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> Gen III 3S-GTE WRC build - Finished!
post Nov 15, 2005 - 3:20 AM
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GT4WRC



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What a lovely way to spend a day - pulling the motor and box out of the 4 rolleyes.gif

Dropping the subframe...
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Subframe and exhaust removed...
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Driveshaft out...
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Engine and box just about ready to come out (loom was the worst part!)
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Part of the WRC version's antilag system...
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With the motor resting on 'supports', the car was hoisted upwards...
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Thanks to my mate for the use of his workshop biggrin.gif
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My, what a big gap!
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Uses for Holden Ute wheels #24
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Looking a bit sorry for itself right now :cry:
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Next step is to start pulling the motor and box apart so the real fun can begin biggrin.gif
Gary

This post has been edited by GT4WRC: Jan 17, 2006 - 1:17 AM


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IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
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post Nov 15, 2005 - 9:19 AM
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CelicaZR



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Good Luck with the search for more power smile.gif
Keep us posted.


--------------------


98 ST204 ZR - Black Beauty - Roaming the streets of Sydney
73 TA22 LT - Tiffany Blue - Mint Classic Weekend Cruiser
75 TA22 LT - Snow White - Mint Classic Weekend Cruiser
77 RA28 LT - Flubber Green - Mint Classic Weekend Cruiser
94 MX-5 NA8 Clubman - Red Racer - Looking for corners
WIP Project: 69 RT40 Corona, 2nd WIP Project: 66 RT40 1600s Corona
86 Corona RT142 - Daily Driver

6GC 4 Life Baby!!!
post Nov 15, 2005 - 11:15 AM
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nik



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nice keep us updated


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yea your 3sgte is cool but ill stick to my 7agte
post Nov 15, 2005 - 11:55 AM
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mmmm yum
post Nov 15, 2005 - 2:37 PM
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nice. wat ya doing to it anyway?


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Turbo install made possible thanks to Team J.D.M.
officially 5SFTE junior member
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post Nov 15, 2005 - 2:40 PM
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GT4WRC



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QUOTE(shin @ Nov 15, 2005 - 2:37 PM) [snapback]355890[/snapback]

nice. wat ya doing to it anyway?



http://www.6gc.net/forums/index.php?showtopic=30784


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 15, 2005 - 3:33 PM
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playr158



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this is his plans
"Bench flowed cylinder head with HKS 264 cams, adjustable cam wheels and uprated valve springs. Will also look at the inlet manifold when it's off to see if the flow can be imprioved. Block to have oilways cleaned up (rough castings as standard) to improve flow and will be reassembled with fully balanced crank, TRD shells, OE rods and ACL pistons (0.5 oversized). That will be coupled to a lightweight flywheel and uprated clutch. This will allow the rev limit to be increased to at least 8000rpm.
Will also be fitting some GReddy 750cc top feed injectors too and a much bigger Koyo aluminium rad. Once this is all put together, boost will be turned back down and the engine will be given time to run in properly. Will also give me chance to sort out a decent intake system using an A'Pexi filter and custom made carbon fibre cold air box.
I can look at a tubular exhaust manifold, BB turbo (probably a GT30) and an A'Pexi ECU"
post Nov 15, 2005 - 4:55 PM
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BBoYRuGGeD



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wow...must've been fun! good luck man! keep us updated! smile.gif

bboy


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..(formerly daily driven) 3S-GTE powered celica currently set @ 12psi..
post Nov 16, 2005 - 4:29 AM
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GT4WRC



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Where to start? confused.gif
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The WRC version antilag control valves...
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Almost there...
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Crank will be coming out over the weekend before the block's off to be cleaned, tested, re-bored and painted...
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Pistons are in excellent condition. Wouldn't have sussed they were nearly 150,000km old!
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Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 16, 2005 - 4:48 AM
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macavely



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great pics GT ... got me thinking of back in the dayz when i would brake down a motor to be rebuilt.... wish you the best of luck .... don't forget to post pic of everthing thing you get done ...


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post Nov 16, 2005 - 4:50 AM
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celicast3sgte

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so why did the motor come apart? internal upgrades?


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94' ST Coupe - 5sfe Motor swap and brake swap.
post Nov 16, 2005 - 8:20 AM
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presure2



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hehe good work man, keep us posted!


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post Nov 16, 2005 - 10:23 AM
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this is great! keep us updated, I'm loving these pics.


DEF


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post Nov 16, 2005 - 12:58 PM
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GT4WRC



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QUOTE(celicast3sgte @ Nov 16, 2005 - 4:50 AM) [snapback]356213[/snapback]

so why did the motor come apart? internal upgrades?


http://www.6gc.net/forums/index.php?showtopic=30784


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 16, 2005 - 1:03 PM
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gt_driFFter



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awesome, whose MR2 is that?

post Nov 16, 2005 - 7:03 PM
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GT4WRC



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Not mine wink.gif

It's a customers of the garage owner. Ran the bearings when the owner allowed the oil level to drop rolleyes.gif It's sat there in teh corner while the lad saves some more money to get the 3SGE repaired.
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 17, 2005 - 11:52 AM
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Very Interesting Project Gary.Are you changing the fuel pump also?Did you order the Greddy injectors?I am suggesting to you Sard injectors and Sard in-tank Fuel pump with harness for ST205.You are thinking about GT30,a/r??
Another one by Toyota smile.gif 150.000kms on pistons running on a turbo engine (probably most of the kms wasnt with standard boost tongue.gif tongue.gif ) smile.gif
Please post news and more PHOTOS wink.gif
post Nov 18, 2005 - 10:23 PM
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GT4WRC



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Block stripped down and ready for the engine shop on Monday where it'll be cleaned, tested, oil galleries opened up and re-bored for the new pistons...

user posted image

user posted image

Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 19, 2005 - 8:01 PM
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BBoYRuGGeD



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damn that motos gunna be sexy smile.gif

bboy

This post has been edited by BBoYRuGGeD: Nov 19, 2005 - 8:01 PM


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..(formerly daily driven) 3S-GTE powered celica currently set @ 12psi..
post Nov 20, 2005 - 12:39 AM
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GT4WRC



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QUOTE(BBoYRuGGeD @ Nov 19, 2005 - 8:01 PM) [snapback]357384[/snapback]

damn that motos gunna be sexy smile.gif


Not sure about wanting it to be sexy, just producing a shed load of power will be good enough for me tongue.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 20, 2005 - 12:44 PM
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Jdog1385



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QUOTE(GT4WRC @ Nov 20, 2005 - 12:39 AM) [snapback]357443[/snapback]

QUOTE(BBoYRuGGeD @ Nov 19, 2005 - 8:01 PM) [snapback]357384[/snapback]

damn that motos gunna be sexy smile.gif


Not sure about wanting it to be sexy, just producing a shed load of power will be good enough for me tongue.gif
Gary


You're the man
post Nov 26, 2005 - 1:23 AM
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GT4WRC



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Just finished lagging the Water to Air Intercooler for the GT4. Left it soaking in an acid bath for a few days to strip it back to bare metal and clean out the insides. 'Lid' was then cleaned up (removed a few bleamishes etc) before it was given a coat of etch primer. A couple of layers of gloss black closely followed the graphics before the paint fully dried (I designed the graphics myself and simply sent the design to a vinyl cutter. I'm also swapping from a twin to single entry turbo soon). A couple of layers of clear coat were then added to seal in the graphics. Once that had been give a day to dry, I then lagged the lower half with a roll of Thermo-Sheild Tape TM. Job done smile.gif

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While the car is off the road, decided it would be an ideal time to 'bling up' those calipers too...

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Once the paint is fully cured, I'll paint the 'Celica' lettering using some white enamel paint. Rears will also get done to match biggrin.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 26, 2005 - 1:27 AM
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Batman722



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all I can say is WOW. I would kill for a WRC...

great job !!!


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post Nov 26, 2005 - 3:18 AM
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Magic



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Great Work my friend,careful work.
The color of the calipers match to the brembo original color wink.gif

About the chargecooler,i thought you were about to install a GT30 turbine,are you staying with stock intercooler? rolleyes.gif
post Nov 26, 2005 - 3:38 AM
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GT4WRC



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QUOTE(Magic @ Nov 26, 2005 - 3:18 AM) [snapback]359688[/snapback]
About the chargecooler,i thought you were about to install a GT30 turbine,are you staying with stock intercooler? rolleyes.gif


Yep, GT30 turbo and stick with the stock WAI. Will be looking at increasing its efficiency even further by fitting a larger pre-rad. The WAI is extremely efficient - good enough for the WRC cars wink.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 26, 2005 - 3:49 AM
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lagos



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GREAT WORK ! the IC looks amazing!


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15PSI - 30MPG - Megasquirt Tuned
post Nov 26, 2005 - 3:50 AM
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Magic



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Then you should change your driving profile depends on the weather conditions and the temperature, this is actually what the WRC teams are making smile.gif When Toyota used to run with the ST205 in hot weather conditions country they used to tie few blocks with ICE over the chargecooler to keep it cold cuz the place (Above the Engine) was taking all the heat from the WRC Engine.
I think if you have few runs with GT30 using the stock charge cooler and have a look on your inlet temperature will help you to understand if you need a front mount intercooler or original chargecooler.  My opinion is that for just a run the chargecooler its fantastic, because you can prepare it and have the run, after the first run its getting very hot, and hotter etc.The front mount intercooler its getting cold over and over cuz of the fitting place.Another advantage of chargecooler it’s the position and the distance of the turbo, you avoid lag.


This post has been edited by Magic: Nov 26, 2005 - 4:02 AM
post Nov 26, 2005 - 4:31 AM
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CelicaZR



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Nice work Gary smile.gif
I like the new look of the intercooler.
The red Calipers looks hot!


--------------------


98 ST204 ZR - Black Beauty - Roaming the streets of Sydney
73 TA22 LT - Tiffany Blue - Mint Classic Weekend Cruiser
75 TA22 LT - Snow White - Mint Classic Weekend Cruiser
77 RA28 LT - Flubber Green - Mint Classic Weekend Cruiser
94 MX-5 NA8 Clubman - Red Racer - Looking for corners
WIP Project: 69 RT40 Corona, 2nd WIP Project: 66 RT40 1600s Corona
86 Corona RT142 - Daily Driver

6GC 4 Life Baby!!!
post Nov 26, 2005 - 4:44 AM
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GT4WRC



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Magic
Hence the reason why I've lagged the cooler with heat reflective material. Red Line 'Water Wetter' will also help keep the water temps low and as stated, I'll also be fiting a more efficient pre-rad.
A lot of people tend to dismiss a water to air intercooler as being nowhere hear as good as a conventional air-toair. I have no intention of changing the OE set-up as I beleive that it is more than up to the job.
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Nov 26, 2005 - 11:27 AM
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Magic



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GT4WRC i also prefer the original Toyota charger cooler setup but in my country it is too hard to keep the temp at low levels mad.gif I enjoy my car very much by the night time smile.gif but it is what i told you before,it depends from your profile,if you want a daily driving setup and pushing the car over and over i think a FMI will be a good deal. smile.gif

I like your work on the original charge cooler smile.gif
post Nov 26, 2005 - 4:36 PM
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Cutrara



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Wow. Very very nicely done, it looks much better than stock, but not flashy. Beautiful job, keep up the good work.


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hey, nice mod does it come in hetero?


Need parts? I'm parting out a '94 ST
post Nov 26, 2005 - 6:29 PM
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presure2



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looks great man, awesome work!


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Former Team 5SFTE pro member ;)

13.6@108MPH, 5SFTE Powered
post Nov 28, 2005 - 2:49 AM
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97sccelica



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QUOTE(GT4WRC @ Nov 26, 2005 - 1:44 AM) [snapback]359701[/snapback]

Magic
Hence the reason why I've lagged the cooler with heat reflective material. Red Line 'Water Wetter' will also help keep the water temps low and as stated, I'll also be fiting a more efficient pre-rad.
A lot of people tend to dismiss a water to air intercooler as being nowhere hear as good as a conventional air-toair. I have no intention of changing the OE set-up as I beleive that it is more than up to the job.
Gary


the fastest cars i have been in have WAI

i dont doubt the cooling efficiency, the only problem i see is if the intercooler becomes a flow restriction


--------------------
1994 Celica GT4 WRC Edition
@gt4.wrc on Instagram
post Dec 1, 2005 - 6:38 AM
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GT4WRC



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Rods were finished being shotpeened and polished last night along with the pistons, crank, flywheel and clutch cover, they went down to the engine balancer today.

Crank, flywheel and cover plate were loaded up and balanced to within a gnats whisker...
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The digital printout...
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The completed rods. All weighed and within 0.01g of each other...
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The lower end was then 'dummy' assembled to ensure that the deck height was okay. Within 1/100th mm from end to end.
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Just awaiting delivery of the new TRD main shells before the final build can begin.
Gary



--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 1, 2005 - 6:42 AM
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wow progress on ur car is looking real good...keep us updated!

bboy


--------------------

..(formerly daily driven) 3S-GTE powered celica currently set @ 12psi..
post Dec 1, 2005 - 4:34 PM
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celicast3sgte

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that was fairly fast for a build up. that or im just loosing track of time working on my celi.


--------------------
94' ST Coupe - 5sfe Motor swap and brake swap.
post Dec 1, 2005 - 5:09 PM
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i wish my shop went that fast


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yea your 3sgte is cool but ill stick to my 7agte
post Dec 1, 2005 - 5:10 PM
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GT4WRC



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QUOTE(nik @ Dec 1, 2005 - 5:09 PM) [snapback]362204[/snapback]

i wish my shop went that fast


It helps when you actually do 99% of the work yourself wink.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 1, 2005 - 5:15 PM
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nice pics man
keep um comin


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Alexander
-Silver 97 Celica ST
post Dec 1, 2005 - 5:35 PM
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what kind of rods are these? Might be usefull for me too to have some high quality parts in my engine wink.gif

cheers Joerg


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Spec to be found on my website....
post Dec 1, 2005 - 6:54 PM
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nik



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QUOTE(GT4WRC @ Dec 1, 2005 - 4:10 PM) [snapback]362206[/snapback]

QUOTE(nik @ Dec 1, 2005 - 5:09 PM) [snapback]362204[/snapback]

i wish my shop went that fast


It helps when you actually do 99% of the work yourself wink.gif
Gary


i only did about 50% on this project but 100% on my old 7afte


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yea your 3sgte is cool but ill stick to my 7agte
post Dec 2, 2005 - 1:47 AM
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GT4WRC



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QUOTE(snakeloa @ Dec 1, 2005 - 5:35 PM) [snapback]362216[/snapback]

what kind of rods are these? Might be usefull for me too to have some high quality parts in my engine wink.gif

cheers Joerg


OEM. Shotpeened and polished.
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 2, 2005 - 2:41 AM
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thats pretty fast indeed. Pretty soon your gt4 going to be a monster!


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Its Orville's Celica, i just drive it...
post Dec 2, 2005 - 2:53 AM
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snakeloa



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So tell me Gary, why only OEM Rods and not some uprated ones???

What is the difference after having them Shotpeened and polished?

Thank you Joerg


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Spec to be found on my website....
post Dec 2, 2005 - 2:54 AM
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Bigmeanbulldog55



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Lookin good.


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post Dec 2, 2005 - 3:41 AM
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macavely



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wow ... that first pic.. just brings a tear to my eye....


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post Dec 2, 2005 - 4:14 AM
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GT4WRC



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QUOTE(snakeloa @ Dec 2, 2005 - 2:53 AM) [snapback]362403[/snapback]

So tell me Gary, why only OEM Rods and not some uprated ones???

What is the difference after having them Shotpeened and polished?


I'm not after 'silly' power so standard rods will be more than adequate. Shot peening is meant to 'de-stress' the rods and teh polishing simply smooths the surface. Probably a little overkill, but as I'll be increasing the rev limit to 8k, thought it prudent for a little added security.
Gary


QUOTE(orvillescelica @ Dec 2, 2005 - 2:41 AM) [snapback]362400[/snapback]

thats pretty fast indeed. Pretty soon your gt4 going to be a monster!


I'll be extremely disappointed if it's not wink.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 2, 2005 - 4:38 AM
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dude your build is going quick....its taken me 7-8 weeks now and i have only just had the bottom end balanced...start to dummy up the motor monday.

what type of timing are you gonna use.....??


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312whp with more to come....
post Dec 2, 2005 - 9:52 AM
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QUOTE(orvillescelica @ Dec 2, 2005 - 2:41 AM) [snapback]362400[/snapback]

thats pretty fast indeed. Pretty soon your gt4 going to be a monster!



Going to be??? GT-4's are already monsters! Good **** man goood ****!


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Kawi Love
post Dec 2, 2005 - 2:59 PM
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GT4WRC



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QUOTE(ice23q @ Dec 2, 2005 - 4:38 AM) [snapback]362430[/snapback]

dude your build is going quick....its taken me 7-8 weeks now and i have only just had the bottom end balanced...start to dummy up the motor monday.

what type of timing are you gonna use.....??



It's damn frustrating for me TBH as I'm still waiting for the TRD main shells to arrive. Otherwise would have had the bottom end completed this weekend mad.gif

Will be running HKS 264 deg cams with adjustable cam wheels and a 'race spec' cambelt.
Gary


--------------------
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1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 3, 2005 - 2:13 AM
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ice23q

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Cool.....im doing a 5sgte project with 272 toda cams and adjustable cam gears....cam sensors and quad coil packs....

where are you getting your cam belt from ....(as im on the same side of the world as you)....would be interesting..


--------------------
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312whp with more to come....
post Dec 6, 2005 - 1:37 AM
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The one thing that has been holding everything up at the moment has been the TRD main shells. They finally arrived today - at least 8 of them did. The centre bearings weren't sent out due to a mix up so won't be here until tomorrow rolleyes.gif
Still, with the other shells, we could measure up the crank to see if any machining was required. Forget the measurement, but a miniscule amount needs to come off the crank so off it went along with the block to the engine reconditioners. Expecting everything back tomorrow.

Shell sizes being measured...
user posted image

Stuck at work all day tomorrow, but hoping to have the bottom end completed on Thurs evening.

In the meantime, took the opportunity to clean up the gearbox. After 11 years use, it was absolutely caked in cr@p..
user posted image

user posted image

So out came the industrial strength cleaner, a stiff wire brush, hosepipe and lots of elbow grease. Here's the result...
user posted image

user posted image

With that cleaned, new driveshaft seals and release bearing were fitted. Clutch release slave unit was looking a little worse for wear so a replacement is on order.
Gary

This post has been edited by GT4WRC: Dec 6, 2005 - 1:40 AM


--------------------
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1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 6, 2005 - 1:39 AM
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Nice work on the tranny. It looks brand new.


Good luck
DEF


--------------------

I will return one day.
post Dec 6, 2005 - 1:55 AM
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Excellent clean up wink.gif
So much time & effort "clap clap clap" keep it up thumbsup.gif
post Dec 6, 2005 - 1:57 AM
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You should compile all these threads into one for your "build up." That would be neat. It would be long but it would be easy for a year down the road to come back and find it and look through all the things at once. I've already lost track of some of the stuff you've done.


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post Dec 7, 2005 - 1:26 AM
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wow talk about a tear down and rebuild.

are you gonna send the tranny to a reconditioner? you might as well do it while its out of the car.
post Dec 7, 2005 - 1:46 AM
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GT4WRC



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QUOTE(Hanyo @ Dec 7, 2005 - 1:26 AM) [snapback]364302[/snapback]

are you gonna send the tranny to a reconditioner? you might as well do it while its out of the car.


No need. Drivetrain was running flawlessly and the oil which drained out was nice and golden.
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 8, 2005 - 3:27 AM
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GT4WRC



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Was lucky enough to get my hands on a cylinder head which had been gas flowed by NZ's top Toyota guru. It had been previously used in an MR2 which had a dyno proven 450bhp. Head was 10,000kms old and came complete with HKS 264 cams for a price which was too good to be true.
It is actually from a 3S-GE motor which Toyota originally fitted in their factory to an Altezza. When I got my mitts on it, I sent it to a local head specialist who cleaned it up and pressure tested it. New valve seals were installed, valves re-seated and uprated valve srpings fitted due to the rev limit being increased to 8,000rpm.
user posted image

There are a few minor differences between the n/a and turbo heads which meant a couple of bits of creative engineering were required.
The GT4 uses an EGR (Exhaust Gas Recycle) system as part of its emission control which requires a slightly different valve cover. As a result, a small piece of ally needed to be welded between #4 spark plug hole and the end (as can be seen in the photo below). Otherwise there would be a gap for the oil to splash out. This is due to the EGR 'feed' being at this end on the turbo head.
user posted image

Also, the 3SGE uses top feed injectors as opposed to the larger side feed on the 3SGTE. So the injector holes needed to be re-drilled to accept the larger injector nozzles.
user posted image

A fair bit of work has been done on the inlet and exhaust porst to improve flow as can be seen in the next two pics...
user posted image

user posted image

As well as increasing power, should also reduce lag quite a bit too biggrin.gif

Also, decided to 'tart' up the alternator too being as it is in such a prominent position. So it was stripped right down to its single components...
user posted image

user posted image

While it was apart, new bearings were also fitted.

And the finished article..
user posted image

user posted image

Amazing what a bit of chrome can do laugh.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 8, 2005 - 3:30 AM
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95CelicaST



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Dear god that is hot! Lucky!


--------------------
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post Dec 8, 2005 - 6:32 AM
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All this stuff is looking good. Are you considering my idea of making it all one big post though? Seriously, it would be nice to see everything you've done together. Jumping from post to post to check everything is a little annoying. I'd really like to have that stuff done to my car one day. Actually, I know I'll have that stuff done, it's the car that's in question. Keep it up.


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post Dec 8, 2005 - 8:07 AM
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presure2



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head looks good, and that alternator looks BLING!
gotta agree with bigmeanbulldog on the post thing...why not just keep it all in one post? so that its searchable all together...somthing like "my 3rd gen 3sgte build" or somthing?
i can help ya with that if need be, just PM me. wink.gif


--------------------
Former Team 5SFTE pro member ;)

13.6@108MPH, 5SFTE Powered
post Dec 8, 2005 - 10:15 AM
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uh oh, has the chrome bug bit Gary?

what now chrome valve cover?

when are you gonna but this baby back together?
post Dec 8, 2005 - 10:50 AM
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Is the clean gearbox your gearbox??? tongue.gif tongue.gif tongue.gif

Great work...smile.gif
post Dec 8, 2005 - 11:21 AM
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wow... ya sure cleaned it up good. awesome update. make sure you keep us inform of all progress wink.gif


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Turbo install made possible thanks to Team J.D.M.
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post Dec 8, 2005 - 11:53 AM
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oooooooooooo SOOOO NICE
post Dec 8, 2005 - 12:18 PM
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playr158



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oooooooooooooooooh my goodness

gary you wana build my motor next? build my car?!
post Dec 8, 2005 - 3:06 PM
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awesome stuff. keep updating us as much as u can .


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post Dec 8, 2005 - 4:50 PM
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QUOTE(playr158 @ Dec 8, 2005 - 12:18 PM) [snapback]364877[/snapback]

oooooooooooooooooh my goodness

gary you wana build my motor next? build my car?!


No worries. Just send me a return airline ticket and a blank cheque wink.gif



QUOTE(Hanyo @ Dec 8, 2005 - 10:15 AM) [snapback]364813[/snapback]

uh oh, has the chrome bug bit Gary?

what now chrome valve cover?

when are you gonna but this baby back together?



Valve cover has been HPC coated in red tongue.gif

Hoping that it'll be back together before I fly off to Europe in 8 days time.
Gary


QUOTE(presure2 @ Dec 8, 2005 - 8:07 AM) [snapback]364793[/snapback]

head looks good, and that alternator looks BLING!
gotta agree with bigmeanbulldog on the post thing...why not just keep it all in one post? so that its searchable all together...somthing like "my 3rd gen 3sgte build" or somthing?
i can help ya with that if need be, just PM me. wink.gif


PM sent smile.gif


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 8, 2005 - 6:07 PM
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I've been following your whole project and let me say, it's probably one of the most detailed rebuilds I've seen. Keep up the good work. When you're done, I'm sure you'll have loads of power, and the engine will last for ages.


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hey, nice mod does it come in hetero?


Need parts? I'm parting out a '94 ST
post Dec 9, 2005 - 2:51 AM
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Tuesday:
TRD shells finally arrive after their trip from Japan. Though due to a logistical error, only 8 shells turn up, the other 2 are still at the dealer on the South Island. As soon as error is realised, the 2 shells are put on an overnight courier. In the meantime, crank can be neasured up against the new shells and machined to suit.
Wednesday:
Other 2 shells arrive and black and crank arrive back from the engine shop.
Thursday:
I'm at work all day so mechanic who owns the workshop (Mike) where rebuild is being done is tasked with fitting the new pistons and shells to help keep us on track.
Pistons #1 goes in now problem. Piston #4 is being put in its cylinder when disaster strikes. The bottom oil control ring slips out between the clamp and block un-noticed until the piston suddenly goes 'tight'. Immediately obvious that the ring is damaged so new ring is sourced without too much of a problem. However, this has also happened...

user posted image

user posted image

Oh dear frown.gif

By this time, I've finished work and have popped in on the way home to see how things are going. Mike calls the engine shop owner (also a mate) who comes round to survery the damage. He 'offers' several solutions. A replacement block would be a mission to find, especially a good one, a sleeve is not an option considering I'll be running over 20psi and a new cylinder is way too expensive.
So, the block went back to his shop this morning to see if a 1 thou bore will remove the damage. 1 thou being the max we could go to.
Unfortunately, 1 thou isn't enough to cure the issue mad.gif So, only option we really have is for a set of 1mm oversized pistons and a re-bore. That will essentially give a 2020cc capacity which isn't a bad thing wink.gif
New pistons have been ordered and will be here on Tuesday when the block will also be re-bored to suit and the new pistons weighed to ensure everything is kept well balanced.
Downside is that I fly to Europe in 8 days so no way the car will be back on the road before xmas. The bottom end will be completed while I'm away and when I return on the 9th Jan, I can hopefully finish the rest and get it running again. I am already getting withdrawal symptoms laugh.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 9, 2005 - 2:56 AM
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95CelicaST



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Are you having to pay for their mistake?


--------------------
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I'm not really an asshole, but I play one on the internet.
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post Dec 9, 2005 - 3:04 AM
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GT4WRC



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QUOTE(95CelicaST @ Dec 9, 2005 - 2:56 AM) [snapback]365200[/snapback]

Are you having to pay for their mistake?


No. Mike is a good mate and will be covering any additional costs. I'm not pi55ed off with him as it could have happened to anybody at the end of the day - including me. Just one of those things. He was as gutted as me when it happened.
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 9, 2005 - 3:18 AM
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95CelicaST



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What kind of HP numbers are you looking to get after this is all said and done?


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post Dec 9, 2005 - 3:22 AM
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lol that sucks but how freakin sweet

a nice nice gain from a mistake!
woooot
post Dec 9, 2005 - 3:43 AM
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GT4WRC



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QUOTE(95CelicaST @ Dec 9, 2005 - 3:18 AM) [snapback]365205[/snapback]

What kind of HP numbers are you looking to get after this is all said and done?


Good question. TBH, I'm not entirely sure but would hope to expect at least 400 horses at the flywheel.
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 9, 2005 - 6:51 AM
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Good luck with your work, hope that it's more of a gain than a loss to ya wink.gif
post Dec 9, 2005 - 10:33 PM
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GT4WRC



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While the engine internals 'issue' is being resolved, attention was turned to the radiator.
First step was to clean up the engine bay. As can be seen below, it was rather filthy...

user posted image

user posted image

So, once again with the industrial strength cleaner and elbow grease and et voila!

user posted image

user posted image

Not quite like new, but sooooo much better biggrin.gif

The OE rad seems to be pretty capable of coping with 300bhp, but whether it would handle over 400 is questionable. So, rather than leave it to chance, a Koyo unit was ordered from the US. Twice as thick as the standard one (and also the same fitment for the ST202), this unit is beautifully manufactured. Only issue would be with the OE fan fitment. Clearance is pretty tight in the first place and there would be some interference issues if the standard fans were re-used.
So I raided my spares box and came up with a pair of Kenlow slimline fans. 10 minutes later they were attached to the new rad and the rad in turn fitted to the car...

user posted image

user posted image

user posted image

Nice and shiney. Won't have any cooling issues with this set up wink.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 9, 2005 - 10:37 PM
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celicaST



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i dont think your going to be having ANY issues with this car when its finished... except maybe speeding smile.gif


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I think Bigfoot is blurry, that's the problem. It's not the photographer's fault. Bigfoot is blurry. And that's extra scary to me, because there's a large, out-of-focus monster roaming the countryside.
post Dec 10, 2005 - 3:20 AM
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Bigmeanbulldog55



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QUOTE(celicaST @ Dec 9, 2005 - 10:37 PM) [snapback]365463[/snapback]

i dont think your going to be having ANY issues with this car when its finished... except maybe speeding smile.gif

Sadly, your probably wrong, but this thing is still turning our awsome. I don't see a build not having problems. They'll probably be fixed and then it will run great, but they'll still be there at first. I'm really impressed with this thing. I wish I knew as much as you do and had the resourses to do those thing to my car. thumbsup.gif


--------------------
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post Dec 10, 2005 - 5:48 AM
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very nice build here. what is the plan for engine management? piggy back on teh stock ecu or are you going for a standalone or pnp ecu?


--------------------
94' ST Coupe - 5sfe Motor swap and brake swap.
post Dec 10, 2005 - 1:04 PM
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GT4WRC



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QUOTE(celicast3sgte @ Dec 10, 2005 - 5:48 AM) [snapback]365531[/snapback]

very nice build here. what is the plan for engine management? piggy back on teh stock ecu or are you going for a standalone or pnp ecu?


Apexi FC ECU which is modded by Power Engineering in Japan for use with the ST205. Placed an order last week for one and it should be ready by the end of Jan 06.
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 11, 2005 - 4:13 PM
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Beautiful. Really.


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post Dec 11, 2005 - 5:37 PM
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are you worried about clearance issues with the koyo ? It might be a very tight fit...


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post Dec 11, 2005 - 11:49 PM
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GT4WRC



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QUOTE(Batman722 @ Dec 11, 2005 - 5:37 PM) [snapback]365904[/snapback]

are you worried about clearance issues with the koyo ? It might be a very tight fit...


After fitting the rad and the Kenlow fans, I have gained an extra 50mm clearance biggrin.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 12, 2005 - 9:31 PM
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bowdown.gif bowdown.gif bowdown.gif bowdown.gif thumbsup.gif


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I will return one day.
post Dec 12, 2005 - 10:30 PM
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jezuz gary, enough work eh? Looks great though. All in all how much $ r u spending on this project?? Im guessin a good amount. This things probably gonna be bulletproof though. For ur transmission/gearbox, are u just using the WRC spec gears? or are you gonna be changing the gear ratios. Also you doing LSD's front and rear when you move to the rear diff?
post Dec 12, 2005 - 10:50 PM
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I might have missed it but what turbo will you be using Gary?


--------------------
QUOTE(lagos @ Jul 10, 2006 - 1:55 PM) [snapback]454118[/snapback]

i know your trying to do the right thing for your motor, but this is one of those times where you should just trust the guys who have had their swaps for a while and have done a ton of research into this.
post Dec 13, 2005 - 3:06 AM
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GT4WRC



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QUOTE(Valo666 @ Dec 12, 2005 - 10:30 PM) [snapback]366500[/snapback]

For ur transmission/gearbox, are u just using the WRC spec gears? or are you gonna be changing the gear ratios. Also you doing LSD's front and rear when you move to the rear diff?


Transmission will remain standard (other than the clutch). Rear diff already has a Torsen diff as standard.



QUOTE(jgreening @ Dec 12, 2005 - 10:50 PM) [snapback]366509[/snapback]

I might have missed it but what turbo will you be using Gary?


GT30.

Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 13, 2005 - 9:36 AM
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Drocay



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Can't wait to see your beast up and running man, it'll definitly be a monster.


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post Dec 16, 2005 - 4:08 AM
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After the 'bore scoring incident', I decided to get the block ultrasounded to check if it was safe to bore it out to 87mm. Some cylinder walls on the earlier are as thin as 2.5mm between #2 & #3 while others are 4.5mm. As I said above, is a simple case of pot luck. Later blocks were revised with the thicker walls.
Tests on mine, which I got back today, show 4.3mm thickness so boring out to 87mm is going to be okay after all.
I'm off to Europe for 3 weeks Sat am so the bottom end will be all sorted out for me when I get back. Something to look forward too wink.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Dec 16, 2005 - 5:29 AM
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That's absolutely great work you've been doing there Gary. Big props for you. I just hope that one day i can do such work with motors that you do or even a little close to it. It's just so impressive. Wondering how difficult would it be for me to turbo my 3S-GE or just swapping the 3S-GTE and btw still don't know which one would be the better option for me. rolleyes.gif Read that your coming to europe also. What's your location?


--------------------
Please visit on our teams new website. hrp-tuning.com

19in deepdishes - invader bodykit - invader cf hood - x-box - dls audio
post Dec 16, 2005 - 12:03 PM
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damn i gotta wait 3 weeks? haha, have fun in europe man
post Jan 11, 2006 - 1:36 AM
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While I was swanning around Europe, the new pistons were successfully fitted to the revised block....

user posted image

user posted image

... we couldn't get some ACL +1mm pistons so turned to a set of Wisecos from the US...

user posted image

So, with that part completed, I could now start putting everything back together..

user posted image

ARP studs fitted along with the new HG...

user posted image

Oil pick-up and splash pan fitted following a few hours in the acid bath....

user posted image

New crank oil seal fitted....

user posted image

Due to different cams, altered CR and different pistons, a test was required to ensure that valves and pistons didn't come into contact with each other so off to the local toy shop for some...

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This was then put onto the piston crowns where the valves would likely come into contact...

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Once all 4 pistons had been set so they sat half way up the bores, the cylinder head could be fitted and torqued into place....

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The top cam cover backing plate and lower belt cover were fitted next to ensure that the cam wheels and bottom pulley were positioned correctly....

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.... prior to the cambelt being fitted....

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Once everything was properly assembled, the engine was carefully turned over for a few revolutions, taking care to ensure that there was no unwanted resistance.

Then, the belt and head were removed so the doh on the pistons could be inspected. This revealed plenty of clearance between pistons and valves. Obviously a good thing....

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With the doh removed, the head could be refitted. This being the current state and the end of play today...

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Work prevents me from doing more until Friday morning when the rebuild will continue. Watch this space wink.gif
Gary

This post has been edited by GT4WRC: Jan 11, 2006 - 1:45 AM


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IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Jan 11, 2006 - 1:52 AM
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x_itchy_b_x



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bowdown.gif bowdown.gif thumbsup.gif
awesome.


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post Jan 11, 2006 - 2:00 AM
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lagos



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this thread is better then 90% of all the internet porn! my jaw is on the floor looking at this project!


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15PSI - 30MPG - Megasquirt Tuned
post Jan 11, 2006 - 7:49 AM
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OOBE

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Wiseco pistons rock. You won't regret them. Great job and we're all looking forward to seeing that beast put out big numbers. biggrin.gif


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Past - 7A-FTE: Will never forget you
Present - 3rd Gen 3S-GTE: Swap in progress
QUOTE (SinisterSinner @ Dec 19, 2009 - 10:52 AM) *
I dont want to even think of turbos, they blow up way too often...
post Jan 11, 2006 - 11:00 AM
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playr158



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your are a hero!!!!!!!!!a hero i say!!!!!!!

this is hot
post Jan 11, 2006 - 5:36 PM
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Jdog1385



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QUOTE(lagos @ Jan 11, 2006 - 2:00 AM) [snapback]377114[/snapback]

this thread is better then 90% of all the internet porn! my jaw is on the floor looking at this project!


lolol, so tru
post Jan 12, 2006 - 3:28 AM
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GT4WRC



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Managed to skive of work this arvo and managed to get quite a bit done.

user posted image
Finishing off fitting the sump to the bottom of the motor...

user posted image
... including a nice shiney powdercoated sump pan 8)

user posted image
Genuine parts where possible. New belt and idler and tensioner wheels...

user posted image
... finished off the camblet side of things...

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... allowing the bottom cover to be fitted.

user posted image
OE fuel rail (for now) was bolted on. As this was originally a 3SGE head, slight mods had to be made - including the injector holes which needed to be enlarged to suit the 3S-GTE injectors.

user posted image
Then the inlet manifold could go on.

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To the front and fitment of the alternator bracket and bling alternator biggrin.gif

user posted image
State at the end of the day. Loom is now partially fitted along with numerous hoses etc. Really glad I took lots of photos before I stripped the motor down laugh.gif

user posted image

user posted image

Need to adapt the cam cover slightly as I can't use the centre throttle body support due to the lack of castings etc on the n/a head. No real issues asthere is plenty of other support. Once that is done the cover can be fitted. Then, hopefully, time to fit the box. More to follow tomorrow biggrin.gif
Gary


--------------------
IPB Image
1994 ST205 Celica GT-FOUR Group A WRC - running in new engine
1993 Rover 220 GTi tarmac rally car (under construction) 3SGE power here we come....
GT-Four spec list
post Jan 12, 2006 - 3:42 AM
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Jdog1385



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awesome gary, great pics. cant wait to see that motor in its home

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