Stu's 4agte 85 EP71 Starlet and 4age 84 AE86 Levin

[Stu]

My name is Stu, and I like 4ages.  So much so that about 16 years ago I made one fit into a EP71 because I couldn't afford an AE86.  Yes its wrong wheel drive, yes its too loud, yes the intercooler is too big, yes there are many other sins, but it eventually ended up being reasonably fast-ish and just quietly it is a little bit of fun to drive. But recently I redeemed myself by acquiring an AE86 Levin, so I thought it was about time to supply you the reader with double the amusement of watching me waste many hours and many dollars on a couple of examples of Toyotas best metal > rust conversion products from the 1980s...

I'll do a decent post on each of them eventually but here's a snapshot to get the ball rolling.

The EP

I'll start with this, bore you with the details, then switch to the more exciting 86...

It started out as a white 1985 Toyota Starlet Si - featuring the worlds smokiest 2e-elu.  It had a couple of redeeming features in that it was straight, and complete, had 120k on the clock, and came from a very quiet family who loved it and were very sad when i drove away in it.  It drove quiet and smooth and apart from the smoke screen everywhere it went, it was a nice car. I wrecked all that by fitting a 4age, adding boost, vibration and lots of noise and smoke.  It currently has a fairly basic engine setup comprising of an cobbled together 8.0:1 bottom end with some arp bits, lightly tickled blacktop head, single throttle intake, long merge turbo manifold to a GT2876r and stainless exhaust.  Its runs a Link G4+ Storm that I wired and tuned (the later with the help of KPR who I have been annoying for years... oh the shame of tuning a fwd).  It has run a slippery best 11.81@121mph on the quarter mile at a peak of 17psi with a 2.3 60ft so there's more potential there.  Its currently tuned to 23psi but haven't run that much on a track yet.  It only been on a dyno once way back in the day on a aw11 bigport ze and T04e where it made 195kw on 16psi.  No idea what its making now as its street tuned, will one day find out.  It will surprise most but this thing does go around corners and runs surprising straight without too much torque steer #notlies. Anyway, other than that is fairly simple, some strengthening work in the front, coil overs, turret dropped rear, sway bars, fancy short ratio gearbox with LSD etc etc.  Ive done pretty much everything myself bar the paint.  Its been a great learning curve and through practice has lead to me wiring and tuning ALOT of other cars for guys I know.  Will go into that another time. Here's some photos:

 

The 86

This is newly acquired from a mate who I have been pestering about 86's to for years. I have yet to find time to work on it, but its straight and virtually rust free, and comes with a non-running bluetop with quads, Jasma headers and some HKS bits apparently... = win.  This isn't my first AE car, but I'm hoping to build it into as close to my dream 86 as possible (except for the small fault of not being a notch but you can't win them all). Will update on this reasonably regularly this year as I want to get this on the road asap and enjoy it while I piece together a different setup for it.  Its not going to be silly like the EP ended up... well, that's the intention.

 

That'll do for now.

PS: Hi Dave.

 

Abuse here 

 

[Stu]

Levin update:

Rather than being smart and spending a relatively small number of hours to make this turd run and just enjoy it, I opted for the dumb route and ripped it to bits instead.  The engine came out, I trailered it to work, and got stuck in taking 10 steps backwards progress wise.  All the front end came off and it was a pleasant surprise to find it was a virgin and had never been apart before, so is relatively unmolested. There were a few rusty spots to contend with and had to bare metal it around the brake master as it leaked fluid there which did wonderous things to the paint.  Body work is not my forte so when Joe Manji made the mistake of offering to help I took him up on it.  Huge thanks to his hours and motivation else I would have rattle canned that bitch matte black and chalked on cock and balls insignia's all over the place.  

Wire wheeled and cleaned up the inner guards and tunnel and slammed that with some black underbody stuff which came out fairly amazingly.  Joe Manji grappled the spray gun and splooged factory white all over the shop and it looks bloody good! Way too fancy in fact, and now I've realised I'll need to spend an eternity making sure everything that goes back is clean and tidy.  Truth is that I'll probably start cleaning shit up then get impatient and just slam it all back in so I can get on with the fun stuff - watch this space.

 

  

  

  

   

 

[Stu]

EP71 update:

Bits and pieces have been turning up.  Some 3 inch stainless bends and straight for a new exhaust. And this...

[Stu]

Slow progress, hopefully will jam the engine back in this coming week.

 

[Stu]

Not as much progress as I'd hoped but slowly getting there.  Gave the engine a quick rattle can rebuild, swapped on a lightweight flywheel/clutch setup that KPR had lying around, and got the gearbox on and ready to go in the hole.  Will fit that all next time and put on the new oil pump Ive got etc.

 

The -3kw comment is a standing joke between KRP and I.  Years ago he helped street tune my EP in preperation for a dyno day that I ran. His EP82 came out with 198kw , compared to the 195kw in my EP71 .  So from that day forward I claim that everytime he touches or has parts that end up on one of my cars the power figure deliberately reduces by 3kw. 

I also made up some billet radiator brackets and a battery clamp at work, might make a few of these eventually.

Anyway, its ready to go in the hole.

 

Ive got a whole heaps of parts waiting to go into the car, just need to find the time to do it.

,

 

[Stu]

So following on with my 1 step forward and 2 steps back theme, I pulled this apart again... 

I was mulling over the engine and its unknown history so decided to do some preventative maintenance before slamming it back in the hole.  So the box and fly came off again, the engine got slammed on the stand and its front and pants taken off.  Had a bit of a look at the bottom end , all looked very clean - almost suspiciously clean, but looks relatively stock I think. There's a metal head gasket on it and the ports have definitely been played with but who know to what extent.  Its got some HKS cams apparently but haven't pulled the top covers off to look yet.    Anyway, put the new oil pump on, glooped the windage tray and sump back on, dummy fitted some new Toda cam wheels and a fancy belt.  Ive got a new idler pulley for it but need to drop in to Toyota for the new water pump so will fit that next time.  Fly, clutch and gearbox went back on then dropped it in the hole.  Headers fitted and some other bits and pieces.  The clutch hard line was a bit fucked up so made a new one from braid and bled that up.  Making progress very slowly.

Yes the cams are not aligned, the belt is just sitting there poser spec.  All has to come off again so I can fit the hall effect sensors.  Will have a CAS for sale shortly if anyone needs one.

Fuck theres a long way to go.

Anyone know where to buy new passivated bolts for this turd? I can't bring myself to put the old shit ones back in - especially as most are missing.

[Stu]

Small progress is better than no progress:

The fuel rail looked pretty shitty and I want to run -6 lines so I did the old weld it up trick that I've done for many customers over the years.  

 

Also needed to add a wideband bung and slightly change the angle of the collector outlet as it was a bit close to the floor:

 

But shit news, the LSD I have is dead and I really cant be arsed measuring and drawing it all to make new parts on the mill.  Anyone have a decent T series LSD for me before I go and buy one? TRD/Kaaz/Cusco etc, anything considered.

 

[Stu]

So this happens when you leave random carparts in reception at your business by mistake:

 

And I received a care package from @KPR :

 

[Stu]

So I looked at the prices of aftermarket pulleys and said to myself "fuck that, I can make those" so have drawn them all up and will be putting them on the cnc lathe soon.  Idea is to make myself a set and get them anodised.  Will likely sell these eventually too, have got fwd and rwd water pump pulleys drawn up and the alternator pulleys so yell out if anyone is interested.    These are underdriven too.

Nearly there with the design, just need a few tweaks to give some added strength and make them easier to run up on the lathe.

[Stu]

Little bits and pieces starting to come together now on the 86 - painfully slow but any progress is good progress right?

I've fitted the new water pump, cleaned up and painted the coolant bypass hard lines, picked up new radiator hoses and have the heater hoses ordered and on way.  Front of the engine is coming along with the hall effect sensor on the crank mounted, still have the sensor for the intake cam pulley to do but hoping to knock that off next week.  I've found and mounted up an ae85 radiator overflow/washer bottle in the front drivers corner of the engine bay as the ae86 one will melt over by the headers I think.  Found a brake reservoir sock thing to cover tidy up the faded gayness.  Am in the process of cleaning up and painting the brake lines so I can refit those, have some braided lines to go on. The drive shaft is now in with new bolts and a new gearbox rear seal.  Tidied up and painted the strut brace mounting plates.  Exhaust is almost done, just have about 200mm of pipe to do from the merge collector to the rest of the system to build. 

 

How its looking currently

 

Also picked up this which is now fitted:

 

And this which isn't fitted

Pulleys are sitting on the cnc machine so will have them done next week all going well.

[Stu]

Slowly but surely

 

[Stu]

Just a waiting game while the painting guy does stuff.  I decided to take the side trim off so the guards needed a bit more work but are all in primer again now.  Body is coming along very slowly.  Front bumper is off to get fixed as theres a few cracks in it.  Painting is boring so just one photo for now.

 

In other news these arrived... finally.  I run FA stuff in the EP and its pretty good, so thought Id have a stab at it for the AE too.  Spenny, but hopefully worth it.

  

Went with 8kg and 6kg and the shortest possible rear shocks.  Will order some new bearings and maybe rotors sometime soon.  No rush without the car here.

 

[Stu]

Rust repairs and painting gives me the shits, would much rather be doing exciting things... like smokey 11's

Anywho, some more progress, back bumper was hiding some gems which needed dealing to.

  

  

[Stu]

Yawn...

Might slap some white on this bitch next week.  Also might not.

 

 

[Stu]

Can confirm this thing is white now - no photos yet.

 

[Stu]

[Stu]

Plan is to finish wiring Richies KP then hit this thing hard.  For now have swapped out the front carpet as it was a bit shit, and fitted the lights. Its back in storage now.  There's a looooong way to go.

 

[Stu]

Forgot a photo, here's the inside in all its dusty shitness. Should clean up good though.  Wont make it to OS drags but I'd rather get this together properly than thrash on it and have to do it again later.

[Stu]

Yearly update 

Life has been busy, and while juggling kids, a growing business, and another couple of projects for people it's meant I haven't got all that much done on either car. I had visions of making OS Drags this year but yeah nah the 86 isn't running yet and I've left it too late to resurrect the EP71.  

EP71 wise it still starts up and drives fine, except the gearbox is now leaking so will need to come out.  I've got a new Cusco LSD on the shelf along, several good gearsets that I already modified a few years ago, so really just need to put a box together and swap that in.  Will aim to build the traction bars Ive got in my head at the same time. I also still need to build the 3 inch exhaust system from the stainless tube, bends and flanges I have in stock, but finding the time is the hard part.  The alternator bracket that I made years ago has also mysteriously broken while the car has been in hibernation - easy fix though.  I bought a new GTX2867 Series 2 turbo for this a while back and Kris has run this up on his Hilux for a comparison to his GTX2860 series 2.  It made for some interesting results, and I think on the engine in the EP71 it should make some reasonably decent numbers compared to the GT2876 on there now.  Anyway, will work on this car next year and hopefully actually put some effort into racing the thing the following summer.

Pic for motivation.

 

Onto the 86.

I've made some progress, but no way near enough to make the OS Drags. Next optimistic goal is to make Toyota Fest.

Things I have done though:

My boys helped me fit the front and rear bumpers so thats all done and tidy now.  The front lip has been grafted into the bumper, not sure I like this idea now but it will do for the time being.  I definitely don't like the gloss black paint though, will repaint in bumper black once its going.

 

 

Picked up a battery and made a wee bracket for it in the engine bay.  I'm no longer a fan of relocating batteries so thought this was a good compromise.

 

I've also been mucking around a little bit with the front end. Stripped the front end apart, cleaned up the arms, fitted power steer knuckles, new brakes set of rotors and pads. Dropped some lowering springs onto the stock shocks for now so its wof friendly but will swap in the coil overs later.  I've got new rack ends, rack inners with spacers, new front Cusco sway bar and full bush kit to go in too - hopefully onto that very shortly.  I'm considering a Cusco caster arm setup too, haven't quite pulled the trigger on that yet.

Wiring wise Ive had the front chassis loom and rear chassis looms out of the car to make a few changes and re-wrap them.  I've taken the aircon wiring out and added in larger dia wire for the fuel pump in the rear and new wiring for the twin radiator fans in the front.  I'm setting up the fuel pump and dual fans on solid state relays so I can speed control them all.

Jacked it up and ripped the fuel tank out, have fitted a Aeromotive Stealth pump and changed all the lines to AN fittings and black teflon braid that Ive had left over from previous projects.  Also took all the old fuel lines out and have run new hard line through. I need to redo the brake line too at some stage.  Gave the underbody some love so thats all tidy now.  I managed to pick up a new Cusco panhard for a good deal and a new Cusco rear sway bar so those have gone in with new bushes - will get photos of that next time.

I've got various CNC gear at work to play with so have been working on coil plates to suit Suby COP's that will fit under the standard small port cover.  Finished product is in but I havent taken any photos yet so here's so progress shots while making a few trial units.  Should have these for sale at some point.

Other work underway is the dash wiring, have taken the loom out for a strip down/few changes/re-wrap and have the Link ecu wiring planned out and started.  Getting back into the engine bay will be next, there's not alot to do really.  The hall effect setup is all done so I just need to make up a blanking for the CAS location and that's done too.  

Also got this. 

 

And this to fit at some stage

Hopefully will get a good week on this over the Christmas break which should almost see it running, fingers crossed.

 

 

 

[Stu]

So Stu, what have you done in the last 6 months or so? Well, short answer is fuck all really...

In non car related issues a rat somehow got in and ate through the water feed to the dishwasher, the house flooded meaning the brand new kitchen, the brand new t&g floor, and the garage ceiling below all needed to be replaced - yay.  Insurance somehow managed to take 6 weeks longer to do the job than they said it would, and in that time the car and everything else for that matter had to be put in storage at the in-laws. They didn't seem to mind too much but its stole pride of place in their garage somehow - better than outside where it would fizzle away to a rusty pile.

Anyway, its back where it belongs in the garage and I've been sneaking in the odd hour or two and chipping away at it. 

Last year I made up some new fuel lines from bundy tube, i was never 100% happy with it so ripped it out in favour of running new -6 teflon line through instead as I had a roll left over from my car building days. At work I butchered some brackets together on the cnc router using 10mm plate ali. They hold the breather, feed and return, and brake line up under the car.  Here's the first test one I made.

So I made a hole bunch, tidied them up and then ran them all through. It came out reasonably well.

I didn't take any pics but these run through to a billet filter mounted low on the drivers chassis just under the fire wall, then up to the rail.  The fuel reg is mounted low in front of the brake prop valve so its all pretty stealth which is what I was going for.  So that's the fuel system done finally.

Moving back to the engine I dummy fitted the coil plate which will work  - just need to pickup some redtop cam covers that have the bolt provisions to hold the thing down.  Richie might have a set for me so hopefully will try those up with some new breathers at some stage.   The top cover then hides everything.

 

I have finished wiring the hall effect sensors and put all the timing gear together and buttoned up the front of the engine.  Just need to find the top cam belt cover which is currently awol.  Still need to make a dizzy blanking plug. 

 

I got thinking about the factory spark plug cover and that it has the spark lead provision at the front that I don't need, so decided to make a new version without the up step. For now I've made a timber one but will run this from some 16mm plate at some stage and matty b it for a simple look.  Here's the timber one anyway.

Its pretty funny being timber - might just varnish it and leave it till it catches on fire

Other than that, ive been working on the brake lines and have rebuilt the steering rack along with new boots, new rack inner and outer arms etc. Need to get a few hard lines made then check the system for leaks.  Then its onto wiring then skids! See you in another 6 months...