AE86 Corolla Chassis - Formula Engine - Feels like it's taking forever...!

[packman]

Im sure we can all see the high end cars in your shop and very nice they are to !

But to be honest id be picking the keys up to the Corolla every time !

Fantastic detailed build keep the updates flowing .....

[gorilla1q]

Great project it looks like a great car Could I ask what the exhaust mounting blocks are off?

[BillyEdmonds]

Thanks !

I think the exhaust shop got the hangers here:

http://www.bsmexhaust.com/catalog/se...id=112&mfr_id=

[105Ian]

Fantastic looking project the attention to detail is spot on

[BillyEdmonds]

Wait a second, if it's on this lift ( at the other side of the workshop ) then that must mean it's a drivable car !!

[BillyEdmonds]

Set the toe, tidied up the interior wiring and removed most of the aftermarket audio stuff..





Took her downstairs for a wash....



Dried her and took her for a rip up the alley at work. If you've ever wondered if an AE86 spins 1st and 2nd with only partial throttle the answer is FULL YA IT DOES. I'm guessing I was at most using 2/3 throttle. The engine response is unreal

http://youtu.be/afXKI6CDdpQ

Loved the short drive and then put her back to bed...

[BillyEdmonds]

Set the toe, tidied up the interior wiring and removed most of the aftermarket audio stuff..





Took her downstairs for a wash....



Dried her and took her for a rip up the alley at work. If you've ever wondered if an AE86 with an Atlantic spins 1st and 2nd with only partial throttle the answer is FUCK YA IT DOES. I'm guessing I was at most using 2/3 throttle. The engine response is unreal


http://youtu.be/afXKI6CDdpQ

http://youtu.be/ujRBq5Vg038


Loved the short drive and then put her back to bed...

[v8ian]

WOW, that's the Spaniels Spuds!!!! Full credit to you. Do you have any more pictures of the crank sensor?? I am trying to build a 4age with a retro feel into a Hotrod, Im not too keen on a crank sensor in full view, anything would be helpful

[BillyEdmonds]

Thanks. I'll get some good pics of it for you on Monday.

Interior going back together for the last time. The remainder of the interior panels should be back next week, right around the same time as some very special floor mats !

[BillyEdmonds]

[BillyEdmonds]

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[BillyEdmonds]

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[raymondmarble]

Stunning! The attention to detail on this car is just amazing.

[BillyEdmonds]

Took a trip over to Hasselgren and had him configure my ecu to communicate oil and fuel pressure to the dash. I now have all of the working !! The eagle eyed will notice the battery voltage is far too low for a running engine. That's been fixed since the photo... she now charges properly. Fyi: the Toyota diagram shows the layout from the back of the connector, not the front.
Also removed the fuel pump harness and applied the final heat shrink, or so I thought. Was simultaneously putting the connectors on the harness while talking on the phone ( phone held to ear by shoulder ) to the wife about a friend's baby shower of all things ! Finished up, turned the key and saw every man's fear after a wiring job. SMOKE !! wired the fuckin' fuel pump backwards. Thankfully the harness is ok, I do have a nice crispy ground from the pump to body though. More investigation on Monday.... bollocks. ...

[BillyEdmonds]

Took the day off work to get the wiring mess all taped back up and in place. Also always like the idea of having carbon thread plates so bought a thin carbon panel, some 3m double sided tape and tried it out. I actually like it and for $35 you can't go wrong.







Additionally, I finished the fuel pump wiring repair. I put in a connector instead of simply using butt connectors and heat shrink to make serviceability easier.
The video shows how it sounds inside. The oil temp is incorrect, the dash takes a few minutes to display the character that would make the oil temp show in the 90s, not the 40s.

http://youtu.be/JH60iyvAtzo

The next video will feature a pair of AO48s getting the crap kicked out of them, promise.



Also put on the coil cover



Cleaned up the breather for the oil tank by getting rid of the crappy, ebay catch can. Vent to atmosphere.....



Technically the day ended with some disassembly instead of more reassembly but overall I still feel I won the fight.

[BillyEdmonds]

Only a few panels left and the interior will be completely done.
Drilled out the sheet metal for the center console mounts and used nut-serts since I hate sheet metal screws. Got the same allen screws as I used in the shifter plate and polished them up in the drill.

[BillyEdmonds]

No real updates however I did stop by Hasselgren today to pick these babies up. It's their 1800cc kit for the 4age block. When funds allow I'll get a set of pistons as well. Will tuck these away until it's rebuild time. When complete she'll put out over 270bhp !!
The crank is very lightly used, approx. 800 race miles. Looks like it just came out of the box. Everything else is brand spanking new including the DLC coated wrist pins. He even gave me a spare set of coils. Top result..

[raymondmarble]

270+ from an 1800 is a seriously healthy figure! It would be respectable in a turbo motor! Loving this build

[BillyEdmonds]

Thanks. The 1800 only makes a little more than 270bhp over the current 1600 set up but the torque is the main difference. It's approx. + 40lbs.
The turbo engines start at approx. 325bhp with low boost.

The interior is now 4 panels and a center console away from being 100%. Just wish the fella making the last carbon parts would pull the finger out !

[BIG-G]

like

[BillyEdmonds]

Didn't have a lot of room between the Landrover, tow truck & the kirb but you get the idea. My 1st full throttle run !
As soon as I get the bonnet back from the body shop she's going out for a spin

[lotus]

Very nice stuff.. Can you tell me about the transmission seup? I have a Fat Engineering 1750 cc 4AGE in my Lotus, but it came from a rear engine ( Baja Buggy ) application so I had to make do with a T50..

Yours is a 6 speed?

[BillyEdmonds]

Yes, it's a 6 speed from an is200. If you search for "Leen Gearbox Conversion" you have a nice bit of reading to do. Came on a pallet, assembled and ready to install. Was as bolt in as an oem part would be.

[BillyEdmonds]

Made quite a few changes over the last couple of days, most of which aren't too interesting to see in a photo.
My carbon floor mats arrived, made specifically for the car.
I removed the big clunky battery cut off switch as it was a bit on the unsightly side. Instead I installed a momentary switch with a latching solenoid. Way more sano !
Removed the front wipers as well as motor and linkages as she's strictly a dry weather car.
Removed the rear wiper and installed a magnetic battery tender connector to make battery maintenance even easier. The momentary switch and tender set are both borrowed from the Huayra. I've always loved how they look subtle.
The bonnet is coming back from paint tomorrow so if time allows it's proper road test time !

[raymondmarble]

This is looking fantastic Billy, top job!!

Dry weather only so no wipers? Won't you still need to clean off flies and grease?

[BillyEdmonds]

Thanks !
Even for dry weather they're kind of useless since I haven't had a washer bottle in the car for about 4 years ! Hated the cluttered look....

[barry d]

Love the carbon mats mate

[raymondmarble]

Thanks !
Even for dry weather they're kind of useless since I haven't had a washer bottle in the car for about 4 years ! Hated the cluttered look....

Fair enough then, cheers!

[BillyEdmonds]

Picked up the bonnet & unwrapped it. The inside finish is better than the outside finish of the car !
1st time she's had a bonnet in almost 2 years.
Now it's on & ready for a good drive. Went out & got lunch for the workshop in it. What a hoot ! Drove it 3 full miles with a smile the entire way.....
When I fired it up tp leave the burger place I just saw some heads shoot up thinking WTF is in that thing ??

[5hane]

need more videos of this noise, nice work !!!

[finlay]

excellent build and project !!!!!!!!

[BillyEdmonds]

Thanks fellas..

Sent my strut brace out to be powder coated in black. While I'm waiting for it I polished the nuts, bolts and washers. Also thought I'd have a look and see how carbon fiber washers would look and work where the brace mounts at the struts. Just have to sand the and get a bit of clear on them. Today was supposed to be road test day but 6" of rain put a quick stop to that.






The washers turned out to be a pretty shitty idea so they're gone.

Got this exciting picture from the fella making the carbon parts today. They need one more sanding & they're ready to ship.



Got the strut brace back from powder coating.



Bought a cooling panel to cover the gap behind the grill, unsure if I'll keep it gold or have it powder coated in gloss black. Probably black. We'll see if it makes a difference. I have noticed the engine reaching 90c on fairly regular driving so I turned up the cooling fans & brought them in at an earlier temp ( they start at 71c now & go max speed at 79c ). I may fit better fans ( I have two spares that move a far higher CFM rating ).



Here she is warming up to see if the fans come on at the temp I set. The weather has been a real pisser so no drive video yet. Supposed to clear up by the end of the week. These are the worst storms we've had here in years !

[escortinadriver]

Awesome as per usual....

Cant wait to see some decent drive videos. The laneway was such a tease, although the car alarm was funny...

Shaun

[BillyEdmonds]

Sent the cooling panel and bonnet prop rod out for powder coating. I think I'm technically now finished under there !
With that in mind I heated the oil, fired her up and went for a 28 mile drive ! Very noisey, smell and full of vibrations ( very hard engine and gearbox mounts ) but I loved it.
The video's not the best but it shows open throttle a few times as well as what it's like moving in traffic etc...



Back home for the 1st time in almost 2 years

[raymondmarble]

Fantastic! I sat though all of that video there. I enjoyed the tour of the San Francisco area almost as much as the sound your car makes. She can shift eh!! Great work

[BillyEdmonds]

Thanks Raymond,

In total I did almost 100 miles. Had a note pad so I could jot down things down that need fixing, surprisingly I only had a few items...! What a result. The rattling gear shifter is driving me mad so that's high on the list.

1st fuel stop

[wildo105e]

Had a note pad so I could jot down things down that need fixing, surprisingly I only had a few items...!

Thats what happens when you do a quality build first time

[escortinadriver]

Very nice...

Seems exceptionally well mannered for what is such a weapon.
A real credit to your build.

Shaun

[sellick]

Absolutely love this! Looks like a lot of thought has gone into the engine build. That head looks pretty heavily ported too! Looking forward to more updates!

[BillyEdmonds]

Thanks fellas. I was surprised at just how driveable it is as well.
Most of the interior arrived today. Just waiting for the center console...