Ive been busy.. F20C AE86 (56k badness!)

Wataru Joined: 08 Sep 2004 Posts: 118

Ive been working flat out on this from January and February with the actual restoration and buildup/installation, and its come together slowy through March and April with actually getting it running.. But here is alot of pics.. Followed by the almost finished product!

Cut Cross Member. Stripping paint at the time..

Spacer to drop Cross Member

my massively fat lady friend.

I lubed my lady up so i could slide the beast in...

And i bust the back doors in...

a bit of cutting to clear the rack and such..

How it sat on the car..

Shit is TOIGHT.

See?

JSP gear box Mount pics..

First installation..

Started Spotting..

And here is how it looked finished, before i tidied them up..

Then i cleaned, and cleaned and cleaned and then made a small make shift spray booth, and fired some Etch Prime and build at it, and it came out like this..

Cross member welded up:

Smoothed and painted with POR15:

Had to cut further back on this side for sump clearance..

Rough cut of the steering Rack Clamp, needed for clearence, also replaced the captive nut on the rack clamp with a flywheel bolt as its got a smaller head.

POR15 under the arches.. Two or Three coats everywhere in the end..

Stock Clutch line, made to go to the otherside of the engine bay and into the S2k Slave..

Brackets, LCA's etc POR15'd..

Prop..

Took the diff out.. Oh shit.. Explains the knocking.. Every tooth is smashed in half, wont rotate freely as it gets stuck in one place.

Turns out its a 5.375 ratio. No wonder it was so short/gay. Could of sold it for a mint though Sad

But thats 3 years of whining diff abuse!

More Primer and Seam sealer over the spot welds..

Paint-atron.

Building back up..

DW Fuel Pump

And then many an evening doing the bits i forgot to take pics of, and much VEMS'ing went down and there you go...

Wataru Joined: 08 Sep 2004 Posts: 118

And here is how it looks now, ready to be mapped and fit the bumper etc. 95% finished.

It needs a clean..

If you want to put an F20/F22 into your AE86, then www.jspfab.com is the place to get your kit from. NO transmission tunnel cutting other than the aperture.

Posted: Thu Apr 17, 2008 10:08 pm Post subject:

Nice work.
Thumbsup

Wataru Joined: 05 Nov 2007 Posts: 55 Location: Luxemburg

I love how you can see the engine from the hood scoop Smile

Posted: Thu Apr 17, 2008 10:20 pm Post subject:

wow paz looking great,when my ae grows up i want it to be as cool as yours Worship

Posted: Thu Apr 17, 2008 11:27 pm Post subject:

Whowie,

way to go paz!

Posted: Fri Apr 18, 2008 3:35 am Post subject:

That's a top effort Paz, no doubt you shed a lot of blood, sweat and tears (Well, maybe not that much sweat in the depths of a British winter!) with the sheer determination I'm sure it took to put that together working in a small lockup!! Brave stuff indeed.

Good to see the Goodline bonnet fits too.

I hope you'll take these comments as constructive - I'm not bashing your efforts at all, just hope these will help.

As I'm sure you know - the engine moves a fair bit when in use - in all directions (From torque, corners, braking, etc), so:

It's difficult to see from only a few pics, so you'll know yourself - but assuming it's as close as it looks, you may need to run fabricated alloy engine mounts and possibly fabricate an engine brace at the top. If the stainless exhaust manifold's end hits the leg, as it may cause it to crack. Also, your manifold will burn the paint on the nearside chassis leg and may be a fire hazzard, unless you can fit some heat shielding there. Like I say, it's difficult to see from the few pics. IF the engine moved into the steering rack linkage enough, it could potentially cause problems with steering.

I realise it's not finished, there's still lots to do when a project's new engine is fitted. like I say, I'm just trying to offer some helpful comments here. If I'm barking up the wrong tree, just let me know and I'll delete these, no problem at all.

I'll bet you feel a sense of satisfaction & once it's all finally sorted you'll have a massive smile on your face.

Huge, huge well done so far!! - Your effort is truly inspiring.
I know I couldn't have mustered that level of effort working inside just a small lockup in the depths of a British winter. I look forward to seeing the beast run and drift as it's meant to!

Thumbsup

Posted: Fri Apr 18, 2008 7:17 am Post subject:

my dream car Worship

Posted: Fri Apr 18, 2008 9:17 am Post subject:

ITB!!!

Wataru Joined: 08 Sep 2004 Posts: 118

Thanks for the kind words guys Smile

I

know its not a 4AG and isnt the proper engine for the car, but i simply couldnt justify spending the money required to build a 4AG that made the HP i wanted.. Im also hoping that the S2000 motor will be alot more streetable and reliable in the long run, rather than a highly strung 4AG.. Im all for kick ass 4AG's, but as i say, i just couldnt justify it, it didnt make as much sense (to me) as the F20 swap... So there we have it!

Hi Miguel, hope you are well! And i appreciate any feedback too!

The motor isnt as close to the rack now as it was in those pictures, i managed to adjust the posistion of it slightly and remove some more non-essential material from the block, sump and rack to give me a bit more room.. That, coupled with the fresh TRD Engine mounts should hopefully do the trick!

The manifold however is very close to the chassis leg as you say, about 6mm. I dont think it will touch under load etc but i do think you are correct on the heat issue. Ive been meaning to heat wrap the exhaust and stick a little heat reflective tape on the inner leg, something which i'll do shortly to try and help.. I'll also be getting rid of the manifold as soon as i can and selling it on hopefully, id rather take a stock S2k manifold and lengthen the primaries to make it fit, as i get the distinct feeling that the current manifold isnt going to yeild maximum power for me.. But we will see!

Being honest, im sick to death of the car right now (i recently bought an M3 and im enjoying it so much) but ive only to iron out a few niggles, and im sure once its finally finished and im ripping around the circuits and such it will all be worth it! Im certainly hoping it will be fast, at the very least!

Posted: Fri Apr 18, 2008 4:46 pm Post subject:

Hi Paz,

That's cool. I'd be sick to death of mine too if I put as much work into it in tight confines in freezing weather as you've just done!

Yeah, I realise the F20 swap's an issue of budget / power. There's nothing to say you won't get it all working OK after ironing out the inevitable challenges that come with a swap like this.

If I'm not mistaken, from memory and from seeing my engine compared to standard ones, TRD mounts are slightly shorter than standard ones, so this might cause further problems with clearance and perhaps with dropping the F20 engine closer to the ground too?

Maybe a solution for the chassis rail would be to strip the area where it's close and paint it with high temp red paint...? Or you could cut away a part of it, then re-build it slimmer, with strengthening inside (Or both!?)
Or take off the exhaust manifold cut it and re-weld about 1.5cm closer to the engine block?

I guess you just gotta try it and see if there's interference and if so where , then deal with come what may..

Once you're all done and it works good, make a kit so other mere mortals can copy it - or some detailed instructions. You'd maybe sell a few to recoup some of your costs that way?

Keep us posted!

Posted: Fri Apr 18, 2008 9:06 pm Post subject:

always the business man Miguel Very Happy

Paz I bow down to your godly skillz

Posted: Sat Apr 19, 2008 6:12 am Post subject:

Wataru Joined: 18 Nov 2007 Posts: 70 Location: UK

Paz, looking good Very Happy

Wataru Joined: 08 Sep 2004 Posts: 118

Well it works! I had a serious oil burning issue but apparently its a common fix with the breather. It dumps oil into the intake manifold under breaking followed by a sharp right turn/accleration.. Modified the breather setup and the drain baffle under the cam cover to suit, hopefully this will fix my issue.. And aside from that, and killing my bumper, the car ran faultlessly it seems.

But yeah onto the business side of things! I got it mapped and made 215hp and 175ft/lbs of torque. Odd that torque is up and HP is down on the predicted levels... But im pretty sure its the manifold thats losing me 15-20hp. So i'll be making another with 100% equal length runners, as my current manifolds runners are far from equal length. But for now, its fast enough and has massive amounts of traction and grip, linear power is so good for fast drifting!

Onto the pics..

So, i need to clean and finish the interior, hook a few more gauges up and re-paint it as im really not happy with the paint.. And get driving!

Posted: Tue May 06, 2008 9:35 pm Post subject:

who got your old engine?

Posted: Wed May 07, 2008 1:17 pm Post subject:

What a piece of art that is!

Great woth Pazwah! Wink

can't wait to see it in metal screaming all over the place! Worship

adam