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Location:
NSW
Registered:
June 2005
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sat, 13 August 2005 14:18
 
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Nice work i have been reading about the work going in to make fwd motor in to a rwd good pic and informative me and a mate are going to put a gen 2 3sge in to a ke70 out of my st162 that got a st185 3sgte in it now 
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sat, 20 August 2005 07:33
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Hey all, quick update...
Making good progress with the inlet manifold. I was originally going to shape my own bellmouths into the base of the plenum using thick 12mm alloy. But after getting sick of the die grinder killing the air compressor I decided to just buy some machined bellmouths.
Here are some pics :
In the pic you can see the alloy sheet. I'm going to drill holes in this and slide the bellmouths right down so they are flush on the floor. These will then be welded to the runners.
I've shaped the plenum itself, and just waiting for that to be rolled into shape.
While waiting for this to happen I thought i'd start on the turbo manifold. I got the collector done today. I've made each pipe gently merge into the collector so it should flow well.
It's all made out of steam pipe, 32mm. I have a laser cut flange for the head out of 12mm mild steel. I've given a drawing to our forum sponsor Oxy Fab of the turbo flange. Hopefully they'll have that ready soon.
Here some pics..
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Mon, 22 August 2005 10:53
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 01 September 2005 23:18
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Not much of an update really..
Been slowed down a bit because of neighbours not being happy about me cutting/die grinding at night 
I had to scrap that collector I made as it was just too tall to keep the pipework where I wanted it.
So had to bring the pipes into the collector at a slighly sharper angle (60 deg or so).
I got a flange made up by Oxy Fab (Forum sponsor), they are great! So cheap its crazy and turn around was alright too.
I've started drilling the holes out in the plenum base for the bellmouths to come through..
Oh yeah, I also purchased a Tial 38mm wastegate. Looks like this -
This weekend I hope to have the holes all finished for the bellmouths. Then can get the plenum top put on.
Now the collector and flange or turbo are all done, it shouldn't take long to make the bits in between.
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Location:
Rocky Mountains, Canada
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Fri, 02 September 2005 06:06
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Looking good Joel.
I wonder how much of a difference the bellmouths in the plenum will make.
They obviously make a difference with ITB's to open air, but i wonder if they help much with the TB before them.
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Fri, 02 September 2005 06:49
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I reckon off boost they should help draw in more air. Not sure once on boost and its pressuried.
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Location:
On your mum!
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Fri, 02 September 2005 14:26
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Nice work Joel. I will be coming to you for manifold work I reckon.
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 04 September 2005 10:08
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Hey Jase, glad ya approve of the manifold's so far 
Been a busy weekend! Pretty much finished the turbo manifold, and got bit more done on inlet..
I was really pleased with the turbo manifold, for my first one i've made im stoked with it.
Here are some pics..
All thats left on the turbo manifold is to finish off the welds really. Also need to work out how to plumb in the external wastegate which i'm bit unsure on how it's all going to fit.
Now the runners and base of inlet manifold is all done can concentrate on the plenum itself.
Almost ready to pull the engine back out again now for a rebuild and tidy everything up.
Cheers
Joel
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Location:
Canberra
Registered:
July 2005
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 04 September 2005 10:20
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Someone's had a busy weekend!! They are looking noice!
Keep up the good work. It's awesome seeing conversions flying along, especially when they require lots of fabrication. Inspires us all to re-prioritise our time and money!
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Location:
western queensland
Registered:
September 2004
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 04 September 2005 11:56
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hey thats awesome mate, much tidier than mine
what size TB are you using? im going the old XF one.
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 04 September 2005 23:14
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Good to see yours is coming along well too mate. That is a huge plenum, how many litres? I'm trying to keep mine around 3.5ltrs. But may end up a bit bigger.
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Location:
western queensland
Registered:
September 2004
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 06 September 2005 11:06
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it about 4litres.
turbo manifold is tricky, i did mine about three time b4 iwas happy
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Wed, 07 September 2005 01:50
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The Tial wastegate arrived today I got it for $400, which included 2x flanges & gaskets etc. Was happy with this price.
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Location:
perth wa
Registered:
June 2005
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Wed, 07 September 2005 05:29
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wow that intake manifold looks sweet!!!
i rekon the flush intake runners will work nicely.
whats your power aim for the build?
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 11 September 2005 09:53
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I finished off the xmember today.. Thats about all I got done on the weekend 
I ordered the clutch for the 3S which is due in on Wednesday. I went for a cushioned button clutch, which should be a big nicer to drive than the current 4puk setup I have on the 3T.
It's an exedy clutch, 800kg pressure plate, and the cushioned 8 pad clutch plate. Hopefully it'll hold with the power I'm hoping to make.
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Fri, 23 September 2005 12:25
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Quick update.. Things are almost finished now. Just doing a few jobs this weekend before it'll be ready to pull out and get machined up.
Debating who to use to do the engine machining work. Any recommendations would be much appriciated.
Turbo manifold with the Tial wastegate now attached.
Here is the cam/crank angle setup. The Autronic requires 2 lugs 180 degrees apart at crank speed, and 1 at cam speed for reference signal.
I'm going to run 4 lugs on the cam 90 degrees apart which will be the same as the 2 on the crank.
The bits of angle will be trimmed and neatened up once i've finalised the positioning of the Autronic sensors.
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sat, 01 October 2005 10:29
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Howdy all.. Just finishing off as few things this weekend and then the engine will be pulled apart again and given to C&B performance for all the machining duties.
This will include -
Bore block
Full balance
Grind crank
Nitride crank
Head service (shims, possible line bore, valves etc)
Think thats about it.. Then I can reassemble it all.
Just waiting on the inlet manifold really.. Taking ages to get it how I want. Hopefully that'll be done in a week or so though.
Here few more pics of the dump pipe and wastegate pipe.. Also did bit more on the coolant pipe.
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Location:
Madrid - Spain
Registered:
August 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 02 October 2005 11:39
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Looking great Joel, When do you think you'll have it in the car?
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Location:
Melbourne
Registered:
December 2004
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 02 October 2005 17:03
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awesome stuff man! makes me miss my ra28
now i want that bellmouth intake setup on my 3sge would look very different 
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Location:
wollongong
Registered:
October 2004
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Location:
wollongong
Registered:
October 2004
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 Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 02 October 2005 21:12
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just a quick question, will the quad throttles from the 20v fit on the 7afe? 
fuckin awesomr thread by the way, have enjoyed reading it too, great work on the maifold etc dude, keep it up!
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I supported Toymods
Location:
melbourne
Registered:
June 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Mon, 03 October 2005 08:12
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why would you ask that question in this thread?
Joel, the manifold looks awesome, did you have to do much planning to avoid welding yourself into a corner?
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Mon, 03 October 2005 23:20
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Hey Anthony, if all goes to plan I hope to have it in the car by the end of this month. That depends on a few other people doing jobs for me though so never can be sure.
With the manifold, I did some planning in that regards, but none of the joins were that close that they couldn't be welded. It was all tac'd together and didn't need to be broken apart to weld it which was good.
I strengthened up the engine mounts over the weekend.. Will get some pics soon and put them up. But basically took everyones advice and tied them together at the engine side.
Cheers
Joel
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Location:
Terrigal
Registered:
May 2002
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Location:
Melbourne
Registered:
August 2005
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 06 October 2005 05:27
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Great work and only for the cost of a small mortgage! hahaha
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 06 October 2005 05:39
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Haha yeah.. but actually it has been the cheapest engine conversion i've done so far.. Mainly because i've done so much myself.
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Location:
barbados
Registered:
December 2004
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 06 October 2005 15:45
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sweet the manifold looks nice!
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 09 October 2005 08:58
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Another quick update.. All the engine parts are with C&B.. Next day got a call saying the crank was stuffed. So had to hunt down another crank. Found one in Syd though so that was all ok.
While waiting for the parts to come back i've been cleaning up and painting all the external brackets and stuff.
Sump is all welded up now.. After filling it with petrol and letting it sit for awhile I found a small leak though so need to get that welded up before I can paint it.
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Location:
Terrigal
Registered:
May 2002
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 30 October 2005 22:55
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I've made some good progress on the 3S.. All engine parts came back from the engine machiner. Some of the jobs included nitriding the crank, line boring the head, bore block & hone, full head service, etc etc.. All work carried about by C&B seems very good.
I spent the weekend assembling it. I checked all the rings in the block and moved them around until close to equal gaps were in each cylinder. I didn't have to worry about bearing clearances as C&B check all that before giving it back (lucky they did check also as some adjustments needed to be made).
Here are some pics...
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Sun, 30 October 2005 22:58
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more...
Its pretty much ready to go back in now.. Just modifying the block-bellhousing sandwitch plate thing as the 2S & Y ones just are not quite right.
I got a double row race spigot bearing to keep the input shaft of the gearbox happy.
Cheers
Joel
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 11:52
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Well bit pissed off tonight.. I finally got it all sitting in the engine bay which was great.. But with the Y series bellhousing there seems no way to get the starter motor to fit without hitting the steering column uni joint where it goes onto the rack.
So looks like its coming out again, have to find another 2S sandwitch plate as I cut mine up to suit the Y series bellhousing. Argh gotta pull all the clutch and flywheel off again not happy..
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Location:
Adelaide
Registered:
May 2003
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 12:06
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So, your advice on bellhousings if anyone else is going to follow in your footsteps?
Y, S?
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I supported Toymods
Banned User
Location:
Brisbane
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 12:08
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| takai wrote on Tue, 01 November 2005 22:06 |
So, your advice on bellhousings if anyone else is going to follow in your footsteps?
Y, S?
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Custom!
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 19:32
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Yeah I heard Glenn makes one ?
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I supported Toymods
Banned User
Location:
Brisbane
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 21:28
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Yeah I got mine from Glen with a matching chromemolly flywheel.
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 22:25
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Yeah I got one of Glenn's flywheels.
Takai, as for your question.. Gabe & Rokusan are using Y series bellhousings without dramas. So it can be done.
I figure the setup in the Celica just must all be that bit different with the steering column angle hence its not going to work for me.
So does depend on the car its going into..
I reckon i'll just chuck the 2S bellhousing back on, try and buy another sandwitch plate to replace the one I cut up for the Y setup.
WHen I made the turbo manifold I built it so it would clear the starter motor incase I did end up using the 2S one.
Just need to change my dump pipe design a bit.
Damn more work
But it does look very sexy sitting in the engine bay now
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Location:
Adelaide
Registered:
May 2003
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 22:33
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Ok, cool.
Just pondering my options if i do go into Overs. Given that Gabes fits in the sprinter I probably wouldnt have the same issue
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 22:46
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Would you be running NA or turbo? If NA, 2S bellhousing I think is more simple. No stuffing around with filing out holes and stuff.
But if its turbo, probably nicer to get the starter over to the inlet side.
Woohoo found a 2S plate
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Location:
Adelaide
Registered:
May 2003
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Tue, 01 November 2005 22:55
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Heh, sorry about the lingo. Wasnt quite awake there.
Overs is Over 2 Litres, which basically means turbo due to the 1.7 multiplier for turbocharged vehicles.
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 03 November 2005 11:23
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Pic of 3S in the car.
Now i've confirmed the bonnet closes with the inlet manifold and all I can get it welded up.
I've come up with a solution for the starter motor. I'm going to use the Y starter which needs a 10mm spacer. I'm going bolt the spacer to the starter with counter sunk bolts. Then drill another set of holes in the spacer, so I can rotate the starter around and make the solinoid point more upwards so it doesn't interfer with the column.
Pretty quick & easy fix I think.
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Location:
Eskilstuna, Sweden
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 03 November 2005 12:04
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Man Joel!! This thing is really coming together well!
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Location:
western queensland
Registered:
September 2004
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 03 November 2005 12:14
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wow you have a very nice new engine!! What cams are you using?
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Location:
Melbourne
Registered:
December 2003
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 03 November 2005 12:20
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that looks awesome dude - best conversion ever. I'm suprised you didnt get the rocker cover painted in the same colour as the body -
Good luck - cant wait to see vids of it running
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Thu, 03 November 2005 22:46
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Thanks all for the comments.
Rokusan, mate just using standard gen3 cams. Main reason for the adjustable cam gears was because I had to get the head line bored, it can slightly upset the cam timing. So to start with i'll use these just to get them back to factory spec. Maybe if I have time when getting tuned on the dyno i'll play around with them a bit.
Stuc, yeah I agree I think the rocker cover should be colour of car. It all looks too 'silver and shinny' IMO now. I'll pull it off sometime soon and paint it blue.
Cheers
Joel
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Location:
Toronto, Downtown
Registered:
September 2004
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Fri, 04 November 2005 03:37
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black crinkle painted rocker cover would look nice
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Location:
melbourne
Registered:
February 2005
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Fri, 04 November 2005 05:09
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are you have a screamer pipe?
or are you flowing the waste gate back into the exhaust?
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Fri, 04 November 2005 06:13
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Wastegate gases will most definately find their way back into the exhaust
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Mon, 07 November 2005 09:42
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Managed to squeeze the RX7 oil cooler in between the intercooler and radiator.. Bit of a tight fit but at least its in there.
Also can see the remote oil filter setup now.. Just need some piping to connect it all up.
Whats everyones opinion on what hose to use? I dont want expensive braided stuff. On theh 3T I was just using transmittion cooler hose for years and it was fine. But i've heard this was a bit dodgy?
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Location:
los angeles
Registered:
November 2005
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Wed, 23 November 2005 02:30
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hey what up i see nice thing on here but im on the same page here but i got some pic to show im new to this but ill get the hag out it
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Location:
Potts Point, Sydney
Registered:
October 2003
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Wed, 23 November 2005 13:02
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Wow, just read through every post. Conversion looks great, and the work C & B looks very good imo 
Would this be C & B in seven hills?
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Location:
Adelaide
Registered:
September 2003
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Wed, 23 November 2005 13:17
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curious joel.
You are using the ae86/ke70 crossmember and rack yes?
have you tried your old ta28 crossmember or is the rack roughly in the same spot so you would still have the same probems with the starter motor?
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I supported Toymods
Location:
melbourne.victoria.austra...
Registered:
June 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Wed, 23 November 2005 20:11
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nice work joel.
i used pushlock hose on my oil cooler setup. it can be expensive at around $22-25 per metre but it uses speedflow fittings which are insanely expensive but no hose clamps. not one leak either - definately recommended.
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Location:
Terrigal
Registered:
May 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Wed, 23 November 2005 22:43
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Howdy all.. to answer a few questions..
Yup C & B at Seven Hills did a good job on the engine, and their after support has been great. Along the way while I was assembling it I had a few questions and Abe at C & B was more than happy to take my calls.
With the xmember... Didn't really matter what xmember/rack setup I used, the rack really has a set place it needs to sit for correct bump steer, ackermann etc. And that place made it interfer with the steering column.
That problem is solved now though. I was able to make up an adapter that spun the starter motor about 20 - 30 degrees and got the solinoid out of the way of the steering column.
I'll put some pics up of this.
Thanks Grega for the hose suggestions, i'll be working on that early next week.
...
Quick update.. Been on holidays & busy so haven't done much apart from break things.
The sump didn't seal up at the back, so last night I pulled the engine out again and took the sump off. Put a flat edge against it and noticed there is a warp in it, caused I guess by the welding done on it. So once thats straightened out it should seal fine.
But the stupid engine crane let go and engine ended up on the ground, thankfully not hard but enough to break the oil pickup.
Many thanks to Central Vic Auto Parts for getting one sent off to me today.
So the plan is to have sump and new pickup in early next week. Drop engine back into the Celica.. Then get back to finishing it off.
Cheers
Joel
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Location:
Toronto, Downtown
Registered:
September 2004
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Wed, 23 November 2005 22:59
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atleast it didnt let go while the engine was haning over the car nice job cant wait to see the finnished result
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I supported Toymods
Location:
melbourne.victoria.austra...
Registered:
June 2002
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I supported Toymods
Location:
melbourne.victoria.austra...
Registered:
June 2002
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Re: Joel's RWD 3S-GTE conversion - mainly pics
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Mon, 28 November 2005 04:56
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joel, some pics of my oil cooler/filter stuff FYi
its all good stuff. i used threebond 1110 cement on all the fittings = no leaks. notice the lack of hose clamps - no need. this gear doesn't leak at all - the fittings are very difficult to get on (alot of strength needed) but yeah, the end result is excellent.
the straight speedflow stuff is quite inexpensive. the curved pieces are worth a small countrys debt.
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