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Location:
Adelaide
Registered:
May 2003
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Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 04:15
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Since i had posted this on a few other sites and had forgotten about here i thought you guys should have the honour, it is excerpts from my other project diary on another forum. But it is an 86 and some people might be interested in what im doing to it. Sorry if some of the old posts are a bit confusing, as some probably addressed questions that the people on the other forum had. Also there are BIG inline pictures.
Here goes:
<hr>
Car: 1983 AE86 Toyota Sprinter
Engine: 4A-C
Driveline:T50 with S-series open diff (stuffe diff too)
Pictures here: http://www.dysfunction.ws/galleryapp/Sprinter
That url will also serve as a photo diary which may be more comprehensive on some areas than what i post in here. If you have a question about anything that ive done, or what you see in any of the photos then done hestiate to ask. Anyway enough edits.
As you can see from that short description it is pretty stock. But not for long.
This is what i have planned for it
Engine:
* JDM Import 100kw (out of Roxy) - Got
* AE101 Silvertop Quad Throttle Bodies ($200)- en-route
* Wade 272*/285* cams ($440)
* Toda Adjustable Cam Gears ($290pr)
* TRD Head Gasket (0.6mm) ($92)
* 5-way cut and polish on valves & seats ($110)
* Mild porting to intake and exhaust
* Tuned Intake Runners for Quad TBs
* 4-2-1 headers, with a 2" exhaust.
* TRD Engine Mount Set ($74) - en-route
* Microtech MT8 ($550) - Got
* Bosch Heavy Duty Ignitor and Coil ($150) - Got
- Investigating using quad ignitors and coils, dependent on MT8 setup.
Driveline:
* Australian T50 - Got
* Au T18 rear axles, tail shaft and diff housing ($150)
* RT140 Corona Rear discs and calipers
* TRD/KAAZ 1.5way LSD
* Hilux/Landcruiser front brake upgrade (4pot) ($100) *yay eBay
* ROH SSR Mesh's 15x6.5 ($250)
Suspension:
* Corona front strut upgrade. ($40) - Got
* Cusco Upper Pillowball tops Front and Rear alloy tops. ($220)
* HKS Strut Brace
* Whiteline F & R Swaybars
* Adjustable rear strut brace (welded to strut towers)
* Koni Yellows Front ($425) converted to Coilovers using Fulcrum Collars ($80)
* Koni Yellows Rear ($295) w Kings Low
Body:
* JDM Levin Grille ($300) w new Headlights
* JDM Zenki rear full height lights ($180) - Got
* TRD Rear wing copy (small)
* TRD Front Lip copy
Interior:
* Bucket Drivers Seat - Looking at Cobra Imolas ($700)
* Bucket Passenger Seat
* 6point full cage with diagonal cross bracing ($1500 max)
* New Carpet ($110)
* Trust/Greddy Gauges
- Oil temp
- Oil pressure
- Water temp
Im aiming at 160-170hp for the engine, according to Billzilla's great website (www.billzilla.org).
Thats pretty much it for now. The interior needs a bit of work, as does the body. But mainly just surface rust removal. She needs a new bonnet, but i already have one lined up down in Melbourne.
Sorry, i have no pictures of the gear yet as im in Adelaide after just picking up the car. But you guys can discuss things until you have pictures. (EDIT: now have pics)
This project will most likely take a fair bit longer than the GZE into Roxy, as i have no real time limit, but instead i have a money limit. The money which goes into this project will come from working a second job, most likely at Safeway, so all donations are accepted  Also a greater attention will be paid to things like the tuning of the engine and the interior. For Roxy the interior was already almost perfect, and the GZE only needed the SAFC2 to be tuned.
Im not sure what sort of management i will be using for this one yet, but it may be a full management system, or another fuel piggyback. Also on the fuel issue i have to convert the tank to EFI which is something im not hugely looking forward to.
As always there will be huge amounts of photos for people to sift through for the project. And i hope everyone enjoys it.
P.S. Yes i know she doesnt have a name yet, but im waiting for my Girlfriend to name her.
EDIT : She is now called Sparky. As officially christened by my Girlfriend 2hrs ago.
<hr>
Alright, now that im home and have FTP access off my laptop i have uploaded some pictures.
These are what the seller sent to me, and as such dont show some things like the engine bay. But here they are:
http://www.dysfunction.ws/galleryapp/Sprinter
I will post more photos when i get the car actually here on Monday.
That gallery will also serve as a photolog of my conversion and modifications. So check back to it regularly.
<hr>
I have updated the specs list once again, and added a few new things.
Currently im investigating an alternative to the T-series rear LSD and axles which i have sitting in a garage back in Canberra. These are expensive as if they were made of gold. However, a shop down here in Melbourne has come up with an alternative.
This is to use a Toyota T18 rear axles, with RT140 Corona rear discs and handbrake setup, along with a custom LSD centre.
This is quite interesting as the parts are easy to come by and the LSD centre is supposed to be very strong and been used in local rally. So i will be investigating this further. The best bit about it is that the setup would cost around the $400 mark, rather than the $2,000 mark which people want for a T-series. And hence i could sell my T-series and invest that money into other options.
I have decided on using a Microtech MT8 to manage the system too. Especially as i am able to get one for quite cheap, with a brand new loom and ignitor and coil. Premapped with a 4A-GE map too, which is quite nice.
I have also been spending my time designing and computer testing the inlet manifold runners. I have hit upon the 0.75" mark for the length as the best compromise between torque and power. They will most likely be created out of mild steel, although if i can get alloy to hold the weight of the quads then i will use that for weight reduction.
As for monitoring the car i have settled upon a set of Defi Link II gauges, possibly in the BF style although the normal ones are still just as good. Both are the same price and i guess it will come down to ability to see the 52mm (normal) over the 60mm (BF). I will test this in Roxy, as i have 52mm gauges in her. The other interesting device in the Defi Link arsenal is the VSD Concept. Running in at about the $250 mark (needs link control etc etc) it projects a HUD style readout onto the windscreen for easy viewing. This i am quite interested in as it would negate the need to be constantly looking down (across for gauges) at the tacho and speedo.
However, im not certain about the reliability of this, or how it would work in high glare, say at a track. I wonder if anyone has had prior experience with these devices or not?
I have also bought myself a C's quick shift after eliminating the TRD one as it is too short. And actually vibrates at higher speeds. Also due to the length it is really damn hard to get into gear quickly as i found out when driving a friends 86 with one in it. The Cs is about an inch or so longer and shifts quite quickly and easily with little fuss.
Anyway, thats the huge update done for now, i will post more pictures soon. Dissassembly starts very very soon.
<hr>
Alright, after weeks of being unable to work on the car, both through business and sickness, i have finally been able to get a couple of things done on it.
I have stripped a bit of it back. Mainly simple stuff like bumper etc etc, and not really much before i was absolutely exhausted again. But here it is now:
I hope to get a bit more done tomorrow and then a bit more the day after etc etc.
Anyway, onto other matters. My Microtech MT8 has arrived at the post office this afternoon so i will probably go out there and pick it up tomorrow. I have also got my bonnet coming this weekend. And to top it all off the shipment of all my old gear gets down from Canberra on Thursday. This includes Roxy's old motor, a lot of 86 spares and a few more tools. This means i will hopefully get the head into the workshop before i go away on holidays over Easter. That way the cut and grind will be done by the time i get back.
I also spoke to one of the friendly (and tired) local engineers who works a lot with CAMS spec cars. I detailed what i was looking for to him and he said that the best "classification" to fit my car into was the Targa challenge type. In order to be properly scrutineered for this i am going to need a 6point cage with a diagonal cross brace at the bare minimum. Also i will need FIA harnesses. He gave me a rough figure at about $1500 to design and create a bolt in one for the car. As such i will most likely be taking the car out to him to fabricate it after the engine and drivetrain is prepped. Or possibly after it is all ready and simply do the cage last.
I was also advised that so long as my petrol tank is a seperate unit i can do pretty much anything i want to it. So im considering dropping the current tank out and putting a single 40L droptank/fuelcell in there, along with a 5L surge tank sealed into where the spare tyre would normally be. In addition i intend to relocate the battery to the boot in the form of an Oddessy Yellow or Redtop racing battery. This would sit in the passenger side boot panel for some better weight distribution.
Oh yeah, and on another note look what i found under the bumper left from one of the previous owners.
The install looks pretty recent too.
If anyone wants to buy it then PM me.
Also here is a pic of one of those Zenki fullheight lights i mentioned:
A few more pictures reside in the gallery now.
<hr>
[Updated on: Tue, 10 August 2004 23:58]
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 04:16
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Firstly, thanks for that Ben. Ill give it a go.
Alright, continuing on. My engine arrived from Canberra today. A big thanks goes out to my parents and to indigoid for doing this. It is all in one nice piece with ECU and loom all wrapped up in packing tape around it, and also came with everything my parents thought i might ever need out of the old garage (they have since moved out too, and are renting), so theoretically i wont need stuff from there again  .
Here is Roxy's old heart:
Rather boring eh, i thought so too. Not much real mechanics or engineering going on quite just yet.
But i have been expanding my collection of other bits for the project. Like my Microtech MT8 Sequential Fire ECU:
And its associated Bosch High Energy Coil and Ignitor
The MT8 comes with a brand new loom which i still need to wire up, and will probably do after the Easter holidays. Pics of that when i do it.
Other than that i havnt done much, stripped out the interior and left it be. Just been cleaning up the garage today.
Interior:
It needs a good going over with a wet sponge. But i found a small collection of stuff in there: $4+ assorted silver, a couple of old badges, a card of a racing shop in SA and a tampon. Pretty boring really.
Ill strip out the rest later, including those rear seatbelts and plastics etc.
Thats about it for now. Stay tuned.
[Updated on: Wed, 11 August 2004 00:07]
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 04:16
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<hr>
Alright. The world keeps going on around, England no longer rules the waves, and Bush is still bombing people.
Same with this project, it is still continuing along, albiet slowly. Im still waiting for some critical parts, namely the 20v quad throttles for the intake.
But this is where i am at sofar:
The engine is up on the stands, as before. Gonna buy some degreaser to clean it up before i strip the head and sump.
The dash is mostly out, and the shifter has gone walkies to the other end of my garage. A lot of the trim is sitting in the boot area, as seen here:
Tailshaft also went walkies:
So the engine is ready to come out now:
Found some new rust though  , thatll have to be spiffed up and removed:
Oh yeah, and that other rust:
And finally, a Stock 100kw ECU and 240*/7.8mm lift cams.
The cd of the moment is The Jive Express - Covered. Really a good cd, go buy it all [/subliminal advertising]
As for the future, ill be degreasing the engine this weekend, and hopefully getting around to pulling out the engine/gearbox. After that itll be a matter of waiting for the quads, and pulling off the head in order to get it shaved for higher cr, and trimmed up. Along with some minor head work. Depending on availiblity of my cams it may go back in at first with the stockies and then get upgraded a bit later.
I have a set of GZE injectors to go along with this setup for a bit of a flow upgrade.
And im in the middle of getting a surge tank setup to fit in the spare tyre well.
Thats all folks.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 04:17
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<hr>
Got my coilover collars delivered yesterday. Courtesy of Fulcrum suspension. Thanks to Sam for putting me onto these:
<hr>
Alright, today, for lack of things to do (apart from uni work) i cleaned up the garage and pulled the engine out of the Sprinter.
Really quite an easy job altogether, except the stock bracket for the exhaust secondaries runs around the other side of the steering input shaft from where the exhaust runs. Which creates a perfect circle. I only realised this when the engine was half out of the bay , and upon further inspection the bracket was rusted so the bolt and nut were rusted together.... easy solution, angle grinder. So my newfound anglegrinder skills are coming into use now.
Here is the engine out of the bay:
Here she is without an engine:
And in there you can see the little jack which was holding up the back end of the gearbox so i could pull it out. Not too many hassles with that system, except it came off once, cos of the stupid join in the concrete floor.
Ive hit the entire engine bay with a highpressure cleaner (off the airgun) made up of degreaser and caustic soda. Usually used on trucks and stuff it should be pretty good at getting this crap off. Will hit it with some water to rinse it off later.
Here is the humble 4A-C and the T50 hanging off the arse end.
Note that only the T50 has been degreased here, not worth wasting degreaser on a 4AC.
I also got around to pulling out the dash today in preperation for getting my
uncracked dash, which will be painted black.
Its not too pretty under there, but nothing that a good blast with compressed air cant fix.
And in a conclusion to the suspension top-hat saga i ended up getting the upper hats from T3 in the US, and i must say what a tops shop they are, really prompt shipping and great to deal with.
Pics of the upper hat:
And
Thats it for now.
More pictures of the clean engine bay later, and possibly some suspension pics.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 04:17
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<hr>
lwells: the JDM T50 is the same as the Aus AE86 T50. The T50 found behind Tmodel engines is somewhat different though. Different number of splines on the output shaft.
I have also done some other work tonight, fiddled with a few things, pulled the T50 off, disassembled a suspension strut, and stripped the interior.
Some pics are here:
This is a Corona XT142 suspension strut casing. A shock sits in there and is assembled as so:
And this is a hub which is pressed onto it:
The disc bolts onto the back of this little hub into the 4 bolt holes that you can see in the middle of that hub. As you can guess its a bit of a bitch to change discs so i am goign to get some DBA5000 hats custom made up so i dont have to pull the hub of every time i want to change the discs.
The rear disc setup is similar, except that the entire axle sits behind the hub, not just the stub. So i will be using a similar setup on the rear axles, although i dont know the rear caliper mountings yet. Will have to figure that one out.
Here is the S-series, but the T-series is similar:
This is the front suspension setup which that Corona strut will bolt onto eventually:
This leaves me with a few things, and a clean engine bay:
And my wonderful T50 with no clunks, squeals, or whines:
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 04:18
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I thought i would take some overall pictures of Sparky too just so you guys could see what she looks like in all her glory:
And the stripped out rear now:
Still a fair bit to do back there, but its a start, needs a good clean out, and clean up with a wire brush, and possibly a bit of a respray too .
And the trim which came out of it:
G0t Trim Part 2?
And here is the side parts:
I was really suprised by how weak the seatbelt mount is, its mounted up to like 2mm steel at the most. My harness which is mounted onto a welded in cage will be heaps stronger, and yet they dont allow that as a road acceptable restraint?
Anyway, thats about it for now. Just have to figure out what shocks to get.
Currently the debate is over Koni Yellows vs Tokico Short Stroke HTS 102s. The price is about the same, but which one i want is another matter entirely.
<hr>
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 04:20
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Very Very Very quick update so everyone isnt left in the dark.
I recieved a whole LOT of parts today and wednesday.
First of all i recieved my T-series rear diff and tailshaft. Got an AE86 one at first, but i have since traded it for a TE72 one with a guy at work. All good there.
Pics:
Second, i got my TRD engine mounts. Cost: $120 per pair. Replacing the stock ones which are dead. Got a quote for non-genuine replacements at $66 each, not including shipping. The TRD's were including shipping.
Pic:
Bit small sorry, my white desk can cause focusing problems when im in a hurry.
Thirdly, i got my 10cm boss kit. This is really long for a sprinter, as it needs to clear the indicator stalk. And i dont like to have my hands hitting it all the time, especially when wearing gloves. Most kits, like the SAAS etc are like 5-6cm long and made for the MR2.
Came with a wanky gold Toyota badge. Swapping it for a black/red one at work.
Other than that i got my Hilux calipers, which really arnt as heavy as everyone says. Only 11kg was marked on the parcel, but ill weigh them again to make sure. No pics, too messy to take out right now.
With my diff i ordered some RT142 rear calipers, but i got sent front calipers instead. Will phone up about that tomorrow morning and get them replaced ASAP.
I got a CAD file of a good caliper mount for it. Will explain it sometime later and post pics.
Im flying to Adelaide for the week tomorrow. So not much will be done.
That said i have a my Headlights, Grille, Quads and Short Shifter all coming in the week that i get back, and im picking up a Whiteline Panhard rod in Adelaide to save on shipping.
Thanks guys, ill post back in here while im in Adelaide.
<hr>
I intend for the diff to go in this weekend after a bit of a cleanup, and i should have finished removing all the sound deadening from the floorpan. Grr that stuff is crap.
Come across a bit of a snag with the XT130 struts in that they require XT130 hubs (or a whole host of other ones which fit) but the stock sprinter ones dont. Ill be getting RA40 ones off a mate on the weekend. These will just bolt on with the new bearing kits which i picked up today. I also picked up a spare inlet manifold that i can cut the mount plate off so i can weld runners for the 20v quads to. I had a look at one down at Meridian motorsports on Monday and found that itll be pretty easy to mount up the 20v throttles. Especially the accelerator actuator, should be perfectly fine . One less thing to worry about.
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Location:
Adelaide
Registered:
January 2004
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 11:19
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FANTASTIC!
btw i rekon ive seen this car before, u came into my work (Dick smith's, main north road enfield) i didnt have an 86 then, so u prolly dont remember, but i rmember!!
u parked in the top half of the carpark!
do u remember dude? im going by the plates btw, and also that its white, thats how i remember
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 11:36
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Probably not me, but its previous owner, tafebum. I live in Melbourne.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 11:50
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Update
Sam: this is waht i mean:
They are slightly bigger (not pcd) than the Sprinter ones, and so the sprinter hubs wont fit onto the stub axle on the struts. If i could get those off you it would be brilliant.
Onto other things ive been doing.
Ive chiseled out most of the sound deadening as seen here:
Ill take the rest of it out with a spun wire cup brush when remove everything to put the POR15 on. Found a little bit of rust from where the carpet got wet too:
Thats after attacking it with the wire brush of doom as seen on the drill in the first pic.
This is about half of the crap which ive chiseled out sofar:
Minus other bits which flew out of the car. Hurts your back crouching for so long.
Things are moving faster on the inlet manifold front. This is an inlet manifold which i will be butchering up soon, more info on that in days to come:
These are the engine mount brackets:
Can you guess im running out of things to show you guys.
And finally this is a Hilux brake attached to a Corona strut.
And as they say in cartoons.
Thats all folks
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Location:
Perth
Registered:
April 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 14:04
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Hello Takai,
Dood, this looks like a labour of love. I need more love and need more time 
I am also in the process of rebuilding bits of my 86 and was wondering where you got the engine mounts from? - the importer that i once knew is no longer in business.
Thanks.
James
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 02 June 2004 14:08
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Hehe, i have enough love and enough time, but not enough money as they say. As for the mounts i got them from greenline.jp
And there goes one of my secrets, i get a lot of my gear from Greenline.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 05 June 2004 09:23
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Just a quick update. About a pair of things that i wasn't planning to do. First of all, after picking up my hubs i inadvertently drove past a Revolution Racegear up here in Mitcham. And then stupidly i wandered in to see what was on sale (BIG Sale sign in window).
And ended up walking out with this:
A lovely CAMS compliant helmet for track driving.
Also another thing which i had completely not planned to do was to look on Toymods at another setup on there. And this lovely picture of a custom fusebox. Nor did i wake up this morning expecting that at 5pm i would be printing out the wiring diagrams and studying them so i can rewire the engine bay. Should be a pretty simple one thankfully.
Thats about it.
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I supported Toymods
On probation
Location:
Brisbane, Queensland
Registered:
January 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 05 June 2004 09:28
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Hey, would you mind me asking how much a helmet like that is worth? As for the car, looks like its gonna be great when its finished. Good Luck!!!
Jake.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 05 June 2004 09:53
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That helmet was on sale, and cost me $135.
Quite a good fit too.
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I supported Toymods
On probation
Location:
Brisbane, Queensland
Registered:
January 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 05 June 2004 09:58
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Yeah it looks really nice, was looking at it thinking damn that woulda cost a bit, i seem to have this problem with impulse purchases, but at that price
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 05 June 2004 10:04
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Yeah, i have the same problem with impulse buys. Including $800 worth of Willans harnesses which i have to pick up later this week.
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Location:
Perth
Registered:
June 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 05 June 2004 10:13
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Looking good so far mate, heaps of potential here and I like the plan you have for the car. If all goes to plan it will be a little weapon!!
That engine bay could do with a tidy up though, Chop Chop!!
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 05 June 2004 10:21
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Aye, chop chop happens tomorrow. After i find my sidecutters and figure out what some of the wires are for.
Planning on running a 8AWG line to the nose to run the front lights (fogs and driving too), and place relays along the radiator support panel. Should be quite neat. The indicators and parkers will be run off the stock wiring (neatened up of course).
Need to hack at the engine bay with an angle grinder too, remove all those crappy little bits ill never use. Stuff like battery supports, etc.
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Location:
Melbourne
Registered:
May 2004
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 26 June 2004 05:18
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any further progress? looks the goods so far!
I agree about Revolution racegear...Cobra seats sucked me in when I drove there to see about something completely different!
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Location:
Adelaide
Registered:
August 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 26 June 2004 06:36
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takai...first i would say tremendous effort on the car...2ndly...your sparky is fucking raped by you!.. 
i am amazed how you strip the whole car up and when u put them back..i'm sure there are alot of extra nuts around which u might not figure where they came from....(maybe its just me)
i've got some questions to ask you but i couldnt remember right now...will do once i can think properly...anyway...respect for the great effort...
PS: hmm..do u grow money tree behind your house? where the hell did u get so much of ($)-( from?
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 26 June 2004 07:13
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I will post further progress when i get home. Currently im on holidays in Canberra, and for the past couple of weeks havnt had the time or parts to work on the car. By the time i get back ill have a lot more $$$ to work with and all of my essential parts
Sadly i have also found a bit more rust, but im determined not to let this put me off and instead ill be replacing it quick smart.
Most of the interior has been stripped and POR15d and the rest will be done when i get home.
Currently im researching all the road cage options i have available to me.
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Location:
Adelaide
Registered:
August 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Mon, 28 June 2004 11:54
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my old tail lights!!!
Good to see they went to a good home.
as soon as I've got a decent shed to work in im undertaking a project like this. Maybe not as CAMS friendely though :/
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Mon, 28 June 2004 12:06
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Yeah, thats where they went.
Purely a cosmetic thing....
CAMS is what is keeping this car from being a monster
well kinda, my wallet and girlfriend do a good job of that too
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I supported Toymods
Location:
sydney.au
Registered:
August 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Mon, 28 June 2004 13:11
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i hate you because you have a garage
((((
im so envious of your project!
nice man
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Mon, 28 June 2004 21:57
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Hehe, garages ae good, cept that one is freezing. Getting a heater in there when i get back.
I have a large update coming soon, but i left my camera in Melbourne when im in Canberra.... bummer.
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Club Member
Location:
sydney
Registered:
May 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Mon, 28 June 2004 22:18
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some nice work going on there Takai.. did you look into having the shell acid dipped at all?
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Mon, 28 June 2004 22:31
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Nah, i havnt looked at getting it acid dipped, not this shell anway. I am considering making a second shell for a second revision.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Tue, 06 July 2004 12:15
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Just a quick update.
Sorry for not updating this recently, ive been on holidays up in Canberra, and running around doing a whole heap of stuff before i left for Canberra.
But i thought i might just tell you guys what ive been doing.
While ive been up here my Silvertop 20v Quads came in, and so ive already had some flange plates machined up and i plan to get the manifold almost finished by the time i go back to Melbourne.
I have also picked up a new 16v head, without shims, but with the valves and springs. I intend to strip this head out and rebuild it entirely with brand new valves and HKS HeavyDuty springs which i will be picking up relatively cheap. This head will be ported and cleaned up, and the Wade 292*/9mm cams will be added to this head. Also ill be using the Echo or Prius solid shim/bucket setup to eliminate shim spitting. It will also have about 1mm shaved off the bottom. That will be the head which will replace the stock one before it goes into comp usage.
I have also been lucky enough to pickup a Fidanza 3.4kg flywheel which only requires a new friction plate which i can buy from Adelaide Clutch. Just have to measure it all up and take a photo of it. So that will be done when i get back to Melbourne.
While ive been here my Tokico HTS102s were also delivered and i must say they are very very nice. Ive also been able to pickup a new set of Eibach springs cheaply and so that is my suspension setup finally finished, bar the camber plates which will be ordered as soon as i get home.
Finally the tax year is over, and so all those little goonies at the Tax office have released the rest of my money to me for Sparky. So as soon as i get back its full speed ahead on the project. Aiming for a mid sept finish, fingers crossed.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Tue, 13 July 2004 13:13
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Alright, just thought i would give this photo update before i hit the sack tonight. I have just gotten home after driving all day and im absolutely wrecked. So feel special that you guys got this .
Here are the trumpets i have for my 20v Quad Throttles. Yet to be cut down to size.
Eibach 450lbs/in 65mm springs
And setup with the collars and top hats:
Fidanza 9lbs flywheel, courtesy of Ben Wilson who has already posted in this thread. Needs a new friction plate though.
Steering wheel on boss kit, its not so blue in real life.
Big box from Japan
And lastly a teaser of whats inside the big box:
Have a close look, you can see a whole lot. Points to the person who can get the most number of items which are in that box right.
Heads and stuff are in the garage, and ill take photos tomorrow. Need a clutch tomorrow too.
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I supported Toymods
Location:
sydney.au
Registered:
August 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Tue, 13 July 2004 13:54
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20v adapter plates + flanges
throttle bodies
bearing (looks like a thrust bearing)
some kinda blinker lense
JDM neg battery strap
sandpaper(?)
misc. screwdrivers
steering wheel centre cover
socket set?
fuel rail or sorts?
exhaust gaskets (in a seagate hard drive case)
how am i doing so far?
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Tue, 13 July 2004 23:02
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Very close garth, stay tuned for the revelation later today.
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Location:
Melbourne
Registered:
June 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 14 July 2004 00:19
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Fantastic write up... will stay tuned!
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 14 July 2004 02:18
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Getting close guys.
Here is the contents of the box spread out over the floor:
So yes, Kinchrome torque wrench, and 20v manifold in there as well as the throttles. The bearing is a timing belt tensioner which i replaced for a friend and he gave me that new one before i came home. An AE292 Sikaflexed engine mount, cup holders for my AE92, Rola roof rack holders,. 20v sidefeed injectors there too.
Here are the manifold plates for the quad throttles, this is what they will bolt up to:
And the throttles themselves, along with their TPS.
Also in the box, but not pictured were my Tokico HTS 102 shocks, which arrived to my parents house while i was up in Canberra:
And the accessories kit which comes with them:
And the extremely cute little rate adjuster for them:
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Location:
Adelaide
Registered:
September 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Tue, 27 July 2004 17:40
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Looks like you are having fun there and spending well.
I gotta say, 450lb/in springs for the front of a tiny car like that are a bit on the hard side though ?
I had an RX2 Club car (now called improved production), and I had 350lb/in, and they were great in the dry, but not so good in the wet. Most people suggested I should have gone for 275 or 300.
Be interesting to see how it goes.
I have a set of 325lb/in springs that I want to use for the front of my Mk2, but this has a 7M-GTE lump in the front !!!!
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Location:
Melbourne
Registered:
January 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 28 July 2004 03:28
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56k'ers beware , maybe you should add a cable beware warning too
More BLOODY BIG PICTURES .
Nice work , will in all bolt together ? This is going to ready thins weekend isn't it ?
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Location:
Melbourne
Registered:
January 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 28 July 2004 04:45
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great work chris.
lots of wip.
Hope to see the finished product on the road soon.
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Location:
Melbourne
Registered:
October 2003
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 Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 28 July 2004 09:35
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Sounds like everything is going really well Chris!
Can't wait to see the finished product..
One awesome write up I must say!
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I supported Toymods
Location:
sydney.au
Registered:
August 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 28 July 2004 09:36
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| [AE86 |
wrote on Wed, 28 July 2004 19:35]FOR SALE: 1984 JDM AE86 TRUENO GTV
Contact me for those interested!!
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for real?? your selling it so quickly?
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Wed, 28 July 2004 11:02
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Alright, after a pretty long day of working and writing ive done a few new things on the car.
Firstly ive started the final preps on cleaning up the engine bay and stuff like that. Did a bit of surface rust removal and conversion today too. Cut out a few mounts and the battery tray out of the engine bay. Sprayed part of the engine bay too. As well as the diff and most of the interior.
Ill let the photos speak for themselves i think.
Engine Bay
Radiator Panel
Interior Bits
...and more.
Diff
Interior (passenger side next to be matted)
And a general shot:
-------
Alright, just a quick update.
I just dropped off my struts and a shock to the place i used to work in order for my ex-boss to cut the struts down by 50mm and machine up a spacer plate inbetween. I should be getting them back tomorrow. Good quick work.
Also the friction plate for the Fidanza flywheel arrived today:
But im having issues installing it. As you can probably guess from this photo:
To put it quite simply the nuts are just too big, and the indentation too small, for my little 1/4" drive sockets to fit in there
Im going to get a 1/4" drive socket machined down to fit in there tomorrow. Really frustrating.
I have also ordered my ARP head studs, ARP flywheel bolts, and Exedy clutch.
Should be installing the flywheel, clutch and bolts on the weekend. While the studs will wait until i pop the new head on.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Thu, 29 July 2004 08:06
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Alright, here we go with another quick update, mainly for procrastination purposes. But also because some people have asked me for specific photos and because i have new gear. Also in a trend on new stuff, this post will be the first with inline thumbnails, after too many people complained about my huge images. Click on the thumbnails for a bigger version.
First up are the ARP studs and flywheel bolts i bought, and boy is there a story behind these.
Yesterday, i phoned up regarding availability of the ARP bits to their distributor here in Australia. After being fairly rudely asked to hold i was then answered by another person altogether who asked in a bored fashion what i wanted. So i asked for availability of the head studs and flywheel bolts. Now the head studs were ok, as i had the part number for that set, but actually getting information about the flywheel bolts was the hard bit. Firstly i was bluntly told that i didnt need ARP bolts for a "small piece of Jap s**t", then i was told that they had some, but i didnt really need to bother for something which "wouldnt make more power than a mouse". After finally getting the part number out of the guy i asked how many bolts the pack contained, and was told that it contained six, because thats all there were on any revision of the 4A engine. After telling the guy that they came in 8 bolt configuration too, i was told that if i wanted to argue that i could "f**k off back to ching chong land". At this point i seriously got jack of this guy's insulting manner and hung up on him.
So off i trundled down to Bursons to order the ARP bits, with my new found part numbers, and my Exedy flywheel. And today i went back to pick up all the bits. And look what i found:
Oh my goodness.... would that be an 8 bolt pack.... just maybe.... 8 bolts.... gee how hard is it to count. /sarcasm
Anyway, i finally have my ARP bits, and have resolved never to deal with the Australian distributor in person ever again.
My new ARP Head Studs
Exedy were thankfully heaps easier to deal with, and supplied my clutch and pressureplate with no troubles whatsoever, even though they had no stock and made it this morning.
 
Also i thought the instructions on the back of the Exedy box were hugely cute, and quite funny. In a very Japanese style.
Following picking up all my bits from Bursons i went into my old work and picked up my struts, and got a little 3/8" 1/4 drive socket turned down so it would fit in my flywheel.
Cute little guy.
And my shortened struts with the collars machined down to fit over.
Also a friend on IRC asked me yesterday to take some pics of the new engine bay. So here they are:
 
Yes i know there is overspray there.
Anyway thats another update, and sometime soon ill get around to modifying all my previous posts so they are using thumbnails too.
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I supported Toymods
Location:
sydney.au
Registered:
August 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Thu, 29 July 2004 08:21
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takai
whats the part number and exedy contact number for that clutch kit?
if you can
and ARP.. what fuckheads
PM me the shop name so i never EVER deal with that fuckhead.
also, that box is super cute :D:D
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Thu, 29 July 2004 08:56
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TYK-6932HD is the part number.
Ordered it from my local Bursons. Cost me $235 plus $12 shipping.
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I supported Toymods
Location:
sydney.au
Registered:
August 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Thu, 29 July 2004 09:35
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whats included in the box?
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Thu, 29 July 2004 10:33
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Clutch plate. Pressure plate. Thrust Bearing.
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Location:
Adelaide
Registered:
May 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Tue, 10 August 2004 14:44
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Alright, a fairly hefty update since the last one.
I havnt had a chance to update the thread, but i ahve been compiling photos, and had some time on my hands tonight so i have uploaded them all.
Firstly, i recieved the parcel from Japan with a whole lot of goodies. But most of them not mine. The two that were, were my HKS Heavy Duty valve springs here:
 
Hopefully ill be able to take some pictures of these next to some TRD springs so you guys can compare the difference. Its pretty hard getting spring specs out of HKS and i dont want to do spring tests on something that small, and hard to come by.
Next out of the box was my Cusco cambertops. Or "Piro ball mounts" in good Jinglish.
These are quite well made, although i found out that i actually needed the "height adjustable" version, because of a little problem which is easiest to show in a photo:
As we can see here the bolts which locate the camber mount are a bit too long and hit on the upper hat. The first idea i had was to simply cut them down, but if i do that i found i only have like 2mm clearance which isnt nice at -5* camber. Also i found out that the height adjustable version have a little spacer which sits under the ball joint. Upon hearing this i got a simple idea, which ive gone ahead with. And as such im getting a spacer machined up. Should be finished tomorrow, and ill get pics for you then.
With my flywheel, i finally got time to finish off assembling it completely, and here is the wonderful finished result. Also in the other picture you can see the huge difference between the old friction plate and the new one ive gotten. Even a different surface, and it looks like the new one has been heat treated, wheras i dont think the old one was.
 
On Saturday i had a chance to start assembling the engine with the help of a friend. Unfortunately my camera batteries ran out, so i wasnt able to take many photos. Here are the ones i took though, and i intend sometime to make a little writeup on changing clutches. I also had to put on my less dented sump out of the few i have. One is holed, and so in even worse condition than this one. I think ill put a sump plate in too.
I finished off painting the engine bay, and got the engine mounts, flywheel, and clutch assembly on the engine before i realised that they gave me the wrong throwout bearing. During this time my camera batts ran out and i didnt have any more, so here are the photos i have taken after the assembly.
  
The flywheel bolts were torqued up to 54lbs/ft with redloctite stick. Kinda like a uhu stick, but with loctite. This was done while a mate of mine was holding onto a breaker bar and securing the crank pulley bolt. The crank pulley is meant to be tightened to 112lbs/ft so it wasnt going to snap. The pressure plate assembly was initially installed one or two turns to just hold the clutch plate in place while i was locating it. Since i dont trust the generic cheapo locator tools i tend to do all my locating by hand. In this case the pressure plate has three raised areas which make locating quite easy. Its simply a matter of nudging the clutch plate around until it is equidistant from the edge of the friction plate on all sides. Ill see if i can get a picture tomorrow of what i mean. The friction plate was then slowly tightened in a diagonal fashion 1 turn at a time until the bolts were tight, and then it was torqued with loctite to 45lbs/ft. This is where i got stuck as i realised they had sent me the FWD AE92 (where the 100kw engine comes from) thrust bearing instead of the T50 one, so i had to wait till Monday to order one. Ohwell, extra thrust bearing for me.
After waiting 2 days to get the new thrust bearing in i have gotten it pressed onto the mount and will be installing it tomorrow. Hopefully ill also have the time to bolt the engine into the bay, and then start running the 4AWG cabling which i have for it. And the ecu loom too.
Things are progressing along quite nicely.
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I supported Toymods
Location:
Perth
Registered:
October 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Tue, 10 August 2004 23:13
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coming along nicely, its awsome. cant wait till its finished.. EEE!
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Location:
Sydney
Registered:
October 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Fri, 26 November 2004 22:54
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Update needed
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Club Member
Location:
sydney
Registered:
May 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Tue, 30 November 2004 19:51
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starting to get there, why didnt you put some custom rear discs on though? seems a shame to go this far and leave the shitty drums there.
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Location:
SA
Registered:
May 2002
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Re: Project Sparky - Track Car Buildup (56k warning)
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Fri, 31 December 2004 02:46
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OMG, this was origionally my car.
Those are the plates I registered.
Good luck witht he project.
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Location:
Brisbane
Registered:
February 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 30 April 2005 13:46
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I had a look at your photo's site. What happened in the engine bay?!?
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I supported Toymods
Location:
sydney.au
Registered:
August 2002
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I supported Toymods
Location:
Perth
Registered:
October 2003
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Re: Project Sparky - Track Car Buildup (56k warning)
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Sat, 30 April 2005 15:19
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yes, not happy takumi..
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