Stalkers daily AE85 - with 7AGE

[stalker]

Well below is the latest project that ive been doing for the past month. Sorry, the posts below were written over a month period, so if the odd thing in there says im doing something tomorrow, then the next line says its done, thats why lol



Got sick of changing my cars all the time, and decided I may as well get something im going to enjoy!

Got this AE85 Levin totally bog standard!! And in reasonably good condition too. Lovely old lady owned it for the last 10-11 years.

Any left over parts from my blue one will be used on this one to make it a little better.
She does have some rusty spots on her, so will just slowly fix them as I go.

This is what she looked like when I picked her up:





Had to do something with the 2 story height she was sitting at, so in went the old suspension and wheels. (made a HUGE difference to the way it looks, and the way it drives)





:twisted: :twisted: :twisted: :twisted:





And...



Cause 5 projects is never enough...

Must say a huge thanks stolic, for the countless hours he puts in on this, yet another project!
Also a huge thanks to Mark at Toyota for all the parts pricing and ordering im doing throu him (im emailing the poor guy almost daily) :lol:

Anyways, started the 7AGE build for my daily driver. Bearing in mind that it all started with "nah, not going to spend money modding it as my other project takes priority"...then "ok lets 4AGE it as im sick of NO power"...to "bugger this, lets try building a 7AGE" lol
Goal is to have this all done and driving by the start of August! As long as the parts arrive shortly, then it should be do-able.

Once this is done and on the road running, ill change this thread into a rough guide on building a 7A...
Until then, have some pics of the progress lol







Engine, say hello to gearbox!



Anyone wanna take bets on how long the K50 will hold up before it goes pop? :lol:

A view normally only ever seen in Japan lol




Well, the 3AU is now completely removed. Will spend the next few days cleaning and tidying up the engine bay. There appears to be about 26 years of oil all over the place! (the rear cam seal had gone and was spraying oil everywhere)

Its interesting to see that the 3AU intake and exhaust are not only on the same side of the engine, but are almost in the same line together
Bit hard to see, but you get the idea...


Gave the 20+ year old oil a good does of degreaser and cleaned up the engine bay...made a huge difference!



Then spent the rest of tonight putting in the new engine.
it looks awesome sitting in the engine bay!!!











Time to put up some specs I guess.

She is running:
7AFE block
7AFE crank
Was going to run 4AGE race bearings, but they never arrived in time
So running standard 4AGE main bearings
7AFE big end bearings
7AFE rods
4AGE smallport pistons
TRD 0.8mm head gaskit
4AGE smallport head
4AGE smallport (late model) dizzy
Re-ground standard cams (they are 265 deg at .010", though the lift is quite a bit more than std which is .318")
TRD valve springs
Porsche 117 tooth cambelt (from a 944)
Adjustable cam gears
Silvertop ITB's
Brought the TTT ITB adapter plate, which turns the ITB's upside down allowing the throttle cable to sit under the ITB's and clear the fuel rail.
Coby RWD extractors
Link ECU - V4 LEM. Yep, thats the first computer programmable link they made....old school! lol

Currently (but will be changed one day) running the 3AU flywheel, clutch, and starter motor. Most of the research we did kept coming up saying that you couldnt use the 3AU starter and stuff as it was far too small to start the 7A engine. Well this seems to start the car fine! :lol:

Also still running the standard K50 gearbox and open diff that comes in the AE85's, and after a reasonably hard weekend of use, still touch wood is running great!


Now for the breakdown of the build!

Broke down the 7AFE engine and cleaned the block, and then painted.


Add shiny new bearings


Add crank, peni$ optional (long running joke, dont ask :lol


Apply oil pump, freshly painted of course


Brand new pistons pressed onto the rods. Went down to the nice guys in Drury to get these pressed on as the 7A's are pressed fitted gudens.



TRD head gaskit on


Used the 7AFE sump and oil pick up


Time to put the head on


Dropped in the cams (of DOOOOOM!!)


Love the cam covers that the mate did for me. Low gloss black, then filed the lettering back to bear steel. Looks very very awesome!!!



Then came the cambelt fun!
Popped it on, just to find one of the standard bolts for the waterpump sticks out just too far that it was touching the belt. Course once thats spinning at full speed, that belt would end up with a catastrophic fail-copter!!


So out with that, and replace with the flattest one we had in the garage



Putting on the timing cover at the bottom didnt fit the new fan belt, so a large cut was put in to allow it space while still retaining the timing marks



Setting up the dizzy and ignitor, we decided to use the silvertop ignitor that I had sitting in the garage from my other AE project. Which meant that the coil to dizzy plug wouldnt fit. So MacGuyver got his modding on and cut the plugs to make it fit and look standard. To look at it, you would never know that it has been changed. (yay for RTV silicon)



Then came the time to add the K50 gearbox


The TTT ITB adapter plate and silvertop ITB's were added


I have some Harley Davidson carby mesh filter pads coming from the states (been 2 months and they are still stuck in transit, so not holding my breath) which I will stick of under the trumpets meaning for track days etc I can run without any sock filters and not worry, too much lol.
Will kind of look like this, which I totally love the look of!

In the meantime, its sock filters to the rescue!





One other prob we came into was the exhaust hitting on the under body of the car next to the gearbox due to the height of the new engine. But a sledge hammer, gentle tapping, then some tar based paint (to seal from rust etc) fixes that no worries!!

More cleaning of the engine bay (as mentioned in earlier posts) and drop in the new hotness!
Sadly dont have any pics of this, but adding the link ECU and wiring all into the car, and the general radiator pipes, catch can, etc.

All in all, prob one of the best things ever done!!!!
So much fun to drive, plenty of torque, great power, remembering it been an NA engine and a daily driver. And the sound of the intake when you open her rite up is totally AWESOME!!

If it wasnt for the mates knowledge, then I couldnt have done this on my own, but if you, or a mate has the know how on engines and workings, then this build really was an easy one.
Took us about a month from start to finish, and the car was only off the road for about 2 weeks.
We only worked on it at nights, and some weekend days, as we still had jobs and general lifes crap to do :lol:

Any questions, just ask, and ill try to answer lol

[haveaparty]

whoa

[hachi_dk]

goooood shit!!!

[stalker]

Hehe cheers guys!
Will post up some power figures if/when I ever get some lol

[dove grey 64]

love the cam covers. car looks mint

[bradae85]

Nice! Did u give the bay a cut and polish as well as the degrease? It looks realy good for factory paint. Gives me motivation to go make mine tidy lol. Keep up the good work on both ur hachis

[stalker]

Thanks.
No didnt in the end, only degrease and then blast with the hose and wipe it with some rags lol. We were very surprised how tidy it was under all the oil that was around the place. The rear cam seal looked like it had gone and was spraying oil everywhere...guess that helped preserve the paint hahahhaha.

[bradae85]

Lucky every time I've degreased mine out goes kind of oxidized, needs good cut and polish then one day might look as good as yours you lucky barstard!

[stalker]

Forgot to put these dyno sheets up.

Its a wooping big 126.181 ps (92.81kw) lol
And 113.619 lbft





Bob, the tuner did say one thing...(and I quote)...you lose 10hp when you close the bonnet!
lol

[ke_70]

what cams?