SW20 Build

Thread in 'Project Cars and Builds Threads' started by CTC, Dec 19, 2010.

  1. CTC

    CTC New Member

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    OK So here comes the build of my MR2 Turbo....

    As I had a slight argument with a wall while travelling sideways at a Sprint I decided rather than have the car pulled straight I would buy a decent shell and build the car from the ground up. I also decided although my car is not an out and out drift car being mid engined I'm going to take the car to a few drift what you brung days next year to learn how to control the car when it lets go. The car I started with was a 1994 Rev3 in black.

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    The first thing to do was strip down the 1990 Rev 1 I broke....

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    With the white car stripped I could now start on the black car and the engine....

    First I removed the old suspension including all the control arms. The K Sport Coilovers have to go back to the previous owner so I have the front end in the air to sort out all the running gear.

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    As you can see the parts are pretty rusty so I will refurnish all the bits before fitting any new shiny bits!

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    It's amazing what a shot blaster can do!!!

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    So they don't get into this state I painted them....

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  2. CTC

    CTC New Member

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    I then pressed in my new Super Pro Polly bushes! Was hard work as it took 8 tonne's of pressure to press out the old bushes!!

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    I then fitted my front Cusco Strut Brace

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    With the suspension bushes in and ready to go I started to fit my XYZ Coilovers. These are fully adjustable which will be great for the track!

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    I then fitted the control arms etc... with the new Polly Bushes

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    As the car was from up North everything was seized on or sheared off when removing so I fitted new steering rack boots, new lower ball joints and track rod ends.

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    I then fitted my White Line ARB's with new Super Pro Polly bushes as they are better than the bushes that come with the White Line ARB's!

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    Next came the bit I was excited about!! I started to fit my new XYZ 6pot front brake kit... I also have XYZ 4pot rear brakes to go on so the car should stop well!!

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    With this done I really needed to get some wheels sorted out as my 15's obviously would not go on over these brakes! I bought some 16" Skyline GTR & GTS T wheels from R32. The fronts are alloy and 6.5" wide from the GTS T and the rears are forged mag and 8" wide from the GTR. This works out well as they are lighter at the back and the MR2 needs the back to be as light as possible without removing too much from the front!

    They were in a bad way so I got them refurbished and powder coated black after an X-Ray to make sure the mag wheels were ok!!

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    As the A048R Yokahama Tyres turned up I got these fitted by Quedam Tyres in Yeovil. Now I could get the front back on the floor to do the same with the rear!!

    Ok so today I ventured out to my parents place in the snow... The things we do for our cars :D

    I finished off the front brakes and fitted the front wheels so I could get going on the back suspension. I think the XYZ brakes look great against the black wheels... Just waiting for my forged wheel nuts to arrive now so only put on 3 nuts for the time being.

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    With the font back on the deck I could get the back sorted out. I removed the old K Sport Coilovers so they are ready to return to Steve...

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  3. CTC

    CTC New Member

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    Then I removed the wheel hubs, control arms etc.... These will be refurbished next week as they are really rusty. I will be replacing the bushes and ball joints etc..

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    The plan is to get them refurbished next week so I can get the car back on its wheels over Xmas so I can get the engine back in early Jan as its booked in for a respray late Jan!!

    With the engine out I decided to give it a dam good clean. It's harder than you think trying to get really old oil off the engine!! I firstly stripped off the Rocker Cover which as you can see looks really horrible so I decided to paint it in high temperature paint.

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    Rocker Cover Before

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    And after...

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    It looks loads better than it did... Not finished cleaning the engine so I'm going to finish that over xmas and get some new Rocker Cover bolts as the screws are rubbish and hardly hold down the cover which is why there is soooo much oil over the engine in the first place!!
     
  4. nissanr34cal

    nissanr34cal Well-Known Member

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  5. stuartstaples

    stuartstaples Berg Cup FTW

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    Really like the car and I've enjoyed reading the rebuild; did/do you sprint in the TSS? Is the MR2 competitive?
     
  6. CTC

    CTC New Member

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    Yeah raced in the TSS for last two years. Finished 4th in championship last year against about 40 other cars. It was not bad for a pretty stock car. Hope all the mods I have done make me quicker.
     
  7. CTC

    CTC New Member

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    Thought I ought to finish off the build on here. You will have to excuse the past tense as I posted this over on IMOC so am copying most from there without rewording it all ;-)
     
    #7 CTC, Mar 1, 2011
    Last edited: Mar 1, 2011
  8. CTC

    CTC New Member

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    Duplicated bit sorry!!
     
    #8 CTC, Mar 1, 2011
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  9. CTC

    CTC New Member

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    I decided to do a bit more on the car, firstly stripped down the rear hubs and removed the old bushes... at 9 tonnes of pressure on the press one of the control arms started to bend!!! After quickly releasing the pressure it bent back! I was a little worried tho that it had cracked so got out the old dyepen kit and had a look to see if there were any cracks but there were not thankfully.... Decided to burn the rest of the bushes out!!

    I shot blasted everything again and pressed in the new polly bushes. The only major problem the drive shafts are secured with a nut and this nut as well and truly seized on both sides!! Got out the old oxy acetylene and got heating the nut up until I eventually managed to undo them. Only trouble now is I need new wheel bearings and I'm dammed if I can get them out!!!

    Anyways here are some pics!!

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    With this lot done once I get the wheel bearings sorted I can get the car back on its wheels.... I today ordered an excedy paddle clutch and some new rear ball joints! We are getting there!! It will be ready for paint in jan!!!
     
  10. CTC

    CTC New Member

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    OK so there has been a bit more done on my car this week.. Still been having trouble getting the bolts undone so had to cut off some more!! Never buy a car from the North if you intend to rebuild it!!!

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    My lovely new wheel nuts turned up and yes I'm that sad I got really excited about them.... trying to keep everything corporate to match my CTC Performance Company Logo :)

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    I decided to do some more work on the engine.. Fitted my freshly painted rocker cover along with the new CTC Performance manifold and down pipe and then my blitz oil filter.

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    Finally I cleaned out the engine bay and painted it and then fitted my rear XYZ coilovers

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    As I'm still waiting for the rear ball joints thank you christmas post!! the rest of the rear end will have to wait until they arrive so will start working on the electrics and removing sound deadening in the car...
     
  11. CTC

    CTC New Member

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    Here is the TOM's bumper and skirts going on the car. I will put up some better pics once I get fitting the kit. If its a decent fit I will be selling these ;)

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    Today was a good day, managed to get the old broken MR2 back on its wheels so I can move it ready to take down the scrap yard. They the Post turned up with Ball Joints and a lovely new clutch :D

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    This meant I could get the new car back on its wheels too!!! Firstly I fitted the New white line arb to the rear subframe.

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    Next I fitted the lower control arms, ball joints etc with the Super Pro bushes.

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    Once this was done I fitted the rear XYZ 4Pot brake kit, just need to sort out my handbrake with the Hi Spec Calipers I'm ordering just for the handbrake as I want to get the car road legal again :twisted:

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    Next job.. Fit the new clutch then its engine in time
     
  12. CTC

    CTC New Member

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    OK so today I fitted the new clutch. Tomorrow I will be fitting the TOMS skirts, front wing and removing the remaining rev3 wires into the engine bay so next weekend I can put the engine back in the car.

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    You can see how much heat the clutch has had in it from the colour but to be fair it was not in bad condition and would have lasted another year I suspect.. Oh well the new one should be better anyways

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    This is the new clutch... forgot to photograph the paddles tho...

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    and new thrust bearing

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    Like I say on to the last few bits of body work and then I'm getting the engine back in. Not doing bad for time as I only really have 3 days left to work on the car before paint as I miss a weekend as I'm at the Autosport Show!!
     
  13. CTC

    CTC New Member

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    Today I decided to crack on with the inside of the car as I need to remove the rev3 loom before I can install the engine.

    Firstly I removed the rear loom

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    Next the nightmare job of removing the alarm.... Was a pain but it's done now :D

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    Next I removed the dash

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    I then removed all the sound deadening from behind the dash which was a complete pig!! I also removed the heater matrix as I'm not fussed about heating but I did put the boxes back in as they weigh nothing and that way I still have the blowers to clear the screen

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    I then removed all the speaker and stereo wires. I just hope I have not removed any wires I need

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    I also got round to fitting the front wing that was missing and raised the coilovers as it was looking a bit too low!
     
  14. CTC

    CTC New Member

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    My CTC Performance exhaust turned up yay... I'm going to need to make sure its below 102db (well really 100db for Combe) but on first impressions I'm happy with the look of it. Will be good to have a pipe either side as the last two have been single exit.

    These are just some quick snaps as I was excited

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    Welds look nice and neat :D

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    Engine in tomorrow so wish me luck......
     
  15. CTC

    CTC New Member

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    OK so with only 2 weeks until paint I thought I would crack on with the project, so today I did some more work on the car, first job fit pre-rad for my charge cooler

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    Then fit the front wing from my broken car as the black front wing had a horrible kink in it and it just did not look right...

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    We then pushed the car to the workshop ready to get the engine back in... Friends have now had ramps installed :D Made life much easier getting the engine in!!

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    Tomorrow I will couple up all the electrics, fuel, clutch and radiator etc and see if I can get her running :o I also need to get the skirts and front bumper fitted ready for paint in 2 weeks.... She is almost there not long now and we will be itching to get out on track
     
  16. CTC

    CTC New Member

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    Today did some more of the car as I'm fast running out of time!! Firstly as the engine was back in place I put back my ECU and just for the TSS boys I have added a pick of my Standard ECU to keep me in Class A3 Pro ;)

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    I then wired in the HKS FCD

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    While sorting out the boot area as it had been cut out to fit a intercooler and I have a charge cooler I decided rather than get loads of drag to fix the boot floor..

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    With this sorted I put the wires back into place for the rear lights and then concentrated on the rest of the electrics. The loom was fed back into the passenger side of the car. I then fitted the fuse box, coilpack etc.. Before too much else went back in I put the charge cooler core back into position.

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    Re fitted the swirl pot for the charge cooler..

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    Fitted the radiator pipes and all the cooling pipes..

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    Then my greddy boost controller engine side.. and Apexi Filter..

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    Next I could fit the rest of the charge cooler pipes. While doing this I also fitted my nice new Blitz BOV.

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    old BOV on the car when I bought it..

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    Nice New Blitz one.. I figure if I'm selling these parts I ought to use them ;)

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    And this is how the engine bay is now looking.. Just need to sort out a rear strut brace as the standard one will not really fit as the manifold means I have had to put the charge cooler pipes higher than before. I have something in mind for this and will be selling them..... Watch this space..

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    Last but not least, I fitted a new brake line to the front as mine had corroded so much it would not undo so had to cut the pipe off to attach the braided lines!

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    OK so still left to do next Sunday ready for paint... Connect the clutch, gear linkage, wires inside car, charge cooler pump and water pipes to pre-rad, fit doors, fit TOMS bumper and skirts... then finally rub down and prep the paint for respray!! Not much then!! Going to take some doing......
     
  17. CTC

    CTC New Member

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    OK so this weekend I re-fitted the doors and got all the parking dents taken out by WIZ PDR (WiZ PDR) mobile dent guy in Somerset. I then fitted the Engine lid, side panels and the boot lid, I decided to use my lid and panels as they were a bit better than Steve's old bits on the black car along with my old door without a big dent like the black one...

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    I then fitted the front towing eye as the other towing eyes will be inaccessible behind the TOMS bumper.

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    Next I finished off fitting all the charge cooler pipework to the pre rad at the front. I decided to utilise the heater pipes so this meant cutting a bigger hole in the front under the bonnet so that the pipes could come up and attach.

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    Next I fitted the body kit!! I can safely say I won't be selling these kits! Nightmare is not the word!! It took me the whole of today and to be fair its still not 100% but not bad I guess... I will be filling a few bits tomorrow, getting the doors back on then she is off for paint on sunday...

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    After paint I will finish the interior with cage and then see if she runs.. While the car is in for paint it's having new gearbox oil, clutch fluid, brake fluid prob Millers 300+ and then full geometry setup.... Not long now till I can have a drive!!!
     
  18. CTC

    CTC New Member

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    I have so far had 15 days on the car.. not bad without decent tools and my first build!

    OK so I did some last bits of filling in holes, makins sure the fit of the bumper and skirts was as good as possible and then loaded here into the trailer and dropped off for paint..... While the paint is being done it's having the brake fluid and clutch fluid done, full suspension setup and new gearbox oil. I should get the car back in a week then its interior time and see if she runs.....

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    Can't wait until its all one colour rather than 3!!!! Oh ordered some alloy door cards today ;) Need to stop spending!!
     
  19. CTC

    CTC New Member

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    OK so I picked the car up from paint yesterday..... Not 100% happy with it as they went nuts and pretty much painted everything in sight! Every bit of black trim is now white! Also the finish is not great but then I did not pay a lot so I was not expecting amazing finish. Once its stickered up it won't look too bad I guess... On Tuesday night I will be using wet and dry to try and improve the finish.

    So here are some pic's of the paint. I will be putting some of the black plastic bits that are white back to black including the wiper arms....

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    I have replaced the front wipers and the black trim above the wiper motor's so they are black again...

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    Next I spent a fair few hours removing the 10KG of sound deadening from the floors..

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    I then fitted the Alloy Door Cards..

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    Last but not least today I fitted my nice new exhaust, I just hope its below 100db as that tends to be the limit on most tracks. I'm not holding my breath tho!!

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    So the plan is tart up the paint finish then test fit the roll cage ready to be fitted next weekend all being well. I also ordered my HiSpec SVA spot callipers so that I can get the car MOT'd as there is no handbrake at the moment. Not long now till the first round of the TSS so better get cracking!
     
  20. CTC

    CTC New Member

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    I drove the car today.... although I had no seat so was a bit of a rubbish drive but the car works!! Well happy.

    So basically I got the new front lights fitted

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    I then fitted the plates to bolt down the cage and welded them in place.... This was a fairly difficult job and took me most of Sat to get the cage in. I had to use shorter bolts than provided as they ended up marking the roof in a couple of places as its a tight squeeze to get the cage in but we managed it ok...

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    With the cage fitted I finished off removing the sound deadening, I then sorted out all the wires so they were neat and tidy. I fitted the rest of the wires behind the dash including the clocks and the dash trim so it actually is now looking more like a car!

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    I then painted the floors where the sound proofing had been removed so this meant I could do no more to the interior. I then moved on to the rear lights. I fitted a reversing light and fog light into the center panel and then the tail lights and rear number plate although this will be changing soon as there is a crack in the plate.

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    So basically I still need to fit the Hi Spec Handbrake calipers if they ever turn up, fit my new OMP steering wheel, Ultra Racing rear strut brace, two Cobra Seats in Red, TRS Harnesses, refit the chargecooler pre-rad and then its off down the MOT garage ready for the magazine feature shoot! That will leave me about 2 weeks to get the car stickered up ready for Rockingham.... Not bad timing!!

    That's me up to date... this weekend it should be finished!!! It's been hard work and now need to see when I can get to a Drift What You Brung day to start to learn to keep the thing sideways as I can sometimes but not always hence the build!!
     

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