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Location:
Wollongong, NSW
Registered:
April 2004
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Psychofox's AE86 - 20V Conversion 95% Complete
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Wed, 21 September 2005 01:20
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I've been around on toymods for a while now, but I never posted anything on my car, so I've decided to. I bought my AE86 as a bog stocker for $2500 in April 2004, subsequently been doing mods on it slowly. I broke my right wrist around Christmas last year, so I didn't do anything on it for about 5 months... I finally got the engine back in it and on the road recently. I got a bit bored of the 16V hybrid 4AGE so I just put the 20V I had lying around (lol) in, with a Microtech LT10s ECU. Seems to go quite well.
This isn't my daily driver, I have a Company ZZT231 Celica for that, it's a bit of a play car, I intend on doing some Hillclimbs, Track days, Drags (lol) and some Drifting in it.
SPECS: UPDATED....
1985 ADM AE86 Sprinter 176,000kms
ENGINE
AE101 4AGE Silvertop modded for RWD (no dizzy, blanked off thermo housing, etc.)
No-name Extractors (not great design) + 2" Straight through System.
Microtech LT10s + X4 Igniter
Bosch HEC715 Coil Packs
Bosch 8mm Ignition leads
NGK Iridium IX Plugs (BKR6EIX-11)
Stock Radiator w/Camry Thermo fan.
Mazda S5 RX7 Denso Fuel Pump in JDM Fuel Tank with 3/8" Lines.
DRIVELINE
Xtreme Clutch Heavy Duty Pressure Plate + Exedy Clutch disc + AE101 212mm Flywheel
Gearbox Stock T50
Tailshaft Stock
Diff Stock S-Series
BRAKES & SUSPENSION
FC3S RX7 Front Calipers and Rotors (276x22mm)
Braided Front Brake Lines
Mitsubishi Triton 15/16" Master Cylinder + Stock Booster
Stock rear Drums
Shocks(F) Monroe GT Gas (soon to be replaced they are shagged out)
(R) Koni Sport Adjustables
King Springs 30mm lower all round
Whiteline RCA's
Crap Front Strut brace
All Urethane Bushes up front
WHEELS
MX73 15x6 w/Kuhmo Ecsta 711 195/50/15s
EXTERIOR
Stock apart from:
Kouki Levin Whiteline Tail lights.
INTERIOR
Stock apart from:
MOMO Corse Steering Wheel
TRD Gearknob
Pioneer MP3 Headunit + JBL GTO 4" Speakers in stock locations.
Some pics:
With my Celica in the background....
Back of Car
Engine Bay - now with the 20V installed...
PLANNED MODIFICATIONS
Get a set of trumpets for the 20V
Coilover conversion on front struts + Short Stroke front shocks
Fit LSD G-Series Hilux Rear Diff
Fit Forged pistons/rods (which I have) to 20V and turbo it.
Get Brakes / engine engineered....eeekkk!
Any thoughts/suggestions?
Regards,
Fletcher
[Updated on: Fri, 28 October 2005 04:27]
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Location:
Newcastle
Registered:
June 2004
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Re: Psychofox's AE86
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Wed, 21 September 2005 02:43
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Thats awesome dude.
very nice motor
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I Supported Toymods
Location:
Wollongong
Registered:
June 2003
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Re: Psychofox's AE86
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Tue, 27 September 2005 04:42
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ahh so this is the beast. Whitelines look the goods.
Just a few questions:
Have u got it tuned? What kind of power?
Did u have to put some kind of heat protection over the starter motor?
Did u do the wiring? I never knew ou could use an AE92 loom
Great work.
Craig
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Location:
Sydney NSW
Registered:
July 2004
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Re: Psychofox's AE86
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Tue, 27 September 2005 07:39
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Nice car, like the "custom" pod filter plumbing too  
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Location:
Outer Sth East burbs, VIC
Registered:
July 2004
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Re: Psychofox's AE86
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Tue, 27 September 2005 12:49
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You say you want to upgrade your master cylinder, i just put a r32 15/16th master, aparantly its off the non abs model.
I found it really easy, it bolts straight to the stock booster and the stock brake lines are fairly easy to bend to fit onto the master if you remove the brake junction thingy inside the engine bay.
I have stock fronts and corona rear discs and the pedal feel is good. Thats my suggestion for ya anyway 
But nice car man, good luck wit future mods
Cheers
Shtock
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86
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Wed, 28 September 2005 09:55
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Craig:
Yep, I did the wiring. I took the wiring loom out of my old AE92 SX Seca and stripped out all the crap, and wired it into the stock fuse/relay locations on the sprinter - it's nice that they left the EFI relay placeholder in the carby version. The engine loom isn't really long enough, I had to remove the air con condensor and mount the computer in the box it was in under the dash, it wouldn't really fit anywhere else.
I haven't had the car 'tuned' as such, as I'm running a stock computer, you can't do anything with it.  . I probably should get it dynoed in it's current form, but meh, I'm planning on putting the 20V in soon (next month) with a Microtech LT10s, so I'll do it then. Then I'm going to sell off all my 16V stuff.
The starter motor is the stock AE92 one, it has a heatshield from the factory. It's also smaller & lighter than the AE86 one.
How's your 86 going? I should come up and have a squiz now it's finished...
cannonball:
yeah I was at bunnings and saw they had 65mm storm water piping, and I was like...that would work quite nicely. 2.5" hose is 63mm ID, so you have to stretch it a bit, but it works ok.
StockAE86:
Thanks for that, I was told a mitsubishi scorpion, but I'd say a R32 master might be easier to come by these days. I was quoted $3-400 to get mine resleeved to 7/8"...eek!
What diff are you running for the corona rear discs?
Thanks for the encouragement guys, sometimes I just think the car is a money pit (well it is), but I enjoy it all the same.
I got a full set of MX73 cressida rims the other day, so it won't have the full sick dorifto 14s on the back look...
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Location:
Outer Sth East burbs, VIC
Registered:
July 2004
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Re: Psychofox's AE86
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Wed, 28 September 2005 14:24
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I got my r32 master for $100 but i know you can get them even cheaper than that.
Im running a T-18 rear end, the brakes bolt on but you need to relocate the shock mount so the shock clears the caliper.
Cheers
Shtock
OH yer, go the MX73 wheels!!!!!!!!!!!!!
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86
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Fri, 30 September 2005 07:26
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Thought I'd put up some pics of my brake conversion.
The calipers and rotors are both from an FC3S RX7. The rotors were drilled for 4 stud. The plates are made of 13mm plate (aint gonna move for sure), which is mounted onto the stock position without spacers, etc. The rotor is then mounted over the top of the wheelhub (floating like most cars these days), as opposed to bolted to the back of the hub. To do this, I had to machine the outside of the hub by about 5mm for it to fit inside the hat of the rotor.
With this setup the disc doesn't quite line up with the centre of the caliper(out by 6mm), so I had to get some spacers made up that sit in between the hub and the hat of the rotor. this also was to make the rotor hub centric rather than lug centric as the hole in the RX7 disc is about 15mm larger than the hub diameter on the AE86 hub. I had to run longer wheelstuds as well.
I got some braided lines made up to suit this - which weren't really needed, the stock AE86 ones fit fine - but I thought it would make the braking better.
I had to get bigger wheels after this, as the MA61 wheels don't clear the caliper in it's posision, so I got a set of MX73 wheels, which are 15x6" and I wanted to run 15s anyway. The way I have done the brakes - floating rather than bolt on the back - increases the front track by about 15mm per side. So the wheels sit out a bit nicer at the front.
So the cost of this....
I got the calipers and the mounting plates for $300 (dirt cheap - but I had to mofity them anyway)
The spacer/locaters cost me $350 (OUCH!)
I had the rotors from another project
Braided lines cost me $145
New Ferodo pads cost $55
so a total of $850 for the conversion.
I'm probably going to get a R32 master (say $100) and the rejigged brake lines ($50)
and some slotted rotors ($300 for the pair)
which will bring the total conversion to $1300. Not cheap, but the brakes are chalk and cheese better than the ADM AE86 offerings. The rotors are now 276x22mm (vented) vs old 234x12.5 (solid). Best thing is the new calipers are heaps lighter than the old ones, which offsets the fact the discs are a fair bit heavier...
Pics:
Front on, showing the spacer/locater ring
Side on, see the thickness of the new rotor and the size of the calipers...
Back of caliper - see the plates and the Whiteline RCAs
Pic of the braided lines
I haven't got them engineered yet, but I'm pretty confient they should pass...
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Sun, 02 October 2005 07:29
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I've got some pics of the 20V motor I'm putting in my 86...
It's a AE101 Silvertop, I'm pretty sure about a '91 model (that's what the ignition leads dates were). It came from jap with the plastic bits painted blue. I'll probably leave them as is it (can't be assed painting it again). The motor hasn't been run in Australia afaik. I've done the usual things to convert to a RWD, capped the Dissy, put a plate over the water lines, etc. I'm going to use the factor 'surge tank' and trumpets, rather than straight trumpets as they are more RTA friendly. I got a mate to cut and shut the top metal piece of the surge tank so it face forwards. I'll probably run a cold air intake to it or something...
Here's some pics of the engine on the engine stand...
Front on
Back of head with thermostat housing & dizzy blanked off.
Exhaust side - note the water line blanked off
Inlet side - with SARD fuel pressure regulator adaptor (so I can run a Malpassi adjustable fuel reg) and factory trumpets in view
Modded Surge tank top - still in dodge ass spray pack primer.
Cont. Next post
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Location:
Ipswich
Registered:
October 2003
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Sun, 02 October 2005 07:41
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Surge tank = plenum. I got a bit confused there bud, so just thought i'd point that out. Surge tank is a container for fuel. The cut and shut job looks great though, nontheless. 
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I Supported Toymods
Location:
Wollongong
Registered:
June 2003
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Sun, 02 October 2005 07:54
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Fletch, seeing that your not far from me, can i burrow your 20V until i fix my engine up. I'll happily run it in for you. Haha *thinking*Hmmm D-Day October 22nd Oran Park *thinking*
Yeah i wish, Looking good mate, the brakes look sweet ay, you defnitly wont have any stopping power issues there. Just pop by if u have any problems with your conversion to suss things out. Good luck with it
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Sun, 02 October 2005 08:14
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Read the Toyota engine manual for the AE101/111 and they call it a surge tank. that's why I put it in inverted commas.
Have a read of this: http://www.onthenet.com.au/~paulp/Blacktop/bt4-em. pdf at about page 22...
What happened to your motor??? I haven't read your thread for a couple of days....
Cont from my prev posting...
This Inlet side water routing, this is the top rad hose - I ground off the tps wiring locator off the alternator bracket so it wouldn't foul the radiator hose. I'm going to use an AE92 remote thermostat that I have lying around off the water pump for the hose back to the bottom radiator.
I also have some stuff for a turbo conversion in the future...
Turbo manifold....for a T28 flange, I think I want to run a GT28RS Disco Potato on it...
But running a turbo on stock 10.5:1 CR...eeek asking for a rod out the block.
I'd say I'll need some of ...can somone say forgies???
They are 81.5mm Venolia Forged Pistons for a 4AGZE. I think thc Comp Ratio is about 8:1. Good for big boost! They have Dish ....lol
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I Supported Toymods
Location:
Wollongong
Registered:
June 2003
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Sun, 02 October 2005 10:17
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Harmonic balancer worked itself loose which put valve timing completly out. Wont even fire up.
So are you going to build this motor up on the side (including the venolia pistons and turbo) whilst running the 16V???
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Location:
cambo
Registered:
May 2002
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Mon, 03 October 2005 10:09
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nice car dood
and yes they are also known as surge tanks, tho most people dont refer to them as such.
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Location:
S.E suberbs, Vic
Registered:
December 2003
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Tue, 04 October 2005 03:45
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| matt_84 wrote on Sun, 02 October 2005 17:41 |
Surge tank = plenum. I got a bit confused there bud, so just thought i'd point that out. Surge tank is a container for fuel. The cut and shut job looks great though, nontheless.
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actually it's an air box not a plenum, normally you would be right but when you have multiple throttles they don't have a plenum at all.
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Location:
S.E suberbs, Vic
Registered:
December 2003
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Wed, 05 October 2005 04:31
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you wont like this but the standard trumpet dont have room to fit on #4 cylender. It may be possible if you start taking things off the firewall but I didn't look at that option. I might be able to get u a pic if you want.
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Wed, 05 October 2005 07:04
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Craig.
Did it snap the key in the crank? I had that happen a twice with my 16V motor. If the bottom timing pulley hasn't moved relative to the crank then it shouldn't have moved the timing...
At this stage I'm just going to put the 20V in NA. I just put an order in for a Microtech LT10s, so I'll be using that. Later on I'll put the pistons & rods in (I have some GZE rods + arp bolts) and the turbo in, but probably a while off (at least 6 months..)
Sam_Q:
Yeah I had a look at that the other day. I think I may be able to "massage" it into place. If you have a pic that's be great. Does it foul on the clutch master or the firewall?
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Location:
S.E suberbs, Vic
Registered:
December 2003
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Wed, 05 October 2005 07:39
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I just had a close look, it's majorly off because of the clutch master. Unless you have an auto there is no way in hell it could fit, sorry man. Check out my worklog (link in signiture) for more details on what I am doing in that area.
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Thu, 13 October 2005 08:29
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Got this today. 20V conversion starts this weekend!!!
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86 - now with Brake Conversion Pics
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Tue, 18 October 2005 08:02
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Did some work on the 20V conversion this weekend, it's not quite finished, but it's getting there. I'm also upgrading the master cylinder to a 15/16" size one from a Mitsubishi Triton of all things
Here's the engine bay...under construction...
A Side view, heaps of wiring still to go...
A Pic of the new Master Cylinder. It's from a 94 Mitsubishi Triton...When I took the exisiting master/booster off, the booster had about a litre (I kid not) of brake fluid in it. It seems the master had been leaking into the booster and filled it up! I had a look through the receipts from the previous owner and he had the master replaced about 2 years ago - but I dare say the booster wasn't even touched. I figure the booster being full of fluid hadn't been doing anything for brake feel!!! I got a new booster from a wreckers and picked up the master (took a while to find a 15/16" 2 bolt one) at the same time. I'm thinking I might not use the proportioning valve anymore and just get some new lines made up to go to the master cylinder directly? Does anyone have an ideas / opinions on that?
So here's what the car looks like at the moment, I have the engine out - it's easier to do the wiring without it there, it's a tight squeeze around the back of the motor. I wired all the power to the microtech, tacho, fan relay, etc. under the front guard so it's neater and out of the way.
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Location:
S.E suberbs, Vic
Registered:
December 2003
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Re: Psychofox's AE86 - 20V Conversion Underway
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Tue, 18 October 2005 08:05
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did u decide what your going to do with your intake? I just finsihed my airbox if you want o have a look in my worklog
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Location:
newcastle
Registered:
January 2004
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Location:
S.E suberbs, Vic
Registered:
December 2003
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Re: Psychofox's AE86 - 20V Conversion Underway
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Wed, 19 October 2005 09:52
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your half right Pete, he might of done the really shonky way and drilled a hole though the head to get water past the divider.
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86 - 20V Conversion Underway
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Wed, 19 October 2005 13:52
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there's a channel cut out of it between the water galleries in the head...hey give me some credit - I'm not that stupid
At the moment It'll be NA, but turbo down the track. I just can't afford it right now.
I'd say I'll just get some trumpets and socks for the intakes. I CBF fabricating anything fancy at the moment.
Tonight I got the 20v back in the car, wiring is 90% complete, just some tidying up to do. I pulled the heater core out and found it one of the outlets had cracked on the braze. That could have been a nasty suprise on the highway....
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86 - 20V Conversion Underway
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Mon, 24 October 2005 08:56
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On the weekend I got The engine in and running!!! Kicked first go....truth be told I'm suprised that I got the wiring right first go. On the base map I took it for a few drives - I'm really impressed with the motor - far more responsive than the 16V I had in there. It really 'comes on the cam' about 6000 RPM. I also love the induction noise from the quads, rather addictive.
I ended up using the remote thermo setup from the previous motor. I blocked one of the heater connections and ran a host from the other one to the top radiator hose. probably not the best way to do it, but it circulates water when the thermo isn't open like the FWD setups do from the factory.
I ended up getting the ignition leads - individual Bosch 8mm - from Super Cheap (I normally hate the place) for $20. I'll probably get some Magnecor ones as these don't have the plug tubes.
For the Intake, I'm looking at the Unifilter Ram Tubes. Any one got an opinion on these trumpets? Any other local suppliers?
Here's some pics. I hadn't quite finished the wiring at this stage, but you get the idea...
Now I just have to get it tuned properly.....
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Location:
newcastle
Registered:
January 2004
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Re: Psychofox's AE86 - 20V Conversion 95% Complete
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Mon, 24 October 2005 11:44
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so ur using the 4age or the 4ac water pump setup.looks good,personally i didnt drill throw the head,dont like the idea.but if it works then yeah go for it,
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Location:
S.E suberbs, Vic
Registered:
December 2003
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Location:
Wollongong, NSW
Registered:
April 2004
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Re: Psychofox's AE86 - 20V Conversion 95% Complete
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Tue, 25 October 2005 02:18
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I didn't drill the head. The cover for the 20V thermostat housing has a channel cut out of it so the water can flow between the holes in the head.
Sam - very interested in your trumpets...Can you send me a pic?
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