The ambitious goal - Early bigport 4agze into AE95 sr5

[PrettyCoolWagon]

EDIT:
posted new question elsewhere:
https://www.toymods.org.au/forums/te...r-options.html

[PrettyCoolWagon]

A quik pic of recently purchased red wagon with sunroof.. up on ramps in my very pokey garage.

7afe block in the fore ground..., now completely stripped down, preparing for 7agze build.

Need to measure the crank & new forged 7A rods to ensure correct sizing...

[PrettyCoolWagon]

Update,

7afe block's been stripped down.
Forged rods are getting the big and small ends machine to exact fit..
Oil squirters have been machined into block.

Can anyone offer some advice on the following.

The machine shop suggested a whole bunch of work but I knocked them back on financial grounds.

Here's the list they provided:

strip & hot tank block $ 77.16
crack test block $ 80.53
check main tunnels $ 77.14
fit main bearings & measure for grind $ 93.16
m/c squirter pads & tap $313.50
hone 4 cyl $ 72.60
surface block $ 87.79
degrease crank & crack test $ 69.64
linish crank per pin $ 50.79
drill/fit 3 x harden dowels crnk/flwhl $ 159.45
check rod tunnels & small end $ 48.31
hone small end for pin clearance $ 77.14
R&R pistons bushed rod 4 cycl $ 52.33 (don't even know what this one means???)
fit rod bearings & measure clearance $ 51.49
balance complete engine assembly $233.53
dummy assembly $123.20
new flywheel bolts $ 52.97
ARP head studs $ 77.00

TOTAL PLUS GST $1,797.75

I originally went in to get the small and big ends honed and oil squirters machined in, ..so the list above and price came as a bit of a shock.
I decided I'd do the deck surfacing and bore honing, I also rejected the crack tests of block and crank, being 7afe with rev limiters I didn't think they would've experienced much stress. The crank and bearings were in real good condition when I dissasembled it, the machine shop also agreed, there was no signs of wear and tear. So I knocked back the checking of main tunnels, balance of complete engine assembly and dummy assembly.

Interested to hear from more experienced builders, whether I should've checked main tunnels and got complete engine assembly balanced or not?

[TERRA Operative]

These are my thoughts, they just appear to be doing over quoting thing to drum up work.

Update,
strip & hot tank block $ 77.16 - I paid $90.00 to finish stripping, hot tank and bead blast a VERY dirty 20v. So this is ok.
crack test block $ 80.53 - Meh, I've never done it, it's not an alloy block and the Toyota blocks are pretty tough.
check main tunnels $ 77.14 - What are they going to do? look at them? If your donor engine didn't catastrophically detonate in the past, not much point.
fit main bearings & measure for grind $ 93.16 - $93 to fit a bearing and put a micrometer inside to take a measurement???? Wow. It should be part of the crank grind.
m/c squirter pads & tap $313.50 - You say you've already done this
hone 4 cyl $ 72.60 - Do this
surface block $ 87.79 - And this
degrease crank & crack test $ 69.64 - Don't bother, these cranks are forged and just don't break. What is advisable though is to check the oil galleries in the crank are clear.
linish crank per pin $ 50.79 - I paid half that per journal. Don't bother if there is no scoring.
drill/fit 3 x harden dowels crnk/flwhl $ 159.45 - If you need it for the 7A to strengthen the mating to the flywheel, then you need it.
check rod tunnels & small end $ 48.31 - You say you took the rods in for honing, so you need this.
hone small end for pin clearance $ 77.14 - As above.
R&R pistons bushed rod 4 cycl $ 52.33 (don't even know what this one means???) - Not a clue, ask for clarification here.
fit rod bearings & measure clearance $ 51.49 - As per the main bearings, this should be part of the crank grind.
balance complete engine assembly $233.53 - I was quoted $180 here in Brisbane, but with your mix and match of parts, I would do it.
dummy assembly $123.20 - You can do this yourself. If they can't machine your engine without doing it, they shouldn't charge for it.
new flywheel bolts $ 52.97 - About right. (if ARP)
ARP head studs $ 77.00 - About right.

[PrettyCoolWagon]

Cheers TO - Most of what you've said confirms my gut feeling ...wasn't sure about the balance...

I'll do the dummy assembly for the main reason of checking that the piston skirts clear the oil squirters..

might get another mob to do the balance...

[Sam_Q]

so basicly he is tring to double charge you for various things and hit with with fees for things you don't need. I say get all your parts and go somewhere else.

[TERRA Operative]

Also, get the ball bearings that are plugging up the drill holes in the crank for the oil galleries pulled out and run a drill bit of appropriate size (6.5mm from memory) through all the passages to clean them out.
Then tap a thread into each hole where the ball bearing was (M8 is what I used) and Loctite a grub screw in. Use something like Loctite 272, THEN get the balance done.

[PrettyCoolWagon]

Picked up all, my gear. Bill so far $1700 - bit pissed off with this guy...
They took the welsh plugs out - everything. I guess I'm still learning.
Will look at dummying it up making sure the piston skirts clear the oil squirters and then taking it to a builder to get balanced.

Tera - The counterweights on the crank of a 7AFE don't have those ball bearings that 4AGZE cranks have, so perhaps Toyota learned from their results and made adjustments to later A-series engines.

7AGZE's on hold.

NEW PROBLEM: stuffed synchros in my daily.
I have 3 AE95 wagons.
I started using another 1 as my daily after getting it rego'd and roadworthied.
Initially bought it for $500 to strip out power windows, central locking & door trims..
But.. Rear suspension was already overhauled with pedders shocks, new alloy radiator & cruise control And.. interior was waaay nicer than my base model!
Thinking of another conversion using a GZE bigport I changed brake pads allround, upgraded to larger slotted discs and got the front end lowered and stiffened.
All-good for a couple of months except occasionally changing from 3rd to 4th & back.
Gears wouldn't quite sync at high revs. They'd 'chat' their way in.

Previous owner was a 'P' plater ...judging by the state of things I got the impression he must've thrashed it a bit. Engine's running very well considering it's done over 400k.

The whole synchros went last weekend and I burnt out clutch in middle of the night between Thredbo and Kosiosko of all places!!!
Thank god for my reliable folks their land cruiser and my credit card for trailer hire. accommodation and fuel!


Anyway... Not sure which wagon to do now... might have to swap them around in shed fix sychros and do a basic GZE conversion while I'm at it.
If anyone's got any tips regarding gearbox swap I'm all ears.

[Kebin]

If anyone's got any tips regarding gearbox swap I'm all ears.

Engine out > replace with gze and new box > refit new gze to engine bay > done!

[PrettyCoolWagon]

I've been told to post more pic's -
How do I get my pics to show in full? instead of being a link?

[PrettyCoolWagon]

Got a custom made bullbar couriered over from Sth Australia.

Had major f-king head ache recently.
Had to shift house entire workshop garage everything.
Gotta get out of rental market.
Found a great place though close to work, more time in garage !!!

Have had so much crap everywhere.. - garage starting to resemble workshop again.
Close to dropping out 4afe and gearbox..

Looking to use this gearbox to replace the one with stuffed synchros on my other wagon...

[PrettyCoolWagon]

Progress.
Ramps set up. Dragged car up using block and chain. Hard yakka but makes working under the car a real breeze. It's freezing down here at the moment so It's nice to have a comfortable garage to work in compared to previous shed..

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[PrettyCoolWagon]

Engine's out... Here's a few pics
Have pruchased new cusco rear LSD
More pic's to come of the 7A blocks with new squirters.
7A flywheel with dowell holes drilled.
7A crank with 3 hardened steel dowels press-fit into flywheel end.
I know this is taking ages and have got a long way to go, just wanna say thanks so far to TurboWgn, Kebin, TerraOperative, Casey G, OldSkewlToy, SamQ, Bazda, Toymods and all the guys over at alltracwagon.net for the support and help so far..

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[PrettyCoolWagon]

oil squirters machined into 7A block...

Attachment 14900

[Kebin]

Good work on the progress. Looking good mate!