Category: IPRA AE86

Had a few hours free today, got started on the brake master box:
Cue one chunk of firewall and spare pedals:
[IMG]http://gallery2.plebeians.net/d/32533-2/1000000911.JPG[/IMG]

Made up a box for the new masters to sit on:
[IMG]http://gallery2.plebeians.net/d/32517-2/1000000913.JPG[/IMG]

And will make up another one tomorrow to sit on the inside that i can weld to stuff 🙂
[IMG]http://gallery2.plebeians.net/d/32525-2/1000000914.JPG[/IMG]

Going decently sofar. Have to wait for my balance bar to be sent down from my parents place, but that should arrive soon.

Oh and checked what the new brake package will look like:

[img]http://gallery2.plebeians.net/d/32529-2/1000000909.JPG[/img]

Found some photos which have been put up on Facebook from Round 2. Thanks Rosalie:
[IMG]http://gallery2.plebeians.net/d/32508-1/247817_10150199272237562_605602561_7122831_1293334_n.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/32512-1/249940_10150199270897562_605602561_7122806_2514174_n.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/32510-1/249795_10150199268362562_605602561_7122750_1934235_n.jpg[/IMG]

Oh and this one:
[IMG]http://gallery2.plebeians.net/d/32506-1/247473_10150199270352562_605602561_7122793_5314116_n.jpg[/IMG]
Trying rallying out for style…. actually trying to figure out where the brake point was, and getting the pads hot enough, and failing dismally.

I swear nothing on this car goes easily.
This weekend i went to install the pedal box i bought from Ireland. I went for that pedal box rather than fabricating my own mainly because they stated on their website:
[QUOTE]Mounts on existing points with external girling cylinders[/QUOTE]
Well, their idea of mounting on existing points in Ireland is cutting and boxing the firewall.
[IMG]http://gallery2.plebeians.net/d/32473-2/IMG_0879.JPG[/IMG]
[IMG]http://gallery2.plebeians.net/d/32476-2/IMG_0881.JPG[/IMG]

Pedal box is nowhere near fitting, and according to them “It is impossible to make it use the original mounts and for neatly into the bulk head”

Apart from the fact that Bill’s pedal box seems to do that requirement pretty bloody well:
[IMG]http://gallery2.plebeians.net/d/32482-2/twincylbrake.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/32479-2/ae86twinmaster.jpg[/IMG]
Oh and wait for it, it doesnt need any big box cut out of the firewall and a new one welded in either:
[IMG]http://www.skynet.ie/~eireae86/DANCOFRP/Small%20Pics/Shell%20Prep%20-%20Seam%20welded%20AE86%20bay%20-%20etch%20primed%202.jpg[/IMG]
Unfortunately RallyDesign dont seem to make that pedal box anymore.

Pretty bloody pissed off at the moment about the whole deal, given that with the IP regs cutting and boxing the firewall would be pretty bloody dicey.

Looks like im going to have to make my own pedal box now :S

[IMG]http://gallery2.plebeians.net/d/32467-2/1000000871.JPG[/IMG]

Full edo spec for you all.

Well that was a weekend which had its memorable bits, and some completely forgettable bits. Went out in Quali and found a pretty greasy track, got tapped in the drivers rear and spun around clipping Ledger on the way. Buggerall damage to both cars, just a smashed parker and bent tow hook on mine, and some paint from his.
At some point during the session the water temp gauge decided to go the way of the buffalo and jam at 80deg, subsequently i spat the fan belt somewhere down near Clubhouse. So im happily hammering around the track until the cooldown lap when the gauge magically decides to start working again and give me a brief glimpse of the fact that the coolant is around 140deg and rather unhappy. Got back to the pits and then the gauge gave up the ghost entirely and jammed off the clock 🙁 Also for some reason my passenger rear tyre pressure was 10psi more than the drivers rear when hot. Same starting pressures though. Very bloody odd and made for a rather skatey ride.

Got a new fan belt and fitted that up, and then got out for Race 1. Immediately noticed that something felt odd and that the engine was down on power, but it wasnt throwing any nasty warning lights at me, and oil pressure was still fine, so i soldiered on… to a 1:31.6… pretty clear that something was wrong. In addition as the track was now dry i quickly figured out that while the brakes were slowing me down, they certainly wern’t doing their job to the best of their ability, because despite being hard on them with my butt almost out of the seat i couldnt lock the fronts. Power was down quite significantly with the top speed into Northern being 35km/h shy of my usual.
After lunch i did Race 2 as well, just to complete my OLT so i could get my proper licence rather than having to run on temporary ones. Managed a 1:30.6 in that race. Off the start line i set the lap timer G-sensor thingy to a “powah test”. Yielded a stunning 65hp. Not sure how accurate it was as i wasnt able to give it the full distance it wanted, but regardless, thats through 3 gears, so its probably a decent enough guesstimate.

Packed up after that race yesterday and brought it all home. Havnt had much time to do any work on the car today, but i did a quick compression test and got:
1: 175psi
2: 70psi
3: 85psi
4: Dead compression tester

Arrrghhh, more stuff dying. Ohwell.

So from this weekend i now have the following to do:

1. Build new engine, pretty urgent now.
2. Install pedal box
3. Make caliper brackets for Wilwood calipers rather than the RX7 setup
4. Replace coolant temp gauge (and probably Oil temp too since they are the same brand/age).

Ohwell. I have RaceChrono data coming soon too, overlaid on video from the Contour.

On the up side though i have my OLT done, and the car is handling reasonably well, once the tyre pressures were sorted (dumped and refilled the air, perhaps something in the valve). Was a good bit of fun too. New engine time 😀

Took 45mins to get the engine in last night and hooked up, everything except for the exhaust and starter.
That was because i bought one of these previously:
[IMG]http://gallery2.plebeians.net/d/32337-2/1000000815.JPG[/IMG]

Its a firewall lug for the starter and alternator and should speed up the removal and reinstallation of the engine even more than i could before.
So after 30mins work this morning fitting the new starter cables and then the exhaust manifold over the top of the starter it looks like this:
[IMG]http://gallery2.plebeians.net/d/32345-2/1000000816.JPG[/IMG]

Starts and runs quite nicely, so the new crank seems to be doing its job well. Saturday seems possible now. Just have to tidy up some minor stuff on the car, and finish fitting the brake controller to the Hilux.

Just a tiny update. Ive been redoing the wiring in the car. Pulled out the old stuff:
[IMG]http://gallery2.plebeians.net/d/32273-2/1000000760_001.JPG[/IMG]
All back from when i only had red wire to play with. But now ive set about getting the new Ez-Wiring kit into the car. Stripped out all the unneeded wires and its pretty much ready to go:
[IMG]http://gallery2.plebeians.net/d/32277-2/1000000759_007.JPG[/IMG]

Just needs a bunch of zipties and then laying out in the car and finally soldering it all up. Not too many wires though, only about 50 or so 😛

In bigger news though i picked up a rather sweet set of wheels for the car too:
[IMG]http://gallery2.plebeians.net/d/32225-2/1000000774.JPG[/IMG]

Set of Lineasport Utmosty, which are Compomotive licenced wheels but made in Japan. Pretty hot, and fit perfectly over the brakes. Beautiful size and offset too, its like they are just made for the car 🙂
[IMG]http://gallery2.plebeians.net/d/32213-2/1000000777.JPG[/IMG]

Minor update. Finished off the wiring tonight:
[IMG]http://gallery2.plebeians.net/d/32313-2/1000000796.JPG[/IMG]

Still a bit messy, but at least everything is labelled now, and i shouldnt have too many issues with figuring out what goes where etc if i need to modify it. Plus the switches are now decent quality and amperage ones rather than the little microswitches i was using before.

Last night i pulled the crank out of a spare engine and popped it into the engine which busted the flywheel:
[IMG]http://gallery2.plebeians.net/d/32297-2/1000000792.JPG[/IMG]
That should keep me going until TK finishes off the head for the new engine.

Also, painted my wheels:

[img]http://gallery2.plebeians.net/d/32293-2/1000000785.JPG[/img]

White plus a bit of halogen yellow from the heat lamps.

And decided to put a bit of bling on the headlights as the only heat-resistant covering i could get for the headlights (to comply with Sched.B) was yellow:
[IMG]http://gallery2.plebeians.net/d/32317-2/1000000794.JPG[/IMG]

Need to put the dash and engine in tomorrow night, and get tyres swapped onto the Lineasports. Hopefully all will be fine for a practice day on the weekend, provided its not pissing down with rain.

Just a little update. Not much has outwardly changed on the car since the last track day. I didnt make it to the state round as i didnt want to be spewing oil all over the track, although it seems that someone else did that for me.

In the mean time ive stripped down my spare engine to just a block and bits and delivered it all to TK along with my shiny Wiseco pistons and Belfab rods. That should be a goer soon, although im always tempted by these cheap 3SGTEs and BEAMS which keep coming up.

Anyway, the big moment of insanity has come in the form of a pair of Wilwood calipers and trying to squeeze 298mm discs under 15″ wheels. Tonight i quickly borrowed the BA Falcoon discs from my Supra and testfitted:

[img]http://gallery2.plebeians.net/d/31229-1/IMG_1277_s.jpg[/img]

[IMG]http://gallery2.plebeians.net/d/31233-1/IMG_1279_s.jpg[/IMG]

Still needs the 25mm spacer with those wheels as they curve back a fair way. But i think i might be able to get away with not needing a spacer with other designs of wheels.

Its still pretty tight though:
[IMG]http://gallery2.plebeians.net/d/31225-1/IMG_1275_s.jpg[/IMG]

Thats about it for now, ill get started on rewiring the car soon, but for now it sits dormant… like this:
[IMG]http://gallery2.plebeians.net/d/31219-1/IMG_1272_s.jpg[/IMG]

Oh yeah, these photos got snapped of the car on track:
[IMG]http://gallery2.plebeians.net/d/31111-1/72252_445397188842_566963842_5386047_7725716_n.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/31113-1/67407_445397243842_566963842_5386048_3937216_n.jpg[/IMG]
Thanks Svenmate.

Also this got recorded by Sophie at the track. Its actually a video of Davey, but it gives you a good idea of what the car sounds like.

[youtube]Je6_VcBTp2Y[/youtube]

[QUOTE=the buttonman;840894073]a few i snapped before explosion:
[IMG]http://i170.photobucket.com/albums/u279/helbrandt_grimm/AE86%20annual%2010/IMG_3232.jpg[/IMG]
[IMG]http://i170.photobucket.com/albums/u279/helbrandt_grimm/AE86%20annual%2010/IMG_3231.jpg[/IMG]
[IMG]http://i170.photobucket.com/albums/u279/helbrandt_grimm/AE86%20annual%2010/IMG_3229-1.jpg[/IMG][/QUOTE]

So… uh… BANG.

Wasnt the engine in the end though. Ended up being the flywheel. Got the engine out and the clutch off and it looked like this:
[IMG]http://gallery2.plebeians.net/d/31095-1/IMG_1258.jpg[/IMG]

[IMG]http://gallery2.plebeians.net/d/31097-1/IMG_1259.jpg[/IMG]
Closer inspection

[IMG]http://gallery2.plebeians.net/d/31101-1/IMG_1261.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/31103-1/IMG_1262.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/31105-1/IMG_1263.jpg[/IMG]
And off

Did some damage to the bellhousing too:
[IMG]http://gallery2.plebeians.net/d/31099-1/IMG_1260.jpg[/IMG]

Currently my plan is to get the head off and see if there is any damage in the engine, but i suspect not. Feels ok when turning over by hand. If no damage then ill pop the head onto another spare short bottom end and race that (with a limited rev range) next weekend before rebuilding over the summer.

More pictures to come from Mallala, and the week leading up to it.