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Thread: Making engine mounts, 4age to KE30. A how to.

  1. #1
    My Missus is a Domestic Engineer BradW's Avatar
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    Default Making engine mounts, 4age to KE30. A how to.

    The following is a guide to the steps I used to make the engine mounts to mount the 4AGE to the standard KE30 cross member.
    This procedure could be used to make custom mounts to suit any engine in any car.

    I decided to use ford escort engine mount rubbers, mainly because they are a common part that consists of a cylindrical shaped rubber section with a single bolt mount from either end.
    The other reason I chose the escort rubbers is because a friend gave me a set of neoprene ones for free .



    You could use any engine mount rubber you like. I considered using TA22 celica rubbers as these also have a single mounting bolt out either side but are a square rubber.


    After getting the engine sitting in the engine bay and mounting up the gearbox, I put a piece of timber in between the sump and the crossmember to give the height that I wanted the engine to sit at.




    I then centered the engine in the engine bay making sure the gearbox output shaft lined up pretty well with the diff flange so the tailshaft uni's would be straight and the engine was sitting at the right angle.
    I got the angle by making sure the base of the sump was parrallel to the crossmember.




    This has the head sitting on a slight angle which is pretty much how they sat in the AE92.




    I then made cardboard patterns of the pieces I wanted to bolt up to the block and the rubber mounts.
    The piece to bolt to the mount was just a square with a hole in the middle, and was the same for both sides so I only made one cardboard pattern for it.




    These were then cut out in steel, drilled and mounted to the block and rubbers.




    The next step was to make cardboard patterns for the peices to complete the mounts.





    Last edited by BradW; 15-07-2007 at 11:00 AM. Reason: Speeeling
    Brad

    Old Corollas never die...

    My KE30
    Updated 15/7/2007............ yes, I need to pull my finger out.

  2. #2
    My Missus is a Domestic Engineer BradW's Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    Cont...
    These were also cut out in steel.






    Then tack welded in place.






    The mounts were then removed from the car for final welding.
    I also trimmed the wings off the flat plate to allow easier access to the bolts on the block.


    Final test fit.



    This can be done even with minimal tools at home. All you would need is an angle grinder and drill (very cheap from bunnings, super cheap, etc) and a welder to tack them up, which you could hire from Kennards, etc. You don't need to be a good welder to tack them together, just as long as they hold so that they can be welded properly.
    Hope this helps some one out.
    Brad

    Old Corollas never die...

    My KE30
    Updated 15/7/2007............ yes, I need to pull my finger out.

  3. #3
    Junior Member Backyard Mechanic Hash_ra23's Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    great guide mate! I'd do it but i dont have a welder nor can i afford it

  4. #4
    My Missus is a Domestic Engineer BradW's Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    You could probably pick up an arc welder for around $100 which would be good enough to just tack them together or as I said you could hire one for half a day. Once they are tacked together you can remove them and take them somewhere to be welded up. I only tacked these together and had them welded by a mate because I couldn't weld to save my life .
    Brad

    Old Corollas never die...

    My KE30
    Updated 15/7/2007............ yes, I need to pull my finger out.

  5. #5
    Welcome to the Darkside! Automotive Encyclopaedia -==L=a=N=c=E==-'s Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    mate great write up... and you could do it for anycar for that matter, not just the ke30.

  6. #6
    Junior Member Domestic Engineer NeoNasty's Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    Awsome.

    Although what I need for the 1JZ VN is a little more complicated. I will use this basic format to produce what I need.

    Thanks a lot man

    +rep!
    HZJ75, RS41, JZZ30

  7. #7
    i 8 a p00 Carport Converter rob's Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    do u still have the pattern pieces? you should put them onto a cad file or PDF or something
    - ma61 + 2jz-gte + v160 + 3.5 torsen

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    MR 18RG Chief Engine Builder The Witzl's Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    very nice guide... has been copied to the FAQ.

    I like guides like this - simple, easy to follow instructions with pics to match.
    ...... butt scratcher?!


  9. #9
    Junior Member Automotive Encyclopaedia
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    Just thought i would also add, tacking with an arc welder is fine, but as far as final / full welding goes according to my engineer when i did my conversion he said he required the welds to be migged .... I never asked why, but i suspect probably due to the fact with arc welding you can get slag in the welded section if your not very experienced & hence a weaker weld .. No such issues with mig ....
    It might pay to check with your own engineers first, if doing a conversion ...

  10. #10
    umop apisdn Chief Engine Builder twentyEight's Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    Nice guide...

    I hope your going to use a remote oil filter on the there 4A-GE...
    ([][][]II--LT--II[][][])


    Green '77 RA28 Celica - VVTi V8 Goodness...

  11. #11
    My Missus is a Domestic Engineer BradW's Avatar
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    Default Re: Making engine mounts, 4age to KE30. A how to.

    Quote Originally Posted by rob
    do u still have the pattern pieces? you should put them onto a cad file or PDF or something
    I still have the pattern pieces but they aren't exact sizes. I had to do a bit of cutting and grinding on the pieces before I tacked them together to make sure they were a good fit.

    Quote Originally Posted by lexsmaz
    Just thought i would also add, tacking with an arc welder is fine, but as far as final / full welding goes according to my engineer when i did my conversion he said he required the welds to be migged .... I never asked why, but i suspect probably due to the fact with arc welding you can get slag in the welded section if your not very experienced & hence a weaker weld .. No such issues with mig ....
    It might pay to check with your own engineers first, if doing a conversion ...
    Yeah, the final welding was done with a mig. I haven't had an engineer look at these yet so I'm not 100% certain that they will be right but I'm not expecting any problems. We'll see what happens.

    Quote Originally Posted by twentyEight
    Nice guide...

    I hope your going to use a remote oil filter on the there 4A-GE...
    Most certainly am .

    Thanks everyone for the feedback.
    Brad

    Old Corollas never die...

    My KE30
    Updated 15/7/2007............ yes, I need to pull my finger out.

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