The Green Machine - AE71 4AGTE Pano Build

[Futo_gt86]

Finally getting around to do this.
4AGTE is not going ahead.
Motor will be Blacktop 20V.

BODY/EXTERIOR:
2pak hot house green with gold sparkle.
Has small rust bubbles coming up in the bottom of the tailgate that needs attention.
Has a 50c bit of cancer in a front passenger rail where the factory shipping/tow point, small pin dents in passenger 1/4 and front guard, scratch mark in paint on bonnet.... Good base...Have no idea how many Km's its done
Upside down Toyota Badge on grille
Staying pointy nose

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INTERIOR:
Has had 5 seat conversion done with mod plate.
Driver Recaro LS fishnet head rest seat.
Has KE70 Non Tacho Dash installed with full KE70 donor wiring loom (cabin and engine bay)
Battery re-located rear

ENGINE:
Blacktop 4A-GE 20V
SQ rwd conversion parts
SQ 50mm billet stacks with ITG Twin DCOE Foam Filters with mesh inserts (don't suck in)
SQ COP conversion Yaris coils
Microtech LT10S with hand controller
Stock injectors
Ebay AE71 alloy 3 row radiator
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FUEL SYSTEM:
Has modified stock AE71 Pano tank - Has sump / surge tank welded into the bottom of it with 10an fitting, steps down to 8an to aeroflow 30micron pre pump filter, to Walbro 155LPH (supports up to 400hp) with 8an fittings up to 10micron post pump filter in engine bay, to factory 4age blacktop fuel rail,
All hose is stainless braided 8an.
All fittings and filters are stealth black finish.

DRIVELINE:
W55? - Was sold to me as W57, but isn't, ratio's are wrong for W57.
Niteparts W series bellhousing
Niteparts 1GFE starter motor conversion
NPC ceramic 5 puk sprung centre clutch with custom beefed up Pressure plate
Driveline services Custom Tailshaft rated to 300hp
Stock Diff S series with factory pano 3.5:1 ratio
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BRAKES:
MA61 Hubs and Vented Disc's (fits larger XT130 stub axle)
MX62 Calipers with custom machining on XT130 Strut/Caliper mount to make it works!
Standard rear drums

SUSPENSION:
XT130 Struts with Otomoto weld on coilover sleve kit
8kg springs
Front Gaz adjustable shock absorbers
Cusco? blue adjustable camber tops
Billet Techno Toy Tuning PS knuckles
XT130 Lower Control Arms with brand new Ball joints
AJPS Motorsport Adjustable tie rod ends
Stock rear leave's with blocks

WHEELS:
Work Equip 01's 14x7j with185 60 14's

[haveaparty]

Nice rig mate. Just an FYI. Rn25 hilux diff bolts in. Diff mounts over hang the leafs about 5mm on each side but shouldn't be a drama. I'm fitting one into my pano now. Just need bigger u bolts and no doubt need to drill a hole in the bottom plate a bit bigger.

[Futo_gt86]

Legend!
Are RN25 rare?

[Matt]

hot wagon man...

[Low Style]

I know the person that used to own this. Should be a good base

[Futo_gt86]

Is he on these forums?
Its been raped, as in I have to rewire the entire car from scratch.
Has KE70 engine X memeber, dash is busted up.
Interior will have to be redone also.
But yeah, your right, its a good base.

[haveaparty]

Yeah pretty rare as far as I know. And expensive if the person selling knows what's he got. I was lucky with mine. Swapped my set of superlites for mine off of a mate.

[Futo_gt86]

I know the person that used to own this. Should be a good base
Do you know of any vids or pics of it in is day?

[Low Style]

last person i knew driving it was a chick back in the old boostcruising days. Was in ok condition then - must of changed owners a few times since

[haveaparty]

Was this 20v turbo by any chance once??

[Futo_gt86]

last person i knew driving it was a chick back in the old boostcruising days. Was in ok condition then - must of changed owners a few times since
That explains the gold sparkle in the paint.

[ozyvr4]

Hi there mate. I am the original builder of this car.

I made custom harness that was problay removed when the engine was removed. I recall wiring the engine sepeatly to the rest of the car wiring. The fuse factory fuse box was under the passenger headlight.

The dash was stuffed when I had the car & I mounted a fuse box under the passenger dash for the engine.

I did remove an alarm from this car ealy year and notice how much bling crap I fitted into the ca over the 5 years I owned it. I built it nearly 8 years ago .

The paint was just redone tho. I had a forged 20v turbo it this car.

If you need any extra on the car just pm me or email - ozyvr4@optusnet.com.au

[ozyvr4]

I built this car along time ago , before you could easiy find parts for 20v's .Alot of the parts were custom made.

Silver top 20v that I had owned since 1998. Wiseco pistons 7.8:1 on stock rods.
Steampipe manifold with tial wastegate. Garrett GT28r turbo . Supra injectors . Bosch pump feed straight from custom tank. Never surged . PWR cooler . Hyundia radiator with twin 10" fans. Wolf 3d. Remote oil filter & cooler. 3' exhaust. W series box .

Hope this is some goog info for you champ.


27742277432774427745277462774727748277492775027751 2775227753

[haveaparty]

Was this 20v turbo by any chance once??


New I was right. Seen this rig before.

[Futo_gt86]

That is awesome!
Thanks heaps for posting.
I'll do my best to restore her back to something close to her former glory.
Those pictures make it hard for me to change the slant front to quads....
But when I look at haveaparty (http://www.ae86drivingclub.com.au/forums/member.php/4453-haveaparty) build thread and see that 71 high roof with flat front and quads i'm like f#@k yeah!

[Futo_gt86]

Nice rig mate. Just an FYI. Rn25 hilux diff bolts in. Diff mounts over hang the leafs about 5mm on each side but shouldn't be a drama. I'm fitting one into my pano now. Just need bigger u bolts and no doubt need to drill a hole in the bottom plate a bit bigger.

Is LN25 diff the same?

****LN = 4WD 6 bolt pattern**********
****RN = 2WD 5x114.3 bolt pattern****

[haveaparty]

No idea man.

[Futo_gt86]

What is overall Width of yours and center to center on mounts?

[haveaparty]

Ill have to measure it for u tmoro man. But hard to do atm. Garage is a bit of a mess.

[Futo_gt86]

Hurry up!
Nah all good man, when you get there.

[haveaparty]

Google says it should be 1370 wide. And mounts are about 20mm wider then standard. Still sits on leafes fine tho. Just over hangs like not even 10mm each side.

[Futo_gt86]

Swapped over the 4A Xmember and coilovers from wagon into pano, installed longer tie rods and Sigma arms.

http://www.ae86drivingclub.com.au/dcimages/7/7/7/6/506058.jpg (http://imageshack.us/photo/my-images/195/img0044lx.jpg/)

Camber looks bit excessive, but had to set it like so for the stock 71 guards
Where as the flared KETO guards had no limit
http://www.ae86drivingclub.com.au/dcimages/7/7/7/6/506059.jpg (http://imageshack.us/photo/my-images/15/img0050ma.jpg/)
MORE CAMBAH!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !
Picked up final part of drive train 212mm Fly.
More to come

[Futo_gt86]

Moved house, mission, but now have double lock up garage and ability to work into the late hours with out being eat'n by mosquitos


(http://imageshack.us/photo/my-images/16/dscf3764y.jpg/)http://imageshack.us/a/img16/84/dscf3764y.jpg


http://imageshack.us/a/img716/8193/dscf3752i.jpg


http://www.ae86drivingclub.com.au/dcimages/7/7/7/6/507977.jpg (http://imageshack.us/photo/my-images/221/dscf3748.jpg/)

[john84ie]

Cool, when you planning on having finished? What ya doin for ecu and you goin flat front?

[Futo_gt86]

Knowing me, It will take eons, but i'll get there.
Have to finish the hilux first.
The more I look at it, the more I'm ok with the slant front.
External look great.............inside is a dogs breakfast
New dash has been sourced.
I am going to redo entire interior. There is no hood lining.....
The whole car need to be rewired.
I have an AE92 ECU that's been modified to run AE101 loom, and entire AE101 engine and body loom.
Right now, plan is to use that.
I layed the loom out the other day, and a feeling of oh shit, what have i got myself into came over me.
I'm also looking at hotrod 20 circuit loom with view to upgrade to Haltech Sprint or Platinum. Depends on money's.

[Britto85]

im the chick who used to own Lola, i sold her last year and the lad that brought her off of me destroyed her, ripped out the engine and drive train i was shattered when i found out, then some guy brought it from him then you obviously brought it off of that guy, i have video's of her running the quarter at willowbank but it was a bad day had a busted clutch so best run i got out of her was a 12.49 loved Lola my kids hated her but as for the wiring i think the lad that brought her off of me destroyed all of that also to put in his drift car. if you need any info feel free to contact me always happy to help miss her so much i actually wanted to buy her back.

[Futo_gt86]

Must have been devo.
I have been tied up with my bro's project for a while now, a rotary conversion Mazda 1000 Ute.
Will be moving on to Pano once done.

"Lola" as you refer to her needs a bit of a tidy up, but i'm up for it.
She came with the paint and sparkles still sitting in the back. Do you know what the mixture was paint to sparkle?
New engine going in is 1UZ V8 with W57 box.
I'll post up build in here, so keep an eye out.

[Britto85]

I had camo from camos body worx at coopers plains paint her he would be able to tell you the paint to flake ratio I was devo I did the whole put her up for sale then unlist her then do it again lol it was hard to part with her glad she is getting some tlc tho im keen to see what you do with the old girl

[Britto85]

http://youtu.be/O8EGRlqqhGg

http://youtu.be/gqFXZdbukX4

Those are the only two videos I have running her on the quarter and was having a rough day with the clutch two days after this the clutch completely gave out best run I had this day was 12.49 @ 106mph with a major clutch slip

[Futo_gt86]

Plan is to get her sorted, engine box and diff, then bolt on an Eaton run some boost through her.
Built Kit with an M112 is the goal.

I'm going to rename her "Mona" once the V8 is in.
In those vids, she still harlequin paint sames as when Scott owned her.
She no longer is.
Someone painted her like hot house green with glitter sparkles?
My Brother is a Painter, and just wanted to know what the ratio was, but he said no biggy, can work it out.

[Britto85]

yeah in those videos I had only owned her about a year and had never really liked the paint job hence why I spent the man hours myself sanding her all back and then got camo to paint her the custom green its based off the hot house green but I slightly tweaked it as a friends dad owns harts paints in springwood and he did it for me the flake well im female and we love sparkly things lol.......

[Britto85]

oh and forgot to mention the scratch on the bonnet happened two days after it was painted my horse must have thought the car was grass or something and tried to eat it

[Futo_gt86]

Yeah, scratch still there, no surface rust though?

[Britto85]

I only painted it last year June and I had taken it right back to bare metal and there was no surface rust other than around the back window plates but completely removed the rust from there and resealed the plates and rust treated it before repainting the car

[Futo_gt86]

Beer hunch says CRS Hilux 1UZ mounts fits 4A engine cross member and clears most things!
Watch this space !

[Britto85]

whats the update on Mona? god is miss the old girl hahaha

[Futo_gt86]

So its been a while, I have sat on this build for close enough 5 years, and finally I am able to get
going on it.

I couldn't find another set AE86 Power steering knuckles (have a set but RHS one is damaged).
I went with a more expensive option and bought Techno Tuning Billet Knuckles.
When I received them I was impressed with the quality and shocked at the beefy thickness of them.
Instantly I realized that the bolt length that locate the knuckles to the bottom of the strut was going to be an issue.
I emailed TTT and got a response stating that the stock bolts would work, but if not I should be able to find longer replacements.
So I bolted them up and this is what I saw.
Stock Bolts
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Stock bolt mounted up to lower strut mount.
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Alarm bells rang, NFW was I going to use the stock bolts with the TTT knuckle.
So I went to the bolt shop hoping I could find longer high tensile bolts with similar shank in same thread.
And these babies are what I got in 8.8.
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So I test fitted these and am pretty happy with the results.
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Probably 5mm too long, but its not going to interfere with anything so they can just stay like that.

[Futo_gt86]

So when I originally purchased the shell as a roller, I knew I had a mammoth task of sorting out the wiring.
When the car was originally built things like central locking, alarm, gadgets and dohickies had been installed.
Then when the car was parted out, the loom was just chopped with gay abandonment.
I looked at it for hours, then I decided stuff it, I'm not even going to try attempt it, I'm just going to remove
both engine bay and cabin wiring looms, and find a donnor car (a KE70 Wagon) and bring its engine bay and
cabin wiring across to it, and thats what I've done.

Unfortunately I couldn't quite wrap my head around mating up the AE71 van tacho dash wiring with the KE70
wagon cabin loom, So I just bit the bullet and used the KE70 clock cluster instead.

The original Van dash was destroyed, So I sourced a good sedan dash that was beige, which did not match my
light grey on dark grey interior. I bought a couple of VHT Vinyl dye spray cans and went about changing the colour.
I found that this stuff, in dark grey, can be a bitch to lay evenly if you don't shake the absolute shit out of it before use.
All in all, it turned out pretty good, and would recommend it to any one wanting to paint interior parts.
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I bolted up my Nardi Steering wheel (pretty sure its a fake) to a random boss I had, and then mounted up a Recaro LS seat out of a Toyota Surf.
37536
Cabin Wiring is now complete, engine bay is getting there.
A Microtech ECU configured to run 4 coils is installed, but I still have to finish off some of the wiring.
Looks messy now, but once I have all laid out, I will pretty it all up with conduit and tape.
37537
I got a AE71 Specific GTI branded alloy radiator and bolted it up.
I took a risk buying it, its not for my year model. Thinking nah, they're all the same, I ordered it.
When I went to mount it, only the top 2 bolt holes on the rad support lined up, so some custom mounts will have to be made to mount it properly.

And thats all for now, I'll try to update this as I get to it.

[ozyvr4]

Its good to see the shell is still around. I originally built this car nearly 15 years ago. The wiring was my first attempt at wiring. Where is the car located now???

[Futo_gt86]

Out Ipswich way man. Its coming along in leaps and bounds.
You could tell that who ever did the wiring new what they were doing, its just when it got parted out that shit got hacked up.
It's all sorted now, taking a full loom from a donor car was the easiest/cheapest option available to me.
I thought that a high roof KE70 wagon loom would be direct replacement, but turned out to be bit different.

[ozyvr4]

Cool. Keep up the good work. Keep me updated on the progress.
Scott
ozyvr4@optusnet.com.au.

[Futo_gt86]

Hi again,
I went and purchased a RWD 4 into 1 Extractor with a multifit 16v / 20v flange from Anthony at Kaizen Garage.
In this case multi fit means doesn't fit, at least not on a blacktop 20V head.
The flange fouled at the rear of the head, the shape is just not quite right for the water outlet.
I had to open end the already slotted hole at the rear of the flange to make it clear the FWD water passage block off plate.
Not a big deal really, but in my eyes it really should have fit without modification.
SQ Engineering sorted me out with a exhaust gasket, and on she went.
37618

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Still a fair bit left to do, little bit more wiring for ECU, Gearbox mount and tailshaft.
More soon, as i get to it.

[Futo_gt86]

When I installed the dash, I also fitted up a KE Conversions Hydraulic pedal box.
I couldn't find and AE71 item, so I with 2 core deposits in hand (had a couple sitting around)
I went and picked up modified pedal box from Jordo.
Its the same as AE71 pedal box, lines up perfect to AE71 firewall holes, but its actually KE70 pedal box converted
with laser cut pedal and welded/reinforced master cylinder mount, its a little bit beefier due to the conversion.
Sorry no pictures, its already mounted well up behind the dash, but there were no
issues installing it.
It came with a master cylinder.
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and as you can see, fits up and clears perfect with SQ Engineering 50mm velocity stacks.
37620

[burcoty]

Lookin good, keep the progress comin!
Also comforting to see I'm not the only one to sit on a build for years on end haha.
What length are those stacks, 50 or 70mm?

I was wondering where the knuckles I pulled off mine came from and now I know, thanks for that! haha thought the edges on mine were a bit sharp tho so I beveled them while I was cleaning em up.
https://uploads.tapatalk-cdn.com/20170901/5fd47e77096a59b09c94a2856546015d.jpg

Sent from my SM-G935F using Tapatalk

[Futo_gt86]

Lookin good, keep the progress comin!
Also comforting to see I'm not the only one to sit on a build for years on end haha.
What length are those stacks, 50 or 70mm?

They're 50mm size.
Yep, those knuckles look exactly the same shape as mine.

I installed some XT130 LCA's with brand new ball joints.
Due to the extra 10mm length of the LCA's I needed to upgrade the tie rod ends.
There wasn't enough adjustment in the stock Tie Rods, so I purchase some AJPS Motorsport Tie Rods with tubes.
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Set the length equal side to side by eye and counting the threads and turns, and it all looks good.
I'll get proper alignment done once she is finished.

More to come.

[burcoty]

Those tie rods look good, did you just order them from the website? I need to get a set myself for the same reason.

One thing you might find is that, like mine, your steering rack doesn't have enough travel to fully lock one way or the other so you may need to get a lock spacer and adjust your rack ends to compensate. Mine's power steering though so may be different for standard racks. Still, it'll only take 2 seconds to lock it in both directions and make sure it has equal travel!

Sent from my SM-G935F using Tapatalk

[Futo_gt86]

Those tie rods look good, did you just order them from the website? I need to get a set myself for the same reason.

One thing you might find is that, like mine, your steering rack doesn't have enough travel to fully lock one way or the other so you may need to get a lock spacer and adjust your rack ends to compensate. Mine's power steering though so may be different for standard racks. Still, it'll only take 2 seconds to lock it in both directions and make sure it has equal travel!

Sent from my SM-G935F using Tapatalk

Tie rods are from AJPS (vendor on these forums) off the shelf.
There is plenty of adjustment in them now, they cover from stock to 50mm extended LCA's.
I have used these before with GE Sigma lower arms and it worked out great that time as well.
I have used TTT knuckles/steering arms which mimic the shorter AE86 Power steering arms.
There's no issue with lock, in fact there's a second position on the TTT knuckles for the tie rod end that would reduce the amount of turns from lock to lock even further..
The rack is a KE70 item, its out of a DX. It was a spare I had sitting round, so I used it.

Been doing some wiring lately, relays and small fuse box, nothing too exciting.
Will post up more as I get it done.

[Futo_gt86]

Been wiring, re doing the battery in boot and alternator from Blacktop to a KE70 4K fuse box and loom.

Engine bay battery tray was removed already when I got the shell.
The battery had been relocated to the boot, but all the wiring and mounting hardware was long gone.
All that was left was plastic battery box.

I purchased some 25mm2 welding cable to use as the positive cable run, a 150amp re-settable circuit breaker, some crimp end terminals, and a narva 12" battery tray.
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I haven't finished the battery mounting, its temporary, I have just mocked it up so that I can get some power happening to finish off wiring up the ECU. The wiring runs through cab through to passenger side grommet then through engine bay to starter motor terminal. I have to cut 5mm off either side on the battery tray to get it to fit in the plastic battery box. This is to fasten the battery to the car so that it doesn't move around.

With the Alternator I figured I had 2 options here.
Run the standard 4K Alternator charge wire with AE111 Alternator and hope for the best :S
Or
Upgrade :sunnies:

Below is picture of Blacktop stock charge wiring.
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Toyota has used twin 6mm(I think) and i believe the Alternator amp output is 70amp(quick google search said this).

This is a picture of stock KE70 engine bay mounted fuse box
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Here you can see where the stock KE70 Alternator charge wiring is crimp joined to main battery terminal wiring.
I believe the stock 4K Alternator charge wire is only single 6mm and is rated at 40amp.

I don't want to run 70amp through the stock 40Amp wiring.....

I'll just terminated the factory Toyota 4K Alternator wiring run, clean it up, and with whats left, connect to +battery terminal. (in my case, the starter motor +ve terminal)
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Just airing on the side of caution, like it all comes form the same place, the battery, but seems more logical (and safer) to do it this way, rather than run risk of cooking something.....

Wire is 25mm2 welding cable that I had left over from relocating battery to the boot.
It looks like overkill, but that's because its double sheathed, its actually only ~3 gauge wire.
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Fuse is 100amp ANL type.
To mount the fuse, just used an existing speed hole in chassis rail (the engine bay, and chassis rail has multiple holes drilled all over the shop) so just nut-certed it, and drilled out the front one, did the same and sprayed tectile in rail and on hole to prevent rusting.

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More soon

[Futo_gt86]

Little bit of an update.
I finally got the wiring (engine bay and cabin) to a point where I could test it.
It was a F'yeah moment when I turned the key and the dash lights came up.
The indicator stalk, park lights, head lights high / low beams and tail lights all working the way they should.
Microtech powered up also.
Pretty pleased with it all.

I cleaned up the alternator, and the fusebox wiring.
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Cut down the battery tray, so it fits inside battery box.
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Ordered all of my fuel system parts. Got the pump, pre pump filter and a few of fittings, just waiting on the majority of the fittings and the post pump 10 micron filter to show up
Walbro 155LPH, gravity feed from "sumped" fuel tank.
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5m of stainless braided 8an fuel line.
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Aeroflow 30 micron pre filter with male 8an fittings
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This is all for my fuel feed up to the rail.
Previously the car had a 1/2" fuel system for 4AGTE 20V setup.
I could have easily used 6an, but went 8an instead in case I want to go turbo later on.

And this is where i'm at now.
Got to finish off fuel system, get a tailshaft made and the exhaust from the header back...
More to come.

[Futo_gt86]

Fuel system is done.
ECU wiring is completed.
Tried to start it and it kept back firing out no. 4 ITB.
Checked everything, firing order was correct...scratched my head...
Went into Microtech ECU went through the screens looking or answers.
I bought the Microtech 2nd hand for a good price, was supposed to be off a running 20V!
Found that is was set to 6 Cylinder config. changed that to 4cyl.
Found T gap (mazda rotary only setting) map had values...zero's them all out.
Went to Dwell settings for coils, was set to 3.50ms which is good for stock or Bosch coils.
Changed that to 2.50ms for COP's.
Turned key, and first kick she started.
No wonder the guy was selling it, whoever set it up had no idea what they were doing.
Its definitely configured for Toyota, but yeah, just wow.
This is the second used microtech I have bought that had been "Tuned" with T GAP Mazda rotary only settings values set. WTF. T GAP is for rotary only!
On a rota you have lead spark, and then trail spark fired just after lead to scavenge the chamber and help with ignition. T Gap is the setting to fire the trail plugs on a microtech. Is says in bold letters in the manual "MAZDA ROTARY ONLY" Mofo's need to learn how read.

Super stoked, its a good feeling.
Still got more to do.
Will update when I can.

[Futo_gt86]

Yeah been strapped for time, not much done recently
Got some sweet ITG DCOE twin weber airfilters and made them fit over the SQ stacks, a T3 splash guard, and a real carbon fiber timing cover as my stock one was damaged from the importing process and needed to be replaced anyway, so why not bling it up?
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Got this rad Kamei front spoiler, I really like it on the slantly front! its only mocked up with 2 tech screws holing it in place, the corners fit way better then the pic shows.
Treated myself to a custom number plate. Tried to get DOP371, but they canned it cause it was a "drug reference", so got OAE710 as a compromise. Then I see a FT86 parked in the driveway not more than 100m from my house with DOP386 number plates....was not happy, but yeah, he got cool plates!
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Poor thing, looks so neglected.

Decided that 8kg front springs in my coilovers where just going to be stupid on the street, so bought a second pair of XT130 struts with the twin piston calipers. Got a set of GAZ short stroke SW20 MR2 front adjustable strut inserts brand new from UK for $330 shipped, custom valved to suit a set of custom King springs to suit XT130 lower perch and AE71 98mm top perch with a set of K-Mac adjustable camber/caster tops. I could have just got new springs, but I wanted to keep the stiff coilovers as spares that I could just in swap when I wanted. Its like 5 nuts, 2 lines and bleed, meh.
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I also purchased a whole KE72 front end from NZ, just sorting out the details on how to ship it in to Aus.
Got a KE72 diesel grill and lights from Rolla Resources on Facebook. Super cool guy, very easy to deal with and package it all up really well before sending it. Took like a week to get to me with shipping only costing $70.
This is my inspiration! UEO KE72 2 door high roof full glass drift wagon.
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I might go full glass if I can find it all...but not entirely sure, I really like the full metal panels....
So yeah, more to come....