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

[Green_MachToy]

Sorry all, I have had no time. Long story...couple different jobs, now I am finally back to working on the car. The only thing I am missing is an axle seal for the tranny. I am going to try an ST185. I have tried for a couple months to get one from Europe with no luck. If any of our overseas Brothers (or Sisters) wouldn't mind giving me a hand, I would be happy to pay through paypal to have one shipped over.

The status of the project is that I think I bit off more than I could chew...at least at once. Ran into a snag with the wiring. I got a short in the body harness and it fried all the way into the jacks inside the car. That took some time to re-run. Actually got a harness from Supra (sorry can't remeber the guys name on here) and re-ran it and re-spliced the changes for the conversion. The AWD conversion is done except I had a bad axle seal from the shipment that won't seal in the GT4 tranny due damaged along the way. It actually runs (badly) and all moving parts of the drivetrain work correctly. I will video next time I have it running. It runs badly because I also upgraded the injectors and am upgrading the turbo at the same time. I have had a lot of help on this conversion and unfortunately we all haven't been able to hook up to finish. I have also figured out that, I need to adjust my wiring to allow for the second stage of the fuel pump to kick in through the relay. I currently have it wired to immediately run at the second or high speed. The engine is getting too much fuel with the fuel pump the way it is and the bigger injectors. I will go through and try and update the pictures or the links. After the engine is complete, I will then have to focus on re-wiring the car's interior. I had a guy wire up the security system and the stereo, and he did a hack job. Had to pull everything out and practically start over. Botttomline is that I have had some set backs, but hopefully I can get some help and keep moving forward. I would like to be done by the time TORC comes up.