DK AE86 renovation and turbo project - Now driveable

[Veiss]

Hi,

I've seen so many good projects on the forum, that I think it is about time I write a little about my AE86 project.

I bought the car a couple of years ago, from a man in the mid 50's. He had bought it from a guy back in 1988, so I'm the third person to own the car. He had spent alot of time keeping the rust down, but he didn't know about the rear wheel arches, so they are rusted away.
The car has had PAVA (rust protection) every winter he owned it. So I must say it is in pretty good condition.
A couple of weeks after i bought the car i blew the headgasket, and i decided to go for something with a little more power, so I went out and bought a supercharged engine imported from Japan (165HP 4AGZE). I've posted some pictures of the procedure below. I used the original enginemanagement system, which i had a tuning guru here in Denmark modify, with some new parts, so it could manage the supercharger, and fuelnozzles(?).

Just recently I've turned in the number plates and cancelled the insurance, so the car has seen it's last winter on the roads.
I'm going to completely rebuild the car, with rust and accessories. Unfortunately it has an aftermarket sunroof, which is pretty leaky, so I'm looking for something that I can install instead. I'm considering installing an original sunroof, or maybe a glassfiber plate.
After i have repaired all the rust, I'm going to have it painted in the original color, with some metallic and a touch / tinge of blue.

I've started buying the stuff I'm going to install in the car when it is MOT-tested OK.
This includes:

KKK K16 Turbo with 360degrees racing bearing
Noname BOV in red
4A-G Hi-Comp, Small Port / Big Port Adapter
HKS Rep. 2½" In and 4" tip muffler
Polished oil catch tank
T3 Short Throw Shifter
KYB AGX Adjustable Gas Shocks Front and rear for coilover kit
GC coilovers
T3 lateral rod
T3 Roll Center Adjusters

I'm currently waiting for the package with the 4A-G Hi-Comp, Small Port / Big Port Adapter, Roll Center Adjusters and my short shift kit. It should arrive in a week or so.

I'm really looking forward to bringing the AE86 back into mint condition, and I will keep you guys updated on the project with pictures and comments as the progress proceeds.

[Veiss]

The pictures of the engine swap:

[nmwisima]

Very nice...
And wellcome to our forum! Hope this will become you home page soon and we become your net friends

Nice going there (i have a late spec gZe in my 86 also).

Before continuing with the turbo project get that chassis stiffened (bars, cage, whatever), and upgrade your BRAKES man. Never forget the brakes... RX-7 FC calipers is an option, T3 has a big brake kit, Hi-Spec also.

Oh, and get yourself some old school rims, paint the sideskirts and front spoiler (and remove rear door spoiler, but that would be my car not yours )

[Veiss]

Hi nmwisima,

Thx for the reply.
I ain't going put a cage into the car, because it's my daily driver. And the strut tower bars are on the way, haven't decided which model i want to use, and I'm not sure if they are for much use at all?

Yes, brakes are a good thing to upgrade. But I haven't had problems with mine yet. The car was mounted with brand new brakepads and discs all the way around. I don't believe the brakes from a RX7 is worth the trouble, they aren't much bigger than the original ones, and the extra piston, isn't doing that much for the overall brakelength (correct me if I'm wrong). Maybe when I start to race the car it's going to be a problem, but for now the standard brakes will do just fine.

And yes old school rims rock, the one's on the picture isn't going on the car when it's finished. I'm gonna have some Image 8x15 RM1 (see pic) wheels fitted. Or at least a set with a bad ass crome edge(?).

I would like to know if anybody have tryed or heard of a 4AGZE with the KKK K16 turbo mounted?

[nmwisima]

rx-7 calipers are 4piston and alouminum for less weight. So yes they worth it, but need 15'' rims.

Have you closed the gZe blow-off valve?

[Veiss]

No I haven't closed the GZE blow-off valve. Why should I do that? Actualy, I think I can recall that there isn't fitted a blow-off valve on the GZE, there's no need for it, when using the installed magnetic-coupling.

[nmwisima]

There IS a stock blow off valve in the gZe air-circuit, programmed to open when pressure excides 0,8 bar. This wont let the engine have any problems.
BUT if you use a larger pulley as I do (mine is now working 1,1 bar at 6.000 with 5th gear), this wont let pressure go up.

Anyway, since you 're gonna turbo-it, you re gonna use your own HKS blow off

[Veiss]

That sounds like an exiding project, have you measured the HP when driving with that setup?
How about fuel- and enginemanagement?

Ups forgot pictures of the "suspension stuff".

[nmwisima]

No engine manadgment yet, I was thinking of a fuel controller (like SAFC) but I think its better to wait and go for a piggy back like e-manage.
More fuel, yes, by impreza fuel pump and fuel regulator.
You can read more here:
http://www.aeu86.org/viewtopic.php?t=624&start=0

[Erik_dk]

looks nice.. can't wait to see more of this danish AE86..