Jamies 86 Hilux Sr5 bargain basment build with added boat anchor

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Progress?

 

 

Went  to pickapart last weekend to get fuel lines off an LN65 which are different to the 3Y ones because they cross the trans tunnel and come up into the engine bay on the passengers side to suit the 1GGZE plus the main feed is alot bigger so shouldn't run into fuel supply issues.

Time to get the tray off so I can sort out fitting the baffled EFI fuel tank I have from a later 3RZ hilux

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Haha 6 years of nothing except putting the reg on hold and turning the motor over by hand every so often but plans are afoot so watch this space

 

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Looking like a barn find but atleast the sheds tidy. Found all the bits I need for the engine swap and its ready to get trailered off the fab mans house

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Got it loaded on the trailer and trucked off to @MaxPowers shed this arvo. Even gave it a bath at washworld on the way to get rid of 10 years of barnfind smeg

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Productive day at the Powershed

Got the modified sump and pickup onto the GZE, installed spigot bearing flywheel and clutch to engine and offered it up to the engine hole

Much fucking around ensued because of the loooongboi crank pulley and SC clutch on the GZE making a small engine rather long so pressure plate and clutch off the engine slide the gearbag back as much as possible rotate the engine 45 degrees in the engine bay while tipping it to precarious angles then scrape swear and twist til its in there

 

 

Gearbag tunnel needs a slight massage to fit one of the heater hardline/mod the hardline as the engine is sitting not quite center and on a slight angle as the photos show

This is minimum clearance on the  draglink for steering which I hope is certable @cletus

AAAAND  I have minimal room for a radiator thanks to looooongboi pulleys but I will get the engine in its final position before measuring where how much room there is to play with. The bonnet closes still which is nice but I dont wanna have to deal with putting wheelbarrow in the firewall as tunnel notch with all the bullshit of having to move everything back shorten the Dshaft etc

 

 

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Dug thru my stock of engine mounts and rubbers today and found a combo that will work. Bit of plate for the mounts to sit on and some box section off the chassis rail will work

Got a few things stripped out of the engine bay and mocked up how the intake will go. Making an air box will be required but thats easy enough and iv got an idea for something a bit different

EFI fuel tank out of an 08 hilux is a bolt in swap but this one sat in a chassis exposed to the elements for a while so didnt have much luck with removing the old rusty fittings for the fuel filler etc without the bolts snapping so map gas and patience is working at the moment

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Got 99.9% of the snapped bolts out of the fuel tank 

Wire wheeled it rust killer then black enamel is baking off on it at the moment

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Fab'd up and fizzed on some mounts today with @MaxPowers help with the flash welding

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Heater hoses ticked off the list today.

Drivers side was easy with a hose off a 90s hilux going straight on with a slight bit of trimming.

Hot water feed from back of the head to the thermostat housing needed shortening down and a longer length of rubber hose added too. All the hard to get to stuff is done and the motor is back on the mounts and bolted in its final position so hopefully it can stay there now while I finish off other bits and pieces.

Passengers side was tighter so required shortening down the hardline off the back of the block and a bit of a jigsaw of 2 different hoses with a brass connector that @MaxPower cobbled up on the lathe but the result looks factory which is what im going for.

 

No pics but started on the exhaust too.

The factory crown downpipe wasnt going to work it fouled on the torsion bar so cut the manifold flange off it and tacked it to the 3RZ Y pipe which by luck had the same size primaries with the same spacing as the 1G flange then started hacking the aftermarket exhaust from the 3RZ hilux up to make it fit down past the bellhousing while tucking up between the torsion bar and cab floor so the chassis rail will still be the lowest point. It will be a bit of a snake til it gets back past the gearbox x member then there is plenty of room for it to go wherever it like

 

 

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Derp

Heater hoses looked good but forgot the tap so got that in today with some more parts bin heater hose

 

Front half of the exhaust done just need a pair of 2.5in flanges to join it to the back half

 

Gotta get the wellside off next to fit new fuel lines and the EFI tank then its only finding a radiator to fit and get the engine wiring done and I can attempt firing the engine up

 

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Got fuel lines in this morning just need to get a couple of longer brackets from pickapart for holding them to the floor. Good ol Toyota has studs in the right place for fuel lines to suit diesel or petrol so was easy once I figured out how to shoehorn them around the driveshaft and gearbag xmember. Got the wellside off and went to put in EFI tank for a mockup on how things were going to fit.

Balls

The EFI tank is slightly longer so doesn't slot into the brackets on the chassis, also its bigger/a different shape on top which hopefully wont be an issue as theres plenty of gap under the wellside but yeah I gave up for the day after that because wasnt in the mood for making a new back bracket which should mean the EFI tank can fit but thats a problem for another day

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Yeah wishful thinking with the EFI fuel tank, no way its going to fit. Too long for the chassis and too tall to fit under the wellside. Could space it down but then it will hang lower then the chassis rail and the thin steel holding lots of flammable juice is not the first thing I want to hit the ground

Back to using the factory tank with an external pump, not the best for fuel surge but if I keep it above 1/4 tank then it wont be an issue.

Fizzed the exhaust together 

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Back on the ground today and yeah the boat anchor does a perfect job of making it the right amount of low

 

Got one of the bucket seats mounted too but forgot to take a photo of that

 

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Noticed when it was back on the ground that the steering lock was almost non existent, since I installed the drop spindles about 8 years ago it has been up on axle stands or just pushed forward or backwards into the shed so never noticed it til now. 

Had a quick look underneath to see what was going on and the top bolt on the brake caliper was hitting the top arm preventing full lock so was slightly confused for a bit considering the spindles were supposed to be a bolt on jobbie but found the details of the shop I purchased them from and flicked off a message asking what was up.

Turns out you need to fit 90s hilux brake calipers as they dont have the long ugly bolt bit that fouls the top arm. Ripoff wreckers on trademe wanted $450 for a pair of calipers! but luckily theres a crashed lux at PaP at the moment so went and grabbed those ones for $80 with brand new pads in them.

 

Factory calipers with fouling lump as modeled by another 80s hilux at Pap

 

90s Sr5 calipers with less fouly design

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The lux is back at my olds place in the barn now as most the major fab work is done so I can easily get the rest finished with my basic setup there so loaded up my tools this morning with the intention of fitting the brake calipers to get steering lock back

 

Balls, maybe the ute at pickapart wasnt an SR5 as the calipers are too small for the disks. Do 90s SR5s even have bigger brakes than a povo spec? I dunno something to look into.

Got the clutch bled up and it feels decent enough. Looks like my cobbled together setup has plenty of throw so it should work

Stripped down the passengers seat rails ready to make mounts for the passengers bucket seat

Made a small bracket out of alloy so the grille badge off the crown will mount up. Looks almost factory

And a few weeks back I swapped some 1G bits with @Jeffs_Emporium for this sweet old school Blitz boost gauge. Had a bezle off a vacuum economy gauge thing kicking round so swapped it into that and it looks perfect. Wont look too out of place tucked somewhere on the dash

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The radiator situation is proving to be a bit of a headache as the available space is minimal thanks to the S/C electroclutch pulley taking up alot of space. where you would ususally plonk a nice thick rad for plenty of cooling.

Did a bit of mocking up today with a couple of radiators I had kicking round its looking like a unit from a GA61 Supra will juuuust fit with a pusher fan on the front of the radiator. This one is pretty beat up and manky so will see if I can find an alloy option

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Went to Pickapart yesterday with tape measure in hand to try find a more suitable and readily available radiator.

Turns out it was quite a mission as most radiators are too wide or too tall or have the water outlets in the wrong place. After checking everything there it came down to 2 options. Honda CRV or a Ford Telstar. Telstar was the winner on the day as it had a thicker core and was that bit bigger than the CRV unit. Quick test fit was promising bar 1 issue, top outlet is right where the alternator sits so getting a hose on there isnt happening.

Was thinking of going to see the local radiator barry and maybe find a top tank that will fit the core but have the outlet on the drivers side then do a swap. Other option is find a diesel Capella radiator as its the same overall dimensions but the outlet is already in the right spot and is a full copper unit with a slightly thicker core

 

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After much head scratching and thinking about the radiator situation I listened to Koro @sheepers and just got a radiator that fits. Using the telstar rad as a template as its the perfect size  I went down a rabbit hole of radiator websites to look up dimensions, turns out the perfect fit while fitting the criteria of cooling a forced induction 2L engine is a EVO 1-3 unit but i wasnt going to drop $500 on a brand new one incase it wasnt going to fit so haggled a deal on marketplace for this Fenix unit with electric fan for $150, few bent fins to straighten and a rattle can overhaul but im not complaining for the price.

Yeah it just fits but I couple of quick mods will give me as much room as im going to get without hacking the whole front of the ute to bits. Water outlets will be easy to run with a few bends and straight sections but glad to have that headache sorted. Just the loom to sort out and mount an external fuel pump somewhere then il be close to firing it up