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My AE86 Build


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Finally got the subframe spaces made. I have a couple different cars I need to work on this Sunday so I'm unsure whether or not I'll get them installed. I purchased some 1/2-13 bolts to secure everything, but I need to open up the holes on the subframe just a bit to allow the bolt to pass through.

 

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I have the subframe spacers in and extended the MKIII Supra Intermediate shaft a bit to get the steering column to reach again. I may end up removing the spacers to trim the bit that sticks out past the frame rails. It really doesn't bother me too much. One issue I need to address is finding some bolts that are a bit longer. The current bolts are 1/2" x 6" long. The nut only threads on about 2-3 threads. I need a bolt at least 6.5" long. Friday/Saturday I'm going to clean and install the DET girdle and pan so the engine should be buttoned up on the bottom end at the end of the weekend. I may also take the time to pull the transmission apart again and clean the internals down. The casings had been pulled apart and some dirt and other items got in there. Shouldn't be too hard.

 

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You can see the column is just past the retaining bolt for the u-joint.

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DET Pan

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DE Pan

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DET Girdle

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Should be ready for the 8,000 RPM range. Assuming the rods hold out.

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Picture the seller sent me:

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The rusted section near the tail used to be a flex section that was cut out and replaced with a pipe section. This header was actually part of the sellers CA->AE86 build, but he decided to go with a DET instead. It may need a bit of cleaning up, but I figured I could have it cleaned, heat coated and/or wrapped to give it a newer look.

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Crank girdle is installed and torqued down using stock main bolts:

 

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The counter weights look immaculate:

 

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The RS*R CA18 RWD header:

 

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I started cleaning up the DET oil pan. I got most of the grime off and did an initial sand. The primer was primarily to halt flash rusting. I'll see how it comes out and if it's clean enough I may just prep and do some final coats. The only issue remaining is the oil return line. I need to weld a plug over it to cap it off to use with the DE:

 

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I also got my 7" Grade 8 bolts in for the subframe and now have it firmly in place. The only thing definitely missing from the front suspension is the sway bar. After I get the clutch and have the engine installed I'll pick up a sway bar and get the front end completely finished.

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Started putting some finish coats on the oil pan. I decided to keep the oil drain unplugged and use it as a oil drain for a catch can...if I go closed circuit.

 

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I also modified the oil pickup to work with the crank girdle.

 

You can see how the DE oil pickup is mounted to two points on the pan mounting face.

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With the girdle there is only a single mount. The DE mounting points are inaccessible with the girdle:

 

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Got the engine/trans mounts from Flipside Customs. Things look very good so far. I only have an issue with the trans mount. It was designed around the stock or Nismo mount bushing. I'm using a Peak Performance piece and it is a bit wider.

 

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Started getting the radiator support ready to be a bolt on/off affair:

 

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Here you can see the space between the trans bushing and the mount bracket. The bushing actually rests on the brackets welds:

 

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Started to clean the inside of the trans. It was opened in the junkyard when I was swapping bellhousings out and I just wanted to clean things up and get the dirt/rocks that may have stuck to the gear lube out:

 

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I decided to use the clutch that was on the engine when we got it. It has low miles on it. The only reason being that I'm going to break in the rear diff, so I'd rather use a junk clutch while the rear diff is breaking in. Once I run the engine and rear diff for a while I'll upgrade the clutch and flywheel.

 

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Once I get the trans cleaned the only thing I'll need is a set of flywheel bolts and a snap ring for the trans main drive gear bearing. I'm going to try to pick up some flywheel bolts today. The snap ring will have to wait until I get the bellhousing and everything bolted back together b/c I have to measure the snap ring valley after the bellhousing is torqued down.

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I was able to get the engine and transmission completely bolted in on Saturday. It's in there solidly. It doesn't move a bit even when applying a lot of pressure.

 

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I ended up with a couple inches of clearance between the pan and the cross-member.

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Here are some updates:

 

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I still have some updated photos on my camera that I need to get on the computer.

 

-I've started cutting the floor to relocate the shifter.

-Painted and installed hood hinges.

-Started cleaning headlight trim so I can get the headlights completely installed before I start wiring the engine bay.

-Installed AE86 Clutch Master cylinder, S13 Clutch slave cylinder. I used a AE86 SS Clutch line and mated it to the Auto-to-Manual SS Clutch line that is sold for the S13s. So the clutch is all hooked up. Just need to fill the system and bleed it.

 

After I get the engine wired up I'm going to set up the brake lines.

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Some updates:

 

-Dropped the 8.8 off at the weld shop at work to have the brackets completely welded on. I should have it back on Monday so I can start cleaning it up and doing final measurements for the axles.

 

-Started trimming the J-Blood replica bumper to fit over my Fortress Fab front bumper bar. Still running into some issues so I'll be tweaking it a bit more.

 

-Received my Powered By Max Gen II Fender Roller. I'm planning on getting the AEs fenders rolled, working on my S13 and then doing my dad's turbo Grand Am.

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Once I get the 8.8 back I'll snap some pics and post them up.

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Got the rear end back today. It looks great. Definately beefier than the GTS rear. Now to get the rear brake equipment ordered so I can do some final measurements in order to purchase the axles. I already have all of the diff/lsd rebuild items, including carbon lsd clutches from Ford Racing.

 

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Well, today was a great day. I found a CA18 equipped pulsar in the junkyard and was able to get a complete set of coilpacks. I was having trouble finding a set. I just hope they're still functioning.

 

As far as progress, I've been working on the interior of the car to change up the pace. I finished trimming out the trans tunnel to fit the shifter. Everything fits great. I do have a 3 or 4 inch interference issue with the ebrake now, but that won't be difficult to overcome. To finish the tunnel I just want to weld in some sheet metal to box in the layers of floor metal I opened up. I like the positioning. The shifter should be just adjacent to the steering wheel in my seat position.

 

I was also able to get the blower motor rebuilt and installed. I still have some things on the climate control system to hook up, but nothing is hard to reach with the dash installed, so I installed the dash as well. Things are starting to feel right on the interior. Starting to feel like a car again.

 

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I'm also looking for a couple things if anyone has them laying around. I'm looking for a set of stock springs so I can mock up the rear end. SR5, GTS...doesn't matter as long as they'll support the car. I'm also looking for the rear upper corner trim piece for the passanger side door. It's the window trim on the exterior of the car that's missing in the pics below.

 

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I had a lot of comments i wanted to make...but after all the pics, I forgot what I was gonna say.

Awesome work. Get after it.

I love me a good Corolla.

 

And Skib...How the hell did you sneak a post in there?

:P

But I'm with you. Win. Good job. Way to save an awesome junkyard find.

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This is like 8 magazines worth of gearhead porn.

Wish I had me a Corolla. I would love to do every bit of this to a TE72.

Minus the CA treatment. I'd do a 20v. Stingy purist.

 

Was this a GT-S model already, or an SR-5?

Looks like a GT-S, but they're so close. With out seeing the 4A-G or the 4A-C its hard to tell.

 

Supra diff going in? Gonna use the W-58 trans also?

 

Those TEIN camber plates go loose alot, and the bearings are weak. Keep an eye on 'em, and keep 'em tight.

Also, while you're on the Techno Toy kick, but their rear links. Going low, you'll want to adjust diff angle. Bad vibrations if you don't. And with that new diff, ya know?

 

I'm loving this though. So awesome. Way better than doing my homework.

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It was a GTS to begin with.

 

The rear is a Ford 8.8 from a '96 Explorer XLT. The transmission is one from a '93 240SX with a SOHC CA bellhousing adapted to it.

 

Yeah, I plan on watching the camber plates for wear.

 

As for the rear links, I was waiting to get the rear end done before I purchased those. For now I'll just use the stockers with the prothane bushings to get everything mocked up and on the ground. I'll get adjustable links when I'm ready to get it fitted for a driveshaft.

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It was a GTS to begin with.

 

The rear is a Ford 8.8 from a '96 Explorer XLT. The transmission is one from a '93 240SX with a SOHC CA bellhousing adapted to it.

 

Yeah, I plan on watching the camber plates for wear.

 

As for the rear links, I was waiting to get the rear end done before I purchased those. For now I'll just use the stockers with the prothane bushings to get everything mocked up and on the ground. I'll get adjustable links when I'm ready to get it fitted for a driveshaft.

 

Der. What was I thinking? Why would it have a w58 if it has a CA.

Nevermind me. my brain is fried from school.

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I already owned one at the time, but it had body damage. This body was straight, and for $350 I couldn't pass up the opportunity. I've sold my first one since then (about a year ago). I'm driving a '92 S13 now. The money since I've picked this up from the junkyard is a different story. But better it go toward this car than one with severe body damage.

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Not too many. I've been working on prepping the driver side door for primer. That should be done now, but I won't have time to spray it until the weekend of the 13th. I also started flaring the driver side fender. I figured that will be my test fender.

 

I received another gauge cluster that I'm going to use to make a custom gauge setup to use with the CA. I haven't taken any pictures yet, but I'll get some this weekend.

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Some photos of the work on the doors and driver's fender:

 

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I haven't done too much to the fender except roll the inner lip. The outer was pushed out slightly, but will take some hammering to get where I want it.

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Compared to the passenger stock fender:

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Started on the passenger fender:

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Just received my CAN-AM box.

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So last night I primed my driver-side door. I didn't want it to start rusting heavily and I figured I'd see any serious imperfections after the primer had settled.

 

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This morning I wanted to do some more work on the driver-side fender. I was hesitant to start hammering on it without really knowing what I was doing, but I figured what the hell. This is my progress after two hours with a hammer and dolly.

 

Passenger-side for reference:

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Driver-side:

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I measured from this point on both sides:

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Passenger-side:

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Driver-side:

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Installed the Tanabe Sway bar and Cusco Lower Radius Bar:

 

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I also worked on the passenger-side fender. I came within 1/16" of being the same as the driver-side (measuring from my initial point):

 

Driver-side:

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Passenger-side:

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Comparisons:

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The previous owner of these fenders...or at least one of them...drilled those three holes in the fender in order to help secure bondo to smooth out a dent in the fender. After I cleaned up a bit of the bondo, I stretched the metal a bit and evened out the area so there wasn't an evident dent. Now I just need to weld up those three little holes.

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