Consolidated AE92 RS-X (nee SX-Z, SX) build

[PooJou]

Hey guys,
I figured I'd put something on here, as I'm finally getting around to fixing/improving the corolla.
(as you can see, this is takai's old car)
Here are the current specs:

http://www.users.on.net/~scheah/images/satrip20.jpg
quick hit list:
AE92 smallport 4AGZE
165mm HKS pulley
Large FMIC
Uprated superstrut brakes + GT4 rotors

http://www.users.on.net/~scheah/images/enginebay.jpg

As you can see, there isn't much room in there at all - Basically what prompted this sudden acitivity was my need for airconditioning, which atm. is impossible to implement due to the FMIC sitting bang smack in between the headlights, taking up valuable AC condensor space.

Pondering this, we have figured out this list of "things to do"
1) Move the pod filter to sane location - pretty much where the oil catchcan currently resides (just out of picture to the right of the battery)
2) remove the oil catchcan (doesnt seem to do much)
3) relocate the battery to the rear of the car
4) Complete the Cold air intake for the pod filter
5) remove the front mount and it's massively long tubing
6) purchase full WAIC setup from a Subaru Liberty RS Turbo (done!)
7) modify aforementioned WAIC setup to suit the corolla

So i've got a 79,000km WAIC setup from a Liberty RS coming sometime this week (consisting of intercooler, radiator, pump and lines + electronics) and will be figuring out how to mount everything etc. possibly this weekend.

CAI stuff minus some odd ends from jaycar

http://www.users.on.net/~scheah/images/CAIstuff.jpg

For thos who don't know what i'm working with in the Intercooler department:

http://www.users.on.net/~scheah/images/LibertyRS%20Bay.jpg



Oh and, yeah, it was dubbed RSX by my mate, SX-Z was takai's old moniker for it

[PooJou]

Went to get the WAIC setup from one of the guys off the RSLC forums today (thanks!) - he had a bit of a hard time extracting it from the car it was on lol. Low milage so the pump should be in ace shape - 79,000km

http://www.users.on.net/~scheah/images/RSstuff01.jpg
Box Of Stuff!!

http://www.users.on.net/~scheah/images/RSstuff03.jpg
The Pump (notice, 1/2" inlet/outlet... 12v... Swiftech MCP655 mod anyone?)

http://www.users.on.net/~scheah/images/RSstuff04.jpg
I Think Nippon denso make EVERYTHING

http://www.users.on.net/~scheah/images/RSstuff06.jpg
Radiator for the water - Looks like two bigarses' put together

http://www.users.on.net/~scheah/images/RSstuff07.jpg
SUBARU INTERCOOLER TURBO! - outlet is 2.75" - inlet is 2" - very odd

http://www.users.on.net/~scheah/images/RSstuff08.jpg
Interior view of the inside of the WAIC

http://www.users.on.net/~scheah/images/RSstuff10.jpg
Underside of the intercooler - note 2" turbo to intercooler pipe

http://www.users.on.net/~scheah/images/RSstuff11.jpg
Water outlets

http://www.users.on.net/~scheah/images/RSstuff12.jpg
Better view of the inlet pipe - everything before the clamp is plastic (ie. going to be removed) the rest is some kind of odd alu alloy or steel?

Anyway, Kinda excited now, - gotta make everything fit !

[PooJou]

Car has just returned from Norm down at Norm's Auto-Air in Ringwood. He had to revert to manual control because the climate control was too much of a mess to work out.

Return to manual control
http://www.users.on.net/~scheah/images/IMG_5497.jpg

Aircon condensor and large fan in the spot where the front mount intercooler used to sit.
http://www.users.on.net/~scheah/images/IMG_5494.jpg

McBodgy temporary fix to move the car around - no intercooler means the car cannot be wrung out - unless its a cool day. However, with the introduction of this, I've noticed that all of the idle seeking issues i had with it originally have disappeared and the car has become far more responsive (or so my mum reckons) - Off throttle lag has been eliminiated. Hopefully the extremely short WTA IC setup should net similar gains.
http://www.users.on.net/~scheah/images/IMG_5496.jpg

I also trial fitted the WTA radiator and it JUST fits between the AC fan and the front bar - wouldn't want to get into an accident with it there tho, oh well haha.
http://www.users.on.net/~scheah/images/IMG_5499.jpg

Les from exhaust worx came round today to have a squiz and he reckons it's an easy fit, all that needs to be done on my end is a battery relocation + possibly getting rid of the catchcan. Aiming for an early january finish!

[PooJou]

UPDATE:

Relocated the battery to the boot - was running 4ag cable, but we figured 4ag was a bit... small... so off to jaycar to spend some obscene amount on chunky arse 2ag cable. Running it again was alright, as my mate found another hole for us to run to. All that's left is to vent to air inside the trim, and a bit of a tidy.

Intercoolar ahoy!
EDIT: Pics

BEFORE:
http://www.users.on.net/~scheah/images/enginebay.jpg

AFTER:

http://www.users.on.net/~scheah/images/DSC00133.jpg

http://www.users.on.net/~scheah/images/DSC00134.jpg

This is going to be boxed up later - car is not being driven atm so it's not a problem.
http://www.users.on.net/~scheah/images/DSC00135.jpg

The boot! battery will vent to air in the hole to the right of the battery - it's bolted (the battery) through 18MM MDF.
http://www.users.on.net/~scheah/images/DSC00136.jpg

Ghetto hold down

http://www.users.on.net/~scheah/images/DSC00137.jpg

Earthing and vent
http://www.users.on.net/~scheah/images/DSC00138.jpg

Current ride while car is off the road: :D

http://www.users.on.net/~scheah/images/DSC00139.jpg

[tooch]

You might want to look into getting a sealed battery (optima, odyssey, etc), as it's TECHNICALLY illegal to have a regular battery in the car's cabin. (But who am I to judge when it comes to legalities on a car :D )

Looking good though mate, interested to see how you go with the Liberty W2AIC setup :)

[JP]

for the battery relocation cable, you can run it out the loom hole on the passenger side of the bay near the battery tray. Then cable tie it onto the loom that runs up inside the guard, and through the very large grommet that goes to the interior kick panel on the passenger side ( grommet is blue from memory, even has a nipple that can be cut off to run the 2GA cable through perfectly).

From there it's a nice easy run for the cable up the passenger sill in the plastic loom section to the rear of the car.

You can also get a nice ceramic distribution post at most good autoelectrical supply stores to bolt in the bay and connect the cable and fuse box to, neatens things up nicely.

A pic of one of the ceramic posts I used in my old turbo KE70 is here: http://www.rollamods.com/gallery/posv3/POSv3_57.JPG

Jason

[PooJou]

UPDATE:

I'll let the pics speak for themselves - turns out the clutch was a 3 puck button and it had a bent pressure plate so.... yeah... had to be replaced with an Exedy HD - I have chasers in west melbourne to thank for all this work.

Idea is due to Rage who also has an RS lol.

Need to figure out the best way to either move that pod or get air to it now... hmmm...
Oldest:

http://www.users.on.net/~scheah/images/enginebay.jpg

Next Oldest:

http://www.users.on.net/~scheah/images/DSC00133.jpg

The New Hotness:
http://www.users.on.net/~scheah/images/wta02.jpg

http://www.users.on.net/~scheah/images/wta01.jpg

http://www.users.on.net/~scheah/images/wta03.jpg

http://www.users.on.net/~scheah/images/wta04.jpg

[JP]

that looks excellent!

[PooJou]

New Plates coming - POOJOU

[takai]

Heh, certainly looks different to when i had it.
Get it dynoed at Bennica next dyno day.

[MR 1JZ]

nice rimz dawg...

looks good...man that car did some awesome skids :P

hahaha

[old_mr2]

how much did you pay for the piping? Looks hardcore!

[PooJou]

So these came in the mail yesterday
http://www.users.on.net/~scheah/images/plates.jpg

:bowdow to my gf lol

[PooJou]

So I have approximately 2 weeks to go till my suspension is over and I leave that whole sorry saga behind :)

Updates on the car - as mentioned above, the intake is yet to be reversed, as I tried modifying the stock intake pipe and it fouls far too many random objects on that side of the TB.

One of the kind members of toymods has machined up a flange for me so Simboo and I can weld the intake pipe directly to the TB

http://www.users.on.net/~scheah/images/flange.jpg


When it arrives I will update again!

[PooJou]

So the flange arrived, holes were a little off, but will be ground out a smidge (my own fault)

Have also picked up 3 X 2.25' mandrel bends, one with a flare to 2.5" at the end so my pod filter sits nicely on it.

Pics are as follows:
http://www.users.on.net/~scheah/images/pipes01.jpg

http://www.users.on.net/~scheah/images/pipes02.jpg

Also, i picked up a sub off the forums - it's an Infinity Kappa 100.se - 10inch... 250watt RMS i think, possibly more lol

http://www.users.on.net/~scheah/images/sub01.jpg

Tomorrow is anzac day and the day Simboo and I will start hacking and welding up the intake.

Still need:
- battery
- new oil
- new rad fluid
- fix my dash lights
- sub box

[PooJou]

So after a bit of cutting, a bit of welding, a bit of sanding and a bit of painting, we have this:

http://www.users.on.net/~scheah/images/intake04.jpg

After i make my trek out to vicroads kew headquarters tomorrow, I'll come back and bolt the new intake on, and start her up for the first time in oh 1.5 months? lol.

Still to do:
- Change oil (Wednesday i guess)
- Change rad fluid (also wed)
- change WTA IC fluid (see above 2)
- Fix Dashlights (see above 3 :))

[PooJou]

OK - many thanks to simboo again :)

http://www.users.on.net/~scheah/images/intake06.jpg

http://www.users.on.net/~scheah/images/intake07.jpg

Compare the very before and after shots:
Before:
http://www.users.on.net/~scheah/images/enginebay.jpg

After:
http://www.users.on.net/~scheah/images/intake05.jpg

[Silly Rabbit]

...i now see what you mean when you say there is no more room left under the bonnet!! :D.....good work.

[Talasas]

Man, that cooler is the best thing to happen to a GZE, it's amazing. Top work.

[PooJou]

The car has come back from the panel beaters with the large spots of rust above the windscreen fixed.

http://www.users.on.net/~scheah/images/norust.jpg

The car had a large exhaust leak coming from the flex pipe - that has been repaired also.

It seems the last thing to do is to get it tuned again.

Will get pics of the thing with the grille re-attached in all it's glorious whiteness :thumbup:

Note: will fix wonky front bar... and that front quarter panel... when I can be bothered..
http://www.users.on.net/~scheah/images/frontquarter.jpg

http://www.users.on.net/~scheah/images/rearquarter.jpg

http://www.users.on.net/~scheah/images/ricerview.jpg

http://www.users.on.net/~scheah/images/arseshot.jpg

Glory shot of large brakes + small car

http://www.users.on.net/~scheah/images/brakes.jpg

[PooJou]

So I made an appointment to see the doctor today - doctor DRIFT that is! HOHO i'm so funny lol.

Anyway, went over to the westside so sam could work his magic - here be some pics.

http://www.users.on.net/~scheah/images/tune01.jpg

http://www.users.on.net/~scheah/images/tune02.jpg

http://www.users.on.net/~scheah/images/tune03.jpg
Dr. Drift (sam) in the red on the phone

http://www.users.on.net/~scheah/images/tune04.jpg
Driftdoggah - Keira

Results are as follows:

http://www.users.on.net/~scheah/images/Drdrfit01.jpg

http://www.users.on.net/~scheah/images/Drdrift02.jpg

Comparison of the old tune, baseline tune and new tune.


116.2FWKW - not bad for a mildly boosted 1.6litre :)

[PooJou]

Just had my new steering wheel dropped off by the courier

Momo - Competition - I know, I'm not a big fan of the yellow MOMO but the previous version didn't have that - nothing a little black texta can't fix!

I got it because
1. perforated leather
2. my old wheel was a knock off of it, so they're exactly the same size/shape wise - momo wheel weighs a frakload less tho!

http://www.users.on.net/~scheah/images/momo01.jpg

http://www.users.on.net/~scheah/images/momo02.jpg

http://www.users.on.net/~scheah/images/momo03.jpg

[MR 1JZ]

thats real purdy mate!

[PooJou]

Thanks for all the positive comments guys!

So the car is booked into Ringwood Performance Exhausts to get a hi-flo 2.5" cat put in - this should be the 'final' step in the exhaust setup - I never realised the exhaust was cat-back till recently.

[takai]

Its not quite cat back. Its a full system in 2 parts.
The extractors are Hurricane brand 4-2-1, with a 2.5" outlet, and the flexpipe similar back to the cat.
The exhaust rearward of the cat was replaced when i upgraded to the GZE as it was a 2" exhaust, and was also noisy as all feck.
The new section was done at Ringwood in 2.5" with a Lukey SuperTurbo muffler.
The reciept will be in that BIG file of documentation.

[PooJou]

Its not quite cat back. Its a full system in 2 parts.
The extractors are Hurricane brand 4-2-1, with a 2.5" outlet, and the flexpipe similar back to the cat.
The exhaust rearward of the cat was replaced when i upgraded to the GZE as it was a 2" exhaust, and was also noisy as all feck.
The new section was done at Ringwood in 2.5" with a Lukey SuperTurbo muffler.
The reciept will be in that BIG file of documentation.

Thanks takai - so the cat is the last part of the thing to be upgraded :D

You slacker! shoulda upgraded the cat too ;)

[PooJou]

Car got rear-ended yesterday. Will update with details of fixings when monday rolls around.

[takai]

Ow, :( sadness.
:tear:

[PooJou]

Images of damage, RACV will call me monday.

http://www.users.on.net/~scheah/images/RearEnd01.jpg

http://www.users.on.net/~scheah/images/RearEnd02.jpg

http://www.users.on.net/~scheah/images/RearEnd03.jpg

http://www.users.on.net/~scheah/images/RearEnd04.jpg

http://www.users.on.net/~scheah/images/RearEnd05.jpg

http://www.users.on.net/~scheah/images/RearEnd06.jpg

[tomvale13]

thats fucked,

g/l with the insurance and repairs - nice car

[Talasas]

Bummer about the damage dude. I see Takai's handiwork (and all the work you've done since of course) is still holding together, twas a neat little package that car, all the goodies gathered up. I've actually had the honor of looking over the thing once too. Keep it alive buddy.

[PooJou]

So car is back from the panel beaters... it is now WHITE

http://www.users.on.net/~scheah/images/respray01.jpg

http://www.users.on.net/~scheah/images/respray02.jpg

http://www.users.on.net/~scheah/images/respray03.jpg

[PooJou]

Right, So i went out to attwood last night (which is REALLY FAR AWAY btw lol) to pickup a sub-box for my sub, which has been gathering dust for god knows how long.

So onto the pics (had to solder some stuff.... wasn't that interesting, didn't take pics of that stage lol)

Old sub - some Audioline thing... Didn't have high hopes for it
http://www.users.on.net/~scheah/images/newsub01.jpg

My Infinity Kappa 100.1se (note: dust)
http://www.users.on.net/~scheah/images/newsub02.jpg

Which is the better sub really (and the thing was wired with some pissy little wire lol)
http://www.users.on.net/~scheah/images/newsub03.jpg

Anndd in the boot!
http://www.users.on.net/~scheah/images/newsub04.jpg

[takai]

10"?
Thats what i need, i always had a 12" in there.

[PooJou]

10"?
Thats what i need, i always had a 12" in there.

Yeap, 10" - 12" seems a little too big? I wanted tight punchy bass :) and some semblance of bootspace!

I think i'm going to redo the false floor to cover the whole boot cut to fit - and have a hatch for the rear tyre :D

See how we go -

[PooJou]

So I came across a place that sells Apexi gear in Melbourne - and it turns out they're the Australian distributor for apexi!. So I figured, eh, $75, should probably change my pod (it is in an absolutely atrocious state)

I had never bothered to do this before, because I figured they still flowed well.... when they were ... kinda dirty? Boy was I wrong.

Here we go, box and all.
http://www.users.on.net/~scheah/images/newpod001.jpg

And, here is the difference... destroyed, dirty, crumpled pod on the right.
http://www.users.on.net/~scheah/images/newpod002.jpg

I was surprised to see the new pod had a larger opening than my old one!
http://www.users.on.net/~scheah/images/newpod003.jpg
http://www.users.on.net/~scheah/images/newpod004.jpg

And here we are, all installed - turns out my adapter was custom - Jason, the guy at the place, was all "ooohhhh custom... not a bad job either" and I was like "orly"
http://www.users.on.net/~scheah/images/newpod005.jpg


Needless to say, pickup is insane now - the engine seems to breathe a whole tonne better lol - it may seem obvious to some people, but no one's suggested it so far, and I didn't think it was a problem... I also asked him to please get me a quote on some Tein Flex coil overs to suit my mutant AE92 Superstrut/AE92 Generic SX suspension. Should be interesting to see how much it'll be.

[takai]

Just remember that the struts for the superstrut brake conversion are completely standard tubes, you use the original hubs and uprights for the Superstrut conversion. You just need AE92 coilovers.

[PooJou]

Oh? I was told that coilovers that suited standard spec AE92 wouldn't work with superstrut converted setups?

I figure tein will have superstrut specific coilovers (which'd be the same anyway yeah?)

[takai]

Nope, the struts are stock AE92, the "Superstrut" designation comes from the fact that the brakes are off Superstrut cars.

[PooJou]

Here's a strange one for you takai,

http://www.toymods.net/forums/showthread.php?t=40310

Got any thoughts on that?

[PooJou]

Right, bit of an update here.

Let's just say, tram tracks and rain do not mix.

http://photos-f.ak.fbcdn.net/photos-ak-snc1/v378/90/88/661049975/n661049975_1616749_3774.jpg

Estimated repair bill so far is $1800, after I've bought $200 worth of parts so that the wreckers don't have to buy them.

*sigh*

On the bright side, I've found that the front lips on these cars have holes in them that are ... blocked for some reason - so I've been cutting and sanding them out of the new front bar before it gets painted.

[PooJou]

So I found that the stock front bar had little random restrictions - I'm not sure why, but my pod filter sits almost immediately behind the blocked off parts - I'm sure there's a reason it's there, but there's no longer a reason for it to be there :D

First.
Take some hand tools.
That's a halfmoon 'bastard' gauge file, and a miniature hacksaw ($8 what a bargain!)

http://photos-a.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1690192_5365.jpg

Here's what I was talking about - why are those tabs there?

http://photos-b.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1690193_5700.jpg

Tabs gone!

http://photos-c.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1690194_5981.jpg

The lower (white) section's tabs need to go too, but they're a little more difficult to remove

[PooJou]

So I did some more work today:

This is the left side, sans tabs. (My hands have been WRECKED from sanding now)
http://photos-f.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1693957_7003.jpg

Right side:
http://photos-g.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1693958_7219.jpg

Here you can see how open it is now, should be pumping a fair bit of air through that rather hot engine bay now...
http://photos-a.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1693960_7662.jpg

And here's something I picked up a few weeks back:

http://photos-c.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1693954_6361.jpg

Here's hoping it fits (it's awfully long, measured it should JUST fit, but it really does depend on the exhaust guys.)
http://photos-d.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1693955_6581.jpg

It's not a cannon, it's a 2.25" -> 2.25" out + JDM tip yo
http://photos-e.ll.facebook.com/photos-ll-snc1/v426/90/88/661049975/n661049975_1693956_6794.jpg

[PooJou]

Fixed, once again, hopefully for the last time :upset:

http://photos-b.ak.fbcdn.net/photos-ak-snc1/v1230/90/88/661049975/n661049975_1772089_9818.jpg

New front end detail, note enlarged holes in front bar

http://photos-c.ak.fbcdn.net/photos-ak-snc1/v1230/90/88/661049975/n661049975_1772090_60.jpg

They had to put a new rad support in - for once everything ahead of the radiator actually looks non-broken

http://photos-d.ak.fbcdn.net/photos-ak-snc1/v1230/90/88/661049975/n661049975_1772091_326.jpg

And just a really bad photo of what I'm looking at when I drive
http://photos-e.ak.fbcdn.net/photos-ak-snc1/v1230/90/88/661049975/n661049975_1772092_577.jpg

[legend]

awesome work
how do u find the W2A setup and how did u wire it up for the pump to work

[PooJou]

awesome work
how do u find the W2A setup and how did u wire it up for the pump to work

The w2a setup is fantastic, keeps the temps down all the time - the pump is wired just through a relay at 12v - it switches on when the rest of the car turns on!