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. Nickname for her is 'Fr8kensix'.

Complete timeline of swap (I will be updating this as it goes):

-May 3rd, 2016: Car purchased from Sacramento and towed home to Chico CA. Title is clean and successfully registered to me. Progress will be slow for a while due to planning for my wedding, and most of the time between updates involve finding parts needed for the swap.
-July 30th, 2016: 4AGE 7-rib bigport pulled from an '87 MR2. Although unknown at the time, this 4AGE had spun bearings. It will eventually become the 4AGE to get dropped into the car after being properly machined.
-*Most of Fall 2016*: Wedding spending / planning. Future wife wonders what the point of this car is.
-Dec 16th, 2016: The 4AGE head is professionally rebuilt and machined.
-March 21st, 2017: GTS rear end swapped into the car.
-March 28th, 2017: GTS Zenki Dash Harness installed
-April 6th, 2017: MR2 Manual Steering Rack installed
-April 29th, 2017: GTS Throttle cable and Kouki Headlight harness installed. At this time I didn't know the difference between harnesses, so a Zenki harness had to be installed at a later time
-May 31st, 2017: 4AGE bottom end is finally opened, where the spun bearings are first discovered.
-*Most of Summer 2017*: Life happens and AE86 is on the backburner
-November 10th, 2017: After consulting a machine shop, new rods and pistons are ordered for the 4AGE. Megan lowering springs and new KYB shocks installed
-December 11th, 2017: Bottom end of the 4AGE is fully machined and rebuilt
-December 14th, 2017: 4AGE bare long block fully assembled (progress now on hold is lieu of the holidays)
-February 1st, 2018: 4AGE is fully assembled with RWD provisions (intake manifold, coolant plumbing hardlines, water outlets). New vacuum lines installed
-February 15th, 2018: MSD fuel pump and fuel filter installed to allow use of the SR5 tank and lines.
-February 19th, 2018: Interior carpet removed and washed. Old underlayment scrapped and new underlayment applied. Car smells noticeable fresher
-February 25th, 2018: Big day for the Fr8kensix; 4AGE is mated to the T50 transmission and installed into the car.

Mods on the car (Aka, anything not stock):

-MR2 Manual Steering Rack
-Arias High Compression Pistons and generic H-beam rods
-Megan Springs w/ KYB shocks
-Techno Toy Tuning Aluminum Pullies
-Generic 2.25" Catback Exhaust
-Magnaflow 50 state legal Catalytic Converter
-Mishimoto Radiator w/ electric fans wired up to grounding switch on AE92 coolant neck
-OBX 4:1 Stainless Headers
-15" Konig Rewinds w/ Toyo tires

And now, without further adieu, My worklog:

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:







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





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

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

Another sweet build!!

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.

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?

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.

Nice Man!
Solid Shell!

Any updates?

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.

Yes that's a update!

Congratz on getting married man!

JDM20VAE101 wrote:Yes that's a update!

Congratz on getting married man!

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

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.



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:

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:



-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:
------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!

I been eyeing this keep it up

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)

nice finds!

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.

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.

Awesome job! I'm definitely keeping my eyes on this!

Dude, nice find. Good luck with the build.

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

Degreasing the Bay and Removal of the power rack:



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).



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



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

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.





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

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.







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

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

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.

Finally opened up the 4AGE for the rebuild and my worst fears were made into reality. The block has spun bearings, which explains why the MR2 donor was at the Pick n Pull. The aforementioned MR2 I pulled it from had some front end damage, so I was hopeful that that was the reason it was donated by the previous owner...

Looks like I need to source another short block or find a machine shop to sort this out. The saga continues...

Try

viewtopic.php?f=15&t=20443

As old as these 4AGE engines are, you would be lucky to get a good short block from a pick and pull. I would look at getting the crank turned [probably $90] that way you know you have a good bottom end. Do not but bearings until to get the crank back from the machine shop. Dave W

davew7 wrote:As old as these 4AGE engines are, you would be lucky to get a good short block from a pick and pull. I would look at getting the crank turned [probably $90] that way you know you have a good bottom end. Do not but bearings until to get the crank back from the machine shop. Dave W

That's the route I'm probably going to take. I got some decent quotes to get it turned, and you're pretty much right on the dot with your estimation ( my machine shop quoted $110).

Sorry for lack of updates, life sometimes happens where you gotta put things on the backburner for a bit, but I'm keeping the girl around and I've gotten back to a point where I can re-prioritize the Eight Six again.

One major thing that happened causing the delay; I purchased a new home, with... *drumroll* a two-car garage! So much space for working on the Toyota and she doesn't have to sit outside under a tarp anymore when I'm not working on her.



So I finally found a guy in town who specializes in machining Toyota engines (mostly 22REs, but he's done a fair share of 4AGEs), so he got my crank turned and is milling and boring the block, which should be ready in a couple weeks (hopefully). I got some goodies for the new internals, and some externals.

Arias Pistons (81.5mm):



4340 Steel H-Beams:



Techno Toy Tuning Aluminum pulleys, OBX 4:1 Stainless Header, ACL .25mm oversize Mains, ACL .50mm oversize Con Rod bearings:



I also took this time to lower her on what I've come to understand is a common suspension set up by newer 86ers, Megan Springs and KYB shocks. Eventually I plan to upgrade to Coilovers, but for now I just need a budget suspension setup so I can just focus on getting her on the road:









Oh yeah, I also pulled a spare 4AGE for the hell of it from an '89 AE92 (couldn't hurt to have an extra, right...?)



And lastly, I decided to get rid of the ugly stock 13 inch wheels and got myself some 15" Konig Rewinds (again, a popular choice for 86er's I've noticed) and Toyo tires. It's amazing what good wheels and a drop can do for the visuals:



I'm praying that my engine gets machined soon, There's not much more I can really do without it and it's now been over a year since I first towed this thing home v.v

More Updates:

2.25" Ebay Catback:







And this beauty (as of Yesterday 12/11) (Note those Arias High-Comp Pistons):







More to come in the next few days...

How the hell do you have so much fender gap on the fronts?

This was mine @ purchase with factory suspension:


Factory springs sag, but not that much, plus you have lowering springs???