Dell'orto's nearly-decade-long-project KE70

[Dell'orto]

September 2009it was too cold to go out to the garage ok

Nothing terribly exciting to update with, though my garage is now all complete :yes:

Picked up a TE71 disc brake diff today, no more driveline issues! Just needs an LSD....

Will hopefully get my powdercoating pile off this week, then serious things can happen.

Yay pictures

Ultra Racing strut brace and lower arm (caster rod) brace

JDM as fcuk AE86 calipers (check the paper they're wrapped in )

Fcuk, computer system at work lists the wrong f@%king rotors for AE86's, and there are none of the correct ones due into the country til February :abusive: :abusive:

Options are to either splash out for TGP rotors (~$100 each) or go for Znoelli slotted ones. Irksome, as its a couple hundy that I hadn't budgeted for

Znoelli rotors arrived today, went with the DDS ones as they were only $20 the pair dearer than the standard slotted ones

They do look the part, so later on down the track I'll get the rear rotors too.

Also got TGP caliper kits for the 86 calipers, even though they look in quite good condition with no obvious rust or pitting, I figured I may as well rebuild them while they're sitting.

Originally posted by ae25

dba list the aussie spec ae86 disk.. but they do make the jdm one.. just need to find out thier part number for it! then pay special freight price since they probly dont have any in nz. poos + wees!

how much did znoelli ones set you back if you dont mind the asking? i'll be needing some soon. also caliper seal kit, that looks like a good idea!

TRW do do the correct version for it, Repco's computer system just lists an AE82 rotor :biggun: though they list the correct rotor under the carby version, which I assume is the ADM model. There are no DBA ones in the country (In the repco network at least) and they tend to be really dear in comparison to most other brands so wouldnt bother getting some in.

Retail on the Znoelli rotors is around $400 I think, staff price is substantially less Caliper kits are cheap though, $54inc for the kit to do both calipers.

Also Geartech still haven't looked at this bloody LSD for me :violin:

[Dell'orto]

October 2009

Finally stuff is back from the powdercoaters! The joys of perk jobs I guess.

Ran down to a local workshop this afternoon and had the new bearings pressed onto the axles (Induction heaters FTW), and had the new nolathane bushes pressed into the lca's as well. One of the TE71 calipers looks pretty manky on the inside, so I've stripped both down and have started cleaning them up ready for a paint and rekit..touch wood the bore isnt too far gone on the rusty one :violin:

[Dell'orto]

November 2009

Right, been working madly on this thing as of late. First off sorted out the odd electrical problem it'd developed, where it stopped cranking, then when it did start cranking started flashing the handbrake warning light instead of the indicators...reasonably simple in the end.

Rekitted one of the rear calipers, then got lost as to how they went together. Quick trip to one of my customers who is a brake and clutch specialist sorted it out :yes:

Also fitted keeper springs and the powdercoated LCA's today, so the front end suspension (Bar the braces) is all complete.

Biggest thing achieved this weekend is finally getting the motor and box in for good! Took a bit of fluffing around, as the release bearing in the clutch it didnt fit the carrier...sprinted into work, grabbed one for an AE86. Still didnt fit, WTF? Ended up going down to oldscool and thiefing a bearing carrier from a hydraulic T50 (I think thats what it was) and mashed the AE86 release bearing onto that.

Added a quick earth cable to the motor, and we have cranking and spark :yes::yes::yes: Also found out that RPM clutches for these things are fairly heavy, which is quite promising for the abuse it'll receive :thumbup:

Plans for this week are to finish reassembling the diff and installing

it, then finishing off the last of the wiring jobs.

Still to find/install - AE86 booster/master cylinder and a suitable driveshaft. Really wanna get it fired up for christmas!

[Dell'orto]

March 2010

Haha yeah, definately lacking motivation eh...also new job pays less and no company car hurts the bank balance a bit. Plus trying to get my business up and running takes up a bit of time :bricks:

Latest pics

Though I just bought a new grille which I am a huge fan of, I think its a Jap import one? Its in better nick than the current one at the very least.

I'm also at the point too where stuff is gonna be REALLY expensive...bumpers need to be straightened and rechromed, and the rear seat needs to be retrimmed. Then add wheel refurb for the Excels and a set of tyres and costs add up quick.

Complaining aside, I'm gonna try get some work done over the upcoming months so I can at least get the interior semi in and back together!

And thanks, ever since I got carried away with this project (was supposed to be a quick tidy up and onsell) I've been a big believer of do it once do it right :yes:

[Dell'orto]

July 2010

Kinda a weak update, but one I'm fairly excited about.

Finally, after some 4 years of owning this thing...I have a complete driveline :yes:

Finally got my driveshaft back from Colliers, swapped from 22 spline to 20 spline yoke, all balanced with new u/j's, ready for a good old beating.

Also have the front panels all permanently bolted on, and all the front end wiring done Now comes the fun job of finally refitting the dash and interior back in!

Also have seen these bits here I'd quite like to get - what do you think?

http://www.carbonfibercollection.com/hand-brake_console.html Though need to find out if AE86 consoles bolt into KE70, I assume they will but better check before forking out $500 for bits!

Still trying to find a matching AE86 booster/master set up. I have a prefacelift booster, and a facelift master cylinder

[Dell'orto]

September 2010

Right, possibly the last update I'll get done while living in Palmy. Finally got around to getting the wheels done!

Camera lens was a bit dirty :S

Bought some 316 stainless pipe to redo the heater lines with, now that I'm back working for Repco I'll be able to rummage through the hoses to get the right sized bends to join it all together. Bought a rivnut gun too, which will make mounting things like the heater tap much tidier! Also managed to find some factory black kick panels, so the painted stuff can stay spare. Ideally would like to get some black sill runners too!

Still havent found that elusive switch for the mirror, so I can't really assemble the interior until I find one

Have the above booster/master in my possession now, Unfortunately the booster appears to be knackered, so am going to see if it can be repaired, then can finish off the brake system.

Fingers crossed we can find a house with a good garage down there!

[Dell'orto]

March 2011

So baby decided to come a week and a half early, little wench I took two weeks off from when she was born. In between sleeping, feeding, changing and cuddles I've managed to get some of the fiddly jobs done that I've been wanting to do for an age.

When I had the car painted (all those years ago!) I had the factory washer jets removed, to try make the engine bay a bit cleaner looking. However finding a washer jet that fitted in the slots in the scuttle panel was a bit tricker. After many empty trips to Pick a Part, I actually got some through work...supposedly for a Caldina?

Anyhow, before putting them all in, I figured I may as well try and protect one of the most rust prone areas on a KE70. Armed with a can of cavity wax, and a long nozzle, I sprayed the bejesus out of the wiper tray.

Paying particular attention to the front seam and ends.

As I was tightening up the washer jets, I noticed some surface rust on the scuttle panel itself -

WTF? Its not been exposed to rain since it was painted, its just been hanging on the wall in the garage. Out with my good friend POR15 then

Much nicer, and hopefully the end of the rust.

Now the washer bottle was also pretty yuck, years of crap build-up and filth sitting around, so thought I'd pretty that up too, seeing as they're not available new

From this:

To this:

Bolted it all up in place with the new hose (excuse the dust!)

And it all works!

Will touch wood have another update tomorrow :D

Other update isnt quite ready, due to some equipment malfunction :rocket:

Bought a whiteboard though, so I could make a list

Right, so finally finished off my other job from last week. Making the headlight surrounds look nice!

I've got one factory one that looks like it was plastic chromed from factory, quite neat looking but I imagine hard to find. My current ones were a bit worse for wear, so figured I'd try and make them look like the chromed ones.

The factory gray paint had worn off on the edges, and had a few gouges here and there

So first off, we fill in the gouges, with a light plastic putty

Gently sand it all back smoothly, hit it with some plastic primer, then a white primer.

Go over the bits I missed the first time round reprime, sand, prime, etc etc and spray with VHT chrome finish wheel paint.

Photos don't quite show up the chrome finish very well though Gave the corner lights a plastic polish, and chucked in some fancy Phillips white bulbs. How do they look on the car?

Starting to look like it ought to again! Though I am in need of some more grille clips, the ones in the Champion packs dont fit :shooter:

Chucked a battery in to see how the semi sealeds look, these have Narva plus 50's in them

Plenty bright

[Dell'orto]

June 2011

Hooooooly shit...some 6 months after purchasing it, my booster finally arrived from Japan! Even more awesomely, it came complete with the master cylinder AND proportioning valves! I was a little concerned about running the stock one, but figured plenty others have done so in the past with no dramas, but now its a non-issue

So how well does the facelift AE86 brake booster/master cylinder fit? (apologies for photos, camera batteries were dead so off the phone)

Like a bought one only had to lightly clearance the inner guard to get it in place. Just noticed looking at the photo, the master even lines up nicely with the standard brake line.

For comedy value, heres a picture comparing the various boosters I've collected:

KE70 - TE71/PFL AE86 - FL AE86

In the upcoming weeks, I'll get the booster painted up all nice and purdy, rekit the master cylinder and bolt em up for good. 3 project cars and a baby sure do make things tricky

[Dell'orto]

January 2012

So I've done SFA on the sedan over the past 6 months...baby takes up time etc etc, but also have been spending my spare time and money on the MR2 distraction project. Now thats almost complete, and given it a new year its pretty appropriate to get back into this one!

I managed to find some factory black arm rests for the doors, so screwed them on, and attached the door handle bezels and window winders (brand new ex Toyota!)

The door cards were vinyl sprayed by the previous owner and while they dont look too bad, it looks a bit much being entirely black! I want to get them retrimmed, but need someone to do a photoshop to see what they would look like. Ideally would like to have the centre section a light/mid gray....anyone able to have a crack at it for me?

While I had it up on axle stands to swap brakes over the other day, I chucked on one my spare rims to see how a 185/60/14 would look.

Doesnt look toooo bad...I have a feeling my planned 195/45's may be too low a profile, so might look into 185/55's instead.

Oh, and I haven't raised it for the pics, its bellied on my trolley jack

[Dell'orto]

April 2012

Still chipping away at this, sold the MR2 a couple of months back so have been a bit more focussed on the sedan again.

Brakes are FINALLY done. Been nearly 3 years since I bought the AE86 calipers

Two out of three of the 86 master cylinders I'd collected had decent rust marks on the inside...could have fixed them, but the one that came with the booster from Japan was almost perfect so used that one. As usual, got carried away when rekitting the master cylinder, and decided it'd be a good idea to polish it too

Calipers went from this:

to this

to this

Love having a sandblasting cabinet

Chucked a new wheelbearing in the drivers side hub too, it was looking a bit worn vs the passengers side...Penrite wheel bearing grease is a funky purple colour, kinda cool!

While I was there, I kept noticing the repair from when I had rust cut out just after it was painted...it was done well, but only primed. Couldnt see it with the guard on unless you had your head in the wheel arch (as I did funnily enough) but it bugged me so I blasted the shit out of it with underseal should keep it tight!

Also I manage to get hold of more factory black trim, there was a KE70 being wrecked at pick a part in auckland, and a helpful local went and pillaged it for me

Though unfortuntely the steering column shroud is off something random, possibly 100 series Corolla. Also it didnt have the front passengers side sill runner, so thats on the to find list.

I also spent a bit of time trawling Yahoo auctions, and managed to find C pillar trims

centre pocket/stereo surround

and a black gearlever surround

those will be arriving ex Japan in (hopefully!) a week or so

Thanks for trawling through my gargantuan photoheavy update

[Dell'orto]

May 2012

Finally got the mirrors done! Lots of pissing around but worth it

They're also devil's work to try and fit yourself, definitely a 2 person job. Think they'll be staying off until the bonnet goes on for good

Now to suss this heater tap setup.....

[Dell'orto]

June 2012

I investigated getting the radiator recored with a bigger thicker core a few weeks back, and got a hell of a fright at the cost - $540+gst! Even the radiator guy said it was bloody dear, but I guess being copper it was never going to be cheap.

So I got a custom alloy one made. Didnt like the idea of using the RX radiators you see on TM, and I have so much CBF when it comes to modding other ones to fit.

I got them to add a boss for the thermo fan switch too. I had the option of going with either a stock thickness core, or a larger 55mm core. I went the latter, cause bigger is better right?

I finally got around to swapping the sensors to the VDO ones too, and have run the wires into the cabin. Also swapped the stock oil pressure sender for an adjustable one, mainly because trying to find a normal closed pressure with with the right thread pitch and a decent pressure was impossible!

More little stuff being ticked off the list...

One of the fiddly little OCD jobs I'd been meaning to get around to was making the mounting holes in the top of the carbs the correct size...all bar two of them had been drilled/mangled out. Filled them up with an epoxy metal putty, and retapped em so they all are M6 Also got a throttle wheel from Pick a Part from something, which didnt quite fit the throttle shaft. Couple of zaps with the welder, and a bit of die grinder work and it fits nicely With that out of the way, I finally got around to bolting the manifolds, trumpets and air filter on for good. Looks pretty sweet I reckon

Also made a heat shield to cover the starter, as its bloody close to the Coby extractors, and wanted to keep heat away from the main cable for obvious reason!

I love that ACL stuff, its super easy to work into shapes.

Also drilled the holes in the radiator mounting tabs, and put it in the hole. I think I may have cocked it up, as it looks like its higher than the stock one. Could just be an illusion of the bigger core, theres plenty of room between the top of the cap and the bonnet when its closed anyway

[Dell'orto]

July 2012

So Olds Cool Autos to the rescue once again...when I tried putting the cable in the heater control last time (And this is over a year ago ), I snapped the clip that holds it in place :censored: Mostly due to the cable I want to use being smaller diameter than the original.

So finally got the cable mounted up, and bolted the dash frame in - amazing how something so minor makes the interior look heaps better!. Hummed and haahed for a bit trying to figure out how to hold the cable at the tap end...ended up making a rough clamp set up with a nut and some scrap metal floating about

So far so good, it actually works and holds steady. Have more of an idea now of how to do the proper version. The only issue I have now is that the tap is fully open by the time the lever is at about 3/4 travel...I think trimming the inner cable up a few mm will fix that though. Just hope that the angle it has to travel doesnt cause too many dramas!

Also grabbed the earlier model bumper while I was there...I prefer this type, it just looks a lot sleeker and the short end caps tuck into the body a lot nicer than the long end cap type. Its in pretty good nick, but will go off with the front bumper to get rechromed too

I'll have to make some new mounts to suit but that shouldnt be a major. Looking at the front bumper mounts this morning, I might try and remake some for that too, they dont seem to fit very well :conf:

Not only that, but got the rear seat I was after, and the passengers side black sill runner too much

Upon further investigation, the front bumper mounts are alright, I just had left and right mixed up Still need to add a tab to bolt to the front of the chassis rail though. The rear mounts definitely need a rework though, the current ones sit the bumper too far from the body, I'd like to pull it in a bit more flush. This (at first glance ) appears pretty easy to achieve.

With the heater tap - with the lever on full cold, the tap is fully closed, so I cant get away with shortening the inner cable. Would using a longer lever on the tap help with it? The difference with the lever on full hot and the tap being fully open is literally 3mm.

More shiny shit too, collected the under tray from the local powdercoater...I think the colour is solar silver, or something

Also never noticed this before...wonder if all that vintage Toyotas have the engine designation there!

[Dell'orto]

July 2012, pt2 y u so busy dis month??

These might come in handy

I'm glad that someone still makes em! They'll be for the 5K, so no rush getting the spacer made up etc.

My Whiteline panhard rod finally showed up yesterday...I'm sure the website said it was on car adjustable, but its not

Finally put the front swaybar back on, and finally installed the Ultra Racing lower bar bar while I was there. Be interesting to see if it actually makes a difference!

Front end of the car is nearly all done!

Panhard rod is in

Cursing the fact its not on car adjustable though...Roughly adjusted it to fit, bolted it up, dropped it down - its 5mm offset more to the passengers side I think I might leave it until it gets a wheel alignment, I was taking the measurement from the guard lip, and if one side is different to the other...

[Dell'orto]

August 2012

So finally got the heater pipework done...316 stainless tube. Shit is hard as hell! Until I hit on the idea of mounting it in the drill press

Started out like this:

Then finished up like this:

Also made a new lever for the heater tap so I could have full travel on the heater control lever - such a small difference in length, but it now works perfectly. Made the section that holds the cable a little taller too to put the cable on less of an angle.

Now just have to rejig the tap bracket, and send these bits off to be powdercoated. One more little shitty job off the list

More fiddly shit getting done...wiring is all done and routed for the gauges, coil wiring is all finished off and tidy. Even found a shorter dizzy lead to make it look tidier

Also made a bracket for the throttle cable today, so finally all 3 pedals actually work! Though it hits WOT before the pedal hits the firewall which is a pain. I'm full of a head cold this weekend, so it may not work in theory, but if I get the inner cable shortened more relative to the outer I think that should sort it out.

Thoughts?

Took today off work, and finished off all the various brackets, and blasted em up ready to take to the powdercoater tomorrow.

Also made a start on my bumper mounts today...got them sitting where I want them to

Though I got a bit carried away, and got 6mm flat bar to use...while thats perfect for the section that bolts to the chassis, its miles too hard to bend to shape without a gas plant/press So will get some 3mm stuff and finish the mounts off (hopefully) in the weekend.

Once I'm happy with how they sit the bumpers can finally go off to be repaired/replated!

[Dell'orto]

September 2012

Some little bits:

Took half of TNZ's stock of grille clips, now my grille/headlights actually sit nicely

Stuff back from the powdercoater

And my rear seat finally back from the upholsterer :bananavictory::bananavictory::bananavictory::

Guess I need to pull finger and reassmble the interior now!

[Dell'orto]

October 2012

Not too much been happening sadly, been flatout busy with work and my sideline business and family etc.

STILL haven't finished the bumper mounts! I really need to get my A into G, I need to get these bumpers sent off to be rechromed fairly shortly...there are 11 weeks left in the year, and I know the workshop who's dyno I'll use for the run in will close before then.

Have bought a few neat bits and pieces along the way though!

Pretty stoked that the hinge hasn't (yet!) broken on the console.

Back in March I think, I noticed there was some surface rust on the inside of my valance...it actually looks like the dog pissed on it, and corroded the inside. Lovely :shooting: I took it off with the intention of giving it a bit of POR15 love, but ever since then its been too cold for it to do. Finally got some sun the weekend just been, so gave it a bit of a lashing

Undercoated with silver, then black over the top. Ought to be pretty sweet now.

Before I reassembled the interior, I hit upon the great of dear of assholing the stock external regulator, and using a Bosch RE55 reg. Its tiny in comparison, roughly the size of a pack of matches.

However its not a direct wire up...have been nutting out how to wire it up, and still keep the charge light on the dash working. Finally gave up, and went to a local sparky to get a hand. Will wire that in over the next week days and see if it works as planned!

Also swapped my Equips for these

They're wrapped in Toyo T1R 195/45/14's. I'm actually pretty happy with how it looks at the front, but the rear guard gap makes me sad. It may settle a bit when its loaded with fuel and whatnot, but I may investigate a wider and taller profile tyre for the rear. 185/60/14 actually fills the guard well, but I don't think they're legal on a 7" wide rim.

[Dell'orto]

October 2012, pt2

Hahaha, you know it - f@%k those heavy ass trailer rims!

Tyres got fitted up today

So over the weekend, I'll measure up the springs, and get something softer/taller which will drop it and keep them captive, solving two problems in one hit

Look mum, no hands/axle stands

Will finish welding it up tomorrow night...my welding helmet shit itself, so its just tacked together, eyes closed style Then I'll drop them off to the powdercoaters, and finally FINALLY send these bumpers off! Can't wait.

So I've had a rare combination of time, money and motivation this month, so have actually got shit done!

Made up a pretty line from the booster to the manifold...got the hose finishing clips off TM, while not being as nice a finish as proper AN fittings, they look a shitload better than just having hose clips on there!

So all bar a catch can, the engine bay is all done!

I've put in some long hours in the garage this week finally fixing up the interior loom. When I initially deloomed it way back when, I missed out a few plugs which I wasn't entirely sure were needed. Also with the addition of the extra electrical bits I've added, it'd gotten into a bit of a state.

Started out like this

Fast forward 6 hours....

So now I can get this interior put back together at long last!

New springs arrived today too...they're not as low as I would have hoped, but realistically I can't really get any lower without getting even shorter shocks, and then I'd have next to f@%k all travel. Must be getting old, function over form Its still a 20mm drop over what it was though.

Mandatory on bumps pic:

Also got some new softer front springs too, should make it a bit nicer to drive on the road...250lb vs 390 the T3 kit came with.

Bumpers are at the electroplaters still...they rang me and said my front bumper is pretty badly pitted, and may end up being too thin to use after the acid bath. Struggling to find a replacement!

[Dell'orto]

November 2012

So over the past week I've made some really good progress.

Dash frame all mounted back in, and testing the electrical stuff. Everything works, bonus!

With that out of the way, I could finally get the carpet in! Though the trim bits I've collected over the years are a bit manky looking, so I gave them a bit of a tickle up...photo doesn't really show how oxidised they were. One cleaned up vs as they arrived

Pro tip - cutting compound is magic for cleaning plastic trim pieces up.

I also realised that the door aperture seals were still original and brown...they would look totally arse with the rest of the interior. So I went on the Rare Spares website and ordered new ones. Spendy, but they arrived the next day.

I also thought I should finally retrim the parcel tray, as it was certainly looking pretty haggard, as well as also being brown.

Before

After

With that out the way, I finally got the carpet laid! Underfelt glued in place as per instructions, then a few hours of trimming/pressing/shagging about. Looks awesome

All thats left to do is fit the two outer rear seatbelts, centre console and handbrake lever (Oh yeah, I bought a factory black one off TM the other day!) and we're finished on the inside!

Been plodding away at all the little fiddly bits still. Jesus handles all cleaned up and in, ditto sun visors. Finally swapped over the door lock rods (had changed them when I was planning a different style of lock knob, so had to put standard ones back in ) and put the new window winders and door handle surrounds on. Door cards definitely need to be retrimmed at some stage, its just too much black with everything how it is.

Rear seat belts are in, had to swap to a different type as I couldnt bring myself to cut holes in my C pillar trims

Mucked about with fitting the gauges too, I cut out a section of carbon fibre sheet to mount them in in the centre console. Looks alright, will certainly be better when its fixed properly and clean!

And they even match!

Still waiting for my bumpers to come back too 2 1/2 weeks to til my dead line

[Dell'orto]

December 2012

So I was planning on having it all done this week, but of course things never pan out as they should....

I was removing the front struts to swap to the new 250lb springs I bought, and bumped the strut and heard a PSSSHT. When I looked closer/wiggled the adjuster in the shock, gas and oil was leaking out. Not ideal! I sent it back to Stocks to see what the story was. Long story short, after 2 weeks, they supplied a new one under warranty, as some little brass thingy inside the shock was .5mm bigger than it should have been. Must have been a Friday shock!

I took the opportunity to make the strut tops look pretty

Also forgot to do the line from the radiator to the overflow bottle, so grabbed some more -6 and hose finishers to make it match

On the interior side of things, I finally mounted the gauges properly, and went to install the centre console, only to find that when I tried to get 5th and reverse, the gear lever hit the surround :barfy: I guess when I initially bent the lever I didn't account for the surround. So I bought a new toy

Only a wee 12T chappy, but it'll do me for now. With that setup, I dog leg'd the shifter more until I had decent clearance, checked to make sure 5th and reverse were good to go, then banged the centre console in for good!

My bumpers finally arrived back today! However, I'm quite disappointed in the rear bumper...looks good in the pic, and might look alright on the car, but up close you can see heaps of ripples in it. It doesn't actually look like it was panelled all that much.

I did think the job sounded cheap when he told me the final total on the phone. On the plus side, the front replica bumper fits really well, and looks really good with a decent chrome plating.

On the underside, I put crush tubes in for the rear swaybar mounts on the chassis...I guess the AE86 has captive nuts or something in there. I took a pic to show the hilarity of my welds, where you can quite clearly make out the point some slag dropped down my sleeve phone pic ended up too blurry though

However having the press made short work of the swaybar bushes!

So much easier than trying to drill/burn them out!

I've also made a start on my exhaust! Have ordered a shorter resonator and some more bends, and will hopefully finish it off tomorrow night

So close I can taste it!

Oh, and given I have to take the manifolds off to change the flange on the extractors, I'll take the opportunity to fit this

Much to my neighbours delight, I finally finished the exhaust tonight. Ran out of gas on Saturday, so had to wait til today to finishing welding it up

Its tucked up quite close to the floor, as ground clearance is pretty minimal Will give it a clean up with the flap disk tomorrow and throw some paint at it.

Really need some end caps for my bumper so I can get it all finished! Though the dyno place will close for the year at the end of next week, so it won't be getting done til January anyway

Reduction gear starter motors sound crazy!