Category: IPRA AE86

This weekend i had a quick little brainfart and decided that, 10 days before the car is off to get tuned, i should make a new airbox. Made it out of fibreglass, and its not quite finished yet, but it looks like it will work well. Ill let the pictures do the talking:

[IMG]http://gallery2.plebeians.net/d/31043-1/IMG_1240.jpg[/IMG]
Firstly, finished building the airbox, so i can figure out where to put the intake.

[IMG]http://gallery2.plebeians.net/d/31047-1/IMG_1242.jpg[/IMG]
Commitment ++. Just cut in half the airbox.

[IMG]http://gallery2.plebeians.net/d/31049-1/IMG_1243.jpg[/IMG]
Refitted so i can figure out where to put the shape of the manifold.

[IMG]http://gallery2.plebeians.net/d/31053-1/IMG_1245.jpg[/IMG]
Bit of aluminum bracing to put the intake snout where it i want it.

[IMG]http://gallery2.plebeians.net/d/31059-1/IMG_1248.jpg[/IMG]
Insert florists foam.

[IMG]http://gallery2.plebeians.net/d/31063-1/IMG_1250.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/31065-1/IMG_1251.jpg[/IMG]
Add one part fibreglass…. or many parts FG.

Just added a little bit of reinforcement to the base tonight and tomorrow after its cured ill be popping it out of the mould to see how its worked.
Its not as good as i had hoped, but it will work for an initial job, ill probably redo it over the summer, but it will be good for now.

Other than that there is buggerall left to do. Add a few coats of paint to the bonnet and guards and a quick retune and we will be good to go racing.

Just a little update on how its gone. Popped it out of the plug tonight, which once i had released the glue on the paper tape it released quite easily. Well most of it anyway. There is still a layer of the foam/hifill primer stuck to the inside of the plenum where the resin has saturated the foam and essentially glued it together. Unfortunately its not completely integrated, so ill have to pull it out.

Anyway, pictures speak louder than words:
[IMG]http://gallery2.plebeians.net/d/31069-1/IMG_1253.jpg[/IMG]
Fresh from plug

[IMG]http://gallery2.plebeians.net/d/31071-1/IMG_1254.jpg[/IMG]
Fitted up, ran out of washers and bolts for the remaining holes.

[IMG]http://gallery2.plebeians.net/d/31073-1/IMG_1255.jpg[/IMG]
Closer

[IMG]http://gallery2.plebeians.net/d/31075-1/IMG_1256.jpg[/IMG]
Other side

In addition while i was already all itchy from fibreglass i rewrapped my extractors and then went one step further and made a heat shield for them too:
[IMG]http://gallery2.plebeians.net/d/31077-1/IMG_1257.jpg[/IMG]

Bit OTT? Never.
Bought some heat wrap stuff from Andy San for the oil cooler lines too, plus i might build a little Alu heat shield for that area too.

Thats about it for tonight, as im itchy as all hell from the fibreglass.

As much to keep me motivated as anything, a little update.

Fixed up the coilpack mounting plate, including machining some little spacers for it and adding rivnuts to the plate:
[IMG]http://gallery2.plebeians.net/d/30830-1/IMG_1236_s.jpg[/IMG]

Made up the oil cooler lines to the right length, and testfitted:

[img]http://gallery2.plebeians.net/d/30832-1/IMG_1237_s.jpg[/img]

The one from the cooler to the remote filter isnt particularly nice, but i cant use a 90 off the remote filter because it wont curve down enough to fit through the hole. Ohwell.

And from the front:

[img]http://gallery2.plebeians.net/d/30834-1/IMG_1238_s.jpg[/img]

Oh and redid the brake bias valve lines:
[IMG]http://gallery2.plebeians.net/d/30836-1/IMG_1239_s.jpg[/IMG]
Just a bit neater than they were before.

Very little to do now, just need a new battery clamp as the old plastic had perished and broke in half when i tried to tighten it…
Have to slap in the tailshaft and add oil to the gearbox, plus oil for the engine and put the starter/exhaust/intake on, and its good to crank over and start.

One nice productive weekend over:
[IMG]http://gallery2.plebeians.net/d/30816-1/IMG_1229_s.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/30818-1/IMG_1230_s.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/30820-1/IMG_1231_s.jpg[/IMG]

Popped my new hatch clips on too:
[IMG]http://gallery2.plebeians.net/d/30822-1/IMG_1232_s.jpg[/IMG]

Figured out a nice little spot for my oil filter. Not entirely sure how the lines will go, but im sure ill work that out 🙂
[IMG]http://gallery2.plebeians.net/d/30828-1/IMG_1235_s.jpg[/IMG]

Fixed up the coilpack mounting plate, including machining some little spacers for it and adding rivnuts to the plate:
[IMG]http://gallery2.plebeians.net/d/30830-1/IMG_1236_s.jpg[/IMG]

Made up the oil cooler lines to the right length, and testfitted:

[img]http://gallery2.plebeians.net/d/30832-1/IMG_1237_s.jpg[/img]

The one from the cooler to the remote filter isnt particularly nice, but i cant use a 90 off the remote filter because it wont curve down enough to fit through the hole. Ohwell.

And from the front:

[img]http://gallery2.plebeians.net/d/30834-1/IMG_1238_s.jpg[/img]

Oh and redid the brake bias valve lines:
[IMG]http://gallery2.plebeians.net/d/30836-1/IMG_1239_s.jpg[/IMG]
Just a bit neater than they were before.

Very little to do now, just need a new battery clamp as the old plastic had perished and broke in half when i tried to tighten it…
Have to slap in the tailshaft and add oil to the gearbox, plus oil for the engine and put the starter/exhaust/intake on, and its good to crank over and start.

Started rebuilding the car yesterday. Blacked out the front rad support, and bolted in all the front suspension:
[IMG]http://gallery2.plebeians.net/d/30661-5/1000000071.JPG[/IMG]

Big brake package, and struts in.
[IMG]http://gallery2.plebeians.net/d/30669-5/1000000068.JPG[/IMG]
[IMG]http://gallery2.plebeians.net/d/30657-5/1000000072.JPG[/IMG]

And flushed out the fuel lines and redid all the bolting points to nutserts:

[img]http://gallery2.plebeians.net/d/30653-5/1000000074.JPG[/img]

Ive pulled the brake lines out of my wreck to put into this car, just to neaten things up a bit. Hoping to put all the brake bits in tonight, plus put the diff and fuel tank back in.

Need to have the car back on wheels and ready to be retuned by the 15th before we head off to Malaysia and Singapore.

Brief update:
[IMG]http://gallery2.plebeians.net/d/30514-1/IMG_1199_s.jpg[/IMG]

[IMG]http://gallery2.plebeians.net/d/30520-1/IMG_1201_s.jpg[/IMG]

Should be finished sanding the rest of the car this weekend. Will need a couple of guide coats, but its pretty straight overall, main issue is a few little stone chips around the guards, oh and none of the colours matching, damn 25 year old paint… 😆

Yellow cast in first picture courtesy of 1kw of heat lamps

Now featuring a red engine bay:
[IMG]http://gallery2.plebeians.net/d/30363-2/IMG_1180_s.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/30366-2/IMG_1181_s.jpg[/IMG]

Blue bits are spray putty.
Might be a bit before i can continue on as my air compressor was sounding quite sick last night and then stalled entirely. Will look at that tonight 🙁

Picked up some JDM skirts though, which are the same as the ones homologated in the documentation. Win.

Brief update:
[IMG]http://gallery2.plebeians.net/d/30514-1/IMG_1199_s.jpg[/IMG]

[IMG]http://gallery2.plebeians.net/d/30520-1/IMG_1201_s.jpg[/IMG]

Should be finished sanding the rest of the car this weekend. Will need a couple of guide coats, but its pretty straight overall, main issue is a few little stone chips around the guards, oh and none of the colours matching, damn 25 year old paint… 😆

Yellow cast in first picture courtesy of 1kw of heat lamps

Got a bit more done today.
Finished off the front suspension:
[IMG]http://gallery2.plebeians.net/d/30685-1/IMG_1212_s.jpg[/IMG]

Started rebuilding my wheels, and testfitted them on the suspension:
[IMG]http://gallery2.plebeians.net/d/30711-1/IMG_1225_s.jpg[/IMG]

Got lock?
[IMG]http://gallery2.plebeians.net/d/30701-1/IMG_1220_s.jpg[/IMG]

Picked up new 210lbs springs for the rear:
[IMG]http://gallery2.plebeians.net/d/30709-1/IMG_1224_s.jpg[/IMG]

Refitted most of the engine bay:
[IMG]http://gallery2.plebeians.net/d/30699-1/IMG_1219_s.jpg[/IMG]

And then most of the dash:
[IMG]http://gallery2.plebeians.net/d/30703-1/IMG_1221_s.jpg[/IMG]

Plus the submarine strap:
[IMG]http://gallery2.plebeians.net/d/30705-1/IMG_1222_s.jpg[/IMG]

Also i dropped off some bits to Gavatron tonight and he had his Wilwood Dynalites arrive during the week. They are bloody small in comparison to the RX7 brakes, and they are even smaller than the R32 brakes.
If i had to do a brake conversion again i would definately go with these, they would be much easier to fit, and are just as cheap courtesy of the crap US$.
Here it is dummied up on mine:
[IMG]http://gallery2.plebeians.net/d/30687-1/IMG_1213_s.jpg[/IMG]

Tons narrower too:
[IMG]http://gallery2.plebeians.net/d/30689-1/IMG_1214_s.jpg[/IMG]

Fairly easy stumpy mounting locations:
[IMG]http://gallery2.plebeians.net/d/30691-1/IMG_1215_s.jpg[/IMG]

All around quite a nice caliper.
Overall today i didnt get as much done on the Sprinter due to a massive headache and finishing off the Supra.

Little mini update. First of all i found the photos of that car above:
[QUOTE=takai;279821]Found the original pics, and then mirrored them here:

[url]http://gallery2.plebeians.net/v/cars/random/ae86/martinharjani/[/url]

Pity the pics are still pretty weeny in size, but hey beggars cant be choosers:
[IMG]http://gallery2.plebeians.net/d/30244-1/gallery2Farticles2FToyota20Corolla20AE8620Martin20Harjani2F002.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/30256-1/gallery2Farticles2FToyota20Corolla20AE8620Martin20Harjani2F008.jpg[/IMG]

Unsure as to the charcoal bumpers and whether i like them or not, but the rest of it i do. Will end up doing mine white with a black bonnet and then possibly some red in vinyl. Possibly a cross between Martins and Yates’ TRD colourscheme.[/QUOTE]

[QUOTE=takai;279823]Found a couple of higher res ones too:
[IMG]http://gallery2.plebeians.net/d/30284-1/001fk2.jpg[/IMG]
[IMG]http://gallery2.plebeians.net/d/30287-1/002to9.jpg[/IMG]

Wish people would fix the white balance on their cameras though :([/QUOTE]

So thats probably the colour scheme ill be going with.

As for progress on the car, i stripped out the engine bay on the weekend, and it now looks like this:
[IMG]http://gallery2.plebeians.net/d/30311-1/IMG_1168_s.jpg[/IMG]
Painted the guard inners, rad panel front and lower cowl a nice matt black, and then started bogging up the spare bolt holes in the engine bay:
[IMG]http://gallery2.plebeians.net/d/30329-1/IMG_1174_s.jpg[/IMG]

Gotta give it a sand and then hit it with more 2pak white.

While ive been sick i also fabbed up a little box for the fuel gauge:
[IMG]http://gallery2.plebeians.net/d/30317-1/IMG_1170_s.jpg[/IMG]

Thatll sit in the rear window with a switch so i can check fuel levels.

Also picked up a TRD N2 rear wing copy:

[img]http://gallery2.plebeians.net/d/30332-1/IMG_1175_s.jpg[/img]

[img]http://gallery2.plebeians.net/d/30335-1/IMG_1176_s.jpg[/img]

Will be attaching that and bogging it in after i clean up the rear. Will have to figure out a new boot release though as that will cover the key.

Expect to have painted the engine bay by the weekend, and then be onto bodywork.

Tonight i got a whole bunch of stuff done on the car, predominatly focusing around the front suspension and brakes.
Firstly i replaced the bearings in the hubs:
[IMG]http://gallery2.plebeians.net/d/30130-1/IMG_1142_s.jpg[/IMG]

and then popped new studs in and added the disc locating collars:
[IMG]http://gallery2.plebeians.net/d/30136-1/IMG_1144_s.jpg[/IMG]

After that i machined up some little spacers for the spherical upper hat to sit on, so i could use my spare Cusco cambertops as i had some better nuts for them (still need to get aroudn to machining up some tube nuts for the T3 items)
[IMG]http://gallery2.plebeians.net/d/30142-1/IMG_1146_s.jpg[/IMG]

And voila, assembled:
[IMG]http://gallery2.plebeians.net/d/30145-1/IMG_1147_s.jpg[/IMG]

I then popped it into the car, and added the brakes to it (as its a pain lifting the lot as a whole), and the 20mm bolt on spacer:
[IMG]http://gallery2.plebeians.net/d/30154-1/IMG_1150_s.jpg[/IMG]

All in all it fits quite nicely, no fouling anywhere, and its all quite solid and sound.

Popping a wheel on it revealed just how close the entire setup comes to the wheel:
[IMG]http://gallery2.plebeians.net/d/30169-1/IMG_1155_s.jpg[/IMG]

I think im going to have to get some 25mm spacers for the front and then use those 20mm ones at the rear. The bearings wont be any issue as the rims are +24 offset, but as it is there some of the bolts holding the 3piece wheels together just clip on the caliper itself. Only some of the bolts though, due to the manufacturing differences in the length of the bolts.
All in all i dont think you could run this setup without spacers, finding wheels which would fit in a 0ish offset would be a complete nightmare.

Also today i managed to run around half the city picking up gear and getting stuff done. Amongst that i managed to get the caliper mount helicoiled, which solves that issue, and i also had my radiator delivered:
[IMG]http://gallery2.plebeians.net/d/30163-1/IMG_1153_s.jpg[/IMG]

A nice 2″ alloy radiator, which is absolutely huge compared to the weeny little thing that i had in there before.

Thats about it for now, I currently have to wait for the brake shop to get in a pair of caliper rebuild kits, so i can do that, and then i can assemble those brakes for real, loctite and all.
From there im going to chuck some wheels on it and roll it outside to give it a good wash and then start sanding it back so i can paint it soon.

The engine is ready to go back in soon too, but i think ill probably paint it first and then put the engine in again. Thats about it for now though.

Just a brief update, over the weekend i got the diff back together:
[IMG]http://gallery2.plebeians.net/d/29916-1/IMG_1089_s.jpg[/IMG]

And then today got it back in the car:
[IMG]http://gallery2.plebeians.net/d/29928-1/IMG_1093_s.jpg[/IMG]

While i was at it i popped the steering rack out of the engine bay and started retrofitting that with the new Quaife rack (last one was faulty):
[IMG]http://gallery2.plebeians.net/d/29934-1/IMG_1095_s.jpg[/IMG]

I added some bling to the engine and engine bay too. Firstly my little underdrive alternator pulley arrived:

[img]http://gallery2.plebeians.net/d/29907-1/IMG_1086_s.jpg[/img]

And i decided to put the 2L catchcan that i had for the Supra into the AE86:
[IMG]http://gallery2.plebeians.net/d/29910-1/IMG_1087_s.jpg[/IMG]

Thats about it for now. Gotta finish off the other caliper adaptor, and shorten the struts and convert to coilovers. Moving along at a reasonable pace now. Should have the suspension done during the week i hope.