Tommys Rev 3 3s AW11 T-Bar

[Tommytank]

Heres the long awaited start to the 3s project. Been on hold for a few weeks whilst ive been moving into my new garage, but we're all settled now and the carnage has begun...

This was the day of the big shift to the new shop...
http://file035a.bebo.com/4/large/2007/09/25/10/1297287959a5645262834l.jpg

and in the operating bay...!lol
http://file035a.bebo.com/4/large/2007/09/25/10/1297287959a5645263074l.jpg



Engine is out and old mounts ground back:
http://file035a.bebo.com/0/large/2007/09/29/21/1297287959a5685244250l.jpg

and a few holes cut here and there...:P
http://file035a.bebo.com/0/large/2007/09/29/21/1297287959a5685243813l.jpg

now some creative stuff. Intercooler will be in the boot so some venting will be needed. Cue some donations from my previous mk1s!
http://file035a.bebo.com/0/large/2007/09/29/21/1297287959a5685244711l.jpg

and after more cutting...
http://file035a.bebo.com/0/large/2007/09/29/21/1297287959a5685245290l.jpg

Held up now as im waiting for the engine mounts to be fabricated, as i sent them to an outside company. once they come in it'll be jig time then spunk some money on the new 3s engine before it goes in...:thumbsup:

[Gary Symons]

Good luck with the swap :thumbsup: and keep the pics coming.

[Rosssco]

Looking good mate, fooking love those wheels... Deeeeppppp...

[adamh]

good luck :thumbsup: what set-up are you going for brake wise and other bits..?

[Murf]

Thought Kenny had the engine rebuilt before his car ate mud?

[Garbe]

Nice - I like the different appraoch to cooling

[OlberJ]

Thought Kenny had the engine rebuilt before his car ate mud?

At great expense.

[millentubby]

Was told it went like a train too!

Looking good Tom-Tom - watching this thread closely :)

[Tommytank]

good luck :thumbsup: what set-up are you going for brake wise and other bits..?

i'm undecided at the moment. Suspension is gonna be koni spring and shocks, got them already and prob gonna put them on this week whilst waiting for the engine mounts to arrive...

[Paul Woods]

tommy make that hole in the rear firewall bigger chap,taller,wider and deeper! take it halfway under the engine lid catch,right to the top of the firewall and as far to the drivers strut as you can go....and right down to the boot floor....anything else isnt big enough.

Love the wheels on that thing.

[Tommytank]

haha, indeed i shall paul! Of all the people to notice that, i knew you would!

Truth is, that hole isn't actually there to be finished size, and in truth i didn't actually need to cut it when i did.

Oh fcuk it, might as well own up:liar: :liar: :liar: I was bored pissing about waiting for the mounts to arrive, and i had a few hours of work time left one day so i decided to attack what i knew needed done. So i cut the hole without checking how much needed cut etc, just to make a start on it as i knew a hole would need to be there. Welcome to the first arse up on the project. I didnt need to cut it, and i should have just waited and done it right. Idle hands make for devils work etc. Anyway, look closely at the engine bay shot of the O/S with the hole in it. you can see the cleanly severed engine lid release cable. Wascutting in the boot and was certain it was cleared out the way. It wasnt. Luckily i plan to remove it altogether in favour of bonnet pins and that the engine was out so i could crawl under and get the lid open again.

Todays lesson was brought to you by the letters D,O, and H, and the word TIT.:slap:

What can i say, when the angle grinders in my hand i'm on a mission!lol

[OlberJ]

It's not fecked, it's all coming out anyways, you've just cut a hole in the scrap metal, that's all.

[Tommytank]

y6ea, exactly. Just reinforced the measure twice cut once rule!

[jimi]

If you fit those side inlets on the boot lid how are you going to stop the boot filling up when it rains ?

[OlberJ]

Another 2 vents in the bottom of the boot? :mrgreen:

[Tommytank]

no, the licencse plate is comin off and a big exit vent going there, and the whole boot is getting alu plated to direct flow, so they will drain to a couple of drain holes. Having previously owned 2 rustbucket AW11s, i dont plan to turn this into one!

[Tommytank]

Got some progress yesterday...

New koni adjustables are now on, along with some heavy duty droplinks. Reckon there will be a full poly bush kit in the pipeline before the 3s spins a wheel..
http://file032a.bebo.com/12/large/2007/10/03/12/1297287959a5719608113l.jpg

and as i stated on another thread, i pinched the repositioned spoiler idea. All bolted in, just needs a bit of reprofiling now...
http://file032a.bebo.com/12/large/2007/10/03/12/1297287959a5719608352l.jpg
:thumbsup:

[msherry21]

Tommy, you're flying, I can't believe how much you've got done! Superb work!

[OlberJ]

What's the problem with the mounts? Just print them off and get someone to cut them out for you.

Took 20mins when we got them done.

[Sponge Bob]

I can't see any pictures :cry:

[Tommytank]

What's the problem with the mounts? Just print them off and get someone to cut them out for you.

Took 20mins when we got them done.

Its this company, been trying to do a cheeky corner cut and get a full section done, that way there are spares for group etc, long and dumb story, but its just taking too long for them to arrive. Where did u go for your mounts olberJ?

[OlberJ]

Local blacksmiths me dad went to, cut all 8 plates for about £30 i think including the 5mill steel.

You can do it with a grinder if you're bored.

[Garbe]

Those drop links do look good - where'd ya get em?

[Sponge Bob]

Meh?? Can everyone else see pictures...? I've just got error boxes...

[Jiff Lemon]

Pics all here bob; You going through works firewall?

Bebo.com (where pics are hosted) is usually on a coporate filewall block list ;)

[Tommytank]

off an ebay company IIRC, they have been waiting to go on for months so i cant remember exactly. They look food quality, but until i do the acid test of actually usin the car, i cant say for sure how good the rose joints quality is...

They were as cheap as the Mr T items too!

[Tommytank]

well a wee update here, got fed up waiting so made the mounts myself, gonna get on the jig thread next and see about some weldy time!:thumbsup:

That said i did get a bit confused when looking at them, anyone got a pic of them welded in? Just in the interests of helping it make sense a bit...

Took the front rad out for a flush too, has anyone changed or uprated these? will it cope? If not what have folk gone for?:eh:

Also, been fettling with the boot and my plans are getting lairyer and lairier, looks like it should be... different. ;)

What solutions have folk used when using big, and i mean BIG intercoolers? Anyone fancy showing off a bit and letting me see?:thumbsup:

[Gary Symons]

From my build site:
(note that i didnt use the jig so positioning/mounts may not be exacly the same)

http://www.mr2mk1turbo.co.uk/diary5.htm
http://www.mr2mk1turbo.co.uk/diary9.htm
http://www.mr2mk1turbo.co.uk/diary11.htm

I used a new standard mk1 rad and it works fine.

Finally my IC install:

http://www.mr2mk1turbo.co.uk/diary36.htm
http://www.mr2mk1turbo.co.uk/diary38.htm

[Tommytank]

damn. that was almost exactly what i was gonna do. Nice work with the ally sheeting! looks like i'll need to get even more creative now!!

mwuhahaha

[Rowdan]

May also be worth checking out the famous Podges' intercooler install:

http://forums.twobrutal.com/showthread.php?t=699&highlight=podges+intercooler

[Tommytank]

ok folks, pics to come soon on my current status, just got a couple of questions first...;)

Engine is prime to go in, but im at the scratching of head regarding alternator stage...

Can a 3s ge celica bracket be used? I can get one of these, and will the alternator i have bolt straight on with no hassle exept getting a new belt?

or...

Can i bodge it onto the power steering bracket? anyone done this and is it more hassle than worth?

Also, im using a rev 3 engine, whats the exact CV joints i'll need to connect to the mk1b hubs? anyone know places doing deals on them?

:blabla: :blabla: :blabla:

thats is all!!:thumbsup:

[Paul Woods]

yep any celica 3s-ge bracket will do,and then just make a tensioner out of a slotted bar and a 30mm spacer.

cv joints are available from www.partsinabox.co.uk (http://www.partsinabox.co.uk) part number OJ-0220/30

[Tommytank]

cheers paul, that solves that query...

so heres the pics!

Firstly, got my engine moved a bit closer to its destination, looks like i'll be needing a shoehorn! If i hadnt seen it in before id be having doubts about it fitting...
http://file037a.bebo.com/9/large/2007/11/04/16/1297287959a6017791353l.jpg

drivers side mounts welded in, i know they look squint in the pic but they're jigged bang on in the flesh!

http://file037a.bebo.com/9/large/2007/11/04/16/1297287959a6017789070l.jpg

...and the passenger side!

http://file037a.bebo.com/9/large/2007/11/04/16/1297287959a6017789690l.jpg

Started knocking the firehall back a bit where i could see it would easily foul with the turbo, but unsure exactly how much it needs panned in? Any hints?

http://file037a.bebo.com/9/large/2007/11/04/16/1297287959a6017788498l.jpg

This is the cambelt side of the 3s, was curious about this hose take-off, it looks like its bound for hitting the firewall, is this normal or will this need to be changed/modified to fit?

Thats where we're at at the moment, reasons for holdup are lots of other bills slowing things, and this...

http://file038b.bebo.com/7/large/2007/10/17/19/1297287959a5849683072l.jpg

The daily squib driver, which i kitted out with a spare stereo, fully serviced and even chopped springs and gearshift on, only for it to spit its big end bearings out 40 minutes later. Bloody malasyians.>:[

[millentubby]

Apparently a Mitsi Evo engine will jump straight in those Tommy ;)

Progress is looking good though! :)

[Paul Woods]

dude i hate to tell you this but you have totally welded two of your plates in the wrong side and the wrong way up

the passenger side rear mount should be on the drivers side front and vice versa,they are upside down!!

the mounts are supposed to look the same each side,you will need to cut the pass side rear mount off and weld that onto the drivers side front mount,do the opposite with the drivers front mount.

[Tommytank]

yea, its as good as an evo 1, but just had to fork out on a bmw to get about in, and one project is enough for just now..

Besides, im not spunking good cash on a wrong wheel drive car..

[Marksman]

Tommy! You've used the mounts in the wrong place mate!
http://www.woodsport.org/forum/images/recovered/2005/04/52.jpg

The one on the right is OK but the one on the left is from the other side of the car and you've got it pointing straight up!



http://www.woodsport.org/forum/images/recovered/2005/04/52.jpg

See the mount on the left in this pic? That curved profile on the top should fit nicely into the side profile of the car...

If you've used the jig then the engine will fit between the holes but it'll be hard to weld tops on them.

http://www.twobrutal.co.uk/forum/images/recovered/2006/07/100.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2006/07/5.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2006/07/6.jpg

Owen.

[Paul Woods]

this is how they should be....

http://www.twobrutal.co.uk/forum/images/recovered/2006/08/28.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2006/08/29.jpg

[Tommytank]

dude i hate to tell you this but you have totally welded two of your plates in the wrong side and the wrong way up

the passenger side rear mount should be on the drivers side front and vice versa,they are upside down!!

the mounts are supposed to look the same each side,you will need to cut the pass side rear mount off and weld that onto the drivers side front mount,do the opposite with the drivers front mount.


Fcuk.



Now you say that though, it does make sense..:hidesbehi :rant:

Hmm, i dont think they'll be coming off with ease, slugged em down with some healthy big 12mm welds.

oops.

they sat in the jig spot on, may look into reinforcing the front o/s one a bit, trimming back the n/s one and then questioning the whole point of fabricating them to template size in the first place.

Typical me...

[Paul Woods]

yeah you may be able to rescue the situation by trimming down the passenger one so it looks like its partner,then bridge them with a top.... the drivers side one id cut that off and do it again or use more plates to make it right

[Tommytank]

got some spare plate, will make something up next weekend..

Not been the best weekend all things considered. Bah.

Oh, and also found that the 2 mount bolts for my engine have been kidnapped. Are these high tensile or will an ordinary bolt do to replace them?

[Paul Woods]

ordinary bolts will do for those,they are just holding weight.... dont worry though mate we all make mistakes sooner or later,if id a quid for everytime!!!

its easy to get things wrong bud dont worry about it

http://www.twobrutal.co.uk/forum/images/recovered/2007/11/27.jpg

[Marksman]

Just for test fitting the engine and making up the torque mounts just a screwdriver pushed through the mounts could do, but to weld on the tops to the chassis mounts I'd recommended a bolt through the holes to help prevent the metal pulling as it heats.

Have fun,

Owen.

[Tommytank]

oh yea, another thing i meant to ask (there should be a list!)

Took this pic as i thought it a bit odd...

http://file037a.bebo.com/9/large/2007/11/04/16/1297287959a6017790373l.jpg

Will this water take off fit in place ok or will i have to change or modify the git?

[Paul Woods]

no it will fit fine tommy :thumbsup:

[Jiff Lemon]

hey, at least the mount mistake makes you a firm member of "the club" (http://forums.twobrutal.com/showthread.php?t=7335) :thumbsup: lol

[Tommytank]

Hehe, updated myself into the club appropriately.

Got some bracing made up to strengthen the mounts, then one cold and frosty morning, found myself stuck for something to do. So...

http://file038a.bebo.com/2/large/2007/11/13/02/1297287959a6097867483l.jpg

Decided to whip the engine in. The jig works spot on (as if there was any doubt!). Also figured that the boot wall might as well come out altogether. Its not like this cars going to be subtle underneath, so no point in doin things by halfs.

http://file038a.bebo.com/2/large/2007/11/13/02/1297287959a6097867588l.jpg

All in all it was simple enough, proof if ever that preparation is the key. Only ended up with a staved finger, forearms like those of a self harmer and mild concussion.:freak3:

Next up is front and rear torque mount fabrication, a bit of mincing about with sizes now the engines in, then whippin the lump back out for painting and sheared stud removal. Bloody exhaust studs...:rant:

[Tommytank]

Another wee update, just blagged myself a fantastic bargain, got hold of a set of ST185 front calipers from a scrappy for 40 quid, so a cheeky refurb should see me with decent stoppers!
What do people usually run on the rears with the 185 front setup?

also, got the torque mounts made up, these are pretty much standard copies on the front as everyone elses, but have got a bit creative with the rear one! So engines back out for painting and detailing, and the intercooler for the boots in the post!

Pics to follow soon!

[Marksman]

Sounds interesting, well done that man :thumbsup:

Owen.

[Tommytank]

Heres the festive update. Took the enine back out so i can finish welding (read: correcting dodgy mounts) and prep the engine bay. In the process i also tack welded the torque mounts. The front one is the usual thoroughfare, put i got a bit creative with the rear. By which i mean i didn't look at any previous ones and just done my own, lol.

Heres the finished article:
http://file041a.bebo.com/0/large/2007/12/22/20/1297287959a6432809586l.jpg

Have also chopped and rewelded the rear bush slightly to the left with a new bush to line up with the new mount. Finished that and gave them a lick of paint.
More toys have also arrived, shiney new intercooler!
http://file041a.bebo.com/0/large/2007/12/22/20/1297287959a6432809336l.jpg
Next few days will see that gettin properly fitted and the ducting fabricated for it.
And finally, have started the fab of the rear boot wall...
http://file041a.bebo.com/0/large/2007/12/22/20/1297287959a6432809854l.jpg
I was planning on running ali sheet from the angle bar and sectioning off the boot that way, but been thinkin and reckon i'm gonna be a bit neater with it and maybe make a new sheet steel wall for it. Will have a ponder.

Im still without a daily driver tho and 2 weeks ago got laid off, so cash is gonna be tight for a few weeks. Will still need a cheap rev3 ecu, celica discs, st185 CV joints and some other bits and bobs to make it all work too. Bugger. Anyone got any of these lying around? or a mega cheap daily driver with an MOT?

[Tommytank]

New update. Had to put the mr on the ground to shuffle it about a bit, workshop is gettin a bit of work done. This was a good chance to see it as it'll sit ride height on the konis, and i'm happy to say, very well!!

http://file043a.bebo.com/3/large/2008/01/17/19/1297287959a6644917765l.jpg

Turns out the camber means the stretched rubber on the back is now JUST covered by the rear arch. No more arch mods needed for me!

Connected up the gear linkage, and as per most folk, looks like my left/right cable needs bodged. Oh well.

The throttle cable also needs a new bracket too by the looks of it...

http://file043a.bebo.com/3/large/2008/01/17/19/1297287959a6644917450l.jpg

And finally got ANOTHER new daily driver. Nice s12 Silvia. Clean (ish) too.

http://file042a.bebo.com/8/large/2008/01/17/19/1297287959a6644874265l.jpg

The compo MOs were a temp measure, its gettin its stock wheels put back on today, albeit refurbed!

And... that is all.

[weegaz22]

good stuff, be ready for the meet at crail on march 2nd?

[Tommytank]

hope so. Just got a new job today so gonna be pumping my finances into it!