AE92 GTi-16 Corolla

[ElDopesta]

The sun roof is not that rust free, I had a good look at it again the next day but hey, it will still do the job just fine and the rust is easily treatable and the sun roof will not cost you a penny except for the postage. I will have it off for you in the next couple of days buddy. I did say this week end but it is more likely going to be Monday.

You will get a cheaper new copy radiator for less then that buddy. I can take a look at some prices for you from some of my suppliers on Monday if you want. I will see about the switch too for you as I can not part with the one on the bucket, I will be taking the engine out complete as that is the only thing salvageable on the car.

What is the condition of the water pump??? are there any visible leaks??? Have you had an afer market cap on it???? Take the thermostat out and run the car like that to see how it goes buddy.

I am going to send you a PM in a while, PM me back once received.

El

 

[KPARRIS-JONES]

Sounds great, but please do check the rust closely because I have spent £50 one s duff one already, I don't want to get another mini-project on the go again!

I'll check for radiators on the places that I know of, but your help is gratefully received!

I get a members discount so I'll have a look on what I get quoted from Toyota (Lindop) first.

Cheers,

KP

 

[KPARRIS-JONES]

Some good progress has been made over the past two days, I smoothed out a dink along my replacement O/S door (which was caused by a trailer hitch by the looks of things) and also pulled out and smoothed off a crease which was caused by the previous owner slamming it against a wall.

The crease;

It wasn't too difficult to do, I used a clamp to pull it back out and then applied 3 layers of filler paste to make sure it was perfect. The hot weather was perfect for this work because the paste dried within 20 minutes.

The dink from the trailer hitch;

Thanks for looking, comments are welcome.

KP

EDIT: El, I'd like that sunroof, if you could PM me a few pictures that would be great. Thanks.

 

[KPARRIS-JONES]

Ok I have managed to source a fan switch for free and I'm looking at some new radiators on Ebay selling for £50. Not bad.

I'm just gonna plug away at the body work to shave off those pennies for the respray cost.

 

[Nick]

Top job with all of this! Im impressed!

 

[KPARRIS-JONES]

Cheers!

Should get the Poly-Bush kit put in tomorrow or Tuesday.

I'll also get the bumpers rubbed down and ready for some decent plastic primer, something that Toyota neglected to include...

I'll get some better pictures up of what I do tomorrow, new iPhone 4 is great for HD videos!

 

[KPARRIS-JONES]

It's confirmed that I am getting another 7 ribbed TVIS 4A-GE for my 200BHP build. Sweet complete with C52 Ally Cap gearbox.

Should be perfect N/A because of the early "light" crank and rods, less inertia = easier to rev

I'll keep the thread updated as I get it and rebuild it etc.

 

[KPARRIS-JONES]

Sadly the war on rust has now ground to a halt, where it will stay for a long while.

The garage that was going to weld up the turrets and sills has now gone bust. So I now have to pay to find storage and rent it, then I need to find someone else who can do it for about £1500 and no more.

Real ballache considering I would really like a WIN with this thing right now....

So I will go and sort the bushes, brakes and maybe the suspension this year. I will be getting a radiator for my birthday and I have the Fan Switch so those can be fitted up and maybe the engine will work properly lol.

Things are going to take much much longer than I thought...

I do have a list of the goodies that I am getting for the Blue Top Poject (new engine).

There are a few other things that I am adding to the list, still in the R&D stage right now.

 

[KPARRIS-JONES]

I have missed A LOT of progress out with the car and Blue Top Project:

The car: Blow water pump, sitting their with a few polybushes fitted.

Engine, see for yourself:

It's here!

Up at 5:30am and out by 6am we were all tired and yet very excited for the day we had ahead, three guys all good friends working on an engine supping tea in the sun, rain and cloud.

We managed to get down to Taunton in good time at around 9:30am despite colossal caravan traffic and we met up with Leebo and his gorgeous compressor. I tell no word of a lie when I say that those things can shift! :lol: He took us to the GTi to be removed of its heart and we began at roughly 10....

What we had to work with:

The fatties begin:

Bits are out and the coolant, oil, PAS, gearbox oil and fuel are all drained after one hour:

We finished the second hour with some good rape:

A good few hours later we were almost ready to lift out, only engine mounts to go:

 

[KPARRIS-JONES]

We started lifting at 5pm.....

....and the chain top link snapped! Luckily the engine was only hovering in the bay about 10 inches higher, and me and Dean both whipped our hands out of there so quickly there was no chance we were getting trapped.

We were cattle trucked.

We went out to go and find a chain but with no luck from B &Q, Halfords and Screfix. Finally we were pointed to A1 Motor Spares who gave us a two tonne tow rope to use.

Which worked very well!

Eventually she was out and on the floor:

Then we shifted it into the Omega:

Riding the Axle:

END:

We are getting it out of the car and into the garage today, and I'll begin the strip down.

 

[KPARRIS-JONES]

Packed up and waiting for tomorrow, which hopefully should bring the crank, rods and pistons and maybe the valves all into the daylight.

All that I need to do is remove the sump and it's co-parts and the oil pump then I am free to whip out the crank after a few checks of the end-float with feeler gauges.

Annoyingly, the two bolts holding the water temp sensor and CSI sensor sheered because the aluminium has reacted with the steel. :censor: :censor: :censor: However this is no big deal because I won't need to deal with it any time soon, the tension pulley bracket bolt (auxiliary) also sheered off, and I am annoyed but again not thrown off by it.

The valves appear to have quite a bit of grit on them which is only slightly concerning, but overall it seems to be a very healthy engine!

Enough waffling, here are a few pictures:

Intake removed, TVIS revealed :drool: ;

Sheered!;

Head off;

Flywheel off;

A few more bits have been done since the last photo but you will get brighter pictures tomorrow.

 

[KPARRIS-JONES]

Ah thanks mate. I have all of the Valves out now but I will do the seals tomorrow.

Here are a few more pictures to try and get some interest. :lol: ;

Polished and primed the fuel line;

Sanded off the "1600", "TOYOTA" next;

VSC in action;

Valve Spring checked and cleaned;

Valve:

Painted the Fuel Line in Hammerite Smooth Dark Blue;

The Exhaust Valves have a fair bit of Carbon build up which is a little concerning;

Stripped Head:

I will remove the Oil Seals tomorrow and hopefully find the engine mounts and get it up on the stand so I can work on the crank.

 

[KPARRIS-JONES]

Here's today's main update;

Spent my time working on getting the gearbox painted up and ready for storage down in Turvey, spent roughly 6 hours cleaning, grinding, degreasing and prepping all to get about 30 seconds of painting... :lol:

Warming up my paint lol, been very cold here today:

Polishing and degreasing the Gearbox, spent about 6 hours doing this:

The stuff around the drive shafts was untouchable so I simply painted around it and will neaten it up nicely later

Preparing the 'Box:

Prep finished and in the first coat of primer:

Due to the cold weather I will leave an hour between each coat of the Anti-Rust primer, I'll be back out later tonight to do another four coats. Also, due to the weight and awkward shape I will paint the top tonight and when it has all dried off properly I will flip it up and do the underside.

 

[KPARRIS-JONES]

Cheers bud, here it is! Two/Three coats thus far and the fourth, fifth and sixth will come later on once these have dried out properly:

On the new Stand:

Prepped on the Underside;

First Coat;

Second/Third Coat;

Tell me what you think, I spent too long on this to get no feed-back! :laughing:

 

[KPARRIS-JONES]

Here yas all go, got some pictures of it in the daylight:

All dry and ready to have the linkages fitted back up once they have been painted.

 

[KPARRIS-JONES]

Don't we all??? :laughing:

I have the engine on the stand and will start working on the Crank and Pistons once I have the 'Box away and I have tested the End Float.

Some tasters:

Organising the garage:

THESE HAVE BEEN COPIED AND PASTED FROM MY MAIN FORUM THREAD HENCE WHY CHRONOLOGICALLY IT MAKES NO SENSE!!!

 

[ElDopesta]

Hi buddy!
Looks like you have been a very busy beaver indeed!

The project looks like it is coming along very nicely and you HAVE spruced everything up which will all add to the final picture.

Just make sure that all internals are cleaned thoroughly as it will add to better performance in the end.

I look forward to seeing more as time goes by.

El

 

[KPARRIS-JONES]

Hi mate, haha tell me about it! Been great fun though.

Cheers, yeh my goal is to learn patience with this one to get each part perfect i.e with all metal parts painted I derust, degrease, rust protect, use rust preventative primer and paint. So it should all be durable too.

I will get the block and Head hot dipped to sort out the grime of the basic parts but yes I will be sure to get everything properly clean. It's not too important to clean the standard parts right now because everything is getting replaced.

I'll try to get one here more often to post up the progress.

KP


P.S. still can't remove the Cranks damn Woodruff Key....

 

[KPARRIS-JONES]

I'm so sorry that I have posted nothing in the way of progress! Long story short, we have her pretty well resprayed!!!

She'll be back in my care in about a week or two, ready for me to do the final slog to get her to Japfest for a Banzai photoshoot with the AE92OC.

And get this, she's not even polished up yet!!!

Any comments/questions welcome!

KP

 

[m7gsr]

Coming along nicely. Will look great once all complete