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Full Version: Operation: DARKSPYRO, AWD Conversion
6G Celicas Forums > 6th Generation Celica > My Project
Pages: 1, 2, 3
Malek
Mission: Do it right the first time

Phase 1:
-Gen 3 3sgte swap

Phase 2:
-Complete AWD conversion
-Clean


28 JAN 13
Purchased 1999 Toyota Celica from a private seller in Boulder, CO.
Apparent timing issue and suspected head gasket issue.
Drove it 30 minutes back to Golden, CO with coolant spewing. And when I got back, I beat on it some more.
Back at the shop, wasted no time tearing into it

Had to stop once to let it cool down a little


Ripping into it that night



29 JAN 13
Engine and transmission pulled

Signature Tweak pose


31 JAN 13
Ordered ST205 front clip
-coming with bumper, fenders, hood, lights and a set of projectors
-rear subframe
-rear diff, axles, brakes, drive shaft
-Ton of extra stuff I don't need






1-9 FEB 13
Ordered:
-Berk gen 3 downpipe ceramic coated with wideband bung
-Clutchmasters FX300 assembly for swap
-Triple gauge A pillar (for boost, oil press, wideband)
-Hose for remote oil pressure sender location
-Walbro gss342 + 400-765 kit
Cut a hole in the fire wall for wiring harness

9-15 FEB 13
-Have been collecting parts for the swap
-Installed new Walbro fuel pump

17 FEB 13
-Final decision has been made
FULL AWD Conversion
-I plan on using the GT suspension and GT4 brakes
-Have not decided yet to cut floor pan and weld or make custom brackets


ETA for clip 11 MARCH 13
Until then, I will be researching boost controllers and wheels.

11-18 March 13
PHASE 1: COMPLETE
see page 2
-3rd Gen 3SGTE
-FWD
-OZ Crono

30 April 13
PHASE 2: BEGINS
see page 3 and 4
-Fuel Cell
-AWD
-GT4 Brakes
enderswift
This is gonna be a good thread, I can tell already. AndI'm jealous of that clip. Let me know if you ever want to part with the rear floor
cheela
looks great! that clips is really clean too!
Malek
I'm really debating doing a full AWD swap.

I had a few subies. AWD is pretty damn cool but idk..it's quite a bit more work. I'd cut and swap floor pans..

What do you think? Do it all at once?
richee3
I'd keep it FWD for now and decide on the AWD conversion later. That's just me though That clip looks great! It's a shame that it's going to take so long to get here. Keep us updated!
mkernz22
You might as well do it if you have everything....You could just weld the front and rear clips back together, then just weld on what you need for the body / upper half and it would be a legit GT4....I mean the engine, transmission, rear end, and everything is already in there so you wouldn't need to remove anything. It kind of makes sense.

Edit: And where did you order it from?
Malek
QUOTE (mkernz22 @ Feb 10, 2013 - 4:55 PM) *
You might as well do it if you have everything....You could just weld the front and rear clips back together, then just weld on what you need for the body / upper half and it would be a legit GT4....I mean the engine, transmission, rear end, and everything is already in there so you wouldn't need to remove anything. It kind of makes sense.

Edit: And where did you order it from?


I'd much rather swap over engine, tranny, rear end..than cut the top half of a car and reweld it to a different bottom half. I am not THAT confident in my welding for all of that tongue.gif

Ordered it from Ho Wong at Sun Shing Trading Company. They're on eBay as new_stars. I lowballed them hard core and they took it laugh.gif
mkernz22
You got a lot of good sh!t for a cheap price then! usually they send less of a rear floor pan than that lol
I'll have to write down that name for when I do something with my car in the future!
Malek
For sure! Not only did everything look clean, he sent me a TON of pictures, a video of it running AND has responded to my emails within 15 minutes with perfect english.

I was extremely impressed with his service. smile.gif

Small Update:
Getting packages in the mail feels so good!
Ted95
You have a really good start to the awd conversion, this is the first clip I've personally seen as complete as this one with the rear floor ect.. There aren't many awd conversion celicas state side and would probably be one of the only ones in Colorado unless imported from up North. You could always swap down the road it's your choice.

You'd piss off alot subies up there with a fasttt awd celica haha

You have a great parts list and parts at hand should be a fun build to watch good luck man!
ClevelandGaint


Do you have a website or a telephone number where i can order the st205 front clip with engine?





QUOTE (Malek @ Feb 10, 2013 - 6:57 PM) *
QUOTE (mkernz22 @ Feb 10, 2013 - 4:55 PM) *
You might as well do it if you have everything....You could just weld the front and rear clips back together, then just weld on what you need for the body / upper half and it would be a legit GT4....I mean the engine, transmission, rear end, and everything is already in there so you wouldn't need to remove anything. It kind of makes sense.

Edit: And where did you order it from?


I'd much rather swap over engine, tranny, rear end..than cut the top half of a car and reweld it to a different bottom half. I am not THAT confident in my welding for all of that tongue.gif

Ordered it from Ho Wong at Sun Shing Trading Company. They're on eBay as new_stars. I lowballed them hard core and they took it laugh.gif

Malek
Ladies and Gentlemen,

The AWD swap is happening.

That is all.
Ted95
QUOTE (Malek @ Feb 17, 2013 - 12:25 PM) *
Ladies and Gentlemen,

The AWD swap is happening.

That is all.



thumbsup.gif
mkernz22
WOOOOO
Malek
OK, so let's get into more of the details here.

We're talking full conversion.
E154F with axles
Super Strut, hubs, brakes
driveshaft, rear diff, gas tank.

what the hell, might as well do GT4 gauge cluster and auto climate control swap while I'm at it. Should be pretty easy since I am keeping it LHD. I'd just need to swap out interior harnesses right?? I know the auto cc has 3 sensors and I'd need to swap the 3 fan assembly but as far as the GT4 interior harness, it should fit with quite a bit of extra slack right? Correct me if I'm wrong on that..

AWD conversion:
I plan on dropping the engine and transmission in and getting everything bolted up and connected (As if it were a normal swap). Swapping out the front axle, hub, and strut assembly as one unit, if I can haha From there, I plan on starting from the transmission and working my way back making sure the brackets for the drive shafts are straight and strong. And when I get to the rear, I'll need to figure out just how much of the GT4 floor pan I will need to cut and transfer over. I'm hoping it's just the trunk area but that will most likely not be the case.

Well, damn..no longer need that hybrid clutch haha
Malek
yep..just collecting parts haha

homebuilder
Mind if I ask, where did you get the front clip with engine? What did it cost?

Looks great!
playr158
for the rear all you need to do is remove the spare tire well and weld in a flat panel.
Then you can remove the mounts from the underside by drilling out the tack welds and moving it over.

see here:
http://www.6gc.net/forums/index.php?showto...5&hl=mounts
Malek
QUOTE (homebuilder @ Feb 25, 2013 - 9:30 PM) *
Mind if I ask, where did you get the front clip with engine? What did it cost?

Looks great!


Check ya PM!

QUOTE (playr158 @ Feb 25, 2013 - 10:23 PM) *
for the rear all you need to do is remove the spare tire well and weld in a flat panel.
Then you can remove the mounts from the underside by drilling out the tack welds and moving it over.

see here:
http://www.6gc.net/forums/index.php?showto...5&hl=mounts


Much obliged biggrin.gif
Ted95
Which stage clutchmasters did you go with? .. Looks like a CM box in the pic.
Malek
It is an FX300. Though i jumped the gun getting it because its for mating the s54 and 3sgte haha
Malek
11-18 MARCH 13
I took delivery of the package!


And again, I went straight to work on getting it all out and in




That size difference redface.gif


Got some help


Got her in! (This pic was right at start up. I tidied up the wires and stuff. Don't worry haha)


At this point, I was having a fueling issue. I ran a 12ga wire and relay for the pump thinking it just wasn't getting enough current.
Turns out the fuel pump resistor pack wasn't completely plugged in.

Still have to fix that little gap rolleyes.gif


Finished!


References used:

-Pump wiring by Lagos
-3SGTE wiring explained
-Wiring by Manny

Phase 1 Debrief:

-I ended up pulling the frame over the 3sgte engine. Rear output shaft housing kept getting stuck in between the subframe and steering rack.
-Missed the sneaky fuel return line to the gas tank. Spewed gas all over the floor on first start up kindasad.gif
-Fuel pump resistor pack wasn't completely plugged in. Ran for 20 seconds and then died. Plugged in now. Works.

Upcoming:
-Until Phase 2 begins, I will be focusing on cleaning everything up, exhaust, tuning, wheels, and suspension.

Stay Tuned!


richee3
That was fast. Good work!
cheela
you make it look easy. very nice work!
bsamps4
Good Work!!!
ricochet1490
How did I miss this thread?!

I can't begin to tell you how frustrating cutting spot welds are. I did mine as full rhd so I cut the firewall out. The floor pan would suck. But new-stars is great! Good buy.
You also changed the motor how I did. Drop the subframe out the front.
You would have had to have changed the steering rack though right? Or did I miss something there?
This is my kinda swap though! Quick. Enjoy it and drive it, don't spend 1500 and a years worth of time rebuilding an engine that needs no attention.

Malek
Thanks for the replies guys! I definitely wasted no time last week to get it done!

QUOTE (ricochet1490 @ Mar 20, 2013 - 11:52 AM) *
How did I miss this thread?!

I can't begin to tell you how frustrating cutting spot welds are. I did mine as full rhd so I cut the firewall out. The floor pan would suck. But new-stars is great! Good buy.
You also changed the motor how I did. Drop the subframe out the front.
You would have had to have changed the steering rack though right? Or did I miss something there?
This is my kinda swap though! Quick. Enjoy it and drive it, don't spend 1500 and a years worth of time rebuilding an engine that needs no attention.


Yeah, I don't think I'll be swapping floor pans haha It's easy enough to make the brackets for the rear subframe for the awd conversion! But I'm not doing rhd at all. Nothing needed with the steering rack. Unless I use the GT4 suspension, then I'd just need the tie rod ends tongue.gif I have emissions and visual tests and cops to worry about here so it's staying LHD. (I used to live in Dayton. I really miss their registration process laugh.gif )

I will definitely be driving and enjoying it wink.gif
njccmd2002
how in gods name did that clip get delivered like that, must be heavy...
richee3
You can pass emissions with e 3S-GTE in Colorado? The wifey wants to move to Colorado but I'm fairly certain we couldn't register our Celica there, so I'll be interested to hear how it's done.
Malek
QUOTE (njccmd2002 @ Mar 20, 2013 - 9:12 PM) *
how in gods name did that clip get delivered like that, must be heavy...


2,095lbs to be exact wink.gif it was..interesting to say the very least. At the distribution center loading dock, they used a fork lift to push it across the floor and into my truck. From there, I used a fork lift with fork extenders and chains to get it in the shop. Very sketchy..for sure..

QUOTE (richee3 @ Mar 20, 2013 - 9:14 PM) *
You can pass emissions with e 3S-GTE in Colorado? The wifey wants to move to Colorado but I'm fairly certain we couldn't register our Celica there, so I'll be interested to hear how it's done.


I'll let you know laugh.gif Worst case, I have a buddy in the Springs that will let me register it at his address. They don't do emissions there..Actually, quite a bit of colorado doesn't do emissions but the parts that do, really flaunt their environmentalist/hippy facade. Bunch of BS though. I'd venture to say a lawnmower spits out more s**t in a year than a car does..

Other than that, Colorado is absolutely beautiful biggrin.gif I moved out here for school. My entire family followed me the next year haha Definitely a great place to live if you're into the outdoors!
Malek
From here..pushed through the bay door the guy in back is opening.


Into here...Barely fit haha


That poor fork lift haha
match220
QUOTE (Malek @ Feb 10, 2013 - 8:23 AM) *


haha..I have a picture of me like this somewhere when I pulled out my 5s. Except I'm sitting in a chair reading a magazine.

Nice build though! In hindsight I should have had a clip shipped to me instead of building one from a parted out 3s. It's hard enough trying to find 1 part from the engine (brackets..mounts..etc), but 30 - 40 parts..ugh. I'm glad I'm done!
njccmd2002
dang, thats it. there is no way i can order that clip like that, where in gods name i get a fork lift.
Malek
A little bit of an update:

Drove down to the Springs...


To get these woot.gif It's finally legal *kind of* haha Had to register it with my friends address...


Cleaned it up a little bit..Still very dirty. Previous owner trashed it.


Have to rewrap the steering wheel and get rid of that awful pseudo-wood
playr158
Nice work dude! Drive down to the springs isn't bad when its not pouring like it did when I got my car lol
Malek
QUOTE (playr158 @ Mar 24, 2013 - 10:40 AM) *
Nice work dude! Drive down to the springs isn't bad when its not pouring like it did when I got my car lol


Haha thanks man! I drove through a blizzard the day I bought the Celi though. It was up in Boulder! Half an hour seems like an eternity when your car is overheating and you can't see anything!

I went up some canyon roads today. Wow, I missed driving a Celica haha
Malek
Ordered:
-Optima Red Top Battery
-HKS Hi-Power Silent Exhaust 3in

woot.gif
playr158
QUOTE (Malek @ Mar 24, 2013 - 11:18 PM) *
QUOTE (playr158 @ Mar 24, 2013 - 10:40 AM) *
Nice work dude! Drive down to the springs isn't bad when its not pouring like it did when I got my car lol


Haha thanks man! I drove through a blizzard the day I bought the Celi though. It was up in Boulder! Half an hour seems like an eternity when your car is overheating and you can't see anything!

I went up some canyon roads today. Wow, I missed driving a Celica haha



I miss climbing in that area frown.gif

glad you're enjoying the car though!!

you still going to do the AWD on it?
Malek
QUOTE (playr158 @ Mar 26, 2013 - 8:52 AM) *
QUOTE (Malek @ Mar 24, 2013 - 11:18 PM) *
QUOTE (playr158 @ Mar 24, 2013 - 10:40 AM) *
Nice work dude! Drive down to the springs isn't bad when its not pouring like it did when I got my car lol


Haha thanks man! I drove through a blizzard the day I bought the Celi though. It was up in Boulder! Half an hour seems like an eternity when your car is overheating and you can't see anything!

I went up some canyon roads today. Wow, I missed driving a Celica haha



I miss climbing in that area frown.gif

glad you're enjoying the car though!!

you still going to do the AWD on it?


Are you still in Colorado??
But yeah, so far I'm still on for AWD conversion. I dropped the rear subframe yesterday. I just need to drill out the driveshaft mount. I only got the front mount but it's better than nothing!

I won't start the AWD conversion probably until the summer. Need to give my hands a break laugh.gif
playr158
I've always lived in VA. But I visit Denver a few times a year and I bought my Audi in Colo springs. Would like to move their eventually!
Malek
Why would anyone want to add so much more weight to their car?!? Is AWD reaaally worth it? hahaha



The ocean really did a bid on that subframe frown.gif
match220
QUOTE (Malek @ Mar 27, 2013 - 11:36 AM) *
Why would anyone want to add so much more weight to their car?!? Is AWD reaaally worth it? hahaha



I had a turbo talon (non-awd) and I had a problem with wheel hop on launches. So the wheels wouldn't grip the ground because it was only fwd. It even had a heavy duty LSD that made parking lots irritating. I would imagine the celica fwd would be the same (minus the LSD)
Malek
QUOTE (match220 @ Mar 27, 2013 - 5:48 PM) *
QUOTE (Malek @ Mar 27, 2013 - 11:36 AM) *
Why would anyone want to add so much more weight to their car?!? Is AWD reaaally worth it? hahaha



I had a turbo talon (non-awd) and I had a problem with wheel hop on launches. So the wheels wouldn't grip the ground because it was only fwd. It even had a heavy duty LSD that made parking lots irritating. I would imagine the celica fwd would be the same (minus the LSD)


I was just kidding haha I just got back from the Subie game. AWD is definitely worth it laugh.gif I wheel hop and spin all over the place!
match220
I thought it might have been a joke (hence the "hahaha" and the end), but it's so hard to tell in plain text..lol
ricochet1490
Please document the heck out of this. This intrigues me.
Malek
QUOTE (ricochet1490 @ Mar 27, 2013 - 9:19 PM) *
Please document the heck out of this. This intrigues me.


I plan on it..I'm also hoping to get dimensions of the mounts, build them up in SolidWorks and have some made.

Until then, I'm thoroughly enjoying the Celica biggrin.gif

qatar11
Hey -

What are you doing with all your FWD GT bits? I may be interested in them for spares for the race car.... lemme know...
Malek
PM'd ya! ^^
Malek
Small Update:

The woodgrain is no more!


Got some new kicks


A friend of mine (with a built subaru RS) introduced me to his sponsor, Metro Performance, today. I talked and bull****ed with the owner for a good two hours. Anyways, he's more than interested in my project and will help me out with the AWD conversion. They are mostly a subaru shop but he wants to get in with other cars.

I'll be making some dimensions and throwing it in SolidWorks so he has something to go off of. Fab up some mounts and go from there! I'll keep ya guys posted!
match220
nice! Good luck with the sponsor guy!!

I like your interior, did it originally come with the tan and black interior or did someone do it custom that way? Mine is all black, and it's horrible in a convertible. The interior gets scorching hot when the top is down, worst idea ever for a convertible.
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