Dawesy's 2, finally an update. :)

[dawesy]

time i started a project thread now im getting things together.
so a bit of history.
i used to own an AE-92 corolla in which i fitted an ST-205 3S-GTE engine. all was good and with more mods i got the engine to 470BHP and 380ftlbs but obviously traction was an issue so i decided to make it RWD by putting the engine in the rear. good progress was made but looking at the shell it wasnt really suitable for such extensive mods (rust was setting in).
i had brought a rev3 MR2 turbo from a freind for parts for my conversion but looking at it it was too good to break. so a plan was formed.
the original engine in the MR2 was sold along with parts from the rolla and the engine from the rolla will be fitted in the MR2.
the engine spec is as follows:-
gen3 block with hardblok block stiffener added
86.25 JE forged pistons
THS Forged rods
ARP fasteners throughout
ACL race bearings.
APexi RHX6 turbo (TCW76 with P20 exhaust housing)
ported and flowed head.
stock cams and valves
HKS 1.2mm head gasket
Exedy twin plate clutch
Blitz 850cc injectors
ERL water injection
MoTec M4 ecu with pro upgrade.
zigen fireball exhaust
Blits SUS air filter
walbro 255 fuel pump
car spec:-
rev 3 Tbar
yellow bilstien shocks and eibach springs.
grooved discs on the front.
braided lines all round
side skirts (not sure on make)
copy border front bumper
genuine rev5 spoiler

so thats where we are at the moment.
got a delivery today though

only the fronts arrived though, rears are stuck in france and will be here monday :ranting1:
and these a few days ago


things to do,
get bumper fitted properly and modify side skirts to give clearance to the bottom of the door and paint the car.
fit engine, ecu and my SPA gauges.
fit wheels and tyres.
make exhaust manifold and down pipe and screemer.
fit BMIC
poly bush all round
things im planing to do in time,
rev 6 front lights
whiteline ARB's front and rear
1000cc injectors, swirl pot, bosch044 fuel pump and aeromotive FPR
MT drag radials on stock 15" rims
remap to 2.2bar.

ill get some pics up of the car tomorrow.
thanks for looking

[dawesy]

finally got the tyres on the rims today so thought id give them a test fit.
rev 5 spoiler is on as well.
just a few pics, it really dosnt look that good at the mo so things can only get better.
also please note the engine is remote mounted (in the workshop lol) so the rear end is a little high.
anyone know what make sideskirts these are too?


wheels fill the arc quite nicely (sorry iphone pics)


nice dish to them too








also got some of the parts to start my custom manifold last week, just waiting on a length of 316 stainless pipe and i can start cracking on with that.
hopefully some more frequent updates from now on
thanks for looking

[jasongtr]

skirts look like g-reddy

[dawesy]

Wow been a while since i updated this thread,
So whats been happening?
well It's been resprayed





And a new engine fitted. Spec for the engine is :-
Gen 3 block with HKS stroker kit and carillo rods, ARP fastners throughout.
ported head with Ferria 1mm Oversize valves controlled by a pair of Piper 264 cams and HKS verniers.
25row Mocal oil cooler and thermostatic sandwich plate, stock cooler bypassed.

Also fitted the intercooler to the rear


So more bits done this weekend.
Now the oil cooler is fitted and the stock cooler bypassed engine temps are a lot better and under control.

Inlet temps though are too high, upto 46-48 deg after a sustained full boost pull. They also take a while to come down when cruising, these are being read by a sensor in the cold side pipe about 12" from the throttle body.

So time to do some serious heat management.
Here's how things started.


A bit of a mess under there to be fair. A failed down pipe gasket scorched the paint under the engine lid and covered everything in soot

One of the larger jobs i wanted to tackle was fitting fans to the intercooler. These will be controlled by an output on the MoTec based on IAT.
Fabricated some brackets and welded these onto the intercooler to mount the fans, 2 X 10"



While wiring these up i took the opportunity to tidy up some wiring around the ECU.



Also to come it a turbo blanket, exhaust wrap and some aluminium coated cloth to wrap the intercooler pipes.
I've also reinstated the stock intercooler fan control to run a 10" fan in the engine lid. I'll mount this on the drivers side of the lid to pull as much heat as possible from the engine bay.
more pics and updates to come

[Magic Beans]

It's been a while since there were words in here

It's a lovely looking car in the flesh

The work you're doing and have lined up should help things temp wise. I'll be interested to hear about the results though

[craig]

Excellent work mate, car looks great!

[matt-mr2]

Also fitted the intercooler to the rear

Love the ass mount intercooler

[dawesy]

Also fitted the intercooler to the rear
Image Replaced With URL For Quote http://i80.photobucket.com/albums/j183/ ... R2Rear.jpg

Love the ass mount intercooler

Yeah i wanted to keep the A2A rather than go chargecooler route (Though that may have been better ) But didnt want to add scoops etc to the boot lid, Then i remembered id seen a pic of a similar setup (Think xxxx did it). It's fully ducted and picks up air from behind the rear wheel (Duct can just be seen in that pic). The duct also isolates it from the exhaust and engine heat.

Got all the fans wired up and working now, Just got to mount the engine lid fan.
The Intercooler fans run from a spraybar output on the MoTec ECU and switch on when IAT's go above 36 deg c for more than 5 sec and switch off when the drop below 25 deg for more than 15 sec. There's quite a breeze behind the car when they are on as well.

More to come

[Magic Beans]

I've been pondering the benefits of adding a spray bar to my Radtec rad. Shouldn't be too difficult to do and the extra weight at the front end is welcomed

We'll have to organise a meet up after Le Mans

[matt-mr2]

Also fitted the intercooler to the rear
Image Replaced With URL For Quote http://i80.photobucket.com/albums/j183/ ... R2Rear.jpg

Love the ass mount intercooler

Yeah i wanted to keep the A2A rather than go chargecooler route (Though that may have been better ) But didnt want to add scoops etc to the boot lid, Then i remembered id seen a pic of a similar setup (Think xxxx did it). It's fully ducted and picks up air from behind the rear wheel (Duct can just be seen in that pic). The duct also isolates it from the exhaust and engine heat.

Got all the fans wired up and working now, Just got to mount the engine lid fan.
The Intercooler fans run from a spraybar output on the MoTec ECU and switch on when IAT's go above 36 deg c for more than 5 sec and switch off when the drop below 25 deg for more than 15 sec. There's quite a breeze behind the car when they are on as well.

More to come

Cool any better pics of the shrouds and duct to rear arch ?

[dawesy]

heres one, sorry about the pic quality but i took this on my iPhone and its got dust between the lens and case somehow



and heres one up to the fans



defo need to have a meet phil, gotta get mine cleaned first though

not sure how much benefit a spraybar would be on a charge cooler rad, might have to look into it

[dawesy]

managed to get the engine lid sorted, now this wasn't as easy as i thought.
the holes for the rain tray securing screws in the engine lid were shot and it was impossible to tighten them. now I'm not sure if this is a common problem with tubby engine lids but I've managed a successful fix.

first off you will need some M5 rivnuts (like a pop rivet with threads) **apologies for the pic quality but my iPhone has dirt in the camera, its off for repair this week**

drill out the hole for the fixing screw in the engine lid (put tape around the drill at the right depth to prevent drilling through the lid. you will need a drill bit that gives a snug fit to the rivnut.
mix up some 5 minute epoxy and apply a small amount around the rivnut, press firmly into the hole. leave to dry thoroughly.

i then used some M5 A2 stainless button head allen screws to fix the rain tray. i applied a little thread lock on them so they dont work loose

i also had to form a bulge in the rain tray as i wanted the fan on the drivers side. this done and fan fitted the lid now looked like this.


attention was then turned to the engine bay. i had already fitted the turbo jacket a week before but noticed that it looked a bit tatty. further investigation revealed

thinking it was a poor quality item i contacted the seller and got a full refund and ordered one of these
http://www.ptpturboblankets.com/product ... &pro_id=35

a bit more investigation revealed that the downpipe had come loose at the turbo, something that keeps happening.this could have lead to the failure of the jacket or it could have just been poor quality or a mixture of both.
so i decided to kill several birds with one stone.
i removed the manifold, turbo, wastegate and downpipe and set it all up on the bench for some mods.
first i added a flexi joint in the downpipe and then one on the dump pipe from the wastegate which i routed back into the downpipe as, although a screamer pipe sounds good it doesnt sit well at track day noise tests then covered the whole lot in a double layer of wrap.

still got to add a couple of braces to the downpipe and wastegate but its nearly done.
looking at the manifold its holding up well. this thing has had some serious heat (id say heated up to yellow, judging by the colour of the pipes) with only one small fracture evident where the wastegate meets the collector. this has been drilled and welded and a brace added as the whole wastgate and screamer hung off this point.
thats it for now, more updates soon

[Magic Beans]

Nice work Lee

My lid did the same thing on the old car. They seem to be ultra delicate threads