Great SS-Four rebuild 2010-2011, Thanks Wolf... (VIDEO update April 22nd) Options

[malpaso]

What to say. The time has come to share in pictures with the great re-build . Works it self are not finished yet and exact due date is not known as well (since as always something unexpected can pop up anytime). Everything has started in August 2010 after my Alpine road trip (also some pics here). I really wanted to say to my car decent good bye (before I leave it thousand miles from home in Italy) for many months. As time and money comes and goes things has changed a bit from the beginning but that is not important. Important is that everything is on the best way it should be now. I will share more with pics than with words because I know everyone likes pictures more than reading ...

Primary target = rebuild the engine
In fact engine it self was not any bad. But it do not mean everything was mint with the car/engine (as can be seen in some pictures later).









Since my mechanic wolf_tm is super-precise person everything must be clean and perfect.





















Almost everything in the engine was replaced by performance parts or new OEM parts.





Of course also clutch was replaced by more durable one and flywheel was skimmed and balanced.





So engine done... almost (done means "closed" ). To be continued...

This post has been edited by malpaso: Apr 22, 2011 - 9:19 AM

[SwissFerdi]

That looks like an immensely precise rebuild. Awesome, just awesome. Best of luck my friend, can't wait for another ride when the engine's new and improved!

This post has been edited by SwissFerdi: Feb 20, 2011 - 10:50 AM

[Urputus]

Looks like you'll have completely new car So many new nice parts, Wolf's precise work in addition to it, what else to wish for?

[malpaso]

Ferdi, you remember when driving in Switzerland I was complaining driving up-hill I would need more power sometimes to enjoy ride better? So I decided to make it double this time to be sure . When we meet again you see how much difference it is

EDIT: Just read note above and realized it may look like I plan the engine with 500HP. To make things clear no I do not . It would be possible if I had more money now and more sense of reality two years ago . Anyway... true is as found by mechanic later my 3SGTE had around 160-200HP driving Stelvio. Not more.

Paul, no one else but you knows how hard it is for me... You hear my complains how I miss my car almost daily . Thanks for support!

Now... lets share bit more pic again...

Time for turbine
Sad is because of budget problems (and my stupidity in 2009) I needed to use turbine that has been bought for previous project. Now I would buy definitely some different but... Nothing is perfect. However as noticeable in one previous picture header skim was needed as well...



...and also small upgrade of the radiator.



Here turbine it self and installation.









This post has been edited by malpaso: Feb 21, 2011 - 4:31 AM

[Bigstring]

Cracking buddy, what have you paid out so far for this re-build?

[Sunny]

Hi Martin,

looks liker very good
when do you plan to pick your car up?

greetz

[makis]

Good job but with intake by caldina will be better great!

This post has been edited by makis: Feb 21, 2011 - 1:08 PM

[Ted95]

good job broo!

[malpaso]

Cracking buddy, what have you paid out so far for this re-build?

Honestly I'm afraid to calculate . But true is it would not be easy anyway because original plan was use as much as possible parts I have bought in 2009 for previous project. Unfortunately most of them were useless for my build and replaced... and some used (due to budget issues or just because they were fine to use). What should I do since I'm not millionaire... However exact amount I really can not calculate at all since first part bought two years ago, some of them sold and bought another... Really hard to say. I only know I'm dry with budget now .

Hi Martin,

looks liker very good
when do you plan to pick your car up?

greetz

Not easy to say Alex. Probably in next 4-6weeks but who knows... "to do list" is still too long for predictions.

Good job but with intake by caldina will be better great!

Technical details are fully in hands of my mechanic. His opinion is untouchable for me .

good job broo!

Thanks! Can not wait to see it...

Just few more pictures...

Engine management
First plan was to use Motec but because of budget reason (as usual) in the end I have bought APEXi ECU for ST205. So no wiring issues at all and easier tune up.



Also decided for wide-band sensor and A/F ratio gauge (so gauge no.5 since I already have boost, oil temp, oil pressure and EGT).... it will look like airplane cockpit . Custom pod is under construction by DCW now .



This post has been edited by malpaso: Feb 22, 2011 - 6:10 AM

[808celica]

Awesome work as always Martin I wish I had the patience and money as you do

[Sunny]

Hi,

i hope it is not between the middle of march until the first april week as i have a further education this time

let me know when you plan to visit me

greetz

[malpaso]

Awesome work as always Martin I wish I had the patience and money as you do

Thanks mate... fortunately this time I'm just moneybox and work is made by some who know damn good what to do and how . No experiments allowed this time

Hi,
i hope it is not between the middle of march until the first april week as i have a further education this time
let me know when you plan to visit me
greetz

Alex, that is the plan. I will definitely drive back to CZ through Austria so this is clear . What is not clear is time . There is really a lot of work to do as you will see from pics later...

[malpaso]

Secondary target = to get rid of the rust
During installation of stronger fuel pump issue with the rust has been found… From first sight it was not that bad but when fuel tank was removed everything was clear. That rust must go first. It is useless having perfect engine when can drop out from rusted body anytime. First run of new engine must be postponed until this is resolved . See pictures below what is the condition of under-body parts…

[3WayStunna]

Wow thats alot of rust. How do you plan on takling that? Wire wheeled tools, and some paint perhaps?

[malpaso]

Wow thats alot of rust. How do you plan on takling that? Wire wheeled tools, and some paint perhaps?

Yea... It makes me really desperate... there only way to replace what is in really bad condition, what is not that bad sandblast and cover with anti-rust paint. So far everything that can be removed from under-body is removed to find the right way what to do.



Also as you can see was not possible to remove an arm from the crossmember because the rust jamed the pin inside



This post has been edited by malpaso: Feb 25, 2011 - 3:58 AM

[BonzaiCelica]

oh my!!! Flawless work Malpaso, keep it up so far so good!

[gt4st205]

I really hope you can get that cleaned up without having to replace to much! Great work so far!

[Sunny]

Hi,

i would advise to powder coat the parts as it is stronger

greetz

[malpaso]

Hi,
i would advise to powder coat the parts as it is stronger
greetz

This is on my mechanic. He knows there is needed to remove rust and protect part from rust... also my problem is budget so also money talks.

I really hope you can get that cleaned up without having to replace to much! Great work so far!

Thanks a lot. I hope so... every more serious complication means delay and more costs .

oh my!!! Flawless work Malpaso, keep it up so far so good!

Thanks. At last the "to do list" is short enough that worth to try write it down .

- take rusted parts to sandblaster
- take them to painter
- install them back

(this will be in waves not all at once probably)... than after:

- install downpipe (with wideband O2 sensor this time)
- install turbo support
- make and install downpipe support
- make and install cold intake box
- install trans shaft, rear diff and supports
- install exhaust

and... at last switch the engine on and make running for 30 minutes.

- very first map check to avoid any detonation with stock PFC map
- check wiring and Datalogit logs (especially O2 sensor)
- check everything (leaks/levels/pressures etc...)
- had a little trip to control boost controller is working

That would be the moment I will travel to Italy and to follow with:

- 1000 kms running in
- change filters and oil
- Dyno tune
- recheck everything (leaks/levels/pressures etc...)

Get her home

This post has been edited by malpaso: Feb 27, 2011 - 1:19 PM

[FORGMANN]

Not sure you can get in Europe but get some POR 15 and do
all the susp etc in this stuff.. stuff is awesome and will not
come off and will not rust ever.. I am doing my st205 in this ..

Also it dries in gloss black so all the bits underneath look brand new

http://www.por15.com/POR-15-Rust-Preventiv...int/products/1/

[malpaso]

Not sure you can get in Europe but get some POR 15 and do
all the susp etc in this stuff.. stuff is awesome and will not
come off and will not rust ever.. I am doing my st205 in this ..

Also it dries in gloss black so all the bits underneath look brand new

http://www.por15.com/POR-15-Rust-Preventiv...int/products/1/

Only place in Europe is Germany (as searched through the dealers list) however it reminds me two products available in here: Hammerite paint or Alkyton.

However small update: It has begun! First results of sandblasting .





This post has been edited by malpaso: Feb 28, 2011 - 4:18 AM

[SwissFerdi]

[HectortheRican]

Makes me want to sandblast my whole underbody... that's purrrrrdyyyy.

[Urputus]

Now it looks much better! Seeing those pictures I realized what would be my next project
Can't wait to see the whole car live!

[malpaso]

Thanks folks! It is really slow process and weather is against me but at least I can say it is moving forward every day . Another batch of parts is done (especially I'm glad that damn fuel tank is done!!!). Thanks to this they are looking like new again

[malpaso]

Just half way to go

[SwissFerdi]

Oh wow, that's fast work.

[malpaso]

Oh wow, that's fast work.

Ferdy, In this case I was lucky with progress. Next parts should be here by the end of the week and everything sandblasted and painted next Friday. So after 10days from now. At least there are a lot of other things to do so updates will be more often than once a week

[Urputus]

I believe that no other problem occurs and that you will have your celi soon.
Can't wait to see your car again

[Shigexile]

splendid

[malpaso]

splendid

Thanks a lot. From someone who put a lot of effort to the car as you it is the real compliment.

I believe that no other problem occurs and that you will have your celi soon.
Can't wait to see your car again

You bet you see it first

Again small update:
wideband O2 sensor flange is ready



And also OEM instructions how to maintain JDM car .



I know it is more for fun because now the engine will have different specs but it is so cute to see those instructions there and interesting to compare differences between markets when to change what, etc... only what I do not understand is what is that LLC???

[delusionz]

Lookin good!

LLC = Toyota Long Life Coolant (Aka the red stuff!), Not sure if they're saying 2 months or 2 years though

5000km for oil, 10,000km for oil filter, not sure on the others. 100,000 will be cambelt

[malpaso]

Lookin good!

LLC = Toyota Long Life Coolant (Aka the red stuff!), Not sure if they're saying 2 months or 2 years though

5000km for oil, 10,000km for oil filter, not sure on the others. 100,000 will be cambelt

AAAAAH! Coolant! It is in years (年:)) and also it is mention difference between first change and other changes. The rest is absolutely clear (oil, oil filter, cam belt even also other things like clearances or idle rpm ) .

Only note about aircon filters is funny - "clean every 12months and replace after 50K kms". Manual A/C in European/US models has no filters to replace or clean as I know ...so this automatic one seems must have something I need to find and check from time to time .

[malpaso]

Since still waiting for batch of sandblasted and painted parts downpipe and exhaust was prepared (downpipe support bracket included). Also sensors are in place now...

[Urputus]

That's great! Another part from the schedule completed!
So the rest of the exhaust will fit without further modifications now, right?

[malpaso]

That's great! Another part from the schedule completed!
So the rest of the exhaust will fit without further modifications now, right?

Correct... exhaust is fully prepared

[snapshotgt]

Looking good Martin, keep up the good work. I'll need to return and visit you again to see the finished version.

[malpaso]

Looking good Martin, keep up the good work. I'll need to return and visit you again to see the finished version.

Thank you Collin. I really bet it will be different car than you remember

Now. Let's look at the "to do list":

- install all refurbed parts back (in next 5days hopefully happen)

- make and install cold intake box
- install trans shaft, rear diff and supports
- finally install exhaust

and... at last switch the engine on and make running for 30 minutes.

- very first map check to avoid any detonation with stock PFC map
- check wiring and Datalogit logs (especially O2 sensor)
- check everything (leaks/levels/pressures etc...)
- had a little trip to control boost controller is working

That would be the moment I will travel to Italy and to follow with:

- 1000 kms running in
- change filters and oil
- Dyno tune
- recheck everything (leaks/levels/pressures etc...)

Get her home

So bit shorter, but still a lot of things to do...

[malpaso]

Another batch of parts sandblasted and painted



So only rear cross-member is missing now to continue

[HectortheRican]

When you're done, I hope you have a picture of the underbody of your car on a lift. I want to see it all.

[malpaso]

When you're done, I hope you have a picture of the underbody of your car on a lift. I want to see it all.

I will have it for sure when installing this but I'm afraid you will not see anything special since only one color is used for under-body parts = black. Sure I had vision if something like below



But my mechanic had different opinion and just black paint around

[HectortheRican]

Hey, straight black is still a lot sexier than dirty/rusty

[TRDGT4]

how cool it would be to have the white sumframe and be able to keep it clean would be an absolute mission!!!

[malpaso]

Hey, straight black is still a lot sexier than dirty/rusty

agree to the letter... that rust really scared me

how cool it would be to have the white sumframe and be able to keep it clean would be an absolute mission!!!

that is true... at least my mechanic has the sense of reality

Update for today (again small one)

The last part returned from sandblaster and now is being painted (in black of course )



I have also received note about some DCW parts for interior. I know... nothing I can not drive w/o but I like to keep everything clean . One of those beauties below already lie in the box at home



Unfortunately I'm not that lucky with custom shifter pod that should look something like below (draft photo-shop picture)



Should be ready in two days + a week shipping but now it is month I asked for it and still not delivered... Hope I will receive it soon enough.

This post has been edited by malpaso: Mar 17, 2011 - 4:04 AM

[malpaso]

Al last I can share with big update after loooong days

Tertiary target = suspension upgrade
This is something that was not originally planned at all. However since underbody was stripped once and suspension was last and only thing I have not touched yet I have decided for suspension upgrade. Let’s do all things right. I know it hurts (more money + another delay for first run) but suspension counts as well. So fill front engine support, rear diff rear support, rear diff front support with urethane, change endlinks, swaybar, and to install coilovers…



Unfortunately BC coilovers are not plug-and-play for ST205. Some welding was needed…



...however in hands of good mechanic result is perfect .



At least they are for this price good enough to deal with that . Now the list is complete. For last two years everything on the car is after upgrade:

- Complete body paint
- Brakes
- Cooling
- Engine
- Underbody
- Suspension…

Maybe interior should get some facelift… . But let’s not be that fast. Now let’s make new engine running at last!

[HectortheRican]

I can't wait to see this thing in action!!

[SwissFerdi]

Wow, big changes. I expect this thing to handle like it's on rails.

[malpaso]

I'm like on needles last few days because it is really close... Just looking at the latest pics I have feeling my next part replaced is exhaust



However at last on all four again! I almost hear it running

[TRDGT4]

looking great man keep up the good work!!!

[delusionz]

How many mm of tube did they leave on the stock strut?

On mine they left about 15mm and at the lowest setting mines still alot higher than yours infront...

What size tyres you running?

[makis]

Good job Martin !

[malpaso]

looking great man keep up the good work!!!

Thanks a lot! Words like this counts especially form someone who do not take his car as just "consumable part".

How many mm of tube did they leave on the stock strut?

On mine they left about 15mm and at the lowest setting mines still alot higher than yours infront...

What size tyres you running?

Honestly I do not have any details about cutting+welding. Job done by guy who did that already for his GT-four so just followed . I run 205/50 R16 tires (instead stock 215/50 R16) so diameter of wheel is for 5 mm less.

Good job Martin !

Thanks makis. Now after almost 3/4 a year I pray only for successful quick end

[presure2]

EPIC!!
great work by you and your mechanic, martin, cant wait to see it all finished up!

[SwissFerdi]

^ I agree with that.

Out of curiousity, why are you running 5 MM less?

This post has been edited by SwissFerdi: Mar 25, 2011 - 10:28 AM

[malpaso]

EPIC!!
great work by you and your mechanic, martin, cant wait to see it all finished up!

Thank you Manny. My role is more "money-box" or "manager" that mechanic... According to Wolf my knowledge of rebuilding the engine is joky .

...Out of curiousity, why are you running 5 MM less?

it is no purpose... it is just a consequence I have wanted narrow tires (since ST205 is like tank w/o a chance to spin as you remember ) to lower price (the are cheper because they are more common) and lower consumption (less rolling-resistance force). So no point to have 5mm less diametr of wheel. It is just consequense of using more narrow tire on the same size of wheel (215/50 R16 vs 205/50 R16).

Last news for today... here is one picture from mapping so...

IT IS ALIVE!!!

[SwissFerdi]

it is no purpose... it is just a consequence I have wanted narrow tires (since ST205 is like tank w/o a chance to spin as you remember ) to lower price (the are cheper because they are more common) and lower consumption (less rolling-resistance force). So no point to have 5mm less diametr of wheel. It is just consequense of using more narrow tire on the same size of wheel (215/50 R16 vs 205/50 R16).

Ah, makes sense.

Funny that you say that though, seeing as you were down on power before the rebuild...I bet you'll notice the difference now!

[Urputus]

It's good to know that the project is approaching its finish.

I hope the engine will run soon, so that I can see your car live

[delusionz]

...Out of curiousity, why are you running 5 MM less?

it is no purpose... it is just a consequence I have wanted narrow tires (since ST205 is like tank w/o a chance to spin as you remember ) to lower price (the are cheper because they are more common) and lower consumption (less rolling-resistance force). So no point to have 5mm less diametr of wheel. It is just consequense of using more narrow tire on the same size of wheel (215/50 R16 vs 205/50 R16).

In addition, And it may be different over there in Europe but here in New Zealand since Bridgestone dropped the GIII range in favour of Potenza, they no longer produced a 215/50R16 and the only tyre available in that size that I've found doesn't have a high enough load rating for the GT4 weight. Unfortunately this only leaves is with options 205/50/16, 215/55/16, 225/50/16 and 225/45/16 the only choice is to go up to a 17" wheel to get 215/45/17 which is a near perfect match in rolling diameter to the stock 215/50/16, but that also cripples us because its very difficult to find 5x100 wheels with the right offset to clear the gt4 brakes and clear the springs of the lowered suspension (the lower strut height increases the camber negativity as the pivot point cant change when theres no adjusting nut on the rear swingarm.) In my case I'm running 225/50ZR16 with 15mm spacers at the rear so the tyres dont rub the springs.

[malpaso]

...
Funny that you say that though, seeing as you were down on power before the rebuild...I bet you'll notice the difference now!

My mechanic said the same thing .

It's good to know that the project is approaching its finish.

I hope the engine will run soon, so that I can see your car live

IT IS ALIVE means engine is already running (see vid on youtube)

In addition, And it may be different over there in Europe but here in New Zealand since Bridgestone dropped the GIII range in favour of Potenza, they no longer produced a 215/50R16 and the only tyre available in that size that I've found doesn't have a high enough load rating for the GT4 weight. Unfortunately this only leaves is with options 205/50/16, 215/55/16, 225/50/16 and 225/45/16 the only choice is to go up to a 17" wheel to get 215/45/17 which is a near perfect match in rolling diameter to the stock 215/50/16, but that also cripples us because its very difficult to find 5x100 wheels with the right offset to clear the gt4 brakes and clear the springs of the lowered suspension (the lower strut height increases the camber negativity as the pivot point cant change when theres no adjusting nut on the rear swingarm.) In my case I'm running 225/50ZR16 with 15mm spacers at the rear so the tyres dont rub the springs.

Wow... that is unbelievable. I would not be able to run on 17" (with Superstrut Suspension) on CZ roads at all. They are so horrible I would be like shake after few miles .

[Urputus]

IT IS ALIVE!!!

Aaaaah, GREAT!
I'm packing my suitcases to Italy

[malpaso]

Count down is running! Dyno is booked on 19th this month so will share with much more by the end of the month . Now relaxing and making my mind busy with collecting small things together and preparing for trip only to spend the time somehow and to not go mad till 19th .

So as already shared have prepared airbox with new design...



...new gauge pod delivered today (from DCW )



Only news about car I have:

- there are some issues with ABS (damn light on dash is on) so speed sensors to be checked and wiring as well (because has been modified during conversion might be there something as well).
- heater clamp changed as it leaked.
- some clutch pedal adjustment...

Just few things that pop-up after few miles driving. Nothing serious .

[malpaso]

Last piece of the puzzle received today

[HectortheRican]

That is sex.

[rave2n]

That is sex.

x2

[malpaso]

"D-Day" is here



...for more stay tuned

[Batman722]

NICE !

[delusionz]

I just bought my turbo today, and i noticed yours looks identical (Really tiny compared to CT). You say you would choose something different?

Yours is GT2860RS with .64 A/R? Apart from it being tiny, why do you want something else (unless your chassing alot more than stock)?

From all the information I could find, this is the only ball bearing turbo that will spool up before 3000. I don't see the sense in being torqueless out of tight corners (2nd gear 2500rpm) with 4wd traction



It's a shame I wont get to see how yours runs on a stock ECU since you have the Power FC there, that part is out of my budget for now

[Urputus]

Wish a looooong live to your rebuilt engine, Malpaso.

[SwissFerdi]

Wish a looooong live and many high RPMs to your rebuilt engine, Malpaso.

Couldn't have said it better myself.

[malpaso]

Thanks a lot folks. I have for you one vid I have made on dyno... it was 5hrs session so I had tons of footage... that means some clip is on the way as well

CLICKY

[enderswift]

always awesome to see another well rebuild celi. good work

[RoyO]

Nice topic, very nice rebuild / upgrade!!