mk2 cortina ...sleeper

[d.p.n.s]

Hi all
Just thought i would start a build thread on TS of my old cortina here in NZ
Well last year I sold my race car that I was building and build and sold a few motor bikes and once I sold the last one I want really wanting/looking for another project.
Then one day a mate rang me to ask if I new of anyone that was after a mk2 cortina for $500 I asked around and no one was keen so I thought I would buy it..(thinking if its rotten I'll cut the floor out and dump it on a mx5 or wrx chassis)

After looking at it it wasn't all bad .its mk2 1600 super and has been in a shed since 1988 very little rust and a few dents mainly on the roof as its sat with a few pallets on the roof.
All the door card ,rear seat ,parcel shelf and roof lining are in very good condition..
Looks link its had a wee shunt up the arose at some point and the passenger front gauge has been replaced some time ago.
After replacing a carb gasket and rigging a fuel system I got it to run and drove it up and down the drive..
This is what it looked like the day I got it.
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Now I'm a massive fan of the old school small fords and have had my shear of them but I'm not all about keeping the original running gear and I don't mind putting Japanese turbo engines in them.

I have wanted to build a sleeper for a long time and once this came along I knew this was the car to do it to.4 doors ( roof for the kids) bigger engine bay then the escort and wider.
All my mates keeping asking me when will I sell it as I have a habit of getting 90-99% done and selling them...that's mainly as I enjoy the build more then anything.........but I'm keeping this one.....its mine.

So if your a purest and believe all old school fords should stay original then I'm sorry but this may not be the thread for you but if your like me and enjoy seeing something different then have a read.

Cheers.

[d.p.n.s]

So the 1st thing I did was strip it down have a good clean and check it out.
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All in all I have found 4 rust spots in the chassis .as for the body I'm not going to do anything with it
I want it to look exactly like it does now with all the dents and maid matched colours.

[d.p.n.s]

Like most people building cars this is on a tight budget. So after selling the motor, 4 speed column change box and a 4speed floor change box that was sitting in the boot I had just over a grand to find a motor and box..I wanted a ca18det as I put 1 in my old escort van andthat was a hole heap of fun......but none could be found . so iI decided to look on trademe
( NZ version of eBay) for motor and box ,local for a grand.
And that's when I found this
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Its a gen 3 Toyota 1g GTE from a 1990 supra so basically a 2.0 inline 6 cylinder twin turbo motor makes 210hp from factory and can rev to 10200 rpm. But like most Toyota motors de-tuned from factory.
Its an old motor but pretty strong . not much after market stuff still available but things can be made. It was from a factory manual so came with flywheel, p.plate , clutch and most importantly the w57 all alloy 5 speed ( couldn't find 1 for my last build under $800 ) so bargain.

[d.p.n.s]

Now I know from some cars I've seen that the 302w v8 can be put into a mk2 Tina without cutting the firewall and I also know from googling the 1ggte that's its only 15mm longer then the 302w so it should fit with out cutting the firewall............ Well no.
I removed all of this from the motor to fool myself into thinking is smaller than it actually is.
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Then I bolted the box up and sat it next to the shell to do some measurements......... Oh dear
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So after measuring everything I could fit in in the engine bay without cutting the firewall but there wouldn't he any room for a radiator let alone anything else. And the gearbox tunnel would have to be cut out for the gearbox so with that in mind I thought stuff it I'll take some of the tunnel and firewall out and go from there.

[2010deathproofcapri]

Nice choice. Something a little different. There are actually a ton of gte aftermarket parts! Squeeze some good power out of them too. Interesting. I'll keep watch

[d.p.n.s]

Nice choice. Something a little different. There are actually a ton of gte aftermarket parts! Squeeze some good power out of them too. Interesting. I'll keep watch

Yes I'm glad I chose this set up now..parts are still out there in nz but are getting harder to fibd and the guys that are into are hording the parts as I would.

[d.p.n.s]

Firewall and tunnel cut out
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And got the engine and box in the hole and started leveling things up
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It was around this time that I realised the cam cover on the intake side isn't going to work asthe oil fuller is so huge and iI could make the firewall around it but it would look shit .so I bought a set of cam covets from a non turbo and they look so much better
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[d.p.n.s]

Next step after getting it all in place and cutting more firewall and tunnel out so I could move the motor back ( also leave room for a 2jzgte to fit as another option down the road) is to start with the mounts.
I started with the gearbox mount as there is a chassis rail that runs from left to right of the car threw the gearbox tunnel and I had to cut that out for the new gearbox.
So I made habit to be welded in to replace the cut out part and also be able to bolt the gearbox mount to.
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Gearbox mounting plate
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Bolted together
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[d.p.n.s]

On to the cross member.... I have read and looked at a lot or rack and pinion options and decided to go mostly with the cortina stuff mainly not to mess with the steering geometry.
So will use cortina cross member ( modified) cortina TCA,s cortina sway bar and cortina struts..
There are also a lot of different steering racks I've seen used like Toyota starlet mx5 sect.
But with going cortina and escort I can keep the costs down.
So I will use a escort steering rack but it will be mounted Behind the cross member ( get to that at a later date)
So to get the engine mounted for now I cut the engine mounts from the cortina cross member and bolted it in place.
I cut the middle section out and braced it behind to be able to place the engine in ( for about the millionth time) and then made the engine mounts.
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Once I fabricated everything needed in the engine bay then I'll remake the cross member for now I just needed to get the engine mounted and in place to make everything else

[d.p.n.s]

Also while I'm on the cross member part . it had to be modified as the turbo sump was right in the middle I did swap it out fro a non turbo sump witch is a front bowl sump and that allowed more room but a little less I'll capacity..... So I didn't really want to mess around with the sump.

[d.p.n.s]

Once I had the engine and box in place I started to make and tack the fire wall in place.
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Will be fully welded once the engines back out

[d.p.n.s]

The factory rain turbo setup was never going to work as they are pretty shit and not designed the best.and the back turbo had nmo room what so ever.
So I got my hands on a single turbo manifold and modifyed it to fit and work the way I wanted.. I then got a t04e turbo and bolted it on.
I had to remove and Mount the tail waste gate in a post ion that allowed me to remove and fit the manifold with out hitting anything.
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Next came the intercooler and I used a slightly smaller one on my escort and had to cut lots out to fit it......didn't have to cut a thing to fit this in there.just holes for the piping.
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Once its all black behind there it should be hidden nicely
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Once that was in place I decided to make the air box/intake for the turbo..didn't want to go the old pod filter way so I bought a evo 5 k&n panel filter (good dimentions) and made a air box
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Then I made the cold side intercooler piping
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And that's as far as I have got.... Cheers for having a read.

[escortinadriver]

Love it so far.....

Going to be a weapon.

Shaun

[2010deathproofcapri]

Fucking hell mate you didn't hang around. Good progress! It's rewarding to see the engine sitting in the bay. Looks like it's going to be a tidy swap. Good for you mate

[nmhbodyrepairs]

love this nice to be different

[CrazyPolak]

Cool

[d.p.n.s]

Cheers for the comments lads.
Things will slow down as money dictates.

[d.p.n.s]

I made the hot side intercooler piping today and the brackets to bolt the air box in.
All in all I'm happy with it so far and will only need 4 silicon joiners from air box to intake fannymold.
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[Seanymk2]

Love the pipe work it's so much neater without silicone hoses everywhere, top job!! Look forward to seeing it finished

[d.p.n.s]

All 4 silicone joiners in place and that's the air system all done from air box - turbo - intercooler - inlet manifold.
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[d.p.n.s]

Not much of an update .
Got to the point that I was going to make the down pipe from turbo but there's not much room in that corner of the engine bay so..........engine and box and everything came out so I can make the steering just to see where I can put the down pipe.

On another note found a diff I've been after for a while...hilux diff have been done to death over here and are so expensive now..and all the falcon diff need to be shortened and an LSD carrier for the escort rear end is moon beams..

So after looking around and trying all sorts of other options I found a 76 Volvo 264 at the local wreckers spent the morning in the mud and rain pulling it out ..
You guys will know the Volvo diff more then most of here.
Just under 1400 overall length , disc brakes ,strong.
And being a1030 diff the dana30 parts are off the shelf here for LSD and locker parts.
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Cheers

[madragon199]

Cool great project...nice read...will go well when its done....mark

[d.p.n.s]

started making the steering set up.
i wanted to keep the steering geometry as factory as possible but use a escort steering rack but behind the cross member .so i flipped the car on its side and bolted all the cortina parts back in place and ran a string line from steering knuckle to steering knuckle .
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made plates to bolt to the chassis rails and use the holes for the out cortina steering box.
then cut down a escort crossmember and bolted the escort rack in and got it all in line and ended up with this
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\took it to work and made some bracing so it still cleared the sump and kept everything where i wanted.
ended up with a new cross member/k member
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thats it for now .we have just moved so once the garage is all sorted ill get back into it.
\cheeers

[d.p.n.s]

just mounted the oil cooler ....tight as a nuns nasty in there.
but once the inter cooler is black it should be to noticeable
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[Graham]

nice work

[rwd2ltrfiesta]

That's awesome, you leaving the exterior as is??

[raymondmarble]

I've only just read this thread. Fantastic work and great fabrication! I'd never heard of a 2.0 turbo 6pot in a Supra, I only knew of the 3.0.
Brilliant project, watching this closely now

[d.p.n.s]

Yes that's the plan ....just fix some wee rust spots and a few other things.

[d.p.n.s]

I've only just read this thread. Fantastic work and great fabrication! I'd never heard of a 2.0 turbo 6pot in a Supra, I only knew of the 3.0.
Brilliant project, watching this closely now

Yeah its from a 1990 suora but they did a 1ggeu (na) 1ggze ( supercharged) 1ggte (twin turbo)
Cheers for the comments

[sierra1off]

Keep posting.

Love a sleeper

[d.p.n.s]

Well its a new year and I thought I should do some work on the old girl.
1st time I've tryed the new cross member since making it and its a nice fit.
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Then mounted the escort steering rack and the to is a good fit with full movement and nothing hitting...so far
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Then I put spear motor and box in and that was not straight forward at all....thanks to the shut loads of rafters in the garage roof ....so close together and low.
Ended up leaving the motor hanging while I lifted the front of the car so the wife could take the axle stands out so the car was low enough.
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Once all in its good to see plenty of room around the master pipes at the rear of the motor and also around the steering joint.
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Now I can continue making shit.
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That's it for now

[madragon199]

great work...great fab...keep posting ,,keeps us all motivated...cheers mark

[d.p.n.s]

Ford laser tx3i turbo vented discs and Volvo 4 pots.
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[davblue]

Nice mod on this car there

[d.p.n.s]

cheers man

[d.p.n.s]

great work...great fab...keep posting ,,keeps us all motivated...cheers mark

thanks man

[d.p.n.s]

I wanted to lose the old distrbutor setup as its was to big and in the way and also wanted to run wasted spark setup with the ecu.
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The 1G range came in turbo , supercharged and N/A versions and a lot if the parts are interchangeable.
So here's thhe CAS from a 1ggze (supercharged) compered to the 1ggte ( turbo)distributor
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But as you can see the CAS wouldn't fit.
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This was due to the 1ggte thermostate housing being just to big as it has all the pipes for heater and coolant feeds and returns for the factory twin turbos.
So I found a housing from a 1gge (N/A) here's the comparison
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The housing was a direct fit and bolted up to the heater pipe once I drilled the top 2 bolt holes out to 7 mm as the 1ggze bolts are thicker
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So now bolted on
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But the CAS still wouldn't fit
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So I thought that maybe carefully milling the top eadge of the housing without going threw the housing would do the job.
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Oh by the way here's my milling machine
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And now it all fits with heaps of room.
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That's all for now.
Cheers
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[Graham]

good stuff thanks for the up date

[madragon199]

well found..my kind of engineering....keep updating...cheers mark

[d.p.n.s]

Cheers guys