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Thread: Prime86...The rebuild.

  1. #21
    Senior Member turn69up's Avatar
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    Laurence
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    Thats a sick gear box, flat shifting ftw what did u pay for it? if u dont mind me asking

  2. #22
    Senior Member Prime86's Avatar
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    Brad
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    Hey mate...Yeah will be special to drive with this gearbox that's for sure...Lol.

    I wont post up the exact price of the gearbox as its scarey to think of just how much I have spent on the whole car and my wife may see this post...Lol. Lets just say after it was fully rebuilt including some over night parts from the UK it was the same price I was quoted from Albins for a gearset alone with the same ratio's and dogleg shift pattern conversion. The benefit of this box over the Albins apart from it been a dogbox is the Albins box would have cost an extra $1000 or so more with all new bearings and syncro's.

  3. #23
    Senior Member Prime86's Avatar
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    Brad
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    I was pretty lucky to find the Quaife gearbox and snapped it up so at least I would have it to use even if I used a different gearbox when not on the track. After the gearbox was completely rebuilt I looked around for a clutch and I had to sort a shifter for it as I have heard that these gearboxes break shifters quiet easy. I had a C's quick shift off my old gearbox so I set about modifying it to make it easier to shift and to make sure it was chunky enough to hopefully not break. Also I looked at different shifter bush options as the standard one wouldn't handle the abuse for long. What I came up with was an extension for my short shifter slightly modified and a Cusco brass shifter bush that will last with the hard shifting.
    Once my shifter was made I moved onto a clutch and I managed to find a guy who was bolting a Hasselgren formula atlantic engine into an AE86 who brought a clutch from Hasselgren engineering. He decided to sell the formula atlantic engine and clutch so I landed up with that clutch. The clutch is a Tilton twin plate with billet hat and is smaller in diameter than a standard type clutch, it also came with a steel flywheel to suit that was surprisingly light only 3.8kgs so the same as a Toda chrome molly flywheel. I also brought an ali adaptor plate that bolts into the front of the T50 gearbox to fit a hydraulic clutch release bearing setup. I'm still looking into the release bearing setup but think I have found what I'm looking for as I would like to remove the standard clutch fork etc.
    While at it I brought some Cusco engine mounts and transmounts for when the engine goes in. Here is a few pics of the clutch, shifter bush and modified gearstick, once in the car I will see where the gearstick sits and make adjustments from there.




  4. #24
    Senior Member Prime86's Avatar
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    Brad
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    So I've gone as far as I'm going to go with the gearbox setup for now as it wont go in till my new motor is built. I will move onto the engine side of things and what my plans are, as it stands my current engine will simply be removed. It's a very strong motor but the combination I'm looking at it simply isn't worth playing with it, someone else will get better use out of it.

    I managed to buy a complete spare engine with a few items I require so that will be the engine I'm going to build. As far as a base for the build it will have a 7 rib block with oil squirters, 42mm crank, 16V small port head and quad throttles.
    My spare engine had all of this so it was a matter of stripping it down to inspect the condition, all other items other than mentioned above we scrapped or sold to build the new engine back up again.

    So I got onto stripping the spare engine, it was in pretty good condition and the items I require were suitable for rebuild so I was pretty happy. When stripping the engine I found the intake cam had been damaged and a few other small things but that was it really. Here is some pic's of the engine in pieces.





    After it was completely stripped I took the block to work to put it through the acid tank and cleaned it all up, then everything was measured to see if it need boring etc. I also measured up the crankshaft and had a good look at the cylinder head after finding the damaged cam.

  5. #25
    Senior Member Stej's Avatar
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    Very detailed Brad. I notice you are using a small port head. I thought the big port head flowed a bit better and gained better results? What cams are you using?

  6. #26
    Senior Member Prime86's Avatar
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    Hey Steve, thanks mate. Yeah I'm using a small port head to start off with as I feel its better for my build. A big port head has very large inlet ports that pretty much you cant do anything worth while with as far as porting, great for a turbo application not so much for N/A. By starting with a small port head then porting it you can shape the port opening it up where you want to achieve a better flow and in turn make more power N/A even if the port is close to the size of a big port when finished.
    I'm almost finished getting a parts list of what I have for the engine build so I will post up the specs and what I plan to do later tonight but cams are 304 on the intake and 288 on the exhaust.


  7. #27
    Senior Member Prime86's Avatar
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    I have been collecting parts for my engine build for awhile now and I'm very close to having all the parts to start assembling the engine. So my new engine will consist of the following parts:

    Bottom end

    7 Rib silvertop block with oil squinters
    Silvertop 42mm crankshaft
    Wiseco high comp forged pistons
    Tomei forged H beam rods
    ACL race bearings, mains and bigends
    ARP main cap studs
    ARP flywheel bolts
    Tomei main cap latters
    New OEM timing belt cog
    New high comp oil pump
    HKS oil up kit
    BHJ harmonic balancer
    Toda chrome molly flywheel or Tilton flywheel (yet to decide)
    Custom ali high energy racing winged sump and pickup
    New OEM rear water pump housing
    New OEM water pump
    New OEM belt tensioner, pulley and spring
    Formula Atlantic additional belt tensioner

    Top end

    High comp 16V cylinder head (extensively ported)
    1mm over size valves
    TRD .8mm head gasket
    ARP head studs
    Toda racing shim under bucket conversion
    Toda racing 304 deg - 9mm of lift intake cam
    Toda racing 288 deg - 9mm of lift exhaust cam
    Toda adjustable cam gears
    Greddy timing belt
    Cas
    Sam Q COP conversion
    T3 small port quad throttle body adaptor (match ported to head and throttles)
    20V quad throttle bodies
    TWM velocity stacks modified
    Power craft tornadeo header (match ported to head)
    RWD water outlet with new OEM ecu water temp sensor
    Golden Eagle vacuum block & mounting bracket

    Modified small port fuel rail
    Billion 65°C thermostat


    Parts to get


    Injector dynamics injectors and plugs
    Toda oil pump gear set
    Tomei fuel reg
    Engine managment (Motec)


    My head is out getting done as we speak and my block has only just come back for my machinist. I will post up what I have done to the block and other components as I go throughout the build.
    Last edited by Prime86; 7th July 2013 at 10:54 AM.

  8. #28
    Senior Member Prime86's Avatar
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    Brad
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    I found some pic's of the car at the track, thought I would throw them up! Might give me the modivation I need to get it finished...Lol.





  9. #29
    Senior Member Prime86's Avatar
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    I thought I would throw up the specs of the car before I started work on it. Just while I'm wait for the last of the parts to start my engine build for those interested.


    Engine
    4AGE 1600 16V bigport.
    TRD head gasket
    HKS 264 Deg camshafts
    Multi Discharge igniton system

    Exhaust
    Section silk road 4-1 stainless headers
    Full 2 1/4" Titanium custom made race system (under diff)

    Gearbox
    T50 Gearbox
    AMKREAD racebox with helical gearset
    Excedy heavy duty clutch

    Diff
    Modified diff housing to run camber on rear
    T series with 4.33 ratio fitted with a TRD 2way.

    Suspension
    Custom Front coilovers
    Eibach front springs
    Cusco rear springs
    TRD front shocks
    TRD 8 way adustable short stroke shocks
    Cusco pillow ball camber tops
    Cusco fabricated tension rod holders with pillow ball tension rods
    Cusco rear adjustable panhard rod
    Cusco rear four link


    Section rear trackion brackets
    Section pillow ball adjustable lower control arms
    Section front strut barce
    Section rear strut brace
    TRD front sway bar
    TRD rear sway bar
    Cusco 30mm RCA'S

    Brakes
    Standard JDM calipers
    Project MU N1 race pads front and rear
    Project MU front slotted rotors
    Standard rear rotors
    Braided lines throught
    Cusco master cylinder stopper

    Wheels
    Wantabane RS forged race rims 15x9" rears and 15x8" fronts
    Wantabane wheel nuts
    Advan AO48 tyres on the front 15/195/55
    Advan AO48 tyres on the rear 15/225/50

    Body modifications
    Rear flares to fit the 15x9 rims
    Fibre front gaurds flared
    Fibre front bar
    Carbon fibre boot lid
    Fibre bonnet

    Interior
    Cusco saftey 21 chromemolly rollcage
    AMK READ gear knob
    Nardi signature series steering wheel



  10. #30
    Junior Member
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    mike
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    very nice

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