Building a "Big Bore" 5sgte, '98 5sfe Block, 3rd gen 3sgte Head, 3sgte Crank Options

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Hey All,
As some of you may know, I've been doing some work for Jim, building up his Alltrac. ( Click For Alltrac Build Thread )
He came across a deal on a build, 2nd Gen 3s bottom end here on the forum,(from itchyb) and figured we could use that, with a 3rd gen head and oil system to make a nice bullet-proof bottom end to use with a nice medium sized turbo to build a great "street beast" ....~500 AWHP that comes in quick and holds out to redline.
So Jim and his bro, Joe, brought me up the bottom end, and a stock 3rd gen engine set to get started with.
I got the built block up on a stand, and immediately noticed a serious issue with it.
The surface of the block is all pitted, and especially around the bores, like it had been shot with a Shotgun or somthing!
A few pics:









What exactly caused it, I dont know, but what I do know is I definetly wouldnt trust it to seal with a metal headgasket, and I definetly wouldnt want to have the block machined that much to bring it back to flat.
So, I figured to myself "Well, at least it has really nice pistons (it was supossed to have Arias pistons) and good rods (Eagle rods), so we have good stuff to work with" and continued to tear it down.
When I got the oil pan off, it was more "bad" news.
The pistons were not Arias, but CP pistons, which really isnt "bad", but wasnt what Jim was told was in there.
A couple pics of that: (sorry for the crappy quality, the ipod cam isnt the greatest)

Before taking it apart:



Eagle rods, ARP2000 Bolts:



CP Pistons:



Once I had that info, I called Jim.
We talked over the options, and Jim and Joe decided that if we were gonna have to have machine work done, it might as well be on the setup they'd like to do most, which would be a stroker setup.
Jim has Shannons old 5sfe bottom end, which is a 98+ block (the 98+ Celica blocks all are thicker in the waterpump corner of the block) so he said he would ship it up.
Since I still have my 5s bottom end here, I told Jim that we would just use that, and he could just bring up Shannons bottom end to replace it the next time he comes up.
Because MCS motorsports (the guys who built itchys bottom end) had some serious issues before they went under, I wanted to check the main bearing clearances before we did anything else, in case the crank needed any machine work.
The bearings that were in it were all .25mm undersized.
pic:

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I had a little time to go out to the garage today, and play with the setup some.

Like I had mentioned earlier, Jim wants to use the complete Gen3 oil system, including the oil cooler, on the 5sgte I'm building.
I know guys have used the Gen3 oil setup on Gen2's before, but I've yet to see a setup where someone used a 5s block, with the Gen3 oil cooler.
One of the problems is that the 3sgte oil cooler mounts to a base with a thru bolt, and the base is mounted to the block with 4 bolts.
The 5s does not use a base, the oil cooler bolts right to the block using the center thru bolt.
After messing with as many 5sfte variations as I did, I am used to messing with the oil coolers and how they mount, so I figured that if the 3s cooler had a rubber seal on the bottom, that was smaller than the outer diameter of the 5s oil cooler boss, than I would just have to figure out the mounting bolt situation.

Here are some pics of what I did.

First, a pic smaay posted of the 3rd gen oil cooler in its stock location, you can see the base it is mounted to that bolts to the block. (just like the 2nd gen 3s)



The 3rd gen oil cooler, after i removed it from the 3s block:



the bottom:



The thru bolt that bolts it in place on the 3s block:



After bending one of the lines for a little more clearance for now, I could sit the oil cooler flush against the 5s block, but the 3s thru bolt is not long enough to reach the threads....So,
the 5s oil cooler thru bolt is longer, but has the mount for the oil filter.
I tried that, and it works perfectly and has the appropriate holes in it to allow the oil cooler to work properly.
once my tig welder arrives, I will cut off the oil filter mount, and fill that with weld.

problem solved!! WOOOOOT! I just KNEW all that time spent messing with the 5sfte's would pay off someday! lol

::EDIT:: The 5s oil cooler bolt will not work. The easy solution is to use a 4th gen oil cooler, and thru bolt. (Its a bolt on deal with the 4th gen parts)

The 3rd gen oil cooler, bolted to the 5sfe block using the 5sfe oil cooler bolt, that will need to be modified.



The line on the right will be cut and modified to line up with the 3rd gen water bypass lines, and the one on the left will be cut and a 6an fitting welded to it to run the coolant back around to the back of the block like the 2nd gen 3s (the 5s has a plug in the spot where the water return fitting goes on the 2nd gen.)
Now its just a matter of getting the upper oil pan and windage tray off the 3rd gen block, drilling and tapping the appropriate holes for it in the 5s block, and the 3rd gen oil system on a 5s block will be complete!