My 85 Corolla GT-S build / F22c swap thread

mtmetzger
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My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:16 am

This is a project I started back in August 2012. I guess the original thread got deleted so this is a copy / paste of it. Enjoy!


I recently bought this car from a friend who has owned it the past 8 or so years and it is the first one I have ever owned.

It is an original GT-S car and it also has:

-KYB AGX short stroke shock setup
-T3 camber plates
-T3 roll center adjusters
-TRD 8k / 6k springs - I'm thinking these will be pretty harsh for such a light chassis
-Cusco sway bars
-T3 panhard bar
-Prothane bushings
-Koyo radiator
-Trust DD exhaust
-Bride seat
-Konig wheels
-brand new redline tail lights
-MR2 manual rack

The original 4AGE engine was pulled and rebuilt / upgraded, but never found its way back into the chassis, so the car has been sitting for a while.


Coming out of hibernation:

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Getting used to its new home:

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So the first thing I did was a little interior cleanup and swapped the drop vent hood for a stock one. Didnt really take a pics of it, but its sitting on top of the car.

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Emtpy bay:
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Then I sourced an F22c from a wrecked 2004 S2000. Worked the deal out and just picked up the entire swap and some extras out of the car.

Truck load of S2000:
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The star of the show:
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That's about all so far.

I'm debating on using some mounts from a company called JSP fab (http://www.jspfab.com/catalog/i61.html). The kit uses 1.75" subframe spacers to allow more room for the swap into the tunnel, which I'm not too excited about. The other option is to cut the trans tunnel and leave the subframe where it is. My concerns with dropping the subframe down that low are suspension geometry getting screwed up and less ground clearance. I'm still talking to some folks who have run the setup to get feedback.

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mtmetzger
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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:16 am

Got my bible out and mocking up some wiring connections to see what I can eliminate. (All door wiring, convertible top motors, EPS circuit, air pump circuit, etc)

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In theory, most of this stuff will make it in the corolla...
Last edited by mtmetzger on Mon Mar 04, 2013 11:20 am, edited 1 time in total.

mtmetzger
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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:17 am


mtmetzger
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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:19 am

Sorry it's been so long since I've posted. Progress has been slow as I was deciding what to do about which direction I want to take the car. Full interior with all S2000 controls or simple, gutted race car. I guess it will be somewhere in between.

I know I'm using the S2000 ignition, key and stalks because the corolla ones were worn out. I couldn't adapt them onto the corolla column so I'll be using the S2000 column with a modified shaft. Random tidbit - S2000's and corollas share the same steering wheel mounting hub, if anyone wants to run an S2000 steering wheel for some reason.

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I need to get the dash and S2000 bezel back in before I set the final length and position of the column

Then I got a new toy:
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Had to build a cart for it, so I obtained a small shopping cart. Cut it up and make a welding cart. Works great!
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Buddy Rob testing out the new cage in the corolla LOL!
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Then Rob decided to get a little project of his own:
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It's a 1JZ vvti swap for his Sc300. This slowed me down for a couple weeks while I worked through the wiring and a few other things. See how much fun it was?
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OK, it's done and out of my garage. Back to the Corolla. The S2000 engine had no good lifting points, so I made these:
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Fancy, I also got the oil pan sitting level so I could get an idea of the angle of the engine in the bay.
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Pulled the oil pan off for modifications. It needed a little more clearance near the subframe so I could drop it down further. tadaa
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couple templates for the filler plate:
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The radiator inlet and outlet need to be on the driver side rather than passenger, so I had to cut everything off one site (inlet, outlet, fan mounts, and petcock) and move to the other side:
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New holes and existing inlet and outlet:
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Both items are at Andrew Dimartino's shop for welding. (http://dimartinofabrication.com/)

On to the mounts! I went with 3/16" for the mounts
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That brings everyone up to speed. Should be getting to play with a plasma cutter tonight to get them cut out! Stay tuned!

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:21 am

There really is nothing cooler that cutting metal with an arc and some compressed air.

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:21 am

There was a little learning curve with the plasma cutter so my cuts weren't the greatest, but it's nothing a little grinding couldn't fix:

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Test fitting:
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I got the oil pan and radiator back from Dimartino Fab. He did a great job as usual! The oil pan plate was welded inside and out and should work nicely. The radiator turned out very nice as well. You can see the patches he made for the radiator as well as the oil pan:

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Then it was time to pull the subframe out...

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Test fits (you can see why the oil pan had to be cut now):
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Cut:
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More test fitting: Looks good now!
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Welded up:
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Then I got it mostly cleaned up, almost ready for paint.
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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:22 am

Update! :)

Got some paint on the subframe and reinstalled it:
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Then it was time to make some sparks fly!
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Daaaaaaaamn!
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Threw the transmission back on the engine:
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...and put it in the hole. Took quite a while to find the final position and get everything adjusted exactly where I wanted it:
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Subframe assembled with mounts and plates:
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Then I made these templates and cut them out of 3/16" plate:
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Tadaa! All tacked up
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Plenty of clearance down here.
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And that's how it sits currently. Next up is making the driver side mount, then the transmission crossmember. Hope to have the car supporting this thing over the long weekend.

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:23 am

I got the other mount tacked up the other day and pulled them back out for welding. I think they turned out pretty good for a novice! Feedback is welcome. :)
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Look Ma! No hoist!
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So Close!
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A little trimming here...
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A 1/4" spacer at the hinges and dropping the subframe a 1/4" and it shuts! ...with room to spare.
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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 04, 2013 11:24 am

So I took a pretty good break from working on the car around Christmas time and recently started back on it. Things are starting to move along nicely again.

Here's the process of making the transmission cross member. I used the stock S2000 mount.
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Painted:
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Installed:
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Finally the car is holding the drive train by itself!

The next step was to remove all this
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From here:
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And here:
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Then I tackled the clutch hydros. I used the stock rubber line from the S2000. It met up to a hole in the frame perfectly so all I had to do was run a bolt through to secure it and make this:
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It goes under the master cylinder and brake booster so it's fairly hidden. You can barely see the slave down there.
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I was pretty excited about this... I was started getting into exhaust mode and realized I had a new flange and gasket that is the same pattern as the outlet of the S2000 cat. From a Turbo II RX7. SWEET!
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Next step was making the transmission tunnel. Template:
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My redneck metal brake. Worked pretty well!
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That's where I am now. I need to do a little more fitting of the tunnel and weld it from the top. Then it's time to pull the engine again. Hopefully I'll be getting the updates out a little quicker next time!

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby Island_DC5 » Wed Mar 13, 2013 9:01 pm

Nice build thread Metzger. Im debating selling/trading my gixxer for a corolla to eventually do this swap. Although I do not have the custom fab skills you have so I would have to go through a shop for most of the work. Your thread is giving me a good insight in what all this swap requires though so keep the updates coming!

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby RuizXIII » Fri Mar 15, 2013 2:57 pm

Loving the home made metal 'brake'!
Sweet handy work
irony.cc

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Mar 18, 2013 12:59 pm

Thanks! I try to be thorough. :)

I got a little more done last week.

Welded the end plate on the tunnel and smoothed it out. Didn't want any rough edges:
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Pulled the engine back out...
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Welded the tunnel inside:
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and outside:
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Slapped on some seam sealer:
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Started cleaning up the bay for paint. Don't need these brackets or tray:
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POOF! (still need to remove one more)
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Then I had just a little more time so I chopped this
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to fit here:
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Then I decided this bracket was unacceptable:
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So I made this. Not sure if I like it, may scrap it and just do a rod.
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Should be getting my hands on a stock heater core and blower motor soon. Then I can finish up any changes that need to be made on the firewall and get the bay painted... More to come soon!

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby Island_DC5 » Fri Mar 22, 2013 9:04 am

Nice progress. So do you already know what all from the center console/dash you will be able to re use with the new tunnel?

And I say keep the wrench brace lol

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Fri Mar 22, 2013 12:49 pm

Thanks! Not sure what I will put back in just yet. This is mostly going to be a track car, but I still want it to look respectable. :)

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby marley4us » Fri Mar 22, 2013 1:37 pm

very cool progress!
1985 Corolla Hatch widebody w/ SR20det (The Project)
1993 5SGTE stroker widebody MR2 Turbo (drag car)
2002 Miata SE hardtop (daily Driver)
1994 4runner (The truck)

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby goodknight » Sun Mar 24, 2013 5:54 am

Great build thread. Appreciate you taking the time/effort to update it.

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby Bigwhite07 » Tue Mar 26, 2013 2:44 am

Great build thread so far Matt, Im going to be doing an F20C swap in my coupe after my 16V blows. So I'll be checking in on the thread quite often, can't wait to see it finished and running.

Justin
Hahahaha Japan, I have one of your Corollas. Feel salty about it.

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Tue Mar 26, 2013 2:22 pm

Thanks guys!

Not a very exciting update, but it's what I've been working on... Figuring out the climate control. The car needs to at least have heat and if I can use the S2000 controls then that would be awesome. The blower box / heater core / diverter boxes from the S2000 were huge, but I think they will work nicely.

A workbench full of junk: S2000 and corolla stuff mixed in. Tried to adapt the S2000 actuators to the corolla stuff, but it wasn't happening.
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Decided to trim the fat off the bulky S2000 boxes and use them. Got rid of the evaporator core and some of the casing.
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Made some mounts and bolted it up
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New location for heater hoses
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The diverter box even fits in there pretty well! Go pedal clearance:
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This port on the rear is for floor mode. I can't fit any ducts in this car though...
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So I got creative and made little diverters.
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This is what it looks like from the driver side floor board. Should work pretty well at keeping my piggies warm in the winter!
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Like I said, it's not a very fun update, but I needed to figure out what I was going to do with climate control before I painted the bay. I'm hoping to wrap this part up soon so i can patch a few things, stitch weld and paint the bay.

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Thu Apr 11, 2013 8:21 am

I've been working on the engine bay again. This part is not much fun at all!

Here's where original heater core came through
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Cut
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That will work nicely. To the left you will see where the A/C lines will come through.
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Ugly, but will work
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Started welding the seams. You can also see where I welded up several holes that I wasn't going to use. I'm not really shaving the bay, just doing a little cleanup.
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Almost just a bare frame right now
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I need to finish welding, seam seal and get some paint on the bay and undercoating in thewheel wells and trans tunnel. I'll be happy when i hit that milestone!

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby Island_DC5 » Fri Apr 12, 2013 1:31 pm

Coming along nicely!

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby kyoo » Fri Oct 25, 2013 10:01 am

amazing.. what's going on with this?

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Fri Jan 17, 2014 12:09 pm

After putting this project on the back burner last year, I started working on it again recently. Hoping to have it done in the spring. Here's what I've been working on:

Disassembled, cleaned, painted, lubed and reassembled front suspension: I love this rust oleum Hammered black!
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Undercoated the inner fenders:
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Made a bracket to hold the S2000 fuse box. It fits so well right here and the wires tuck nicely through a hole behind it.
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Hopefully it wont be long until the next update!

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Fri Aug 29, 2014 6:26 am

I finally painted the engine bay! I went with a silver hammered finish and I'm pretty happy with the way it turned out...

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Cleaned up and painted a few more things...

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Installed the flywheel, clutch and transmission. All ready to drop back in the hole. Hoping to do that this weekend.

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Sep 01, 2014 10:41 am

Made a little more progress last night.

Cut the hole for the shifter and rolled the edge:
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Hopefully the last time I drop the engine in! :)
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Here's where the main harness passes through the firewall. Turned out pretty good I think.
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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Wed Dec 10, 2014 8:57 am

small update:

Front suspension back on -

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Header modified so it would fit:

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Wed Sep 16, 2015 12:01 pm

After about a year break I started working on the car again..

The gas tank was removed and I swapped the S2000 fuel pump into the corolla bracket. It fit perfectly like it was meant to go there.

S2000 fuel pump & sending unit - original Corolla pump - S2000 pump installed in corolla bracket.
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The S2000 pump is much smaller
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I was even able to swap the S2000 sending unit to the Corolla bracket and use the corolla arm. It should read the level perfectly to the S2000 cluster.
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Next I made a block off plate for the air pump diaphragm since the rest of the air pump system was deleted. Pretty simple - trace the gasket onto some aluminum, cut it out.
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Then I got all the brake and clutch hydraulics installed and bled.
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I've been making some good progress lately, hoping to keep up the momentum.

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Sep 21, 2015 5:45 am

Throttle cable has been made. I used the S2000 cable inside the corolla sleeve. Shortened the whole thing about 18":
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Also made the brake booster vacuum hose:
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and the radiator hoses:
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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Nov 02, 2015 9:38 am

Here's where we left off:

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I had a little setback after I filled the engine with oil. After a week I had a little puddle under the car so I crawled under there and found that it was between the engine and trans.

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I pulled everything back out and replaced the leaking rear main seal.

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While it was out, I took the radiator back to Andrew Dimartino and had him add a bung for my fan switch and weld my radiator mounts on:
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The fan is from a civic and fit nicely on the Corolla radiator

Then I tackled the steering column. There wasn't a very good way to mount the S2000 ignition cylinder or stalks on the corolla column so I had to make a Frankenstein column with pieces from both.

First step was installing the seat and figuring where I wanted the wheel to be.
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Then it was time to start cutting! Here are some of the parts from both columns.
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This is why I couldn't mount the S2000 stuff to the corolla column. The Corolla has a cast aluminum key cylinder / lock / bearing that bolts to the column. The S2000 has a bearing built into the column itself. Corolla on the left, S2000 on the right.
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So I had to remove the mounts from the S2000 column:
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And mock it up in the Corolla mounts:
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The rest of the Corolla shaft (which is really a Supra shaft because it has an MR2 rack in it):
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Finding the length:
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Welded them together. Don't make fun of my welding table! :)
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The hybrid shaft welded together and fit back into the S2000 tube that is mounded to the Corolla mounts:
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Installed in the car:
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With the wheel:
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Ever seen an S2000 column that tilts? I thought that feature might come in handy so I kept it.

Now that the column is done, I can go back and finish the wiring:
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I should be able to start it in the next few days.

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Mon Nov 16, 2015 1:00 pm

Working on the wiring. You can see the S2000 climate control unit is in for more mock-up. Not bolted in in this picture.
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Working on the wiring to the rear - tail lights, fuel pump, fuel sending unit, door pins, etc
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Watch this video:
https://www.youtube.com/watch?v=4_VfMH-O4mg


I had a little issue with the fuel injectors being clogged up / locked up after sitting for 3 years. I pulled them out, pulsed them with 12 volts a few times and they started opening again. Then I attached a tube to my air hose, filled it with seafoam, attached it to an injector and put about 40 PSI of air pressure behind it. Then pulsed them to force the seafoam through each one. After that it fired right up!

https://www.youtube.com/watch?v=YrxlFUP71Xc

Next step was making the drive shaft. I wanted to try to make it myself. If I can't get it to balance, I'll see what drive shaft shop can whip up for me.

Cut the S2000 shaft. For some reason it has rolled up cardboard in it.

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Cut the Corolla shaft and put them together
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Welded and painted.
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Next update will be exhaust and hopefully the first test drive!

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Re: My 85 Corolla GT-S build / F22c swap thread

Postby mtmetzger » Thu Apr 21, 2016 7:32 am

After the drive shaft was done, I started integrating the Corolla lights to the S2000 wiring harness. It was pretty simple. Run the wires to the lights, solder the corolla connectors and plug them in. Everything works like it is supposed to. I included the circuit for the headlight retractor motors so they flip up when the lights come on and back down when off. Just like factory but with the Honda controls. I even retained the "winter mode" so you can keep the lights up if you want.
One of my buddies lending a hand:
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All wiring is neatly tucked under the fender now:
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Fenders back on:
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Next it was time to start on the exhaust. I didn't get many pictures of the process because I was by myself. I'll try to add a few more later. I did mount the factory S2000 catalytic converter and it fit perfectly. Then made the rest with 2.5" piping and a muffler I had laying around. It had a really nice deep tone and screams in the higher RPMs. I still need to make a tail pipe for it from stainless.

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The car sat on jack stands for 3 years. This is the last picture of the car on stands.
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The final wiring I had to do was the windshield wiper motor. It took a little bit and a couple relays to reverse polarity but I got the Honda controls operating the corolla motor like it should High, Low and intermittent. :)

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Last edited by mtmetzger on Thu Apr 21, 2016 10:41 am, edited 3 times in total.

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