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

  1. #1
    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Smile Consolidated AE92 RS-X (nee SX-Z, SX) build

    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
    Last edited by PooJou; 12-06-2008 at 08:41 AM.
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  2. #2
    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Default Update!

    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 !
    Last edited by PooJou; 12-06-2008 at 08:41 AM.
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  3. #3
    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    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!
    Last edited by PooJou; 12-06-2008 at 08:41 AM.
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  4. #4
    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    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:

    Last edited by PooJou; 12-06-2008 at 08:42 AM.
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  5. #5
    has no Toyota anymore :( Conversion King tooch's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    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

  6. #6
    Backyard Fabricator Automotive Encyclopaedia
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    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

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    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    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...
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    Last edited by PooJou; 12-06-2008 at 08:42 AM.
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  8. #8
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    that looks excellent!

  9. #9
    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    New Plates coming - POOJOU
    Last edited by PooJou; 12-06-2008 at 08:43 AM.
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  10. #10
    Gary Motorsport Inc. Too Much Toyota takai's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    Heh, certainly looks different to when i had it.
    Get it dynoed at Bennica next dyno day.
    -Chris | Garage takai - Breaking cars since 1998
    Sparky - AE86 IPRA Racer | RZN149 Hilux - Parts and Car Hauler
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  11. #11
    Party Animal Supreme Too Much Toyota MR 1JZ's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    nice rimz dawg...

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

    hahaha
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  12. #12
    Genuine Hotty. Conversion King old_mr2's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

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

  13. #13
    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    So these came in the mail yesterday


    :bowdow to my gf lol
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  14. #14
    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Default Re: Consolidated AE92 RS-X (nee SX-Z, SX) build

    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!
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  15. #15
    Wrong Wheel Driven Grease Monkey PooJou's Avatar
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    Default Updates!

    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
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