3sgte AWD Conversion, Trying it anyway! Options

[Green_MachToy]

I got a shipment in of all the parts I was missing to do the AWD Conversion on my ST. Now I am starting to put everything in with a lot of help from a friend of mine.
Parts List 1
Parts list 2
Parts list 3
Parts list 4
Parts list 5
Parts list 6
Here is a shot while we were taking pics.
Plenty of Go Go Juice
The first thing we pulled the rear out, and placed the new ST205 rear on a jack and started measuring. It seemed like we were measuring for hours...but gotta make sure it is right.
Holding it in place until everything measures out.
There were no bolt holes that we could use to tap and bolt the rear up to, so we had to fab a brace.
New Rear
Then as many know...the trunk had to go. We decided to remove the entire trunk bottom to also allow for the gas tank. The next problem we ran into was the bumper support. We had to cut that in order for the tank to fit and to keep the it up high. We are going to fab a mounting bracket for the bumper but that got moved low on the list.
View from trunk where gas tank will go.
The driveshaft and tunnel needed extra mounting brackets and the exhaust to be relocated. In doing this we almost caught the car on fire from the heat of the welds. Luckily the carpet did catch, but rather than pull it back like we had, we removed it all to ensure it didn't catch fire.
Pic of tunnel
When it came to the fromt, that work went a lot faster. The tranny swap was easy enough to remove the MR2 and replace it with the ST205. Since the only axles that appeared to fit were the ST205, I got them from here (thanks celica3sgte)! Just as we had most everything was coming together, my shifter cable broke. It was actually the plastic piece right near the shifter. Got one off an ST185, and tried to put it in tonight...it doesn't fit!
Side note: The front cross-member is the same as ours. I had ordered it just to be on the safe side, and didn't need it. The super strut system uses the same mounting points.
Front disc and strut
Monster Discs!
Another view of front
Rear discs with 18" rims on 'em.
We also installed a new Aeromotive fuel pressure regulator and 680 injectors...was to help a new T4 turbo. But the T4 shaft and fins appear to have been damaged in the mail. I will now have to send it out to have them replaced and balanced. Anyone know of a good place here in San Diego or Southern California? I was going to send it to Performance Tecniques in San Bernadino, but no one seems to have heard of them.

This post has been edited by Green_MachToy: Feb 4, 2007 - 10:08 PM

[midengine3sgte]

I'd drive a distance to get it done.

[Green_MachToy]

My Garage is open and talked to the friend of mine that did most of the work with me and he is game.

I'd drive a distance to get it done.

[Green_MachToy]

Sorry for the lack of infomration....things have been crazy at work. I have had no time for the car. I have finished the hard lines for the new gas tank location and the drive shaft is in. I was a little confused as to why there was a gap in the drive shaft with the front shaft all the way in the transfer case. I then figured out that it is not supposed to be in flush with the transfer case and the shaft, but it should be closer to flush on the dust shields. Once we lined everything up it looks like everything is a good fit. THe reason for the spacing in the transfer case (in case anyone wondered)....is for torque on the engine. When the engine torques down under load the trandfer case slides further down the driveshaft. I verified this with 2 ST165 owners and reviewed pics and the book I have on the st205. I will have to finish the re-wiring of the gas tank due to the differences in the placement of the float, etc. On ours it is pretty much all in one. On the ST205 you have two different ports and wiring to go with. I have tried to take some better pics and placed them up on a shared viewing location. I hope this works! I have tried to allow you to view most of the pics that I have in there. I didn't think you were interested in the family pics, so I tried to remove all of those. I have also changed out the lugs in the front. Due to the caliper size, the offset on my original 18" rims still did not clear them. I was about 3/8" off. In order to at least use a spacer to get this running I cheanged to a longer lug for now until I can afford new rims. The current problem I am focusing on is the front sway bar, end link, and strut mounting point. The stock sway bar appears to be different than the stock gt4. For those that are thinking of this...a rear sway bar new and upgraded is $200. I would imagine the front is the same, but haven't found one yet. I am still looking. If anyone knows where I can get a front st205 sway bar, please let me know. I have also added the OBX Style manifold with extra support and downpipe. I have been told that the OBX style manifolds crack because there is little support for them and the crack due to stress/weight of the down pipe, turbo, exhaust, etc. I have also upgraded the injectors to 680's and added the Aeromotive regulator. I will be sending out a turbo I have and have it upgraded (we had to clock the turbo and lift the intercooler for the new turbo and wastegate to fit...will eventually go to external wastegate). I have also installed the FCON V. Hopefully I will have it running soon. Until I have the new turbo back I have installed the stock one and changed the coolant lines. In the ST165, the coolant runs through the turbo. I have drilled a hole and added a spot on the front side of the turbo cover plate to allow for the recirc line to be on the opposite side of the turbo to allow for flow. What I have left is:
Bumper Modification
Gas tank wiring
Gas Tank fill neck - Adjust to fit into this setup
Front swaybar and end links
Finish putting everything back together in the engine when new turbo gets back
Re-check all bolts
Repair front cross-member bolt on car body (I will have to cut and re weld from the inside of the body. It appears to have broken free and will not let me tighten last bolt on front cross-member