HOT STAFF
There are many stories these days of AE86 with turbo 4A-GE's... But have you come across one with two? Yes Twin Turbo...on a 20V... If you are getting an adrenaline rush... read on.
You should be well aware of what's involved in swapping a 20V into an AE86 by now...(if not see see AE86 and 20V Page) Anyway, This particular car done by the famous Hokkaido, Japan firm, Hot Staff uses a base engine of AE111 "black top" 20V 4A-GE.
Due to the concern of 20V's thin piston head, due to deep recess, a forged custom pistons were used similar to the 4A-GZE's OEM version but with 5 Valve clearance design. With this setup, connecting rods from 4A-GZE were also used. The AE111 black top has very thin rods not suited for forced induction.
To make things cheap, two EP82 Starlet Turbo (CT12) were mounted to a custom made manifold (cheap?!! I think not). Both turbines were fitted with R32 Skyline actuators to beef up the boost capacity and minimize drop offs and synchronization problems. The basis for using the Starlet turbochargers were simple, a cheap replacement can be had for $200 each in Japan if it's blown in the experimental process... Additionally, 2JZ-GTE fuel pump from JZA80 Supra, 550cc main injectors, 2 row radiator, 13 row oil cooler were also necessary items to be fitted..
Although the project car used a MOTEC M4 full control computer, they also provide that a cheaper unit called the Freedom ECU by E&E systems can also be tuned to operate the engine similarly.
I am currently testing this same FREEDOM ECU unit as a NA 4A-GE control and I am seriously recommending it to anyone who wants to do heavy modification to the engine to fine tune the ECU parameters... The unit costs about $1200 US and is available only from Japan at the moment from various dealers. Though the unit functions on the Windows 98 for programming, the software is only available in Japanese at the moment. The nice thing about this unit is it can use Toyota's sensors and couplers for easy fitting and minimal electrical modifications.
The power output when this article was written was at 326.5 hp
JIS bench. Exhaust system is a below-differential unit of straight 70mm
with a stainless silencer custom made. The controversial FC3S RX7 brakes
were used at $1300 without used calipers??!! (no limit to expense?)
Suspension setting as used when test driven by Tsuchiya was 12kg/mm front and
8kg/mm rear springs from TRD with TRD custom made coil over shocks. All
control arms and lateral rods were replaced with ball jointed connections.
Since A/C nor fan was fitted on this car, a Subaru Impreza Rally STI roof vent
was used to clear air into the cabin as well as TRD N2 fenders. RECARO
seats from Honda Civic Type R was selected for it's narrow width to fit into the
AE86 without clearance problems. TRD carbon hood was also selected not for
looks but to resist warping and paint cracking from turbo's heat in the cold
Hokkaido winters. 
Hot Staff can be seen at http://www2.comco.ne.jp/~hotstaff/ but again Japanese only...
Body strengthening - The Hot Staff method (photos from Hot Staff Homepage)
The chassis is stripped of everything and placed on a rotating stand. The paint is stripped and rust removed to bare minimum. Hot Staff takes body structures seriously as seen here. It is the foundation of what comes later and is what makes the AE86 (or any car) develop fully when all is done.
While on it's side, no seams left untouched as they carefully determine what needs to be re-welded, reinforced or left alone. Seems to me like everything's welded but he stresses that there are critical points where welds are not touched...(where?!) Notice both interior and exterior is done in similar places. Also important to note... The welding process tweaks the frame slowly at each spot. to minimize structural damage and excessive bending, body should be welded in small sections at a time and alternated from left to right and fore and aft.
The final re-alignment is taken for all dimensions and the body rust proofed and painted. The car is re-assembled professionally by a seasoned mechanic. Triple checked for alignment and assembly procedures and specs. The chassis of the Hot Staff AE86 is ready to be re-incarnated to modern specs.
Hot Staff can be seen at http://www2.comco.ne.jp/~hotstaff/ but again Japanese only...