Glenn's REV3 ST215, Dynoed @315 hp & 390 Nm!

[Glenn_k]

Hi all,
my name is Glenn, 24 years old and i'm from the Netherlands. I am starting my masters in Psychology in September, so i'm working really hard (2 part time jobs) to drive and modify my car.

In November 2010, I imported a black rev2 from Japan which really got me going on the MR2 virus. The car was a GT edition with all options, making it a lot of fun to drive and own.
Unfortunately, during some rainy track time, I forgot to switch of my traction control and ended up in the tires. The damage was not huge, but big enough to decide to go full track and build myself a new MR2; full race this time.

I purchased a super white 2 rev3 body from a friend and started to take it apart to make it as light as possible. Furthermore, I am currently working on swapping a gen4 (st215) into this body. While swapping, I made sure to renew as much parts as possible for the best drive.

Spec list:
Engine (315 hp / 390 Nm):
-ST215 3SGTE (Caldina)
-Gen2 E153 LSD Transmission
-Custom Downpipe (gen3/gen4 hybrid, home made)
-Custom Chargecooler Setup (A2W set off a ST205)
-Custom 3,5" induction
-Synapse Engineering BOV (synchronic pull-type)
-Mocal oil cooler kit + thermostat sandwich plate
-Fuel cooler
-8" spal fan to supply oil and fuel cooler

Chassis:
-Rev3 Body
-Panda style panels (borrowed off my Rev2)
-Driftworks GT wing (1600 mm, widest available in this price range)
-Phoenix Power rear add-ons
-CarBenfibre creations S-style Add-ons

Suspension/Brakes/Wheels:
-KW variante 3 coilovers
-Tein pillowball top mounts (front & back)
-Whiteline Adjustable anti-roll bars (Front & Rear)
-CRN grooved brake discs / EBC yellowstuff brake pads
-Goodridge braided brake lines
-SuperPro polyurethane bushing kit
-16" Enkei wheels, originally found on TOM's SW20
-Kumho Ecsta street tyres
-Cusco Brakestopper

Interior:
-Interior fully stripped
-Sparco PRO2000 (2012 model)
-QSP deep dish steering wheel
-QSP snap off
-Aftermarket extended hub
-QSP 6 point harnesses
-TRD shortshifter / knob
-Solid shifter base/cable bushings
-HKS type 2 turbotimer
-Blitz dual sbc spec s boost controller
-Classic style oil temperature / pressure gauges
-Omori 42mm Boost Gauge
-Digital Air Charge Temperature meter

As it stands right now


At its temporary hideout with my brothers 98 import Integra


Just a hint of all the new parts i saved up

Prepping the engine for the swap

Dropping the new engine

Some pictures of my black MR2




Really a shame to let her go, but I had to make choices

[KarlBristol]

Sounds nice ... but you know the rules lol

Look forward to seeing the pics

PS - you need 15 posts in order to put up pics which is why you can't yet

[Glenn_k]

I should be able to post the pictures now, one moment

[Glenn_k]

I'm currently working on the exhaust and intake as these have to be fully custom. I already own a stock gen4 downpipe, which I will use as a template for a flange. I also bought a gen3 downpipe which I will customize with a gen4 flange and a few extra mods.
The intake will be a st215 chargecooler, but I still have to think of the best location for my heat exchanger.
The wiring loom is a hybrid between a gen4 and my old gen2 loom.

[David-Edmond]

Looking very smart

[Ricardos]

Hi Glenn

[Toyspeed]

Awesome build!
Love when ppl go All in.

I will follow this tread closely!

[jack-p]

This looks awesome. Are there alot of pitfalls in fitting the gen4 3sgte or is the design very close the the gen3?

Your workshop looks like a scene out of SAW by the way!!

[ashley]

Very nice mate

How have you done your fuel cooler, what kit have you used for it?

[craig]

Great pics! Welcome to IMOC

That black '2 looks brand new!

[Glenn_k]

This looks awesome. Are there alot of pitfalls in fitting the gen4 3sgte or is the design very close the the gen3?

Your workshop looks like a scene out of SAW by the way!!

The major pitfalls you will encounter are as follows:
-Wiring loom has to be custom made (i use a hybrid gen2-gen4 loom)
-Intake Manifold is side-fed as opposed to the center-fed of the lower gens. This has some advantages, but it also means you have to customize the intake piping.
-Downpipe has to be custom made, as the flanges of gen3 and gen4 do not align. Personally, I used a gen4 catalytic converter and welded a slight bend and a flat 3-point flange onto it, to make it fit to my apexi n1 exhaust.
As I need a catalytic converter to pass the MOT, i'm also working on a custom free flow downpipe. I cut the flange of a toysports (ebay) downpipe and welded a gen4 flange onto it. Next, I will weld on a 3" flexi piece and further modify the downpipe to make it fit.

The entire engine drops straight onto your chassis if you use gen2 or gen3 motormounts (they fit on the gen4). Most parts align, as you use your own gearbox (st215 is always automatic).



About the workshop: it's my fathers metal construction shop. A bit rough, but it does the trick. Oh and the 10000kg ceiling suspended crane comes in handy =)

[Glenn_k]

Very nice mate

How have you done your fuel cooler, what kit have you used for it?

I'm still working on the perfect way to mount the fuel cooler, but i'm planning on splicing the fuel return pipe and mount the cooler in between. I'm doing this to ensure a constant and low temperature of the petrol in the tank, as this is located really close to the turbo.
Basically, i'm doing this to reduce knock.

[Glenn_k]

Great pics! Welcome to IMOC

That black '2 looks brand new!

Thanks for the compliment, I do a fair bit of car detailing in my free time. I never let a chance go to get my black 2 shiny.

[jack-p]

That's actually sounds alot less work than I would have thought, far from easy though and it's good you have the sills to do the custom fab and wiring it yoursef

I was only joking about the workshop, I wish I had something like that myself

[Glenn_k]

It certainly isn't easy, and all the credit goes out to my friend who did the same swap on his 91 turbo. He helped me with everything and also arranged the wiring loom to be custom made.
Don't be misled by the low pricing of the st215 engines though. If you add all ancillary costs associated with the swap, you're looking at €3000 without going crazy anywhere.

[ashley]

Very nice mate

How have you done your fuel cooler, what kit have you used for it?

I'm still working on the perfect way to mount the fuel cooler, but i'm planning on splicing the fuel return pipe and mount the cooler in between. I'm doing this to ensure a constant and low temperature of the petrol in the tank, as this is located really close to the turbo.
Basically, i'm doing this to reduce knock.

Sounds sensible- what core are you going to use?

[Glenn_k]

It's some sort of universal kit I bought off a friend of mine. I'll take pictures of the installation.
But first, study for 2 exams next week. Then it's holiday and i'll have more time to finish the car. Can't wait!

[Glenn_k]

Work on the MR2 continues.
In the past couple of days, I:
-Fixed my exhaaust (messed up my Apexi N1 in a crash last year)
-Made a custom downpipe out of the stock gen4 catalytic converter
-Finished the st205 chargecooler setup
Pictures:


My father welding up a new section between the muffler and the b-pipe. This was a lot of work.

Chargecooler pre-rad. Mounted it in the location of the aircon condensor.

Mounted the pump in front of the left wheel well. I did this because it turns out that mounting the pump close to the pre-rad gives the best flow results.


Heat exchanger. Mounted this on the left side of the engine bay and wrapped it with aluminum heat reflective sheets. The reason for this location is because the gen4 throttlebody does not align with the chargecooler. Secondly, the amount of radiation heat is way higher above the valve cover than at this location. I still managed to maintain a really short charge system, while keeping it as cool as possible

Side angle, still got to fix the clearance of the coolant pipes but I think I have the solution. You can also see 2 of the 3 custom brackets I welded.

Wrapped my heatshield with leftover bits of aluminum sheets. Will wrap the entire shield.

My toolbox
Things to do:
-Fabricate custom induction kit (already ordered 3,5" piping and couplers)
-Fix a catchcan setup (how do you do this with the enormous diameter carter ventilation pipe?)
-Wrap the exhaust with titanium fibre heatwrap (already purchased)
-Polybush and mount rev1 tierods (already purchased)
-Hook up al the electronics (turbotimer, boost controller, gauges, cc pump, fans, fuel pump)

[craig]

Awesome developments mate

Great thread

[Glenn_k]

I finished the car over the summer holiday and got it MOT'ed. Last sunday, I raced it in the Dutch Time Attack series.
Eventhough the car needs a lot of finetuning (suspension is set completely random for example), it runs very fast and gave me a good time.
Here is a youtube movie of the first view laps of my qualification.
http://www.youtube.com/watch?v=9UvJa37C9tQ
(how can i get this hotlinked?)