Josh's Rev 3 Turbo

[Peter Gidden]

For some of us, it's just a normal day in the workshop.

For other's. well it's just all too much..... Men and boys eh?

[Gullzter]

Haha was exactly the same the night before too, be sure to tell.the person you were texting that their chat is rubbish Josh!

[JAAASH]

Haha, cheeky b@$!&#d In my defence, it was quite late and that sofa was awfully comfy

[ashley]

[craig]

[slipping clutch]

Peter Gidden works them hard!

[Magic Beans]

These young ones eh, no stamina

Reminds me of my days working up there with you when all the work was done to Mule 1 and 2. 6pm was generally the time my brain ran out of glycogen and turned me into an extra from the Walking Dead

[Peter Gidden]

Reminds me of my days working up there with you when all the work was done to Mule 1 and 2. 6pm was generally the time my brain ran out of glycogen and turned me into an extra from the Walking Dead

Or you had to leave mid-afternoon as you had an appointment at the hairdresser...

[Magic Beans]

Haha, I'd forgotten about that day

I did need it though...

[slipping clutch]

Reminds me of my days working up there with you when all the work was done to Mule 1 and 2. 6pm was generally the time my brain ran out of glycogen and turned me into an extra from the Walking Dead

Or you had to leave mid-afternoon as you had an appointment at the hairdresser...

Mule 4's going to be an mx5 then?

[Magic Beans]

Reminds me of my days working up there with you when all the work was done to Mule 1 and 2. 6pm was generally the time my brain ran out of glycogen and turned me into an extra from the Walking Dead

Or you had to leave mid-afternoon as you had an appointment at the hairdresser...

Muke 4's going to be an mx5 then?

Hell no!

*Drum roll for the big reveal*

[slipping clutch]

What a corker! we will all be queuing up for a ride in the barbie car. - sorry Josh , we will get off your thread now - I am guessing from the picture Peter posted you had a pretty productive day yesterday with your engine swap - everything going okay?

[C35Rob]

This is progressing very nicely... just out of interest where were the vented wings from? Just so I know to avoid them!

[JAAASH]

This is progressing very nicely... just out of interest where were the vented wings from? Just so I know to avoid them!

Thanks mate, next update should be along soon, been a bit busy this week.

I got the wings from someone on here. He claimed they were the woodsport wings so they should be pretty good as paul knows his stuff. Im sure a proper bodyshop would have had them fitted and looking good in no time, haha. It was my first attempt at anything like that.

[JAAASH]

Finally getting round to the thread update, sorry for the wait.

I'll write a quick overview of what we've done / engine specs and then I'll let the pictures do most of the talking.

I started with a standard Rev3 turbo engine with ct20b turbo. Suspected ringland failure so decided to start fresh.

I bought MartinF's forged Rev2 engine and rebuilt LSD gearbox.
Decided that the rev2 block was a good choice as it has thicker walls than a Rev3 so eliminates the risk of cracking.
We took the head from my Rev3 and fitted it to the new forged block. Rev3 heads flows something like 20% than the Rev2 so I've now got the best parts of both engines.
My Rev3 gearbox is LSD but crunches into 1st so decided to get the rebuilt one from Martin.
We've also taken the OS Giken twin plate clutch I was using and fitted that to the new build as it's an amazing piece of kit.
I also bought the GT28 turbo kit that Peter was selling for a customer that was breaking his car.

Simply put -

Forged Rev2 Block,
Rev3 Head,
Garret GT28RS Turbo,
LSD Gearbox,
OS Giken Twin Plate Clutch.


Forged build consisted of -

86.5mm Forged Wiseco Pistons
3SGTE Race Main Bearings
3SGTE Race Big End Bearings
3SGTE Thrust Bearings
3SGTE Eagle forged Conrods
ARP Main Studs
ARP Head Studs
Toyota Oil Pump
Toyota Oil warmer
New Gaskets
Replaced Crankshaft
New Cambelt

The gearbox has been stripped, new 1st and 2nd gear, 1st and 2nd sleeve, new 1st and 2nd gear syncro, rest of parts cleaned and box rebuilt.


Onto the swap. Arrived at Pete's Friday afternoon. Dropped the car off at his workshop and had a little nosey round at my new engine and the various other projects going on in there
Met Munir (Gullzter) who was also down for the Friday/Saturday to do some work on his car. He also ended up helping out with mine quite a bit on the Saturday as well which was very much appreciated

Friday night we all (Me, Munir, my parents, Pete and Carol) went out to the local Indian restaurant. Before Pete pipes up, yes I had a korma - deal with it!
Back home for a good nights sleep (or as good a sleep as you can get when you have taken a huuuge Great Dane's spot on the sofa! She wasn't happy ) ready to start on the car first thing in the morning


Here we go!

Started the removal first thing.




Within a few hours it looked like this




And then this




Meanwhile the new engine - cam cover and inlet manifold removed




Head removed




Soaked in kerosene and then steam cleaned outside.
Gearbox and clutch removed.
Block surface cleaned up ready for new head gasket and Rev3 head.
Hose from hell replaced.






Old engine out - head removed




Rev3 Head - Removed the inlet manifold shortly after this so it could be cleaned up and resprayed along with a couple of other pieces.




End of day 1.
Back in the workshop first thing Sunday morning to rebuild and fit new engine.


VHT Matte Black paint for a few parts, just to tidy it up a little bit.




Gearbox and clutch removed so the clutch can be fitted to the new engine.




New engine fully rebuilt and about to go back in




Almost fully plumbed in




And that was the end of the weekend.

Few little things left for Pete to finish off during the week.

Needed a plug for a sensor hole in the sump before it could be filled with oil - Done!
Coolant hose had degraded and was leaking so needs to be replaced - New hose arrived, being fitted tomorrow.
The downpipe is custom so doesn't match up to my exhaust - Sent to an exhaust specialist Tuesday afternoon and was collected today so now is a perfect match!
I also noticed that my steering rack was leaking when I did my recent suspension refurb/upgrade so Peter has also changed that.
He's also sorted all my tracking using Dino's geo settings as requested for a more track-based setup

Once the leaky hose is been replaced, Pete is going to take the car out and set up the boost controller to 17psi/1.2bar. Hoping to get somewhere near the 350bhp mark.
Going to get it on the rolling road at Japfest to find out for sure - 3 power runs for £30

Picking the car up on Saturday Can't wait!

[JAAASH]

Coolant hose had degraded and was leaking so needs to be replaced - New hose arrived, being fitted tomorrow.

Complete Although it sounded like a pig of a job. Glad it was Pete doing it and not me

[slipping clutch]

Good work Josh - a massive amount of work done in a short space of time - all credit to you and Peter.
Can we have a start up video by any chance ?

[Gullzter]

Great to see the pics dude, im looking forward to seeing the parts being painted when they are finished as ive still no idea what to do with mines

When is it going to be finished?

[Martin F]

Picking the car up on Saturday Can't wait!

So was it worth the wait Josh ?

[MR2 Rich]

Decided that the rev2 block was a good choice as it has thicker walls than a Rev3 so eliminates the risk of cracking.


Really?