Project MR Busa

[DX20VT]

Here is a few pictures of one of the projects we have on the go.

This is a bit of a cut and paste from one of our other project threads on anothe forum,
and the build has happened over the last couple of years,
but thought some on here may be interested since it's a Toyota.

This is not my car, but is the car Dad is building to replace the XR6-T Focus that we sold,

and since this is toyota, is probably more interesting here too.


car is a 200? Toyota MRS, also known as the spider, or new MR2.

ZZW30 is the model.

Almost all removeable parts will be for sale at some stage too,
as the parts are replace with lighter and better stuff.

Now really sure how it all happened but sometimes you just have to buy things when they come up.

Search and search for ages for what you want and then...


We now own Two MRS cars, and two hayabusa engine's,

But no the plan is not to build two cars,
(at this stage anyway)

and also come across a bolt on turbo kit for 550hp on race gas,
which shows the potential of the engines.

The second shell, the yellow MRS, this one is going to be the race car shell,
and the red MRS (which was really too good to wreck) will be re-assembled and sold.

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37276.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37277.jpg

We have also got a semi-complete Hayabusa Bike for the engine donor,

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37278.jpg

The front and rear clips have had moulds made for the front and rear,
so we can produce lightweight complete front's and rear's in one piece.

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37279.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37280.jpg

Have gotten a few of the other projects out of the way now too,
so hopefully progress will be a bit quicker from now.


Car is now on the rotating spit,

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37281.jpg

and we have some of the fibreglass parts out of the moulds made too.

The front clip,
http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37282.jpg

The outer door skins,
http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37283.jpg

and the front and rear panels,
http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37284.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37285.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37286.jpg

Here is a picture of the actual diff.

It has been removed from a FWD toyota geabox, and had the inner workings removed and two spider gear welded in so the axels can still be inserted and removed as per normal.
We fitted bearings to each end and made alloy housings to hold the bearings, and attached the drive gear for the chain in place of the crownwheel. No there is no need for oil apart from to lube the chain.

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37287.jpg


And here is the axel setup and engine on part of the rear frame.
we are using the standard shaft out out one side of the diff, so that the two inner CV joints are evenly spaced across the car, and then using more FWD toyota axels to drive out to the hubs that we modifed to use in the rear.
Will get more pic down the track as it gets more fully assembled.

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37288.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37289.jpg

Here is a picture of the engine in the frame.

The frame mounts the engine and the diff,
and all the rear suspension pickup points and on the subframe too,
which is why it just looks like an overcomplicated engine mount at this stage.

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37290.jpg

and here is the frame in tha car showing where it will sit,

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37291.jpg

and here is the car with the frame sitting on axel stands and on some weight scales.

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37292.jpg

So the body shell, rear frame, engine gearbox and diff,
minus the weight of the axel stands,

250kg as in the pic.

Obviously there is a heap more to go into it,
but there is also a lot more to come out.

more parts arrived from the states,

Rods

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37293.jpg

Cage near completed,

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37294.jpg

It has had all the suspension in too, but has been in and out and no pictures to show.


Did a weight update too,

weighed the car with car full cage, seat, engine, gearbox, diff & axels, all
hubs, shocks, springs, suspension arms etc, and body panels incl roof etc,
but without wheels and tyres,
and came up with a weight of


416kg !! 8O

Pistons

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37295.jpg

Other parts

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37296.jpg

A completed Hayabusa Engine, ( not ours unfortunatly)
http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37297.jpg

some driver controls, Seat, pedals & steering column position all very important.

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37298.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37299.jpg[/img

all the suspension was done enough to send for a wheel alignment to ensure all the suspension pickup points are in the correct place,
and that the camber/caster/toe etc change as required through the suspension travel and adjustments available.

Put all the tempory body panels on it to see what it look like at approx. ride height and get a view of how it will look.

[img]http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37300.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37301.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37302.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37303.jpg

Not a lot of visable progress on the car at this stage. One engine is away having all the go-fast internals bits installed, the other is away having the exhaust manifold & intake/plenum finished. Brake parts & adjustable sway bars at at the engineers having final modifications completed. Most of the welding on the chassis is finished, roll cage all finally approved & the chassis is not far away from being ready for painting.

Meantime all the body work has been completed & moulds made etc. The wheel arches in the guards have each been raised about 50mm & widened about 35mm (per side) but we have kept them standard looking. The front splitter/air dam is from a BA Falcon V8 Supercar, the bonnet vents to let the radiator air out are from a Ford GT40. The spare body has just some back from the signwriters yesterday....

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37304.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37305.jpg

[Kid Karola]

I'm lost for words... is there something more epic than EPIC!!!

[dustyae86]

Simply awesome.

What are you doing for reverse?

Push it at that weight :P
pretty wicked, looks really good, glad we are getting some more knowledgable guys back on the forums.
what do you and your old man do work wise?

[blair]

So refreshing to see a build that is of such ridiculous depth and quality!

Nice man

[ThatsHowWeRoll]

Wow. So so epic.

[DX20VT]

Reverse is just a starter motor and ring gear on the rear axel,
as reverse is only there for emergency's
and because the rules say you have to have a reverse.

But yeah push it will be the way most of the time.


Push it at that weight :P
pretty wicked, looks really good, glad we are getting some more knowledgable guys back on the forums.
what do you and your old man do work wise?

Dad used to own the local Toyota Dealership and worked for the TTE rally team for a while,
and now own the paint and panel shop,
but spends over 1/2 the weekends of the year working for different race teams all over the place in different categories.

[dustyae86]

Reverse is just a starter motor and ring gear on the rear axel,
as reverse is only there for emergency's
and because the rules say you have to have a reverse.

But yeah push it will be the way most of the time.



Dad used to own the local Toyota Dealership and worked for the TTE rally team for a while,
and now own the paint and panel shop,
but spends over 1/2 the weekends of the year working for different race teams all over the place in different categories.

that explains it then, bit rare to see this extent of knowledge on this forum haha
hopefully you will stick around and contribute a bit

[86TRD]

holy batshit , this is awesome

[ThatsHowWeRoll]

Why did you choose to use the busa engine over other toyota options??

Is it to qualify for a particular class or something??

Or was it like 'well, we have one of those and one of these already...lets just put them together!' sorta thing?? Obiously you know the motors well too.


Get some vids of it when its running!

[svenmate]

Holy Balls.

[sun_moon]

FUCK YES !

as a fellow midship driver, im just in amazement at this car !!

[squish_m8]

amazing build.

totally pro-town!

[driftke70]

pretty awesome,

going to turn, i know that much

[joeschmo_57]

Hard.
Fucking.
Core.

[tuff te-72]

lol...okay...then...

what are you trying to do? just rub it in our faces? i still cant believe what im seeing...like...people say rebuild BUT THIS WHAT DO YOU CALL THIS?

im shocked for words, sorry man but this is fucking awesome, man we just wanna build cars, you take it too far...

[sun_moon]

proberly THE best car build to ever grace this website ?

[DX20VT]

A little bit of progress,

Some pictures of the intake system.

Turbo outlet blows into the water/air intercooler, and then up into the plenium.
The water/air cooler is mounted low down and on the passengers side of the car for weight dist.

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/44329.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/44330.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/44331.jpg

The last picture is looking into where the side air vent will go.

[dr1ft-pig]

this thing is just awesome man.... will farking hammer and by the looks of it... wont weigh much more than a hyabusa

props man!!

[DX20VT]

It runs !!

A short wee clip.

http://www.youtube.com/watch?v=MWQ1-yZpoZg

Still has no fuel or ignition program so wont rev well but after a few confusing days setting all the ecu settings and triggers,
it does make noise.

[Gunner]

Pretty cool dude, congrats, can't wait to see it at full noise.

[ke_70]

fuck! i want this for my mira!

whats a busa engine/gearbox worth?

[plohl]

This is an awesome build dude - seriously.



http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/37297.jpg

Also, is the engine using quad throttle bodies? I have been thinking about this the other day, whether it would improve the drivability of a turbo, do you know much about the engine?

[xero]

fuck! i want this for my mira!

whats a busa engine/gearbox worth?

clay, any superbike engine be it a 600cc or 1000cc will be more than enough for the mira man. especially if you hung a turbo off the side!

[macca1590]

ummm fuck yeah, and ae86's are suposta be big go karts haha

check this too
http://picasaweb.google.com/situnepictures/EscortRR?feat=directlink#

cbr900 turbo in mk1 escort

[ke_70]

clay, any superbike engine be it a 600cc or 1000cc will be more than enough for the mira man. especially if you hung a turbo off the side!

i should steal the old mans 600cc bike and rip the motor out with out him noticeing :O

id be happy with 80kws in the mira + abit more depending on how much weights added?

i think i should stick with one project at a time lol. im planning my missile car to!

[Jdm-Mcc]

Ive always dreamed of a suzuki 800 alto with the floorpan cut out, a tube chassis with a 900c bike motor mounted above the diff centre (irs of course) directly driven to the nose of the diff, coilovers all round, fibreglass fix back seat, nice wheel and an aluminum dash panel with an s2000 cluster, n2 kit styled flares and some 14x9's and 11's and a roof wing and front spoiler

Done!

[DX20VT]

Also, is the engine using quad throttle bodies? I have been thinking about this the other day, whether it would improve the drivability of a turbo, do you know much about the engine?

Our engine is single throttle as you get more power from single throttle and it is a lot lighter and simplier.

[ke_70]

so are you worried about loading the chain up to much?

you will have double the weight, and much wider tyres than a motorbike.
the chain will be under way more load than the motorbike would.

[plohl]

Our engine is single throttle as you get more power from single throttle and it is a lot lighter and simplier.

Yeah, its standard on most FI setups. I was just curious as to whether the quads would give better control at low throttle position and better throttle control. Also, how would you tune for the quad's. I mean, generally you would tune of the manifold pressure after the throttle valve.

What ecu are you running?

[LittleRedSpirit]

With this kind of setup and the rpm involved it wont see much time at small throttle openings.

[joeschmo_57]

^^^ Apart from when you warm it up.

Jdm Mcc, forget the Dattos and do itttttttttttttt

[Jdm-Mcc]

Its on the cards joebro

[plohl]

With this kind of setup and the rpm involved it wont see much time at small throttle openings.

What about cornering?

[DX20VT]

Yeah, its standard on most FI setups. I was just curious as to whether the quads would give better control at low throttle position and better throttle control. Also, how would you tune for the quad's. I mean, generally you would tune of the manifold pressure after the throttle valve.

What ecu are you running?

I run Quad Throttles on my Corolla Race car, and we also run them on a GT40 project car.
Tuning with them is fine, but you need a really good balance pipe and chamber to get a constant vacuum signal from.
With thubo setups I dont think there would be any advantage on ITB's as the response gain would be overcome by the smallest amount of lag.

All the cars we have now run the Link G4 ecu range. This car has a Link G4 Extreme.

[ke_70]

so are you worried about loading the chain up to much?

you will have double the weight, and much wider tyres than a motorbike.
the chain will be under way more load than the motorbike would.

in case you missed it

[stx-16]

All the cars we have now run the Link G4 ecu range. This car has a Link G4 Extreme.

yes i love links iv got an old link plus in my sr20 ke70
and one on my friends has a g4 extreme in his mr2
good luck with it

[Sam-Q]

I am stunned- this build is amazing. I never would of thought it would of been possible to lighten a new gen mr2 or any late model car that much, grinder or not.

As KE70 said the chain is a worry. There was another website where guys race cars that have to adhere to a price limit in the hundreds. One of the guys did this exact same thing where he had a front wheel drive where he pulled the gearbox apart to just leave the diff and ran the chain to the "crownwheel". He also fitted self lubbed sealed bearings to run it dry. They found that the chain being so short and under so much load it would burn up. They ended up dribbling oil onto the chain as much as they could without the track marshals throwing them off as it would end up on the ground. The chain in this car is longer but still it might be an issue.

Otherwise I really look forward to this running.

[ke_70]

would you also break the chain? i quized a few people and they said the chain wont last. you might be able to go double row if the chains short enough? otherwise it would throw itself off

i wonder if you could do some kind of supersize belt driven? they seem to work on harlys fine.

[DX20VT]

As promised here is a video of the cars very first run on the track….

We had the opportunity to turn some laps during the lunch break at a Classic race meeting so a good chance to finally give the car a shakedown.
It has a few minor niggles as expected, just things like some tyre rub & things, but overall a successful first run…

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/69324.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/69325.jpg

and the video here.
Camera mount was not the best as we just fitted the camera mount from my car and the bars are on different angles.

http://www.youtube.com/user/Martman77#p/a/u/0/ap64OdGmls8

[Andy San]

That sounds awesome!

dashboard looks nice too...

[brad]

how much did it weigh in the end?

[corknose]

cause you women love shlongs so bad...heres the real thread.

http://forums.performancecar.co.nz/viewtopic.php?f=2&t=53628

[DX20VT]

Sorry its been a while between posts, but there hasn't really been anything exciting to report.... We have had two race days recently.

First was a Club day at our local Levels Raceway & we had the car seriously under sprung and over geared, resulting in stalling in 2 of the 3 starts and in the last race cooked the clutch trying to get started. Still posted a reasonable laptime of 1.07.332
Couple of pics here...
http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/272870.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/272871.jpg

http://www.ae86drivingclub.com.au/dcimages/1/9/6/3/272872.jpg


Second outing was at Ruapuna for the Premier Championship Series where Chris run in "Production GT" class on DOT rated tyres. A boost problem meant only 6th in qualifying, then a harsh call meant starting race 1 from the pit lane, but still managed to come through the field to win. race 2 was reverse grid and another win & class lap record of 1.31.519, but the boost problem came back for race 3 so just cruised round to finish. Happy with the results considered we haven't even started making changes to the suspension set-up yet, plus we were slightly undergeared for Ruapuna, meaning I had to get out of the throttle before the end of the main straight, plus I was struggling to reach full throttle (as the video shows) so a few wee issues to get sorted. Videos of the test sessions are below, the camera didn't work during the races :(
First test session here (part 1)
http://www.youtube.com/watch?v=iGSvW0Sisug&list=UUhJBIPpj4buWJMlnVc8xylA&index=2&feature=plcp

part 2 of first session
http://www.youtube.com/watch?v=Ji6pMv6ACZM&list=UUhJBIPpj4buWJMlnVc8xylA&index=3&feature=plcp

Second session
http://www.youtube.com/watch?v=xUv3CP97HHI&list=UUhJBIPpj4buWJMlnVc8xylA&index=1&feature=plcp

and a video from my car (Corolla DX KE70 Sedan with a 7AGTE 20 valve engine). The MR-S shows up at 32 seconds into the video.

http://www.youtube.com/watch?v=V39xairssNE&list=UUhJBIPpj4buWJMlnVc8xylA&index=5&feature=plcp

For those in NZ, the races from Ruapuna will be on the Gillette Motorsport TV show on January 8th 2012.

[Gunner]

Thats one angry little mr, so cool.