Markstevieandmads Budget Turbo project : PART ONE

Create a post with details about your car.

Moderators: IMOC Moderators, IMOC Committee Members

Post Reply
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

Mot tommorow...

I've fitted some temp brackets to hold the brake lines and bolted the passenger seat down.
The rear tyre has a slight crack in it which I'm hoping he will miss lol . if not I got a set of standard alloys with decent tyres I can swap out.

I did notice slight moisture on one rear shock but it was more damp from the road so fingers cross.

Wish me luck....
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

Ok....

Verdict is....

It failed :(

Good news no advisories and only 1 fail point.
The ns rear shock is weeping. Looks like the original shocks all round with lowering springs so has done well for 23yrs old on these roads.
So I've got the garage to replace it so I can have the mot and then I will save up and replace the rest of the suspension myself.

So that's another BIG thing I'm gonna put on my list. I'm gonna stick with the black billies and lowering springs and also polybush everything under there.

Hopefully she will be back tommorow!
gnzyza
Posts: 1300
Joined: Wed Jun 27, 2007 11:39 am
Location: Gloucester

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by gnzyza »

Good excuse to refresh the handling. I'm currently polybushing mine. I have a set of black billies taken off my car, no leaks...will need rear top mounts.
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

Not so easy it seems..... :(

Got a phone call from my garage this morning saying the mechanic has a problem in that the shock is welded to an arm on the rear and he can't replace shock without replacing the arm. Apparently the garage phoned Toyota and this "arm" is unavailable and so they can't repair this.

Thinking the garage was getting their parts mixed up I went on the net and got tcbparts phone number and spoke to a very nice chap called Trevor.
He said he didn't understand what the garage ment as the shocks are bolted onto the bodywork at the top and 2 bolts to the hub at the bottom.
He kindly agreed to chat to my garage and after 10mins I rephoned trevor to see what he could do.
It seems Toyota no longer manufacture bilsteins for the turbo so the other option was to go for a pair of shocks with refurbishable inserts. Apart from a set of coilovers which I just can't afford at this time ,and with Trevor's recommendation I've ordered these for delivery to the garage tommorow.
Thankfully the cost for this is only a little extra than what the garage had quoted me in the first place to replace one with them supplying the single part and both sides are now going to be done.
Fingers crossed.....
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

TIME FOR A LITTLE UPDATE

So the rear shocks have been replaced and it now has a fresh mot.

Image

Ive had a list of things to do for a while and as the weather has been getting better I decided to crack on.

First was the steering wheel. Since i bought the car a few years back, the momo steering wheel hasn't been straight and always pointed at an angle.
So i decided to sort the easy problem first....or so i thought.

All the bolts came out except one. I tried everything to get the last one out but the allen bolt was too rounded. I tried bigger bits and even an easy out kit but it wouldn't budge so I lost my temper and used my angle grinder to cut a slot to use a screwdriver - which sort of worked. However it damaged the carbon fibre centre ring slightly.
I bought a set of new bolts and a new alloy centre ring from eBay. Unfortunately the bolts were too short so got a refund and bought some longer bolts.
However , it just didn't look right and the bolts just didn't sit square with the centre ring.

Image

So I've used the new bolts with the old centre ring and just used a black marker to make the damage less obvious for now.

The problem is, I've put the wheel back on but it won't sit straight with the boss i got. It sits either too far to the left or too far too the right.
So, I've given up on it for the min...

Next on the list was to fit my new alloy radiator. Ive had this sitting in the garage since xmas and when I had the car checked on last year by a local specialist, it was noted the rad didn't look great.

I decided to get rid of the air con as its never worked and you can probably see why lol. So i removed the air condensor first...

Image

I ended up cutting one of the air con pipes to it as it was near impossible to get a spanner on one of the bolts without taking the bumper off.

Then the rad was next. This was pretty easy apart from the pipes being real hard to remove (ended up using boiled water to soften them) and the rubber mounts being glued to the bottom of the old rad. Also had a few snapped bolts on the fan housings.

Im glad i decided to replace it - it was in a worse condition than i thought.

Image

Also it may have been leaking slightly from the end pipes.

Image

Next up was to clean up the mess that was left and treat and paint (with black hammerite) the brackets and fan housing and anything open to the elements down there.
Also replaced the majority of snapped bolts for new and decided to mesh the front opening to protect the new rad from stones now the air con rad has been removed.
I got a bit lucky with this as went to halfords to get some mesh and found it was well expensive. Popped to the local b&q and found a large section of mesh in the plastering section with the same pattern and galvanised for £11!

Got that all mounted once dry.

Image

Image


Image


Image

I found the new alloy rad didn't have any bleed points to put the tubes on so i could only bleed it from the frunk bleed point. This took a little while longer and at one point i didn't have any hot air from the heaters but eventually after continuous bleeding and refilling i believe its all done. The car gets up to temp half way and stays there and the heaters are nice and hot now. I took the car for a drive round town and all ok for now.

One thing I have noticed is the fans not coming on.As there is no pressure in the air con i believe the fans should be fail safe and on all the time so will need to check this.
If need be i may wire in an override switch for both rad fans and intercooler fan for track use anyway but would like to get them going for now. This needs further investigation. Hopefully something as easy as a blown fuse.
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

FAN INVESTIGATION

I unplugged the pressure sensor from the air con and both fans started at full speed. Strange as there is no pressure in the air con so i could only think that my air con pressure switch was faulty.
I then put a link across the pressure switch connection.
This stopped the fans.

I then disconnected the fan switch temp sensor and again the fans ran full speed.

So this proves all ok with wiring and relays.

After a little bit of searching on the web it seems the fan temp switch doesn't operate until 90c and my car was only reaching 78-80c so I'm confident that it is ok.

However, I have also wired a switch as normally closed going to open to the now unused pressure switch and mounted this down by my fog light switches so i can manually bypass the temp switch and put fans on full speed while on track if necessary and it will still work off the fan switch if i forget.
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

UPDATE:

With japday approaching i decided to get some new rear tyres as even though the tread was ok, they were cheap make so went for 2x 225 45 16s from black circles and had a local garage fit them. In the end, went for too tr1s.

So I had 2 sessions booked at Japday and the car performed brilliantly. My passenger reckoned i hit 140mph on the main straight though I'm not so sure bout that as i still have the limiter on the car as i removed the convertor a while ago!

Anyway,heres some pics:

Image


Image


Image

Image

Image


Quality cakes!Image

Image

Image


Just a few I'm afraid...

And here is one of my front tyre after my 2 track sessions
Image

And here is my vid...The 2nd session starts at 15:45.
I had a problem near the end of the first session in that the plastic covering by the accelerator pedal came loose and jammed by the pedal giving me less control over it...all sorted by 2nd session...


https://youtu.be/YrkRX4w607M

The car handled great and had just the right amount before it started drifting!

One thing i did notice was the clutch fluid was starting to boil during the end of the second session as it felt a lot different though wasn't slipping so will get this fluid refreshed and may throw in a braided line too as they are cheap.

Im also gonna have to get some new tyres for the front so will be going for tr1s again as was well impressed with how they were on track. Just compare the japfest session video from last year to this years sessions!!

Now its gonna be a bit quieter for my turbo i may also install the intercooler and fan i have as well as the decat pipe. It also seems I'm only running about 0.7 - 0.8 bar so will up the boost a bit to 0.9 or maybe 1 bar once i done these mods.
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

UPDATE:

So i decided to have a go at fitting my upgraded intercooler and fan I've had sat around for a while.

To be honest, it was quite fiddly but took my time and got there in the end. The hardest part was removing all the bolts from the original intercooler and shroud.
Unfortunately i didn't take any pics until I had finished.
Image

I realised the pipe that goes to the throttle body had a hole in it for a sensor of some sort. Ive managed to cover the hole with the boost hose for now. Everything seems ok. I will be using the hole for either a temp sensor or to inject some water/meth....time will tell.

Also managed to pickup some clear indicators on a Facebook forum cheap so fitted these with some new orange bulbs. I didn't mind the old tinted toblerones but these have really smartened up the front end.
Image

Image

I had to cut a bit of the trim off to make them sit flush and mod the bulb holder a bit but all in, not a bad job.

Next on the list was removing my tablet install. I was finding when it was hot weather the screen would go ballistic and for a weekend car, it just wasn't usable enough. It would be great for a daily but i wanted something easier to use. I also wanted to use my phone with the stereo too. Again, Facebook came up trumps - however i didn't realise at the time that it was my sister in law selling the stereo lol. Luckily she gave me the stereo which is a JVC and comes with a phone mic so installed that today.
I had a spare centre console and heater vents to hide the holes i had made for the tablet. I also had to make my own stereo brakes to fit it as i had misplaced my old brackets that came with the car (3yrs ago). Thankfully it sounds awesome and is very easy to use.


Image

Looks a bit more "boring" now but does the job nicely.

Now the car is running ok I'm trying to setup some summer runs in the local area. Heres a quick pic of mine and my brother in laws v6 we built.

Image

Insurance has been renewed. Funny enough it was go compare that came to the rescue. Ive had the car insured fully comp, all mods declared and an agreed valuation of £3.5k with admiral for £23 a month.

Im hopefully going to Beaulieu on sunday and I've also ordered a set of crystal front headlights off eBay with some decent osram night breakers to improve the woeful lighting on this car. I should be able to get these installed before sunday.

Hope you enjoyed the update.
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

So just a day before Simply Jap at Beaulieu I decided to renew my old headlights for the new crystal e marked ones i got from eBay and also install some osram night breakers too.

Heres a few before and after shots:

BEFORE:
Image

HALF DONE:
Image

ALL DONE:
Image

I think a much cleaner look. Hopefully I will have a chance to see how well they perform later in the week.

Also, as Beaulieu is tomorrow and the local IMO had a 50% off sale, i decided to go for a full wash and wax.
Image

Im gonna have to give it a good mop and polish and some point but at the mo never seem to have the time.
Im also going to have the bodykit resprayed at some point and the wheels are going to go a different candy colour - haven't decided what yet...
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

PUT AWAY FOR 2016

So after a good summer ive decided to do some major upgrades.

This was always a budget build so ive bought bit and pieces on the cheap or for ,what i would call, a good bargain. Ive been collecting parts throughout the year and now the weather has turned it time to fit them all.

Ive had a decat sat in the garage for a while so this is being fitted.
I decided i didnt like the uprated intercooler. The engine always felt too hot with it and the pipework could have done with some heat lagging or something as they were always boiling hot after a run.
So as luck would have it, i found a poorly described gt4 st205 chargecooler advertised on ebay. After messaging the seller it turned out it was more or less the complete gt4 chargecooler setup including all the pipework, front rad, pump and the actual chargecooler itself and it was incorrectly advertised for the bargain buy it now price of £90!!! So i snapped it up.

Image

Image

Image


Once i picked it up i took all the packaging apart and realised i only needed the st185 throttle sock,bracket and accelerator bracket to complete the kit which i picked up from tcbparts for another £25.

Ive also managed to pickup a genuine walboro fuel pump for £30 from a facebook group.

As the fuel tank is going to come off to fit the new pump and also the chargecooler pipes being ran and the chargecooler being fitted then why not fit a nicer bigger turbo? So I emailed JimGTS to see if he was selling his ct26 hybrid he was using before going back to a ct20b and we came to a deal so a deposit has been paid and postage is being sorted as we speak.

AND, as the turbo is coming off then we might as well do a bit of preventative maintenance and fit new HFH and HFHOE.

AND, while the fuel tank is off then a bit of undersealing and rust proofing wouldnt go amiss!

SO.....

Work to be completed is:

Remove uprated intercooler & Fit complete gt4 chargecooler system
Remove stock cat and fit Decat
Remove old ct26 turbo and fit Hybrid ct26
Drop out fuel tank and fit new Walboro pump
Underseal & rust proof underneath and boot areas and sills.

This should give it a bit more power and help prevent problems in the future.

As the weather has got cold i cleaned out the garage and started to set the car up for all the work to be done.
I jacked the front up and set it on stands and then jacked the rear up to put on stands. However everytime i tried to jack the rear the front would move and vice versa. After a bit of tugging and pulling i managed to get the car in the air.

I thought id give it a good wiggle and shake to make sure it was safe and BANG! The car slipped off the stands and rolled away. Unfortuntely one of the stands got caught under the front bumper which dented the bumper and pushed it out a funny angle. This also damaged the bomex front lip slightly.

With a bit of work i managed to sort the front bumper so you cant see any damage as it popped back into place and ive removed the bomex lip. It will need redrilling and will need a slight bit of filler work to make it perfect again but looks like all is saved.

Think i will jack one end at a time!

So, due to bad sciatica, thats how far ive got so far. Plan is to pull the front bumper off to mount the gt4 chargecooler rad and pump under the headlight then put the bumper back on and start from the back.
I may even hire a ramp for a day to make it all a bit easier.
Draven
Posts: 14965
Joined: Fri Feb 10, 2006 8:34 am
Location: One of the Hamptons.
Contact:

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by Draven »

Nice work dude, I enjoyed reading this. Keep it up :thumleft:
androo007
Posts: 2363
Joined: Mon Mar 03, 2014 1:43 pm

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by androo007 »

Get those hamstrings stretched..! Big sciatica sufferer in the past I feel your pain (literally)

What do you make of the lights, worthwhile upgrade?
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

androo007 wrote:Get those hamstrings stretched..! Big sciatica sufferer in the past I feel your pain (literally)

What do you make of the lights, worthwhile upgrade?


Tbh i havent tried the lights out at night!! They look better tho..

Unfortuantely my plan of having an all nighter doing all the above didnt happen when the missus was rushed into hospital saturday and shes still there now . Family comes first .
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

Now the missus is all better I had a day off work to start on the car.
Got the car outside the garage for more space and stripped off the front bumper and lights to start the chargecooler install.
Image

Oh dear! Cant be having that surface rust on the crash bar so that all came off along with the smaller bar and with a bit of modding to the frame (not the solid frame!) i mounted, what turned out to be, the gt4 chargecooler front rad.
Being the actual rad from a gt4, it is bigger than the usual fiat cinq rad people use which could only be a good thing. The only problem is it now hides my alloy rad! Oh well, will fit some mesh to hide it.
The gt4 chargecooler rad is fitted using some existing points on the bottom and the bar will be supporting it at the top so no movement.
Ive also removed the fog lights to allow a bit more space for pipework. I will also mesh up these holes too.

Image

Ive given the framework a rub down and a coat of hammerite to future proof it.

Ive also given the crash bar and smaller bar a good rub down and coated these in black hammerite too to prevent further rust.
Image

Image

And this is how I have ended up today. Got to wait for the crash bars to dry out but i have trial fitted then and all is good and fit well. Ive also cut a little hole out so it will be easier to bleed the rad and access the bleed screw.

Image

Ive had a look at mounting the gt4 chargecooler pump in the location under the passenger light but cant work out which way round would be best at the mo. I will post another thread for that. Im also gonna relocate the horn in the same location to make the front look a bit better. One of the horns wiring had broken off anyway so may install both horns or one might suffice.
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

With the new year started i thought id crack on with the car....

but due to a close family member suddenly passing away i have just no inclination to do anything.

Ive got the front crash bars back on and thats about it.

I have all these lovely goodies to go back on but the mammoth task of doing everything has really hit me and im left wondering is it worth it?

It is now mid January and i can get the new mot in feb but cant do that until the car is back together. Ive got a small problem with the rear fog light i need to sort which shouldnt be too bad and put the front end back on. With this i could get the mot done.

Ive even asked a couple of specialists to give me quotes to putting the hybrid turbo,decat and fuel pump in for me as i just dont have time at the moment and the weather isnt great. Out of 3 specialists ive asked one has given me a quote for £6-800 quid, one for around £500 quid and another hasnt even bothered responding back. I just cant afford this.

So do i
1. put the car back to the way it was and sell on the additions I had,
2. put the car back together the way it was and use it for the summer and just do the bits as i go or
3.just man up and crack on and get it all done.

The problem with 3. is once i start stripping it down for all the bits, things can go wrong (bolts snapping, extra bits needed etc etc) and then i wont have a summer car to use in the summer!

The problem with 2. is a lot of the things to be done can all be done together...

I was hoping to use the car for Japfest silverstone and JDMday or whatever its called at combe but cant imagine getting it all done for them.

Decisions.....decisions.....
thomp1983
Posts: 1545
Joined: Sat Oct 01, 2011 1:30 pm
Location: newark, notts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by thomp1983 »

Option 3 pull your finger out your ar$e and finish it, I went through similar when my mam died and Ryan s did when his dad passed it's very easy to feel deflated and negative about everything and wonder what's the point but if you never had the thoughts of jacking the project before then why should you jack it now.

When your in grief and shock isn't the best time to make big decisions, look at your project as it is now and break it down into small sections and work out how your going to tackle each bit the work you have to do and the deadlines you've set are achievable you just need to get the bit between your teeth and dig in, trybto commit at least 30 minutes to it every other day and you'll be surprised at how it moves along just be aware of the aim of each of those small sessions and it will all add up
androo007
Posts: 2363
Joined: Mon Mar 03, 2014 1:43 pm

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by androo007 »

Come on man don't give up now....get on with it
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

Its not really a case of jacking it all in..... its just a case of can i be bothered doing all these mods and risking not using the car over the best period of the year if i cant get it done or just basically leaving it the way it is (possibly finishing the cc system) and using it the way it is.
Thanks for the moral support tho.
alanmr2turbo
Posts: 2238
Joined: Wed Nov 28, 2007 7:08 pm
Location: Birmingham
Contact:

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by alanmr2turbo »

To be fair you got a couple of weekends work if that. When i found out my car had been in an accident and reshelled it it took just 3 days, long ass days at that.

That included stripping N/A donor car to a shell, stripping my Turbo down to a shell and rebuilding it.

Just keep plodding on and will soon be done well in time for summer.
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

UPDATE:

So with the weather although cold, it was a nice clear day so thought id try and get some more done on the car.
Started off by bolting up the crash bars.
Image

I then got the bumper back on and secured.Also got the lights and indicators plugged in and secured.
While the car was up in the air ,i sorted the holes where the fog lights used to be by filling the area with the same mesh ive used for the front.
Image

Image

Then i jacked the car up as far as i could and secured it on some heavy duty jack stands i borrowed.
I managed to get the front 3 undertrays off in one piece only snapping approx 3 bolts. Theres enough there to hold them on and i can cable tie the rest if needed.
Ive attempted to run the pipework for the chargecooler. I got as far as the handbrake mechanism bracket about midway past the fuel tank before the car started to get lower again and i couldnt fit lol
Anyway heres some pics of the routing. Ive cable-tied the pipework to the existing air con pipework. I was thinking of removing them but i didnt have much room underneath and didnt like being under there. Maybe if i can borrow a ramp off someone i will tidy it up a bit more and remove the air con pipework and mount my chargecooler pipework in its place.

Image

Image

Image

I did notice there was a wet patch on one of the steering rack covers and this had got on to the undertray underneath. I had a good check of the boot and i couldnt see any splits etc so not sure if this was old or not.
Ive got all the kit for a manual steering conversion to get rid of the power steering if needed so not too worried bout this and the boot can easily be replaced if needed.

Image

And that was about it for now as i was getting real cold and the sun was starting to go down. Ive left the undertrays off for now and cable tied the excess pipework curled up underneath for now so the pipework dont drag when pushing it in and out of the garage.

Hopefully i will get some time tommorow to jack it from the back and remove those undertrays and finish the pipework routing and hopefully mount the pump too.

This is how i left it ,all pushed back into the garage....looking a lot better.
Image
Post Reply

Return to “Member Profiles”