abouts ... ? ;) so im +1 there lol
bloody hell adam..this may be a show stealer knowing your perfectionisms..
been waiting a loooong time to see her...
Marksman
21-01-2007, 14:30
Is it finished yet?
Owen.
nearly, this morning i got the afm bracket made, intecooler piping fitted, exhaust tig welded, heat shield made and fitted, throttle cable fitted, engine coolant filled and bled, oil inserted in gearbox and engine, and turned the key :) ..
soon after.. the gf poked me in the ribs and told me to stop snoring
MegatronUK
22-01-2007, 12:35
Looks like a top job Adam, we all knew it would be something special!
Any progress news Adamh? :)
yes shorty, today alan popped over for some sausage rolls :poke2: and paff who also ate some sausage rolls :poke2:and to lend a hand with bleeding brakes and clutch, also replace an item needed which was a handbrake left extension cable which had perished. good news is the brakes all bled in nicely and i now have a solid pedal ;) .. the clutch bleeding played ball straight away :thumbsup: and the minute i saw the hydraulic piston stroking proplerly i jumps in the car and try's out all the gears and they sink in beautifully 1-5 and reverse. so everythings looking good so far. cheers al.
jobs left; finish intercooler piping (silicon reducers coming in post)
cut & fit turbo heatshield.
remove sump and splash bottom end with oil / re-seal.
stick small amount of oil down the cylinder bores / fill engine.
fill engine with coolant and bleed.
finish (tig weld) join between exhaust mid pipe and flexi down pipe.
.. wait for al to arrive, eat some sausage rolls, turn key. al's coming down weekend after next.
:jump: OOooo exciting.... not long to go now :)
Good man. Soon there now. Nice to know you got brakes there too:)
How did you work out the mod on the gearlinkage then?
nice one ad, cant wait fella! i bet your stoked
nice one ad, cant wait fella! i bet your stoked
right on :driving: the froth has passed the mouth and is on the neck now ..
shorty, there are some of the simple mods for the gear linkages from different turbo builders here :
http://forums.twobrutal.com/showthread.php?t=3756&highlight=gear+linkage+mods
http://forums.twobrutal.com/showthread.php?t=580&highlight=gear+cable
:rant: fudging car!.
today was one of them bad days, it started out with not having any correct sized jubilee clips for 35 o.d collant hose, just a few mm short on a 32. wasted around half hour trying to bodge a smaller one, nope.. wouldnt have it, so i nabbed 2 off my bov recirc pipe fitting eventually. once the pipe was in place, i then put the heatshield down the frontside of the bulkhead ready to spot holes through into various places with a punch/drill. i couldnt quite get the right cutting on the front lower crossmember angle as the sump was in the way, i tried anyway as i thought it aint gonna beat me!.. drill snaps and i put a tasty gash across my finger :) ... no more drills so i decided to carry on and take the sump off so i ca approach it proper angle tommorow etc, undid all the bolts, went to remove the sump with the 2 screwdriver technique, would not budge a millimetre, it turns out the silicon i used before had sealed it so good... it took an amazing amount of force to get it moving off the block face!.. i bent the fudging sump pan flange in the process :banghead:. well, i got the sump off , i was going to remove it anyway as what with lodges misfortunea while back on his big ends i decided to ditch the silicon i had previously used and apply proper sump sealer ;).
i got zilch done in the 2 hours this evening aside cutting hands up and getting covered in oil lol, turn out the light go home. tommorow she pays for putting up a fight :nunu:
fair play ad she`s fighting you all the way mate bet youl go back tomorow and everything will be a breeze well hope so anyway:thumbsup:
well i've done the dirty work now eh. i'll straighten out the sump flange with the fbh & anvil in the morn , wont be bent for long thats for sure ;)
Paul Woods
02-02-2007, 06:25
ah you get days like that adam,even when you do it for a living the odd day nothing goes right,my hands get cut to ribbons,parts break as soon as you look at them and i feel like setting fire to the car.....best thing to do is walk away and attack it fresh minded the next day.
Gary Symons
02-02-2007, 06:50
Had a few days like that myself during the build. Normally I am a very calm relaxed person but it has been known for the odd hand tool to fly across the garage. Makes a very satisfying noise when you are pi**ed off lol
Paul Woods
02-02-2007, 07:04
but it has been known for the odd hand tool to fly across the garage.
Also known as a wellycopter lol
indeed paul;
"wellycopter" - the moment you've discovered you have cross threaded the threads on your crank and you send a spanner flying through the air at the garage wall...
i hate the days where you set out with good intention and end up staring at the project wondering what the hell to do..so you start a few different jobs at once and by the end of the day youve acheived nothing..plus its winter..!
keep your pecker up adamski..
heatshield is now up, played ball today :pumped::) . it covers the front of the downpipe and turbo and stretches over to the fuel filter covers all water / fuel pipes etc. i recessed the sheet at the fuel filter and at the gearbox cables so they poke thru. tommorow spray big ends with oil and re-seal the sump pan. i'll also be re-fitting mid-pipe and working out what cut & joins need to be made in exhaust mid pipe, it just needs a little kink it ;) .
509
510
511
jobs left;
reseal sump
mid pipe cut and join
waiting for silicon hose reducer couplers from china! (half the price on ebay)
and waiting for stainless bends to come in at plumbers.
fill oil engine / gearbox
bleed engine coolant.
im hoping for the bits to get here from land of the rising sun mid week :pray:
From China huh. Whatever works i guess:)
I`m having the day you had today. Was going to paint today but when i tried to remove the right crossmember suspension bracket (left i got off when fitting the engine to get clearance) it didn`t move a at all. The square thing it attaches to came loose on the other side and ended up grinding the thing off in rage. Fun indeed but now i need a new bolt and weld a plate and nut on the other side to make it sit. And some of my spackel cracked as i hammered away on it once again in rage:)
But calm now and at it again tomorrow. Beers now, cheers.
Can`t wait when you turn the key Adamski. I can feel (read) your getting exited. No, not that way!
Marksman
02-02-2007, 21:47
Gooooood man Adam. I've got so used to you being the chap who's doing a never ending immaculate conversion / restoration that it is going to take a major retune of my head to think of you as a MK1.5 driver. Does it seem real to you yet?
O.S.
Marksman
02-02-2007, 21:48
What's spackel....?
The stuff you have to wipe off your monitor at 3am...
O.S.
What's spackel....?
It my word for that sticky thing to cover mistakes:)
Now i`ve been told how you write it and what i know is that now my mistakes are speckled?
Arg, i give up:)
From China huh. Whatever works i guess:)
I`m having the day you had today. Was going to paint today but when i tried to remove the right crossmember suspension bracket (left i got off when fitting the engine to get clearance) it didn`t move a at all. The square thing it attaches to came loose on the other side and ended up grinding the thing off in rage. Fun indeed but now i need a new bolt and weld a plate and nut on the other side to make it sit. And some of my spackel cracked as i hammered away on it once again in rage:)
But calm now and at it again tomorrow. Beers now, cheers.
Can`t wait when you turn the key Adamski. I can feel (read) your getting exited. No, not that way!
ah that square cross member nut, my right side happened aswell. the bolt shank fused with the bush so no other option after taking the nut off! i had to get a grinder and cutting disc and cut up through the bolt between bush and mount ;) then it fell out nicely. i remember the days of chopping through shock absorber shafts with 9" power grinders for top nuts seized! .. now that was fun watching them shoot off under load of spring down the workshop :mrgreen:
Gooooood man Adam. I've got so used to you being the chap who's doing a never ending immaculate conversion / restoration that it is going to take a major retune of my head to think of you as a MK1.5 driver. Does it seem real to you yet?
O.S. i got used to me restoring aswell! not by choice i say but it has been well enjoyable getting head into every nook, it will be surreal driving if i ever get there! ..ive got more work to do yet .. grafting arches on and cosmetic. once its got m.o.t and paint.. thats when the real work starts lol
Marksman
02-02-2007, 22:30
I'm so very jealous!
Not sure that car's safe. Maybe I should drive it first to make sure?
Owen.
Paul Woods
03-02-2007, 07:13
nice one ad,you go there with a fresh day at it,always works! either that or you end up torching it...
oh,ive just been to the toilet,i spackled the bowl ....lol
It my word for that sticky thing to cover mistakes:)
thats no way to talk about the wife..!
good news the silicon couplers i ordered from japan arrived today. so the only thing im waiting for is stainless bends for IC pipes from plumbers mid next week. i got sump re-sealed today , and chopped up the mid pipe roughly for the exhaust, i allready made a flange a while back to go inside the 3" pipe..
515
so ive just got to weld the flange onto some straight at the right length and tig that lot onto the end of the mid pipe, bolt up ;) its going to be restrictive with the standard 60mm bore back box, i'll upgrade to a 3" back box later
514
Fast delivery by the chinese indeed:)
Closer now Adamh,,,, Your soo gonna get some;) Add the car speclist to your adultfriendfinder and off you go:)
if i listed all the metal modifications i think people will ask for gimp hire :hmm:
ooohhh closer now ad :jump::jump::jump:
zorst fitted up fine. i had to mod the standard back box to bring the entry pipe inwards, it was 30mm away from my tyre!, so lopped 45mm off the entry length and re-welded at the box. the mid pipe was finished up on the tig, it all fits snugly up under. i now 'cannot' fit the standard heatshield as i had to reverse my arb as the mid-pipe to back box flange was touching the arb.. bieng the odd recessed shape it is.. i reversed it to get it closer to the boot floor thus providing 30mm or so clearence from exhaust flange. the exhaust is on new rubber mounts, the engine is on a new mount at front and decent rear/side ones.. the engine does 'not' move with hands.... all the exhaust flanges are tight bolted.. it dosent move a friggin millimetre as the engine dosent move!.. im not sure if this is a good thing with the stainless everywhere, im sure it'l crack sooner or later.. maybe the flexi will help here. we'll have to see, maybe the mounts and such will loosen up after a while and give me a little more flex :hmm: . oh and it clears the gearbox torque mount by about 5mil, better than 1mil lol
IC pipes / couplers to finish clipping up tommorow.. roll on saturday.. allthough im sure something will crop up to prevent starting, always does !
519
520
Imminent startup Adam...nice work.:thumbsup:
:popcorn: :popcorn: :popcorn: :popcorn::popcorn:
So you set saturday as startup day? *crossing fingers & legs*
Nice custom work Adamh. You really know your stuff:)
Cant wait for this.:)
looking good ad dont worry about nothing moving thats how they are mate all the best for saturday podge:thumbsup::pray::pray::pray:
lodgeman
08-02-2007, 22:51
make sure the battery,s charged!!;)
about bloody time..:roll:
johnathan
09-02-2007, 05:06
i love adamh's work big fan
superchargedsam
09-02-2007, 09:25
looking awesome Adam ! wanna finsih mine off after once its finished as am sure you will be bored with nowt to do but drive it, polish it, love it, stroke it, look at it, love it, drive it, polish it, stroke it..........................
.......................drive it, love it, polish it, look at it..................
............but well, if you get bored let me know !
;)
Awesome work as ever fella !
love it, polish it ? do that allready!.. the car might get some aswell. have interior to tidy up later in year, its a bit of a trash hole inside :-)
superchargedsam
09-02-2007, 10:24
love it, polish it ? do that allready!.. the car might get some aswell. have interior to tidy up later in year, its a bit of a trash hole inside :-)
yeah but am sure with the adamski touch it will look awesome ! Once this weather stops messing about I am going to sort the interior on mineas once thats sorted at least I can sit in it and make engine noises lol !
;)
any tips for starting.. its been sitting for a while. i was thinking of turning the rear wheel with one wheel off the floor one on and in gear to dip the bottom end. oil in ze top. cranking without king lead until oil pressure is up. antything else?
Gary Symons
09-02-2007, 21:38
Big day nearly here then! Good luck for the startup :thumbsup:
BTW still havent posted those discs yet :doh: been sat in a jiffy bag on my desk at work all week ready to go aswell.
yup, not realised yet.. cant beleve im turning key tommorow, albeit the key in two halves with one half lodged down the barrel lol
dont worry about the disks yet gary, whenever they get here is just fine. what did you do to extend your throttle cable?
ad just put the key in and give it some youve been stalling long enough now fella we want start up
Paul Woods
10-02-2007, 06:35
ad you dont need to extend the cable,just re route it above the front engine bay crossmember instead of under it,this should give you all the length you need ,oeeerr!
good luck with the startup! mobile on standby in case of niggles :popcorn:
Gary Symons
10-02-2007, 08:13
As Paul said, didnt need to modify my cable, just routed it to fit.
If you go down to Adam's garage today, you're sure of a big surprise...
Best of luck matey, can't wait for your start up vid.
Gary Symons
10-02-2007, 15:42
:popcorn: :popcorn: :popcorn:
lodgeman
10-02-2007, 17:11
startup vid in the media section!!!
here go , only one i got today, maybe gary.H got some more will find out later cheers for more filming gaz, more movie footage to come later :thumbsup:. once filled and bled and primed the f*cker it started first try :mrgreen:.. after 2 years thats pretty amazing!. we also have a rattle issue with something... it just may be piston slap from seized rings or ...what i think it may be is the arb which is 'hanging down' lol since i hadnt bolted up one side yet properly as i had to drop that with spacers another 15 to clear the exhaust, so im almost sure its that.. i'm confident it will be fine as once it warms up and the engine steeles down it go's. good news is.. there are no leaks/drips/fault lights/ problems and it runs sweet as a nut :thumbsup:
the fuel rail banjo bolt i modified leaked under pressure, so i had to fly back to the workshop and pick up another one.. got it in and job sorted.
will get some clearer pics when possible
521
hooge thankyou to alan, paul, and everyone on the club :beer:, and brutal for making it possible!
Gary Symons
10-02-2007, 17:48
Feels good doesnt it. Your startup sounds a bit like mine, I was expecting to be spending a few minutes coaxing the engine into life and mine also fired straight up. My startup was a bit of an anti-climax if I am honest, still, better than than a load of problems.
Have you say, that car of yours sounds really nice :thumbsup:
So when is it hitting the roads?
lodgeman
10-02-2007, 17:57
took these pics mate:thumbsup:
http://www.twobrutal.co.uk/forum/images/recovered/2007/02/63.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2007/02/64.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2005/10/19.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2007/02/65.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2007/02/66.jpg
Gary Symons
10-02-2007, 18:03
Nice pics, fantastic work there. I can see a few hours have been put into that bay.
Looks like new mate. Corking engine there :)
yeh its a marvellous feeling gary, know how you felt a few months back now , and all the other brutalers :):toke:
one slight issue aside the rattle is the overheat.. after running for a while the coolant was boiling up in the block.. quick check at the front end showed the radiator stone cold still with the fans blowing which are on permanent at mo, i'd suspect a seized thermostat as there was just no warmth up the rad end. i'll get a new stat on order and re-bleed it, tie up arb properly and see how she fairs then.. ive got boost and other stuff to check in the next few weeks etc. then after that, fabricating some large arches onto the rear/tidying up.. then up to woodpsort for the paint icing :)
cheers for pics al, glad somebody got some my phone cam is clearly not kosher
Gary Symons
10-02-2007, 18:21
Also when the stat is sorted make sure the fans work at the front when needed unlike me! Will save an embarrasing overheating issue that results in filling the pit at the mot station with boiling water rotflmao and causing them to abort the mot.
One serious point, the temp gauge on mine reads normal lower on the mk1 gauge than it did with the 4age.
how were your fans wired gary?.. mine just seem to come on straight away when i turn to accesory position on the key, i just wired them straight up to the mk1 wires.. (turbo fans and rad)
Gary Symons
10-02-2007, 18:30
I used standard mk1 fans and stat on the rad up front. My problem was that the fuses had blown. You should have nothing to worry about, just worth checking that they come on when the rad gets hot.
i have no choice about the fans bieng on, somethings amiss and will need investigating. once the heating issues sorted i'll be trying to hold back taking it out , dont think the locals would appreciate me zipping up & down with no wings on lol .. i'll have to have a test up and down by the garages here off the road etc :driving:
Marksman
10-02-2007, 18:57
Fantastic news Adam, very pleased for you.
All the best,
Owen.
How thick are those pipes Ad? 3inch?
bit of a botch up there shorty, i wanted medical quality thin walled stainless pipe like the small section in the middle of throttle body section which has od of 51mm.. but the plumbers merchants i went to ordered '2" stainless welding elbows' which were only 6 quid each matey, but a little thick!.. the o.d is 60 / i.d 54 to take 2" pipe up its bores with some slack i might add!, i managed to get by no problem although and they tig up nicely :thumbsup:. the stainless flexi pipes were a god send from ex-used stock at work.. they have an i.d of 55mm and a total o.d of 61 on the flat coupled ends , so fitted up perfect with the turbo outlet o.d of 55mm. i used 60mm couplers for the turbo hard pipe side, and 60-51mm reducers on the inlet side, 60mm on the throttle bod. which i chopped down to about 25mm long and bored out as much as i could.
Holy. You really did some work here:) So a bit of everything really, works well i think:)
congratulations ad well done fella it feels good doesnt it all the best with the finnish off podge
feels good yeh, but.. not half as good as nailing it will ;) .
prick the ears up folks... i had an issue with the start up, i know its been sitting for a long while, but as far as i knew it was o.k. i've worked on the bottom end so i know everythings o.k down there, it has new big ends, all torqued to spec so i know that end is kosher. its had new cam belt / pulleys so not much chance of a rattle there. the turbo was bench checked and is in good shape. as far as i know.. everythings good.. so question is wtf is this noise!? ....
the vid is in two halves.. first half noise dominant.. second half dissapers.. and runs sweet
1st...
http://s142.photobucket.com/albums/r89/Gary_H/startup%20day/?action=view¤t=DSCF0310.flv
2nd...
http://www.adamhutchison.co.uk/graphics/startup2.wmv
I know it sounds like nothing to worry about, so i started the thing about another hour later after alan had gone and the noise had come back..let it warm up, it go's..
must be something related to heat maybe piston / ring expansion.. cold be something loose to do with exhaust but i dont think so.. quite odd as it dissapears once idled and warm.. any ideas..
hi ad cant get the second one my software wont play it but in the first one i can hear it plain be honest tho sounds more like someone taping on a pipe than engine what i normaly do is listen down an extension bar put it on the side of the block put you ear to it and listen you will find it fella all the best podge
good idea .. extension bar. will see if I can't get a compression tester on the case too.
I don't know tone, I've had the bottom end off to change the bigs but not the head. the guy who had it before the write off had it imported and knew nothing of its internals / just smashed it pronto and says it was evil quick. I gets it home and find toda 264 cams / pulleys , mines ecu, greddy recirc bv in the clip which might suggest higher boost was run. finger crossed might be some forged pistys in there too :-) the thought has crossed my mind mate, really tricky as the rattle is dead loud then gradually dissapears to nice burbly idle.. takes about 3-4 minutes. wish I knew what it was , numerous checks can only be done now for elimination. endoscope would be great
cant wait for you to dyno this thing adam..!
only when cold yup. possibly oil way partially blocked in rod for skirt/ring lube. i'll slip some oil down the bores, tighten arb up, give it another go later. next step then is compression check. looking forward to testing aswel :-)
Marksman
12-02-2007, 17:46
More more more, sod the day job, we want more 1.5!
Adam?
MORE!
Owen.
patience O' lol
well i tried the oil down bores, tightened up arb, it was a mile clear anyway from the exhuast flange. it does exactly the same, deathly rattle on cold.. 3-4 minutes precisely it burbles about rattle quitens down,.. burbles some more.. gets quiter.. off beat.. settled.. still burbling but no rattles.. infact sounds bloody quiet aside the throaty off beat tick. touch the throttle.. it roars :) , not quite the v6 nightclub but im sure its got a secret weapon in its pants..
bad news is.. theres a frikin leak on the sump pan i think.. at the back bottom corner next to the bellhousing cover plate. a small puddle has appeared since saturday spread to about 20 cm diameter.. so after running i stuck my head underneath again and could see a drip now and again coming off the lowest part of the gearbox cover plate under the block.. it seems like its coming off that sumpcorner as i can see shiny oil on the tiny corner of the block face thats exposed. im praying to the gods that its not the main oil seal. tommorow i'l take off the cover plate and stick some fingers up there to see if theres any behind the fly, if not im afraid the sump comes off again and again seal it up. .....meditating
I read about so many had problems sealing the sump again. What do you use? I got this cork gasket in my rebuild gasket kit but i think i`ll buy some toyota sump seal silicone, if they have it.
I guess some shakedown is needed on such a serious making Ad, but you`ll get there and pumping utube/google with stunning vids:)
Good luck with next step in testing!:)
practising with 'loc-tite blue gasket sealer' for sumps ;) at keast this time it should be easier to take off,, says i
Here's hoping you don't have to go that far Ad.:fingersx: The bonus being you can post the vids sooner. ;)
as tony said ad you could have forgies in there if the builder went to the trouble of cams and all that then could be lucky think thats what id go for
checked. couldnt get my finger behind the fly as theres only 5mm or so clearence!, but i had a good feel about up there in other places, a good enough look, and checked out the bell housing.. no sign of oil there at bottom so chuffed :) nowt wrong with the main seal. pulled off sump, checked there, looks like limited amount of blue sealer in that corner.. so that was looking like the prob, difficult to tell once youve split the sealer.. but there wasnt anyhting wrong with the main seal so re-seal sump tommorow.. practise #2.
glad to hear not the main seal :thumbsup:
Good news Ad :thumbsup:. One step closer mate.
almost there mate..in time for spring too..!
well ive re-sealed the frikin sump :thumbsup:, this time i went double seal instead of a single line!.. no drips yet. and more news is the rattley start up has gone after re-fitting my mid pipe after the sump re-seal. i found a loose bracket bolt which holds the down pipe to the bottom of the block, id imagine this was making the rattle as ive now tightened it and its quiet as a mouse on start in comparison.. forged?.. my ar*e lol im just glad its not rattling.
tommorow see's the thermostat replaced, a bleed, boost gauge and sensor plumbed in, and if i can get the throttle cable extended i'm going to nip it up and down the 'off road' garages to check the gears are working and the boost gauge works ;)
work left is really not much.. wire up IC fans / engine bay fan.
then im afraid its back to bodywork on the rear for the next coming weeks
Paul Woods
16-02-2007, 18:40
great progress mate,the bays looking fab...i especially like the IC hose on the right,whats that stuff? flexi tube of some sort? thats a neat solution.
aye its flexible stainless oo-er , special bendy steam stuff it came with 2" pipe threaded ends which i since chopped off. wouldnt have been abled to afford it to buy but was left over for 2 years now from old job so the steam plumber here donated it, it's f*cking heavenly stuff. you'll see at the show mate, look forward to seeing all your swaps naturally.. it'l keep me busy all weekend,... and more lol
Marksman
16-02-2007, 21:32
Bloody hell Adam :thumbsup:
MORE.
Owen.
today came and went too quick, didnt have time to change the stat, not enough hours in the day!. i'll have to do that during the week. i got the throttle cable connected, needes a mod as it was knackered, new one coming off wayne when i get over that way!. so i starts it up and creeps it off the concrete plateau area which the garages are on, i have a whole 50 yds of dusty tarmac to travel which is not enough by a long shot.. still.. all the gears select fine, clutch is fine, brakes are fine, steering / suspension / exhaust no knocks or clunks under a right foot. quickest 50 yds i ever did lol scrambling for grip on the dusty stony tarmac.. i am very keen to get it roadworthy now and up for m.o.t , it GO'S :icon_eek: .. i just wish i had more room to actually plant my foot and not just touch the throttle! :jump::mrgreen:
a shot of the rear with exhaust on seen it all before i know..
530
this shot kinda shows what work is left
529
coming on nice ad keep it up fella
Love the job you're doing here mate. Not a Mk1 fan, but this is looking superb.
ooohh...nearly there adam...great youve had her up the drive and back..a turning point..!
This will be the neigborhood beast for sure:) Keep it up Ad!
Glad you've sorted that startup rattle Adam :thumbsup:
This will be the neigborhood beast for sure:) Keep it up Ad!
haha.. walked into the diy store to get some jubilee clips.. the shop owner i heard muttering ..... 'its him up and down the back, gasps'.......(behind shop) lol ... yeh right on pal!..you aint seen nothing yet :twisted:!..actually you dim twat i was doing barely 20 and checking for overheat / gears /brakes.
..but a d.i.y shop owner (god of self love) man would not understand the finer points of mechanicals eh. terrorising the locals :hmm:
most of the people about the flats where the garage is are old and i get on fine with them, old man stopped by yesterday to comment and nearly fell over when i told him it was running :rofl: ..
johny i dont like mk2's much neither but i wouldnt mind a run in your motor when its done i guess it'l change an opinion once tried!
happy days.
Ditto mate, and a hint of touché there too!! :thumbsup:
argghh, mouthful of coolant changing the stat. i dont recommend for-life as a tipple.
How was it then? Sitrus flavour?;)
would have been nice lol ,but im afraid it just tastes like antifreeze shorty sorry to dash your hopes!. which i havent ever drunk until then. i knew i shouldnt have trusted the small drip.. 'its o.k i'll pull it right off it must be empty' ... then the contents of the head empties down onto my face as i remove the stat housing
hehehehe next thing ad youl be in the local park with your brown paper covered bottle of forlife and people lookin on saying its a shame to see a good fella gone bad and you grumping about green pelicans
lol toyota bum. one things for sure i wont be freezing over this winter. fo the record mate you wont be finding me in any parks round ere ;)
any tips on bleeding this engine?.. ive tried kneading pipes.. running. 2 valves in frunk undone and piped up ^ etc. im filling into the rad cap hose as you do. so when do you generally stop filling her up?
what i do with mine ad is fill her up when cold bleed the frunk valve top up put cap on fill expansion tank run the engine till warmed up properly then turn off and leave to cool then off with the cap top her up check the expansion tank level and warm through again check heaters are hot and hey presto i just check then over the next couple of days to see how its all holding hope this helps podge:thumbsup:
its all looking good, will run her up again tommrow to check suck and blow levels in the expansion. i found that rattling noise :jump: too, where i had just re-sealed the sump i hadnt put on the bellhousin cover plate..it was quiet. as soon as put that cover plate back on tonight it started rattling again.. the inside lip of the plate was touching the back of the fly. few corrective swings with large hammer sorted the bent plate, glad of that.
Good to know and you must be happy it wasn`t piston slap or stuff like that.. Good call!:)
the car now dosent overheat since a stat change and re-bleed. the coolant level sits between min and max on the expansion tank, when started it sucks in slowly a bit, and when shutting the engine down it expands back into the tank for a short while with a little quiet burbling. the water gets upfront and the fans kick-in now,.. so i ran her for about a half hour and alls well :thumbsup: i noticed the rad fans were only blowing weak and showing 2V on a relatively cool enigne (just under halfway) paul says the voltage increases with engine temp from the temp sender on head so im appy with that i think its all sorted now.
jobs next to do is wire up the engine bay fan on with IGN, and then the weaker of my 2 I/C fans will be wired always on aswell on same feed. ... somehting about efi fuse uprating here.. i take it we take a feed of the cor?
The stronger of the IC fans i havent decided how im going to have that one controlled yet i think im going to run it off the front rad fan stat so when engines running over temp it'l kick in and help the i/c.
boost testing soon :)
ive wired the intercooler fans up. I took a live feed off the m2 power cable.. ran it through a relay.. then split it into two 10A fused feeds for the 2 fans power etc. to power up the relay i used pin 2 on the COR, this had 14.2v going through it while engine running and 0v when off so it'l do ;). the relay now turns them on at the 2nd accessory position on the key.
two left, the side vent fan and the engine lid fan. i'll run them both through another relay with their own fused feeds, and activate relay with the same power feed as other one. but these ones will both run off a n/c @ 25deg bi-metallic stat. i just dont want all four fans running when im trying to start the bastid.
Marksman
01-03-2007, 21:45
Sounds like a plan to me :thumbsup:
Owen.
lodgeman
01-03-2007, 22:37
i came over to you garage yesterday mate! @ 4.30pm where were you? skiving again?:hidesbehi
what the gubbins were you doing there at 4.30pm !? .. wait a minute, at 4.30pm it was hoofing down with rain and like gale force winds.. your telling porkies al,.. you wouldnt come out in the rain lol let alone the wind.. something like 40-50mph blasts
if you did get there at 4.30 .. :hoarder::moon:
bad luck mate!.. i got there at 5.15 and stayed until 7.15
lodgeman
01-03-2007, 23:10
yeah yeah so you say!!!! funny when i was there it was dry and sunny and i have a witness!!!!!:hand:
dry and sunny.. did you see any rainbows?
:rofl: good lsd then ?
side vent fan now wired in to the same relay as ic fans and fused seperately. the rest of the day was spent wiring in some defi gauges they do look good when lit!.. and went to get some parts off of wayne like camber nuts and stuff cheers wayne :thumbsup:.
im needing help here.. anyone with a koni set up have you had your camber adjusted to a specific angle?.. i just want to know that someone is actually running less than 2-3 degrees negative, im down to 2 degrees now. will mess about some more later.. what do you suggest here?
i thought i'd test the boost gauge out you know.. just fitted, i had to test it worked properly :whistle:.. its negative on idle, and when you plant your foot its starts to creep up after a few thou rpm's.. um...i didnt have time to look at the gauge think it went round to 50kpa (7.25psi) first go before i had to hit the anchors, second go.. i thought right i got to know whats what and i shouldnt have really as the road isnt long enough!..started off in 2nd and once rolling planted the foot down hard.. fuck me fellas i thought i was gonna take off :mrgreen: :high: very very fast if only for a 2-3 second burst in second, it was cut short by the road running out .. i had recorded that run as you can do that with the gauges.. and it peaked this time at 68kpa which is 9.86psi for a quarter second before the bend came!. i think its got more in it so boost is looking allright.. i need to check it dosent overboost upto 13/14/15 etc but i cant do that without a real road lol that is to check the wg is working properly. once boost is checked out and proper, i'll stick in the mines ecu and see what happens
apart from overboost checks thats the engine aok.
all thats left now is to finish up on the bodywork :jump:
Great fun it sounds like. Good to hear you got no real engine problems but merely tuning to do:)
About the Konis, are you thinking about the adjusting? If so, set it to stiffest, then go!:)
the konis i talking about the camber (the angle of wheel) !.. once sorted there then i'll fart around with the damping settings.. forgot about that!
Aha. Can`t say much about the camber setting but set the damping to max. Anything less is just grandma;)
i'll see when i get there, i have no idea what its set on now. i'm looking forward to installing a home brew electronic boost controller , got all the parts now just a matter of time.
lodgeman
03-03-2007, 20:42
adam i think the way your car is set up with the lowering springs/spacers/ hooooooge wheels etc you are always going to have around that type of neg camber. ususally anything around 1 to 1.5 degrees neg is ok so 2 degrees isnt that bad, just means you will get a bit more wear on the inside edges. and may make the car slightly edgier on the road. but with 9" rears your may get some tramlining anyway!
i appreciate the negative camber al, just something odd with the camber nuts that were on there before. and now i have some normal offset ones.. they dont seem to swing round properly in the holes like the fronts do.. i'll have to have another go, nothings beyond me although if i have to machine a pair. just a pain..
lodgeman
03-03-2007, 23:25
nothing to do with the 1a and 1b?
mines a b, paul says b's should have eccentric nuts, mine didnt (oddball).. waynes mk1 was a b which i just took the nuts off..
funny thing was .. the setting notch i couldnt get to face 3 o clock.. only either up or down.. where are yours set? anyone..
Paul Woods
04-03-2007, 09:27
ad thats odd,both mk1a's and b's have eccentric camber adjuster nuts both front and rear....still cant work that one out!
Sounds like shes boosting up nicely though,bit of a rush isnt it?!
from memory with the lug facing straight up at 12 o'clock or straight down at 6 o theres no camber adjustment,in other words its just like having a regular bolt in there...i think you only get the adjustment from 12 to 6....but i might be wrong?
ah now theres a thing! just thought of summat,given your struts hand no camber nuts fitted in the first place,which is very odd...do the strut mounting bolt holes have at least one pair slotted oblong instead of just a round hole?
If you think about the eccentric nut turning,if it doesnt have room to move up and down then it cant,in a round hole that is...you are slightly lifting the whole bolt up or down when you turn the lug....see what i mean?
Now if your old struts never came with camber lugs then i bet the top and bottom bolt holes are just round,when at least one pair should be slotted slightly,im sure thats your problem bud.
good thinking batman, i'll check that. i think your right tho i can only recall seeing round holes as i was having trouble getting the bolts in at any other setting other than up.down.
3 choices here
enlarge strut tube mount hole circular,
elongate strut tube mount hole oblong
enlarge eccentric bore on camber nut
.
wtf havent i got oblong holes on the top strut bolt hole!
Paul Woods
04-03-2007, 15:17
its beyond me mate,seen hundreds if not thousands of mk1s here over the years and every one of them has had camber nuts all round...toyota obviously wanted to make life hard for you!
yeah if you slot the top holes on each side that'll give the camber bolt room to move up n down,cant imagine it needing much movement,a few mil probably.
here go.. its the usual hens toof of a toyota part.. the shocker tube with no camber adjustment slots :) .
http://www.adamhutchison.co.uk/graphics/shockertube.jpg
i'lve got both the shocker assemblies off again, them top holes are getting slotted accordingly in ze workshop tommorow. i will have some camber then.. shame on them
on a more positive note that god like creature that survives on generous donations of hob nobs sent down his redundant arches from lil. im very lucky to have them to be honest.. they need some treatment here and there.. but really...they are outstanding!, im chuffed to heffin bits. ive got my work cut out blending the eurosport into the front, and also finishing the front / rear ends off. also only one side of the arches are filler finished the other side is layed with fibreglass still, and needs a good chunk of hours bringing them down and up with sand/filler etc.
this is the last part of my swap now.. the final hurdle. looking forward to maybe finsihing it in time for the show fingers crossed, still.. thats about 10 weeks of bodywork off.. at least.
once again thanks paul mate
http://www.adamhutchison.co.uk/graphics/farch2.jpg
http://www.adamhutchison.co.uk/graphics/farch3.jpg
http://www.adamhutchison.co.uk/graphics/farch18.jpg
http://www.adamhutchison.co.uk/graphics/farch19.jpg
http://www.adamhutchison.co.uk/graphics/farch20.jpg
jiff .. on your marks...
superchargedsam
08-03-2007, 23:02
nice, liked them when i saw them at pauls! got your hands full but am sure lod.....you will sort it no probs!
:hidesbehi
Marksman
08-03-2007, 23:04
That's rather good. :hmm:
wanders off banging into door frames through internal mullage...
O.S.
lodgeman
08-03-2007, 23:07
looking good mate! dont need my help any more then?:hidesbehi
looking good mate! dont need my help any more then?:hidesbehi
whats that al?... be down next weekend.. ok ;)
David Sleith
09-03-2007, 01:04
Looking good Adam.
You gonna spray this yourself?
Jiff Lemon
09-03-2007, 01:10
jiff .. on your marks...
bugger bugger bugger bugger........
ooh..now she looks almost streetable..coming along nicely matey..
whos hiding under the sheet? or is it the long lost spirit of a previous owner unable to pass over to the other side until the 4age is found..?
ooh..now she looks almost streetable..coming along nicely matey..
whos hiding under the sheet? or is it the long lost spirit of a previous owner unable to pass over to the other side until the 4age is found..?
New Dheli weed got a whole lot stronger recently Nik?
lol
Oh, like how those rear wheels fit:) Great stuff Adamh.!!
Looks real nice.. I'm impressed. Like how the car "sits" with those wheels. I was thinking about getting the same sized wheels. just unsure about what offset would fit with stock wings and quarters.
radially.. they are 16" with 215/40/16 rubber..the same as stock (578mm O.D) with the low profiles. with stock wings id imagine the stock offset et35-38 would fit best! not quite sure what you mean matey?. i have 7.5J front and 9J rear the offsets are now 30 f/r. sticks them out 45 past rear, 30 past front (outer arch lips). from the flat of the panels.. 75 rear, 60 or so front.
david i think paul is giving her a coat if he has the space.
ah nik.. what is that thing?.. i didnt notice it when i was taking the pictures.. i think i'll send a copy into the sun / the star newspapers
the shocker tubes went on the operating table for some minor surgery this afternoon.. after a little anasthetic applied by the nurse i applied a cutter and enlarged the hole 1.5mm either way to 18mm instead of a diameter 15 hole. the offset of the standard camber nut is 1.5 so there. and now the little shocker can go and play with the rest of the normal shockers and not lean over too much :).. now 1 degree.
548
549
just a handbrake cable to adjust and brakes to re-bleed tommorow and i'm starting the body work.
Marksman
09-03-2007, 18:45
Nice work Mr. H.
Just how much would a fully kitted out engineering workshop cost TB Adam?
Owen.
We'll just build it into the TB village. lol
Nice work Mr. H.
Just how much would a fully kitted out engineering workshop cost TB Adam?
Owen.
fully kitted out dont get me started matey!. with the machines i use to cover all aspects of general engineering / toolmaking .. around 40k easy. for a bargainh.. and bare necessity machine shop.. probably just about get by on 15-20k.. wanna donate ? :)
Paul Woods
09-03-2007, 19:12
ah slotted holes,just like normal mk1s have lol ,bet you never thought you'd have to modify something just to get it standard mate!
ah slotted holes,just like normal mk1s have lol ,bet you never thought you'd have to modify something just to get it standard mate!
:thumbsup:
i got the handbrake adjusted up yesterday. and also got the camber set to 1 degree on the rear. shes sprung a leak altho which is not good news.. but never mind!.. totally suprised me to be honest its been allright for the past couple of weeks, then come into the garage and find a few spots of red coolant in the drip tray underneath.. and some on the down pipe! running her up shows the leak i think is coming from a pipe join .. the oil cooler pipe join which i think is rubber under some heatwrap? (pink arrow pictured) can someone confirm.. its clipped with the regular mrT 3 prong pipe clips. i cant see anywhere else around here the coolant is coming from.. its very very hard to see as the turbo / downpipe is in the way.. i just felt the wet cloth with my hand thats all and looked above it and saw no shine above it so thought its probably coming from the join itself.
i guess.. unless i can put some jubilees over the ends.. im looking at replacing this bit of pipe which is going to mean a drain and re-bleed..again... and remove down pipe for room to work! pay no attention to green marks old pic
http://www.adamhutchison.co.uk/graphics/leakypipe.jpg
i'd love to know how close the pipe ends are aswell under that heatwrap if anyone knows?..
Paul Woods
11-03-2007, 10:52
argh mate!! that is known in mr2 turbo circles as the HFH,or "hose from hell"...the reason being when it leaks its a full turbo off job to repair!
Its a complete bitch and the last thing you need to hear! theres no shortcut either...bloody hell,wish id better news for you,still at least now you know where its coming from.
anyone got a mrT part number for it? for a 90/91 turbo my epc isnt running just yet..
Paul Woods
11-03-2007, 11:07
ad i think you can just replace the rubber bit with heater hose but i'll grab the part number now for you....
16283-88381
http://www.twobrutal.co.uk/forum/images/recovered/2007/03/79.jpg
cheers fella, i'd better get a mrT part it should come with the heat wrap.. unless that is he asks to take my wallet and bum rape me over the counter.. .. in which case i'll turn around and walk the other way as you do.. and find some eater hose.. and make a shield for it
superchargedsam
11-03-2007, 11:47
Adam not good fella, had to do the oil feed and return pipe here and this is when I totally lost it! when I finally calmed down enough to try again it still fecked up on me and this time I tore it inhalf, it got pissed with me and tore my hand in half(ok well not quite but did piss blood all over the engine and my shiny cam cover and manifold!)! feck knows how anyone replaces this pipe with the engine in situ as I am striggling with the engine out! TOTAL AND UTTER PAIN IN THE ARSE!
ive taken the turbo & manifold / new downpipe off before on this engine so the bolts are not seized i should be allright for once sam!, i dont mind the spannering.. its the re-bleeding.. that'l be the 3rd time lol .
theres an engine bleed valve on the left rear of the block , i should be abled to get the block level low enough to get the pipe out cleanly without draining rad if i tilt the car up on axle stands. or.. i might get away with clipping jubilees over the pipe ends .. we'll see.
Hey adamh. I got a HFH spare here if you want it. I bought two of them just in case:) Brand new with the part # paul wrote. Let me know i`ll send it express monday!!
Paul Woods
11-03-2007, 13:59
now thats the TB spirit! nice one shorty!
now thats the TB spirit! nice one shorty!
Least i can do. He`s my personal advice manager:thumbsup: Might not be faster than mrt but should have it pretty fast. Just need an answer so i can pack it up:)
pack it up matey, i'd rather pay the postman than mrT twice over... your very kind shorty , thanks :thumbsup:
I`ll put it in an envelope in the post office as it`s very small and can take a hit:
f*cking hell.. hows that for effiency!.. :praise2: .
your very kind mate, the gods will shine down on high speed car build.. lol
I posted it at 10am today to it shouldn`t take too long. Guessing 2-3 days.:)
just a quick note on what i have left to do now before m.o.t
1. finish right rear arch.
2. fit three new alarm trip switches as old ones rotted a tad.
3. re-fit the quarter window and seal in (cheers owen for the trim piece :praise2:)
4. strip off back box & por 15 the complete rear end.
should have them bits done tommorow.
5. then underseal going under rear.
6. fit alluminium piece right across under front spoiler.
7. make bracket for front square number plate, coming off under the spoiler.
8. re-fit windscreen wipers / hoses
9. check all nuts bolts of suspension / hubs / drive shafts / mounts / brakes.
10.... sit on toilet and wait :)
Getting closer there. How about painting? Are you doing that yourself?
This car should last a long time after this me thinks. Pretty great build up!!:)
his hobnobship will be doing the paint in the spangley new woodsport spray centre :thumbsup: thats shortly after test and tax.
AARG. SO you`ll have a touch of PW in there too. No way to compete with that. Lucky chap! Can`t wait to see that result!!
^ ah yes, the icing on the cake no less. compete.. you have a superb engine shorty and i have no doubt it will be stunning all round when done. mine was toshed over with a few tins of silver from halfords lol and my bodywork.. looks good from a digital camera :whistle: . my favourite part of the build was and always will be the mechanical work underneath, the restoration, the subtle engineering of bits. once done i drop all them tools, and turn my attentions to tuning / trying out home made stuff
so she'll be at JAE then adam.
even if shes not painted i'll be driving her up, i got quite attached to the technicolor paint work.
i'm glad i dont have to use this stuff again, its the nastiest, i say it every time i use it. i coated the rear underneath, fixed quarter window thanks again owen im glad thats tied up :thumbsup:. and finished off cosmetic on arch.
next week doing ally panel and number plates :mrgreen:
some pics as i'm a pic whore
bits off
667
stuff on
668
managed to kick over the tin aswell.. luckily after finsihing!, bit ragged as its 17 quid a small tin :rant: if i leave it there, i'll be abled to pick up the whole puddle on monday lol ..
i dont like it! i got used to having no bumper which looked raw and i liked that look, i think also the flares looked alot more prominent with the snub end. now the bumpers back on.. forgot what it looked like :shrug:. thanks again owen for supplying the bolts to hold the bumper on :praise2:
http://www.adamhutchison.co.uk/graphics/rearbumper1.jpg
http://www.adamhutchison.co.uk/graphics/rearbumper2.jpg
http://www.adamhutchison.co.uk/graphics/rearbumper3.jpg
671
also got time to stick the under tray up under front spoiler.
http://www.adamhutchison.co.uk/graphics/allyundertray.jpg
slavery left:
fit front licence plate on 'L' bracket and bolt to undertray.
fit wipers.
That reminds me, i've got proper window wipers here to fit before the weekend. Cheers Adam :thumbsup:
Those arches look better everytime i see them. Schweet.
You got spacers to go on the front still?
not yet fella, have to wait until the bank builds up 8O.. ally's expensive in 6" billet
David Sleith
31-05-2007, 00:21
Looking very sweet Adam. Gonna be a masterpiece when its painted.
Not long now. When do you reckon she will be on the road?
Paul Woods
31-05-2007, 06:41
love the front ally under piece ads!
Gary Symons
31-05-2007, 06:49
All coming together now I see :clap: .
Gary Symons
31-05-2007, 07:22
I would go as far as to say its
http://www.whom.co.uk/sugar/fab.jpg
haha..excellent..(added as new smiley)
kerb crawler
31-05-2007, 23:13
Ditch that bumper and build one...:rozzer: .... i broke my vow of silence...oooops:hidesbehi
lol...welcome to tb mate..
may as well introduce yourself properly now..
Ditch that bumper and build one...:rozzer: .... i broke my vow of silence...oooops:hidesbehi
I get the feeling big brother is watching.. (jamie) kerb crawler!. ditch the vw engine and put a camry v6 in elle (vw bus 69')... you know it makes sense...
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