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Thread: 2zzge to AE82 conversion

  1. #31
    Backyard Fabricator Automotive Encyclopaedia
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    Default Re: 2zzge to AE82 conversion

    it's more that the ZZT celica and ZZE corolla firewall's extend out towards the front of the car at the top of the firewall. If they were totally flat then there would be similar clearance to the AE's

  2. #32
    Toyotard Conversion King Cuts's Avatar
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    Default Re: 2zzge to AE82 conversion

    Point still stands.

    So your running a returned fuel system, much better then the stock returnless.

    When do you expect to have it on the road?
    ST205 Group A Rallye GT-Four 307kw atw @23 psi on 98oct, Now on E85.

    1973 TA22

  3. #33
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    Default Re: 2zzge to AE82 conversion

    Month or two I'd guess. I only really work on it on the weekends.

    Custom vipec loom, cooler mounts/pipework, dump, exhaust, driveshafts, AC, thermofans, dash cluster and bodywork to go

  4. #34
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    Default Re: 2zzge to AE82 conversion

    modded the radiator today to suit the 2zz engine, machined up new 34mm inlet/outlets to weld onto the end tanks, chopped off the old ones, plated off the holes and welded the new ones in place:




    Radiator hoses should be fairly easy using bits of chopped up silicone hose and alloy hardline in between:


  5. #35
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    Default Re: 2zzge to AE82 conversion

    Made a start on the dump pipe this weekend... using a section of 2" mandrel bent tubing, I split it in half and then welded a couple of sections in between the halves so the resulting outlet has the same circumference as a bit of 3" tubing. Still a bit of shaping to go on the outlet so it's a nice transition but it will work well enough.

    One cool thing I discovered is that it's possible to install the turbo & manifold as one piece







  6. #36
    Junior Member Grease Monkey
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    Default Re: 2zzge to AE82 conversion

    Well done on a great conversion.
    With regards to the driveshafts. Could you have the gearbox split and have a AE92 series centre fitted (lsd or open)? I ask this because then then the pot joints would slot right in. I have a five speed late zz series model box here and the earlier corolla pots dont fit. But since they are both C series boxes it might be possible to change the diff over to accept the earlier pots?
    I thought it might save you on custom driveshafts.

  7. #37
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    Default Re: 2zzge to AE82 conversion

    I think it may be possible to install an AE diff, but custom shafts would work out cheaper for me

  8. #38
    Junior Member Grease Monkey
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    Default Re: 2zzge to AE82 conversion

    Wow, its like watching a piece of art being made.
    Absolutes amazing work man! Keep it up

  9. #39
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    Default Re: 2zzge to AE82 conversion

    got the fan shroud sorted yesterday arvo and finished it off this morning, used 2mm alloy sheet for the face and 12x3 bar for the top and bottom ribs, then 35x3 bar for the side plates. Since I dont have a pan brake I just welded the whole lot up, also welded some tabs to the side of the cooler and installed some m6 nutserts to them so the shroud can be bolted down securely. The fans are a pair of 11" low profile SPAL's purchased directly from SPAL USA as they're far too expensive locally.





  10. #40
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    Default Re: 2zzge to AE82 conversion

    Sorted the plenum so it can be bolted up permanently. Chopped out a hole and welded in some 10mm plate drilled and tapped for a bosch combo 3bar map/intake air temp sensor. Turned out better than expected:





  11. #41
    Toyotard Conversion King Cuts's Avatar
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    Default Re: 2zzge to AE82 conversion

    The turbos hot bits sit rather close to other "ï'de rather not be hot" things.
    You going to HPC coat it and the manifold? maybe a turbo beanie or heat shielding?
    Last edited by Cuts; 04-10-2011 at 09:58 AM.
    ST205 Group A Rallye GT-Four 307kw atw @23 psi on 98oct, Now on E85.

    1973 TA22

  12. #42
    Corona loving Grease Monkey TTMX83's Avatar
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    Default Re: 2zzge to AE82 conversion

    Wow...........

  13. #43
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    Default Re: 2zzge to AE82 conversion

    Quote Originally Posted by Cuts View Post
    The turbos hot bits sit rather close to other "ï'de rather not be hot" things.
    You going to HPC coat it and the manifold? maybe a turbo beanie or heat shielding?
    I've got a very large sheet of ACL Heat shield which will be used to make a nice shield, the manifold and exhaust housing will be coated by competition coatings like the other turbo ZZE122 I built a couple of years ago. On the ZZE there is a lot less clearance between the turbo/firewall/head/brakelines etc so I'm confident this one will be fine.

    got started on the drivers side cooler end tank and cooler pipe today, a bit of a tight fit to clear the AC/headlight without requiring triming the bumper but it's all in there now.

    The cooler pipe is 2.5" and it goes to a 2" high oval where it passes under the light.








  14. #44
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    Default Re: 2zzge to AE82 conversion

    cooler pipes are now basically done, just brackets, BOV and shield lugs to be added.

    Decided to run the outlet pipe over the turbo/manifold to make the routing shorter and easier. There will be a couple of ACL Race heatshields in between with 10mm air gaps to try and keep some heat out of it.








  15. #45
    Toyotard Conversion King Cuts's Avatar
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    Default Re: 2zzge to AE82 conversion

    Your pipework looks top notch, especially in this case on the cold pipe.
    ST205 Group A Rallye GT-Four 307kw atw @23 psi on 98oct, Now on E85.

    1973 TA22

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