Prime86...The rebuild.

[turn69up]

Thats a sick gear box, flat shifting ftw what did u pay for it? if u dont mind me asking

[Prime86]

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.

[Prime86]

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.

[Prime86]

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.

[Stej]

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?

[Prime86]

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.

[Prime86]

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.

[Prime86]

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.

[Prime86]

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

[koval]

very nice