Astro's Rally Cross / NAVEX turbo Corolla project

[AstroVannin]

I got this car for free a few weeks ago, and hadnt really decided what to do with it. Originally I was just going to make a turbo kit ... rip it for a bit, sell the kit and scrap the car.

Then I decided to do the kit and use it for Rally Cross instead.

Now, after doing the Maple Leaf winter Rally, Im going ta make it a RallyX / NAVEX car. The only REAL difference is that the turbo setup needs to be a little more reliable and it needs to be certified/etested. Other than that, everythign else will be more of less the same.

The car is a 1991 Toyota Corolla DX 5spd. Rear qt's are kinda rough, but overall its a mechanically decent car, so aside from patching some holes, the cert should be a breeze.


The list of mods are to be as follows.

ENGINE
* Stock internal 4AFE
* sinklog manifold
* Mitsu TEO4H turbo
* 1G DSM bov and pipe
* turbo 626 injectors
* GM 2bar MAP
* 2.5" hardpipes
* Supra FMIC used a a TMIC

SUSPENTION
* some kind of DECENT struts (Im thinking KONI Yellows)
* stiffer springs that retain original ride height (open to sugestions)
* Corolla GT-S Sway bars

BRAKES
* Stock size, upgraded pads and rotors (open to sugestions)

WHEELS / TIRES
* VW 14" Alloys w/195/60R14 H rated cooper cobras
* VW 14" Alloys w/ 205/70R14 BFG All Terrain T/A's

INTERIOR
* OG Recaros
* RJS 4pt harnesses
* turbo gauges and whatnot
* additional power outlets in glovebox
* RED LED interior lighting
* straps in trunk for toolkit

EXTERIOR
* fix rust
* removable front light bar
* TOW arrows
* hood scoop for TMIC

And ... for the pics.

[Punkrampant]

Are you gonna have it ready for the golton stage in July?

[jmaz87]

haha very awsome!!! i actually had a supra IC re-welded to be used as a fmic but ended up using a standard fmic.

currently i'm using a ssq bov and a garret T2 w/ fmic and 2.25 piping. and really restrictive but quiet exhaust.

if all goes as planned next week my GT17 center-cartridge should come back and i ordered a anodized black 2.5" piping kit for good measure.
then the biggest DP possible and 2.5 for the rest.

[jmaz87]

i wish there was more rally around here and i wish alltrac's had decent trannies...

[jmaz87]

oh and for now i just have bleeder valves on the stock map sensor... i know... but i didn't think that map sensor would give the right readings...

[AstroVannin]

Originally Posted by Punkrampant

Are you gonna have it ready for the golton stage in July?

Should be ready in all kinds of time.

[AstroVannin]

Originally Posted by jmaz87

haha very awsome!!! i actually had a supra IC re-welded to be used as a fmic but ended up using a standard fmic.

currently i'm using a ssq bov and a garret T2 w/ fmic and 2.25 piping. and really restrictive but quiet exhaust.

if all goes as planned next week my GT17 center-cartridge should come back and i ordered a anodized black 2.5" piping kit for good measure.
then the biggest DP possible and 2.5 for the rest.

Ive got a FMIC too, but I want to use a TMIC on this car just to keep it out of harms way. I dont want "flat out over crest" to turn into mangled intercooler/not finishing. Im going to set it up on the passenger side and just make a fg hood with a bulge on that side to acomadate it.

For the time being, Ive got a GM 2bar MAP sensor with a Toyota plug on it and Turbo 626 injectors, which are just a little over 2x the stockers, so with an SAFC to pull a bit of fuel it should be pretty much perfect up to 15psi. Even without the SAFC it should be good, but I can get the AFC cheap.

Exhaust will be made from the leftover 3" system off my Tercel. Probably be a 2.5" DP 3" if theres space.

Will be using the internal wastegate on the TE04H.

All the charge pipes will be 2" or 2.5" exhaust pipe.

If I could get a decent all trac here Id rock it anyways. Are the trannies really that bad?

Ive also got a 90 GT-S Il be stripping for parts. Sway bars, strut brace, 4AGE / harness / ECU.

Im going on a mission for parts on monday. On the short list is a cluster with a tach, shift boot, 5G Celica GT-S springs... or maybe 2G Camry.

[AstroVannin]

Can somone confirm the cc's of the stock injectors. Im thinking 176?

[Punkrampant]

Yep, you are right.

Nippon Denso 155cc violet 13.8ohm 290 Toyota 4AFE

Nippon Denso 176cc light green 13.8ohm 290 Toyota 4AFE

Nippon Denso 176cc grey 13.8ohm 290 Toyota 4AFE

http://www.tolken.co.za/twincamforum...ight=injectors

Theres a good link to some injector flow equations.

Wanna hook me up with your old springs and the rear disk setup from the gts if you aren't going to use it?

-Andre

[Ghostyman]

I like it. Needs a craploadof lights on the bumper and roof.

[AstroVannin]

Cool , thats what I thought, just needed confirmation.

You want the sedan springs and the GT-S rear brakes?

No problem!

Where are you at anyways? Im in Port Hope.

Originally Posted by Punkrampant

Yep, you are right.

Nippon Denso 155cc violet 13.8ohm 290 Toyota 4AFE

Nippon Denso 176cc light green 13.8ohm 290 Toyota 4AFE

Nippon Denso 176cc grey 13.8ohm 290 Toyota 4AFE

http://www.tolken.co.za/twincamforum...ight=injectors

Theres a good link to some injector flow equations.

Wanna hook me up with your old springs and the rear disk setup from the gts if you aren't going to use it?

-Andre

[AstroVannin]

Originally Posted by Ghostyman

I like it. Needs a craploadof lights on the bumper and roof.

TRUTH, Ive got 2 pairs of KC DAylighters. Im retrofitting one pair with HID projectors, and the other has 130w landing light bulbs.

[toyotaspeed90]

If you plan on boosting the 90 GTS motor keep it low -- those were the highest compression motors that the 4age came with stock in the US (10.3:1).... However, the good parts are that the rods are nearly identical the 4agze rods, the crank is forged and balanced from the factory, and it has oil squirters in the block (all of which the 4afe does NOT have).

4afe's are not good for high boost in stock form. I remember years ago on another forum a rebuilt 4afe in an ae102 with a T3 running with an emanage, at 12psi it was stable. Showed a track run where they bumped it up to 15psi and didn't make it to the end of the track before the motor blew.

[REN69]

Dude, I'll have to come to you for a homemade turbo kit for my 4AGE it's too slow for me.

[AstroVannin]

Ren .. anytime bro ... Come out some time and Il have a look and make you a shopping list.

Port hope is only 20 minutes for you