my 2 Corollas AE86 KE35

Thread in 'Project Cars and Builds Threads' started by Max-san, Oct 18, 2010.

  1. Max-san

    Max-san Member

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    Hi everyone,
    short introduction.
    I´ve tried to go sideways shortly after I bought my first RWD car, bout 2 years ago. It was a 1979 Toyota Corolla KE35.
    But having only 60hp and stock suspension with leaf springs at the back set you a lot of limits. But its still a very unique, cool daily driver!:thumbs:

    I started looking for something more suitable. I came across a mid 80´s RWD Corolla, by the name of AE86, light, enought power for starters and loads of aftermarket parts. I already had a Toyota, so it´s not gonna be that different...
    Cause I´m a student it needed to be cheap.
    Budget was around 1000€ for an unmodified car and according to mods I was ready to pay more.
    Exactly one year ago I found a AE86 in Poland, allready with lots of usefull drift-mods an not to much rust. I payed 2300Euro, wich I still belive is ok for what I got.
    It had some wrinting one the side, a mate told me about initial D (never heard of that before), went onto youtube and there we go, I suddenly realised the "charism" surounding the car, that I bought a few days go :confused:
    It sat in the shed for half a year until I got some more money to spend.
    By now I think it´s worth to be posted here:D
    Hopefully i´ll find enought time to fix it and get a few more mods to suit my "needs". Should become a nice track drift toy:thumbs:

    picture of my 2 cars
    [​IMG]

    [​IMG]

    [​IMG]

    current spec list AE86:

    Engine:
    rebuild 4age bluetop engine
    -new O/S low comp. pistons
    -new ACL conrod bearing
    -ported head
    -crazy high compression (previous owner skimmed the sh*** out of the head)
    -polished valves, recut seats
    -HKS valvesprings
    -HKS adjustable cam gear
    -genuine Toyota Head gasket
    -new Bosch timing belt kit
    -NGK iridium spark plugs
    -K&N Filter
    -stock manifold with 2" self made exhaust system
    fancy bits:
    -Koyo radiator + Blitz radiator cap with twin fans (Audi)
    -cusco catch can

    Driveline:
    -lightened flywheel (still stock clutch)
    -shimmed stock LSD in need of a rebuild

    Suspension
    (needs new parts, too)
    -Koni yellow all around (1 leaking)
    -Coilovers at the front (H&R springs, thread on one sleeve stripped)
    -camber plates (1 pillowball stuffed)
    -some polybushes here and there
    -Whiteline strutbrace
    -P/S arms for more lock

    In/Exterieur:
    -stripped Interieur
    -rear quater window made of macrylon
    -grp bonnet
    -crp/grp hybrid bootlid
    -6pt cage (probably a Heigo cage...)
    -OMP Harness for driver/co-driver
    -HID kit 4000k
    -TRD gear knob
    -MR2 AW11 front splitter

    rolling stock:
    -Hoshino racing mesh 14x7 +4/ 14x6,5 +11 (need refurb)
    -SSR XR4´s 14x6,5 +7 (suits more the KE35, but ok on AE86)
    -unknown white 5 spoke 14x7 +21

    current engine status:

    [​IMG]


    [​IMG]


    Next update will hopefully be next weekend, when the engine is back in and running:wave:
     
    #1 Max-san, Oct 18, 2010
    Last edited: Feb 21, 2011
  2. Max-san

    Max-san Member

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    Engine is back in the car, BUT I couldn´t get it running:cry::cry::cry:

    [​IMG]


    Very weak/ no spark.
    There are not many spare parts I don´t have... but ignition coil and igniter module are one of them.
    I suspect the loom anyway, a common fault on AE86´s.
    The fact that it was working before and now since I replaced the old loom (had few broken connectors), with a "better" one points in this dirction...

    I´ll try to get it working next weekend...
    I kinda hate my Hachi right know, even if my MR2 AW11 front lip and those HKS pulleys look so damn sexy...
    I want to drive my AE86 so badly, I´ve owned it for 1year and couldn´t drive it ever since, cause of mechanical/ electrical faults:cry:
     
    #2 Max-san, Oct 25, 2010
    Last edited: Oct 25, 2010
  3. chaycore

    chaycore Eight-Sixer

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    lovely corollas you have there!

    how did you go about trimming the mr2 lip? i fitted one to the bumper of my 86 when i had it and it required so much trimming along the top and sides. did look good when done though!
     
  4. Max-san

    Max-san Member

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    It took half a day to get the lip on my car, check out the pic to see what I did. I didn´t trim anything on top just at the back.

    [​IMG]

    I think it´s not as cool as the missing zenki lip, but it was way cheaper.:smokin:
     
  5. chaycore

    chaycore Eight-Sixer

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    looks good mate! definately agree, the zenki lip is amazing but i couldnt justify spending so much on one, the mr2 lip only set me back £20!
     
  6. Max-san

    Max-san Member

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    Thanks man! I payed 30Euro, wich is ok for a lip in very good condition! :-)
     
  7. Max-san

    Max-san Member

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    Engine still not running:cry::mad:
    I didn´t get a spare ignition coil/ ignition module by this weekend, wich left me with "troubleshooting with volt/ohmmeter"!
    I´m not sure were the problem with my weak spark comes from, but I checked the wiring and it seems to be ok, so I´ll swap the coil and module and hopefully, fingers crossed, I should get the AE86 running for the first time since I own it (still needs set timing/ mixture adjusting/ other small adjusting stuff)

    Just one more closeup:smokin:
    [​IMG]

    Me and a mate have also been very busy prepairing/building this:

    [​IMG]

    Got any idea what´s it for?
     
  8. pieface

    pieface Go!Go!Auto

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    Loving both of the rolla's. Any plans for the KE35??
     
  9. Max-san

    Max-san Member

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    Hell yeah!
    These are going on there next spring--> TUV time (German MOT)
    SSR Longchamps XR4´s 14x6,5J +7
    Replacing the 155/80R13 with some 185/60/14.

    [​IMG]

    [​IMG]

    These were bought for the AE86 but suit the KE35 very good as well.
    Hoshino Racing mesh 14x7 +4 (rear) and 14x7 +11 (front)

    [​IMG]


    I´ve also collected parts to swap over the old suspension setup from the AE86 including front brakes at some stage, but first I need to get enough money for the new AE86 suspension.:p
    Also plans to renew the leaf springs and add a stiffer swaybar to the front and one for the back.
    I wanted DW C2´s but it looks like that they are no longer avaliable for AE86:cry:

    I also got a longterm engine build, allready collected parts over the last 2 years.
    -bored out Toyota 4K (1,3l) engine to 1,5l with o/s pistons
    -lumpy cam (max lift with stock springs and nice torque band)
    -TRD o/s Valves
    -rebuild Weber single carb 32/36DGV
    -Twin squish head
    -Martelius 4-2-1 extractors
    -chrome moly piston rings
    -a few new bearings
    -genuine Toyota Gaskets

    General n/a tuning with lightening/ balancing/ refacing/ matching/ porting/ will be performed as well.

    I´m aiming round healthy 100hp, wich should make a good daily (820kg), while keeping the fuel cost allright. (sidedraughts are to thirsty round town!!!)

    I´ll probably attend a few classic racing competitions, but nothing crazy, especially no drifting. I´ve done that and it doesn´t feel right, just afraid of crashing a beautifull car:no:
    So it´s not really a matter of Driftworks than...:dw:

    Tidy up the rough interieur,
    and most important,fight the rust, that starts again to pop out on certain places.
    Bloody old cars!
     
    #9 Max-san, Nov 1, 2010
    Last edited: Nov 1, 2010
  10. Max-san

    Max-san Member

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    --Day 0--
    Engine is runnig finally!!!!
    pics tomorrow:smokin:
     
  11. Max-san

    Max-san Member

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    last update before winter!

    I found out my ignitor had an "earthning problem":thumbs:
    Got it started, but we already flooded the exhaust with petrol, resulting in this::o
    [​IMG]

    I send the AE86 to "hibernation", the KE35 will follow in 2 weeks. They´ll be back around April.:wave:

    I´m gonna leave for now with a before after pic of my engine bay!

    [​IMG]

    [​IMG]
     
    #11 Max-san, Nov 8, 2010
    Last edited: Jan 22, 2011
  12. Max-san

    Max-san Member

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    christmas time!

    christmas time = goodies time:smokin:

    I made myself a nice stiff carbon trunk lid for the AE86, weights only 2,1kg (!) the old one is about 8,3kg. Currently getting the final clear coat. I can´t wait to see it finally on my car.:thumbs:
    What you think?

    [​IMG]

    [​IMG]


    I also decided to give my rear axle a full rebuild since the wining noise of my crown and pinion was just a pain in the ass (time for a solid spacer). I just hope I can use the C/P again...
    Unfortunatly I didn´t find the TRD LSD that I got promise by the old owner, it had a shimmed stock LSD.

    What to do?
    Yeap go on auctins yahoo and buy one:p
    Nice fully rebuild with new bearings and 300€ cheaper than a new one (including shipping/tax etc.)

    [​IMG]


    Bad news:
    During last drift action for this year I managed to crash the KE35:cry::cry::cry:
    I was drifting on a huge spot with concrete slabs, I was driving the course it the other way around, 1st time, and on a right corner there must have been a gap between those slabs and a few more unfavourable circumstances wich caused my car to roll over 360° scratching and denting every single panel of it!:(
    Not much happened to me but the chassis is fu****.
    Now I feel bad for ruining such a nice car...
    Whould have been half as bad with a cage in it...

    Time to reshell!
    If anyone knows where I can get one, let me know:nod:
    Thanks!
     
    #12 Max-san, Dec 17, 2010
    Last edited: Dec 17, 2010
  13. BVSX

    BVSX Member

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    sorry to here about your KE35 :(
    The carbon trunk lid looks nice!
     
  14. Max-san

    Max-san Member

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    Thanks,
    yeah still hurts, when I see it in my garage...

    Good news, it took a long time, and a lot of effort, but at the end it was worth it...

    What you think???
    I really like it, carbon just looks so hot... 8)

    [​IMG]

    [​IMG]

    [​IMG]


    If you like our work, and a few of you want to have one of these, I´ll soon be opening a thread in the for sale section, with more informations about it.
    This one weights now with 2 layers of clear coat about 2,7kgs. It has carbon front and rear layer, the rest ist GRP.

    Let me know if you´re intrested... :nod:
     
  15. Max-san

    Max-san Member

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    Small update:
    I refurbed my taillights. The indicator glas was very dull and I removed a a faded clear coat layer from the rest of the light. I just need to buy some plastic polish to finish it of.

    I also fitted the boot lid, and it looks great. But it was quit a job to drill the holes in the right place first time! :shock:

    [​IMG]

    [​IMG]

    Thanks for looking:thumbs:
     
  16. pc18

    pc18 Member

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    great work on that boot lid! how many hours did it take to get the finished product?
     
  17. Max-san

    Max-san Member

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    Thanks.:thumbs:
    Let me say we didn´t count the hours, whould just make us look foolish...
    Prepairing everything takes for ages! All the polishing on the old boot, the mould and the finished item...:no:
     
  18. Kiwi-Richy

    Kiwi-Richy Member

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    Nice i like what you did with the boot lid, Did you have to make a mold of the top and bottom of the boot? Then make two carbon fiber copies and merge them together?
     
  19. o0o

    o0o -=Proud_A31_Owner=-

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    i like your KE ^^

    i had the same KE35 a little bit older and rustier but i love them(i put a sr20det redtop in mine xD )
    do you got pic's from the building or the carbon trunk?
     
  20. x-VORTEX

    x-VORTEX New Member

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    NICE Hachi!
    The bootlid looks superb.
    Actually, where are you from?
    Are you in a club or something? Maybe you´d like to meet, would love to see your Corolla live :-)

    Ciao
     

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