Kitsunami's 86 SR5 to GTS swap

Kitsunami
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Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Mon Aug 08, 2016 12:09 pm

Gotta love worklogs! This might be the last one for a while for me, seeing as I want this Corolla to be my Pièce De Résistance.

Quick background. I've been biding time for the last couple years, waiting until my life was set up to handle the time and financial obligations associated with swapping and building one of these iconic Eight-Sixs out. I've always had the intention of only returning one to clean, working order for a daily driver, not for track or racing.

Firstly, I needed a template for which to start, I've located this clean 86 a couple months ago. I picked her up in Sacramento for $800, Non-op with no back fees. She still has a full interior (although a bit beat up), and a VERY clean exterior. Only missing the engine and transmission:

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Now I've found myself in the shopping list phase, and here is what I've obtained so far:

T50 with GTS Bell Housing
Complete GTS Zenki (85) Rear End
GTS Driveshaft
GTS Engine Harness
GTS Dash Harness
GTS MAF
GTS ECU (From an MR2 I believe)
GTS Dash Cluster
7-rib Bigport from an 87 MR2 (also pulled the TVIS plate)
RWD Intake manifold with EGR provisions

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I plan to rebuild the 4AGE using nothing but Toyota OEM parts, I don't want to go cheap on this.

I still have a couple things left to get, including:

-GTS Gas Tank
-Engine mounts
-Starter
-Clutch and lines
-Exhaust Manifold and EGR lines
-Random bits and ends I'm forgetting

I'll be posting my progress here. I don't have a lot of "ambitious" plans with this thing. I just want something clean and dependable. I'll probably drop some money on suspension, wheels and paint, but other than that, just gonna be going for a clean, stock look.

If anyone is interested, here's my current daily driver, a 95 Del Sol that I've swapped from an S to Si trim (D15B7 to D16Z6):

http://teamsolcal.com/forum/thread-20662.html

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grappletech
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Re: Kitsunami's 86 SR5 to GTS swap

Postby grappletech » Mon Aug 08, 2016 6:47 pm

Car looks great! I wish you all the best with your build

trigun402
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Re: Kitsunami's 86 SR5 to GTS swap

Postby trigun402 » Wed Aug 10, 2016 5:30 am

Another sweet build!!

notnilc20
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Re: Kitsunami's 86 SR5 to GTS swap

Postby notnilc20 » Fri Aug 12, 2016 9:18 am

Awesome build.....i'm undergoing the same swap but slightly different route.....i might need your help on what to do someday.. :) good luck on the build.

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Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Mon Aug 15, 2016 9:06 pm

notnilc20 wrote:Awesome build.....i'm undergoing the same swap but slightly different route.....i might need your help on what to do someday.. :) good luck on the build.


Which route you taking, mate?

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Re: Kitsunami's 86 SR5 to GTS swap

Postby notnilc20 » Tue Aug 16, 2016 8:33 am

Kitsunami wrote:
notnilc20 wrote:Awesome build.....i'm undergoing the same swap but slightly different route.....i might need your help on what to do someday.. :) good luck on the build.


Which route you taking, mate?


Pretty much same except i couldn't get ahold of a GTS rear end so i went with a gm 7.625 rearend. I'm going 3 rib block bluetop. I also am planning to turbo charge after i get it back on the road but run under 10psi. But we'll see how it goes. I'll be dd'ing it too so i want to have it reliable.....no drift rat here but a nice restoration with a twist. My build log is here too with most of it being youtube vids. Good luck with your project.

JDM20VAE101
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Re: Kitsunami's 86 SR5 to GTS swap

Postby JDM20VAE101 » Wed Nov 23, 2016 8:00 am

Nice Man!
Solid Shell!

Any updates?
Ivan's 4AGE BT 20V 6Spd LSD Build Thread
Just Scroll Down & Enjoy!
http://www.club4ag.com/forums/viewtopic.php?f=7&t=4529
Thanks For Looking! :D

Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Mon Dec 05, 2016 10:57 am

JDM20VAE101 wrote:Nice Man!
Solid Shell!

Any updates?


Not too much right now, I've been steadily buying parts I need. I suppose there are SOME updates.

*******************************************************************************************************************************
More Parts Acquired:

-RWD Engine mounts and brackets (didn't have those before)
-Transmission mount and crossmember (Shell didn't have it)
-AE92 Remote Thermostat Housing so I can set up an e-fan

*******************************************************************************************************************************
Still need:

-Coolant inlets and outlets (the things attached to the head)
-Alternator Bracket
-Exhaust Manifold
-EGR Valves and Piping
-GTS Gas tank (but will probably end up jerry-rigging my SR5 gas tank to work)
-Engine, transmission mounting bolts
-Slave cylinder (will probably use steel braided hosing)

*******************************************************************************************************************************
Engine Build progress:

-4AGE Head is being professionally rebuilt and resurfaced and given a chemical bath as I write this
-The bottom end is about to be torn down for new bearings and rings

*******************************************************************************************************************************
Things holding me back from faster progress:

-Just got married at the end of September, that cost an arm and a leg (still paying it off, lol)
-Holiday season means buying gifts for others and not myself :O

My tentative plan is to have the engine and transmission ready for transplant early February, and attach the remaining smaller parts needed as I acquire them.

JDM20VAE101
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Re: Kitsunami's 86 SR5 to GTS swap

Postby JDM20VAE101 » Mon Dec 05, 2016 11:24 am

Yes that's a update!

Congratz on getting married man!
Ivan's 4AGE BT 20V 6Spd LSD Build Thread
Just Scroll Down & Enjoy!
http://www.club4ag.com/forums/viewtopic.php?f=7&t=4529
Thanks For Looking! :D

Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Mon Dec 05, 2016 12:28 pm

JDM20VAE101 wrote:Yes that's a update!

Congratz on getting married man!


Thanks man! I like your 101 build by the way, Clean AF.

Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Fri Dec 16, 2016 3:15 pm

Got the head back from the machine shop. Fully rebuilt, resurfaced, and repolished. Next up is building the bottom end. I hope to have that done in a few weeks. Progress is progress, albeit fairly slow.

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I also decided to start cleaning the valve covers. Can't decide if I'll paint them or not. My drill ran out of juice so I'm charging it up to finish the job, but wanted to mock it up on the head:

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Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Thu Feb 23, 2017 12:52 pm

Dunno how many eyes I have on my humble project, but I'm sorry for neglecting you with lack of updates. The Eight Six feels just as neglected, trust me. All you guys say that newbs get in over their heads with these things and holy crap, I've never known a fanbase to be so right. But fear not! I tread on slowly, never losing motivation, with this still being a very high priority of mine. Admittedly, my income is modest, so it forces me to take my time with this.

Here's some new happenings:

-Cleaned up the rebuilt head and painted the spark plug cover red:

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-Purchased more parts for what I've come to call my "Sourcing List" (aka parts that need to be bought used [Engine Brackets, Transmission Xmember, etc]):
------Recently bought a RWD Alternator Bracket from a guy in the UK (should have that in a few days)
------Purchased the lesser-know Gearbox Stabilizer brackets: Image
------Purchased a slew of EGR and emissions components / vacuum lines

-Still Need (Sourcing List):
------RWD-Specific Coolant Inlet / Outlet
------Exhaust Manifold
------GTS Gas Tank (still pondering an inline fuel pump instead)
------Fuel Rail and Injectors
------AW11 Manual Rack / U-joint, Supra MK3 Intermediate Shaft

-New Parts for my 4AGE bottom-end rebuild that I need to purchase (I don't know why I'm including the part numbers, just let it happen):
------Head Gasket PTR04-17900-03
------Oil Pump 15100-19036
------Piston Rings 13011-16170
------Rear Main Seal 90311-70007
------Front Seal 90311-32020
------Connecting Rod Bearings 13041-16040-01 (Mark1), 13041-16040-02 (Mark2), 13041-16040-03 (Mark3)
------Main Bearings 11701-16010-01 (Mark1), 11701-16010-02 (Mark2), 11701-16010-03 (Mark3), 11701-16010-04 (Mark4), 11701-16010-05 (Mark5)
------Belt Tensioner (Idle Pulley) 13505-16021
------Oil Pan Baffle (and gasket?) 12122-16011
------Valve Cover Gasket 11213-16010

I have a friend who specializes in rebuilding short blocks and he's very good at it. He's been tied up with some other high-ticket stuff so I'm waiting on him to free up some time.

I gotta laugh at my initial estimate of having the engine and transmission in by February. So I'll give myself a bit of a stretch goal of having the swap closer to June. I'm so close... And each part I buy for the 'Money Pit' only furthers my motivation to get this done. I cannot wait to drive my own Eight Six. Hope to have another update soon. Cheers!

scalpel
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Re: Kitsunami's 86 SR5 to GTS swap

Postby scalpel » Thu Feb 23, 2017 3:06 pm

I been eyeing this keep it up

Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Fri Mar 03, 2017 1:23 pm

Got some spoils today from Pick n Pull. Haven't seen an MR2 in the Chico yards for quite some time! Getting so close!

All pulled from an 86 AW11:

Manual rack and pinion
U-joint
Fuel Rail
FPR
Injectors
EGR pipe (only the piece from the exhaust mani)

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aukword1
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Re: Kitsunami's 86 SR5 to GTS swap

Postby aukword1 » Fri Mar 03, 2017 2:00 pm

nice finds!

Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Tue Mar 21, 2017 11:14 pm

I was getting a bit antsy waiting for myself to be able to afford the 4AGE bottom block rebuild parts so I got ambitious today and threw in my GTS rear end.

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Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Tue Mar 28, 2017 6:38 am

Took out my SR5 Dash Harness and installed the GTS Harness. Fun note, I found a spare key buried so far in the dash that I can almost gaurantee the last owner forgot about it long ago. Many of the smaller interior pieces were so brittle. More things for my shopping list, joy.

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Jayrdee
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Jayrdee » Wed Mar 29, 2017 9:12 am

Awesome job! I'm definitely keeping my eyes on this!
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Re: Kitsunami's 86 SR5 to GTS swap

Postby isatoyuy » Thu Mar 30, 2017 6:39 pm

Dude, nice find. Good luck with the build.

Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Thu Apr 06, 2017 6:52 am

Manual Rack Swap done. With minor hiccups (Details below).

Degreasing the Bay and Removal of the power rack:

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No job is ever done without some sort of setback. I spent the better part of two hours trying to separate the outer tie rod from the steering knuckle, using the actual tool designed to pry them apart. I could NOT get these off, and I ended up bending the removal tool. I would wager that the tie rods were the same from when it rolled off the factor floor over 30 years ago. Anyways, I just decided to cut them and buy new outer tie rods (Which also meant drilling out the old bolt from the knuckle).

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Moved over the AE86 PS inner tie rods to the MR2 rack and applied some grease and the MR2 boots:

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Added the T3 bushing and Intermediate Shaft. All done (mostly, just waiting for my outers to come in the mail):

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Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Fri Apr 07, 2017 7:30 am

Whoever said you can't have Christmas in April?

Got some lovely things in the mail over the last 3 days. Mostly to rebuild the 4AGE and mount it to the transmission, but other fun stuff as well.

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Parts worth noting:

-4AGE 16V Toyota OEM Piston Rings
-4AGE 16V Toyota OEM Oil Pump
-4AGE 16V Toyota OEM Rear Main Seal
-4AGE 16V Toyota OEM Idler Pulley
-4AGE 16V Toyota OEM Baffle Plate
-4AGE 16V Toyota OEM Mounting bolts
-4AGE 16V Toyota OEM head bolts
-TRD .8mm head gasket
-Brand New Exedy Clutch kit and lightweight flywheel
-ARP Flywheel Bolts
-T50 Toyota OEM Mounting Bracket
-Coolant Neck Inlet / Outlet
-RWD 4AGE Coolant plumbing
-RWD 4AGE Tranny / Engine sandwich plate
-RWD 4AGE Alternator Bracket

**I haven't yet ordered the crankshaft bearings, because my buddy and I haven't torn apart the block yet to see what type we need, Should be able to order those within a week or so**

She's anxiously awaiting the progress over the next few weeks

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Kitsunami
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Kitsunami » Sat Apr 29, 2017 8:52 pm

GTS Throttle Cable and Kouki Headlight Harness install. Seems the guy who sold me my dash and engine harness sold me a zenki dash and kouki engine. So now I get to find another dash harness and do that job all over again. yay.

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I made a friend too. She didn't like me being there it seems.

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Jayrdee
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Re: Kitsunami's 86 SR5 to GTS swap

Postby Jayrdee » Mon May 01, 2017 10:12 am

Kitsunami wrote:
I made a friend too. She didn't like me being there it seems.

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nopenopenopenopenopenopenopenopenopenopenopenopenopenopenopenopeNOPE!!!!

I would have sh*t my pants if I saw that while working on my car. probably would have set the car on fire too.
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