Author | Topic |
Location: New Zealand
Registered: May 2002
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Wed, 28 January 2004 08:17
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Additional pictures added to the second album above.
I now have a Flintstones car.
Callum
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Location: New Zealand
Registered: May 2002
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Location: Terrigal
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Tue, 03 February 2004 04:16
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I admire your umm, braveness? crazyness? for doing this conversion! esp. the IRS.
Very interested to hear how the project comes along. Good luck!
Cheers
Joel
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Tue, 03 February 2004 08:29
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Actually, was motivated by cheapness. The IRS conversion will work out cheaper than putting in a hilux diff, due to binding issues in the standard SAtarlet suspension meaning you need to shift the 4 link mounting points on the body.
I probably am crazy, but definitely not stupid. I have someone who knows what they are doing to do the actual work for me.
Callum
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Location: Finland
Registered: November 2002
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Re: KP Starlet F Code IRS Conversion
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Tue, 03 February 2004 19:38
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That's awesome! I dont know how I missed this topic.
How are you going to work out the suspension geometry roll center, ride height, camber, etc.
I hope you'll be succesful with that.
BTW. This should be on the tech sections.
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Wed, 04 February 2004 05:45
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Jayem
Basically, the relationship between front and rear crossmembers will be kept the same. Sit the shell level, match up the measurements front and rear and then weld in place. Effectively it is just a shortened TA63 Carina (uses same rear as MA61 etc), so roll centre should not be an issue. Camber, ride height etc will be sorted through modifying the rear crossmember (as was detailed on the forums a little while ago) so it is adjustable for camber and will use height adjustable coilovers.
Callum
PS - If the mods want to move this to the Tech sections, thats fine by me.
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Location: New Zealand
Registered: May 2002
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EVEN MORE SLICING AND DICING
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Tue, 10 February 2004 02:01
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Ok, even more cutting.
CLICK HERE
You may need to copy and paste the link.
Notice how a lot of the trimming has been done by drilling out the spot welds. Will soon be time to start the serious fabrication/welding. Have a full 8 x 4 sheet of panel steel ready to go in.
Callum
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Location: New Zealand
Registered: May 2002
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I supported Toymods
Location: melbourne.victoria.austra...
Registered: June 2002
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Re: KP Starlet F Code IRS Conversion
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Mon, 16 February 2004 04:41
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um, definately time to start welding.
and time to buy some RHS i think.
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Mon, 16 February 2004 07:58
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Strength will not be an issue, will be replicating all the factory bracings and tying the remaining outer skin into the wheel tubs. I am aiming to keep weight as low as possible so prefer to use panel steel with appropriate folds etc for strength. If you look at the side shots with the Carina floorpan in place you can see the factory braces sitting on top of the wheel wells. These will tie the floorpan section through to the roof of the car. The intention is to have the car stronger than factory without resorting to huge chunks of steel.
Also, car will be fully caged from rear suspension to strut towers. I just hope I never crash it as it will be a bitch to straighten.
Callum
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Tue, 17 February 2004 09:34
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Got bored tonight so went and had a play.
Front springs out, blocks of wood in. Crossmember sits 150mm from the ground, not bad for gravel use.
Mounted up a Falken 205/65 rally tyre on a 15 x7 inch mag and fitted the guard up. Needed to see what my flare needs were going to be.
First problem, guard sits on top of tyre. Tyre is also 60mm outside the lip of the guard (widest point). This is with massive negative camber. Straight edge from bottom of tyre is 90mm outside the guard.
Basically the guard needs to be cut up to the swage above the wheel and the flare needs to cover 150mm out from this point. About the same as what we have cut out from the rear guards. Will try to get pics this weekend.
Now that is what I call a F A T Starlet.
No P H required.
Callum
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Location: New Zealand
Registered: May 2002
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Location: Finland
Registered: November 2002
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Re: KP Starlet F Code IRS Conversion
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Fri, 20 February 2004 12:40
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Purple Beasty: did you noticed the magazine article of that Finnish Starlet that I posted here?
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Fri, 20 February 2004 18:52
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Jayem
Yep, saw those links, can't recall where I got that picture of the car from though. I think someone sent it to me about a year ago (I have a pretty big version of it).
Those style flares seem pretty common over Finland, one of the best sites I have found is http://www.vhtracing.com/starlet which has two other cars with similar style flares.
Another really useful and informative Starlet site I found over your way was http://www.orangetoy.org .
Callum
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I supported Toymods
Location: melbourne.victoria.austra...
Registered: June 2002
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Re: KP Starlet F Code IRS Conversion
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Fri, 20 February 2004 21:53
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yes indeed some serious glassing will be required to make that fit make sure you allow for the suspension travel (though i prolly don't need to tell you that)
looks good nonetheless thought bill might have been in here for a look thouhg...
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Location: New Zealand
Registered: May 2002
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Welding has begun
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Sun, 29 February 2004 05:18
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Ok, floorpan is tacked quite solidly in place. Major amount of tweaking and measuring was required to get into just the right spot. New sections were folded up to tie the rear chassis rails into the shell as well as to tie the wheel wells into the area below the side windows. Will be fabricating extensions for the chassis rails to the front and to the rear to strengthen things up a bit more.
Have pics, will hopefully have them posted up by tomorrow night.
Callum
PS - Was interesting to watch how much of a fussy bastard my panel beater is . Everything was measured about 20 times before he even went near a welder. Very reassuring.
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Wed, 03 March 2004 07:33
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http://www.imagestation.com/album/?id=4287542739&a mp;code=8564967&mode=invite
Thats the link to the welding pics.
Went and had a play tonight, the IRS is installed and the car look extemely tough. Whole rear guards gone, wheelbase 4 inches back, huge 225/65 14 wheels on it, negative camber front and rear and sitting on the bumpstops (just for now, will end up with coilovers all round).
No pics sorry, will try to get some tomorrow.
Callum
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Wed, 03 March 2004 07:33
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http://www.imagestation.com/album/?id=4287542739&a mp;code=8564967&mode=invite
Thats the link to the welding pics.
Went and had a play tonight, the IRS is installed and the car look extemely tough. Whole rear guards gone, wheelbase 4 inches back, huge 225/65 14 wheels on it, negative camber front and rear and sitting on the bumpstops (just for now, will end up with coilovers all round).
No pics sorry, will try to get some tomorrow.
Callum
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Location: New Zealand
Registered: May 2002
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Location: Finland
Registered: November 2002
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Re: on 4 wheels
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Fri, 05 March 2004 13:05
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This is what I was bit worried about. Are those swing arms in correct position? is that your prospective ride height?
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Sat, 06 March 2004 07:10
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That pic won't show but I think I know the one you mean. The rear will be raised up a bit with tyres with a lower overall height. Should be fairly similar to the angles on a slightly lowered Carina, will make rear crossmember adjustable for camber etc (as per example that been posted on these forums).
If you look at the front arms the angles are actually very similar to the standard Carina, and the ride height still needs to come up slightly.
Any other questions or suggestions welcome, if there is anything particular you want to see let me know and I will get pics for you.
Callum
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Thu, 11 March 2004 08:08
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NEW GUARD MADE UP CLICK HERE
Pics are poor quality, best I could do at the time.
Callum
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Location: Auckland NZ
Registered: December 2003
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Re: KP Starlet F Code IRS Conversion
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Tue, 11 May 2004 10:53
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i am fully impressed, when i first saw this post i thought you were nuts, and i promptly forgot to follow it. just picked up on it through a link from another post and i can't believe the progress you've made.
nice one, good to see you didn't give up. this should be a mean little starlet, i'm looking forward to seeing it at the drags
Matt
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I supported Toymods
Location: Perth, Western Australia
Registered: December 2002
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Re: KP Starlet F Code IRS Conversion
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Wed, 03 November 2004 02:44
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Yep, much like Matt, picked the thread up from a link, any updates please?
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Wed, 03 November 2004 04:03
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No progress since about March/April. In the middle of buying new house/selling old house/building new garage. Will definitely update once progress is back underway, will then have cash for the big dollar stuff.
Callum
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Location: New Zealand
Registered: May 2002
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Location: Sweden
Registered: May 2003
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Re: KP Starlet F Code IRS Conversion
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Mon, 14 February 2005 22:05
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Cool!
I'm planning to use MA61 rearend on my TA47 but i will not take the whole floor.
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Location: Brisbane
Registered: June 2002
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Re: KP Starlet F Code IRS Conversion
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Sun, 26 June 2005 23:09
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someone hand me a towel
i really want a KP starlet.......even just with a k motor in it, damn u kiwis and your import laws
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Mon, 27 June 2005 00:07
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Import laws?
We got RWD Starlets brand new.
Will do an update soon, rear end if effectively finished except for seam welding. About to start cutting up the floor for my exhaust tunnel and muffler clearance under the passengers seat.
Callum
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Location: Brisbane
Registered: June 2002
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Re: KP Starlet F Code IRS Conversion
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Mon, 27 June 2005 04:13
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damn u and your KP starlets
i would imagine they r getting hard to find over there in stock form? kinda like rotors?
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Location: New Zealand
Registered: May 2002
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Underseal Removal
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Thu, 21 July 2005 22:21
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UNDERSEAL REMOVAL (CLICK ME)
Got very busy yesterday, now have very sore hands from hanging onto an angle grinder with a very harsh wire wheel on the end. Underseal now fully stripped ready to go to the sandblasters (dropped off this morning), then its time to get stuck back in and get the exhaust tunnel in and the floor modified to fit the muffler. Then seam welding before it goes away for the cage to be done.
Callum
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Sat, 23 July 2005 23:37
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How to fit a 3 inch exhaust in a Starlet - CLICK ME
Exhaust tunnel underway, still need to cut out floor under passenger seat for muffler and cut sill for the exhaust pipe to exit through. Hopefully that should be almost done by tonight. The entire exhaust system should actually end up being above the level of the gearbox crossmember, no ground clearances issue then.
Also a bunch of photos of the sandblasted and primed shell, much easier base to work with now. Bring on the seam welding.
Callum
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Location: Kita-Ku, Sapporo, Japan
Registered: January 2003
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Re: KP Starlet F Code IRS Conversion
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Sun, 24 July 2005 20:39
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geez you're a keen bunny
keep up the interesting work
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Mon, 22 August 2005 01:57
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Oops, my passenger just fell through the floor.
CHECK THE DAMAGE!!! (click me)
My panelbeater seems to be enjoying all the cutting just a little bit too much.
Callum
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Location: New Zealand
Registered: May 2002
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Fat Muffler Time
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Fri, 07 October 2005 20:34
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Just got to make the hole in the floor a little bigger.
Notice the steel lying there as well, 25x50 1.6mm wall ready to go in to join the front and rear chassis rails. The muffler is 3 inch inlet/outlet custom made.
Callum
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Location: New Zealand
Registered: May 2002
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Chassis Rails Under Construction
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Sun, 16 October 2005 08:45
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Chassis Rails Under Construction
The work is under way, pics are here.
Click Me - Sony Imagestation
Callum
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Location: New Zealand
Registered: May 2002
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Floor filled in
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Sun, 30 October 2005 10:03
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Passengers floor almost complete, hopefully will have all the photos uploaded shortly (11 in total). Entire 3 inch exhaust and muffler is now above the level of the gearbox crossmember.
Click Me - Sony Imagestation
Callum
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Sat, 19 November 2005 12:48
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Click Me - Sony Imagestation
More work.
Chassis rails almost complete, driveshaft centre bearing mounts welded in, rear turrets measured up and cutting is soon to start on yet another part of the car.
One very good bit of news, handbrake cables match up exactly so no fabrication required at all.
Callum
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Sun, 04 December 2005 08:52
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Yes, more cutting.
But some welding too.
SONY IMAGESTATION - Click Me
Towers tacked in place, just need filling in and tidying. Towers were cut from the front of a KE70.
Callum
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Registered: October 2005
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Re: KP Starlet F Code IRS Conversion
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Mon, 05 December 2005 05:19
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I'm impressed - I admit, but I cant help wonder if an AW11 rear crossmember or basically the ass off an ae82 might have made it easier.
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I supported Toymods
Location: Perth
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Mon, 05 December 2005 05:25
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myne wrote on Mon, 05 December 2005 13:19 | I'm impressed - I admit, but I cant help wonder if an AW11 rear crossmember or basically the ass off an ae82 might have made it easier.
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How would either of those solutions make it easier? Neither of them are front-engine RWD cars!? Neither of them have provision for a rear differential...
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Registered: October 2005
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Re: KP Starlet F Code IRS Conversion
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Mon, 05 December 2005 05:39
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Because the aw11 crossmember would probably come close to bolting onto the stock chassis rails - giving you the needed wishbone points, wishbones, hubs, disc brakes, handbrake etc and the trailing arm would probably have bolted to the stock front leafspring/trailing arm point.
That takes care of some of the most important parts of the suspension too. Strut tops... well... I guess it'd be like you're doing, but I suspect that the ae82 strut towers would line up better with the body - since they're similar shapes/era's and all.
Diff housing is the least of the concerns imo - those are much less important in the scheme of things. I just dont like the idea of cutting/welding chassis much. That's me though.
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Location: New Zealand
Registered: May 2002
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Re: KP Starlet F Code IRS Conversion
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Mon, 05 December 2005 10:18
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For me (being in NZ) transferring the whole rear floor pan section was actually cheaper and easier to get legal than moding the factory floorpan. Just need to work with what you have and the rules you have to follow.
Callum
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