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:


quick hit list:
AE92 smallport 4AGZE
165mm HKS pulley
Large FMIC
Uprated superstrut brakes + GT4 rotors



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



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





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


Box Of Stuff!!


The Pump (notice, 1/2" inlet/outlet... 12v... Swiftech MCP655 mod anyone?)


I Think Nippon denso make EVERYTHING


Radiator for the water - Looks like two bigarses' put together


SUBARU INTERCOOLER TURBO! - outlet is 2.75" - inlet is 2" - very odd


Interior view of the inside of the WAIC


Underside of the intercooler - note 2" turbo to intercooler pipe


Water outlets


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


Aircon condensor and large fan in the spot where the front mount intercooler used to sit.


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.


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.


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:


AFTER:





This is going to be boxed up later - car is not being driven atm so it's not a problem.


The boot! battery will vent to air in the hole to the right of the battery - it's bolted (the battery) through 18MM MDF.


Ghetto hold down



Earthing and vent


Current ride while car is off the road:

[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 )

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:



Next Oldest:



The New Hotness:

[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

hahaha

[old_mr2]

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

[PooJou]

So these came in the mail yesterday


: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




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:




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



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