JD's Boosted Australian GT86
 

Let the build begin...
This has been a very long time coming, but the fun is about to start in earnest! I ordered my car in September last year and took delivery in January. However with my job being the way it is I haven't actually been home all that much this year, a total of 2 weeks to be exact. So as you can imagine I haven't had that much time to conduct the build... Or drive my car for that matter. Instead I've put my time to good use collecting parts, and what I had planned just to be a mild upgrade has now evolved into a full on build.

So let's begin with a list of what is to be done.

Base car:
Toyota GT86, Manual, Storm Black (Aus Spec).
I chose the GT as I liked the black interior and figured that everything that came extra on the GTS I would change out anyway (wheels, lights, basic trim changes and GPS). Plus there was an estimated 2 year wait on the GTS when I placed my order.

Engine stage 1:
AVO Turbo kit stage 1 with ceramic coating and custom wrap.
AVO Billet BOV
AVO Catch Can - Turbo model with Air/Oil Seperator
AVO base map
Cosworth Panel Filter
Motiv Overpipe and Highflow Cat Pipe
Kakimoto Regu Racing Cat back twin exhaust
Custom Oil Cooler (Mocal sandwich plate, Setrab 11 row core, Braided -8an Lines and fittings. Changed to Greddy Sandwich Plate)
Koyo Radiator
STI Engine Mounts

Engine stage 2:
Slight change of plans here. I was going to go straight into a full engine upgrade, but unfortunately the clutch I have planned won't turn up in time for the track days I have booked in. So it's going to a stage 1 build and then an upgrade and tune in early August.
AVO 7Psi Actuator
Omni 3 Bar Map sensor
Tactrix electronic boost solenoid Tuned for 13PSI peak boost, down to 9PSI at redline.

Engine stage 3:
Here's a new one. Something I wasn't planning on doing originally but it seems it is needed to suck more power out of the car.
Amuse R1 Titan resonated twin exit 70mm exhaust. Custom coloured tips.
Further exhaust upgrades are being considered.
Custom long nose 500CC Fuel Injectors
Deatschwerks fuel pump (most likely upgrade)

Suspension and Wheels:
Rays Gramlights 57DRs 18x9.5 +38s Gunmetal. Custom Plasti Dip to gloss Red.
Rays Racing Stainless Steel lug nuts
Michelin Pilot Super Sports 245x35 R18s
KW Variant 3 Coilovers
Vorshlag Camber Plates.
JDM Password Front Tower Strut set (Black)
Beatrush Rear Strut

Track Wheels:[/B]
Enkei Silver RPF1 17x9.5 +38 with 5mm Clap Consulting Spacer rings for RPF1 to Subaru Hub
Yokohama Advan AD08R 17x255x40
Orange TPMS


Transmission:
STI transmission mount
STI short shifter
Legsport Aluminium Reverse Lockout Ring Silver
Custom built performance clutch/Flywheel combination

Brakes:
HEL ADR approved braided stainless brake lines
2013 STI Brembo Brake Calipers (blacks) Custom Gold Repaint
DBA 5000 Front Disks
DBA 4000 custom rears for STI brakes on 86/BRZ
Project Mu HC+ Pads (front and rear)


Misc/Aesthetics:
TRD Door Stabilizer Kit
TRD Fender Canards (Carbon Fibre Version)
AEM Wideband/Boost/Failsafe Gauge
Custom RHD Vent Gauge Pod by Redline
HKS OBII Bluetooth Connector.
TRD Shift Knob.
Zeta carbon fibre TRD look alike spoiler.
Toyota OEM Armrest.
Toyota Japan OEM Leather Seat covers
Toyota GTS head unit with Satnav.
Toyota OEM Revering Camera
Automatic Folding Mirrors kit for GT86
Tom's tail lights
EvoXenon Custom BRZ headlights
Custom Recolour of interior Dash lighting (Blue)
Dabonda Blackbox DBR-4000F Recording Camera
Raceeng Gopro tow hook
GPS Tracking Alarm
Rexspeed Convex Mirrors

There's a few extra things planned for the future, like body kits and colour... But for the moment we'll keep those a surprise. By the end I am hoping to have a street legal, quality built beast, that has a little bit of show to it, but is more a sleeper and less of a cop magnet.

Special thanks:
(in no particular order!):
-AVO Australia - Lee has been an absolute legend
-S-Technic Perth (anyone in WA the team has been fantastic to work with and reasonably priced)
-Import Monster - Aaron and Daniel have both been incredibly helpful!
-Car Mods Australia - Daniel is a champ, and has good taste in mods haha!
-Ravspec
-XXREDLINE9XX
-Subaru Parts Online
-Motive Concepts
-Japan Parts Online
-Vivid Racing
-Cheap Toyota Parts UK
Also big thanks to anyone who has directed me to great vendors, sold me parts they no longer want or answered questions about their builds.

These were taken just after ceramic pro... She looked so shiny I just had to get some snaps at the beach down the road.
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Day after that there was a cruise with the 86/BRZ club and the Honda club. A lot of photographers at the initial meet point.
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This was my baby the day I got her. She got parked up that night and I didn't see her again for 11 weeks!
However whilst I was away my collection of parts for her started to grow... Internet shopping becomes all too addictive when you're away from home for two or three months at a time!
I did managed to get some easy bits fitted like the strut bar kit. The JDM password stuff is really good quality IMO. Massively strong, adjustable and well machined.

First day of ownership.
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I happen to think this is one of the best views of the car... Apologies for glare but I was excited. I actually think the stock rims look good, it's a shame they're so small.
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The pile of goods started small... AVO was the first package to arrive, KWs weren't far behind, JDM password got there really quickly.
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But the longer I was away it just kept getting bigger and bigger. Thank goodness for an understanding Dad with a large garage for me to get deliveries sent to... Motive, AEM, Redline, ECUtek, STI all added to the mix.
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JDM Password Strut bars installed (have a magnet on standby for dropped nuts).
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A few better photos of my baby... I love the TRD body kit. I'm actually struggling to find one I like better. But I don't know if it will suit the style I am going with. So for now I've just added the Zeta carbon fibre TRD style rear wing. Fitment was good, not great. Had to use sikaflex to seal some gaps as the carbon didn't allow any flexibility when fitting it to the boot.

Some better photos as the last ones had lots of glare.
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This is the Zeta performance boot lip spoiler. For the moment I'm going with a black theme with carbon accents. Really happy with the look of the wing even if the fitment isn't perfect.
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Finally I have been realeased from work and am getting a chance to work on the car. Booked in for base runs at the dyno place down the road this week, in the mean time I am fitting everything that I can myself...
Starting with TRD door stabilisers, Beatrush rear strut bar, Toyota centre console and STI short shifter.
Had a few minor problems during the install. The beatrush brace isn't adjustable like the JDM password kit I used in the front and I found that the strut wasn't quite the right length for the car. Nothing a pencil grinder and gentle persuasion (read a hammer) couldn't fix but still shouldn't have been necessary. Only took about 45 to install none the less.
I've had to hold off on the install of the TRD door stabilisers as I've found that a screw driver wasn't enough to break the loctite and a breaker bar was stripping the head of the bolts. I've stopped an I'm now waiting for my impact gun to rock up before I go at those again.

Beatrush rear strut bar. Great piece, love that it is hidden away below the carpets.
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Oh I also verified that you can in fact fit four full sized tyres in the car today, bring on the track days haha!
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This is what part of my office looks like at the moment, yes this is all to go on my car... I think I have an addiction.
There's also a stack of brand new tyres in my garage, an exhaust box at my import agent and several other large items inbound in containers from Japan and the states.

Tires crammed in the car:). Love it

You have a lot of wrench time ahead

Great tire selection, and I look forward to seeing how the AVO kit does on track for you. Any radiator upgrade? Where is the custom oil cooler going?

Haha yes, am well aware that I have a lot of wrench time ahead. Thankfully I have a month off work at a bare minimum so game on!
I'm pleased with the tyre selection, I get a bit of a mix of severely hot weather and lots of rain here so they were a safe choice for me.
The climate here can be quite hot, it's not uncommon to get 115+f days over summer so I viewed an oil cooler as a must and am seriously considering radiator upgrades, although there doesn't seem to be much that suits the AVO kit. The oil cooler is going under the RH headlight. I'm just trying to figure out what if any ducting I run to it. I think the radiation effect on it's own will do a lot but I'm sussing out replacing the fog lamp housing or changing the body kit to give it better air flow through there.

Got a few things done today. STI short shifter in, legsport lockout ring on and centre console installed.
To be honest I didn't think the TI short shifter was going to do anything, when you hold it side by side with the standard unit it's near on impossible to tell the difference between the two. But after going out for a drive I am really enjoying it. For those installing a short shifter follow this awesome DIY;
http://www.ft86club.com/forums/showthread.php?t=31340
I think the STI shifter was a little easier to install than the Kartboy one. Also the STI gives you a replacement for the dust boot under the car, with good reason! I destroyed mine in the process of removing it, and the new one was really easy to slip on.
Minor frustration of the day. I had the tyres mounted on the rims, but have been sent the wrong lug nuts (1.5s vs 1.25s). Have a replacement set airbagged out, but won't be here till early next week.

I got a little 86 accent for where the seat warmer switches are as well. Think it suits the theme of the car nicely. Matches the TRD shift knob and the leg sport lock ring.

Apologies... Didn't realise how badly the last photo turned out until I posted it... Lets try again. Bling lock out ring installed, short shifter installed and armrest installed.
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Also did a trial fit up of my exhaust system to make sure all the components fit together as I've gone with an odd mix. Thank goodness they do, and hopefully fit on the car as well.
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I went with the kakimoto for something completely different. There seems to be a lot of the same sort of combinations popping up so I wanted something a little unique. Really glad I did get this one as the whole system is quality built and just gorgeous to look at.
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Reading through your mod list, you have impeccable taste sir. :thumbup:

I had the same model exhaust on my Supra and it was amazing. Looking forward to hearing it on your car. I had the same experience from @RavSpec, getting a packet with 1.5mm nuts and he didn't send me new ones.

I wasn't able to get enough - camber on the front to tuck the 57s with just the built in adjustment on the KWs. Crash bolts might have worked but I think the inside would rub, so you may have to go to camber plates.

I found after doing sways & coilovers the doors really do squeak a lot over bumps so the stabilisers are worth it.

I'm wondering if the STI shifter will have any rattle/vibration with the engine & gearbox mounts. Interested in your feedback on that. Although it could be my flywheel/diff mounts contributing to that also.

I think your oil cooler will be fine without ducting but you'll want to cut some of the splash guard behind it.

Keep us posted!

This is going to be awesome.

Haha thanks Nix! I was a little worried as to how you would react to this as our taste is so similar! When I found your thread after ordering the avo turbo, rims, and KWs I couldn't believe how similar we were. Your advice on the tyre size was also much appreciated. I finally thought I'd gone down a different path with the STI engine mounts and transmission mount then they showed up in your thread too haha!

I'm hoping not to have to use the top hats on the KWs but after playing with the fit today I think you're right. Anyway I have the vorshlags and will put them on if necessary, but I'd prefer just to mount on the rubber.

I'll let you know how I go with the engine/transmission mounts when everthing is fitted up next week. I'm getting the clutch built out of a stock one (thanks sportsguy!!!) by the guy who does my builder's rally team clutches. So hopefully using the stock will help keep the rattle down.

I have a couple of plans as far as the oil cooler ducting goes. One will be using the APR brake duct on that side, but I have something more extreme in mind down the line.

Looking great!

Small simple question. Your center plastics around your shifter and your TC buttons etc all black, is that a stock thing for the AUS GT86 or did you source those out? Asking I want to ditch all silver crap this winter when I'm parked and doing more minor mods, thanks!

I mounted up my Full Blown oil cooler last weekend, and my APR brake ducts arrive today. I was thinking about fabbing a custom duct to connect to the brake duct and direct air directly at the oil cooler as well.

Thanks mate.

That's the stock trim on the Aus 86 GT, not the GTS, my dash trim/radio surrounds are also all matte black as well. A lot of people prefer the GTS with silver trim, but I'm a big fan of the all black look. Although I've added a couple of silver highlights like the centre plaque and the reverse lockout ring.

Well good god man tell those people that want silver ill trade em, I much prefer the matte black!!!

Inner door handle trim and AC vent surrounds black to??

I'd have to check the door handles but the aircon vents are definitely black. I think the only silver trim I have is the bottom of the steering wheel which I am thinking of swapping out to CF or dipping black.

Credit where it is due to Ravspec, he's offered to replace the lug nuts and centre caps. Thanks Mark!

That's not a bad idea and would be pretty easy to split the duct in two. I was also considering removing the light and replacing the whole grill except the indicator with a mesh.

One of the two little things I've gotten done today. Gauge isn't wired in yet but I promised that I'd get the pod installed and photos up for the guy that made it for me...
Thanks Redline.
Yes I am aware I have a giant phone... I love it all the same and the HKS apps look amazing on it.
The other mod wasn't quite as successful. Little bit of colourful language was used in large amounts today. I'll explain more when/if I've fixed it.

What app is that?

That would be HKS Carscope... For that you'll need the HKS OBII connector. Little more expensive than your average OBII blue tooth connector, but you get the LFA styled digital dash.

Yeah, that's unfortunate but it looks awesome!

Ok colourful language has stopped... For now. This issue was with the stupid trd door stabilizers. Whoever loctited those bolts in originally should be shot. Although the issue was really my fault and I'll own up to that freely.
Words of advice, if you buy a brand new rattle gun to remove the bolts in your door, give it a try on something not related to your car first.
I bought an awesome little dewalt rattle screw driver for another job I'm doing for work at the moment, as it happened you need one to break the loctite on the bolts in the body of the door. Bang two birds, one stone, perfect I can used it to install these trd brackets and move on with my life.
As it so happens the one that I bought packs a serious punch. First bolt pops out no problem, rattle gun breaks the seal with the loctite and I unscrew it the rest of the way with a ratchet. There's where I made my first mistake kids. Leave the first bolt in whilst you rattle out the second bolt. Or else you'll do what I did and torque the nut section inside the door out of alignment and lose it in the frame of the door so you can't see it at all and there's no where to thread the new bolts in. My bad. I had to go fishing and twist it back into alignment and all sorts, but I got it back and the new latch installed. Crisis over.
I learnt from this and didn't pull the bolts out all the way from the second door until I had broken the seal on the other one. However I was now in a bit of a hurry and didn't clean out the loctite very well before inserting the New bolts. One of the bolts binds up half way in, isn't going anywhere so I reach for the torque gun which is still at my feet and put it into the jammed bolt. Mistake number two. The bolt turns a little at then the torque gun strips the head of the new bolt in about two seconds flat! Ba bow. At this point it is almost in, but too far to get a grip on it with a pair of pliers and too far out to get the door to close on it. There is definitely an "oh f@#k I'm screwed up my car thought or two going through my head. It's 8pm at this point and I'm not happy so I decide to walk away and come back fresh in the morning. 2am and I'm not sleeping and trying to figure out how to fix it... a solution pops into my brain... I won't tell you how but I got it fixed using a special form of gentle persuasion and several every day household items and the door closes and the stabilizers work. But it's not a pretty solution.
Moral of the story. Well morals.
Don't use brand new power tools on brand new car without testing them first.
Don't use a rattle gun to extract the bolts all the way in the door of the car.
Break the loctite on all of the bolts with the rattle gun before removing any of them all the way.
Clean the loctite out of the bolt holes before inserting new ones.

Don't worry we all have these moments with our cars.

Mine has a nice big scratch from what looks like me closing it on a spanner or something, I have no idea how or when I did it.

I'm doing the door stabiliser install on my car in the near future & will be careful.

Good to know I'm not alone in the world.
To be honest they're a really simple mod to do. I just made a balls up of it because I was in a hurry and wasn't thinking. If I'd left it to this morning I'm sure I wouldn't have had a problem, but I had a new shiny power tool that looks like a gun and goes vrrrrooom when you pull the trigger... What could possibly go wrong?!? Haha.

I now have to find a replacement for the screwed up bolt and figure out how I'm going to extract it given that it has a torque head on it that I've stripped and not a Phillips I suspect that will be an interesting task. But it is in and the bolt is hidden out of the way so the latch works so I might just leave as is.

Game on!
Work is doing their very level best to mess up the time I have put aside to get my build done... However pushing on I am getting somewhere.
Today I got a base run dyno done. I thought this was really important as I wanted to see the actual progression of my car. So I've found a local dyno that I can use regularly for calibration and tuning runs. Took an hour to get set up and do a few power runs. This is the end result.
There's all these discussions about what sort of dyno people are using and how they affect the numbers. Have no idea where this one sits in the scheme of things but I am using a dyno dynamics and the car for this post is bone stock as far as the power mods go, not even a hint of exhaust or panel filter.
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Bone stock starting point.
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This gives me a starting point. Only up from here... I hope!
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So it's been a big week. The workshop was a little busier than expected early in the week, so we didn't really get the car up on the lift until Wednesday afternoon, but progress has been manic since then.
By Thursday morning we'd stripped the car down, the stock exhaust, coils and intake were gone and we started fitting up the new bits and pieces (engine and transmission mounts went in whilst headers were off). By Thursday afternoon we had the full exhaust in and the KWs (wound up fitting the vorshlags to clear the wheel). For those that are interested the AVO/Motive/Kakimoto combination works a treat. No problems at all with the Motive overpipe on the RHD car. The guys helping me with the fit up said that it's the easiest full exhaust they've ever done, also the quality on the Kakimoto and Motive stuff is incredible. Fitting the overpipe was really easy with the headers off. Also got the bung welded on for the sensor for my failsafe gauge.
By COB Friday I had the turbo/headers and intercooler in and all the plumbing for the oil system done up.
There was a slight hold up with the delivery of a part, specifically the Koyo radiator I ordered last minute. It didn't get here till Friday afternoon. If it had turned up earlier I think I would have been driving the car today, but as it stands we should be done on Monday.
After spending all week listening to worked over STI-WRXs roaring in the workshop I can't wait to hear the growl of my baby!
Stay Tuned!

Wheels off, stripping exhaust.
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KW's Fitted.
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STI Transmission mount.
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Headers off, Overpipe in.
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Motive front pipe, incredible quality!
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Turbo in, full exhaust fitted!
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Kakimoto Regu Racing Exhaust... Pure Exhaust porn!
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Intercooler fitted!
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Turbo and headers in!
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I like this. Certainly DO NOT waste time LOL. Must be making up for lost time from working :D
If your ever contemplating running a 'tow strap' on the car, now would be a fantastic time to cut away or install one of the TRS tow straps(just cut a 60mm x 60mm) square near the front tow part. Also, Hella "SuperTones" too since the bumper is off. Up to you though!.. its like one of those mods that you think in hindsight that you maybe should have done when such-n-such was easy/available to mod(ie.. like engine mounts when my headers were off, d'oh)

just my 2c tho ;)
http://www.ft86club.com/forums/attac...1&d=1374335124

Looking really good :bow: :respekt:

My AVO turbo kit is being fitted next Friday - the first customer one in the UK :happyanim:

Have you wired the AEM Failsafe gauge in yet? If so, I would really appreciate any details you could share as to how you did it, as I am planning on fitting one as well.

Haha thanks Steve, and yes I have a lot of time to make up for. Thankfully everything is going smoothly as I've had plenty of time to plan things out and everything is fitting together. No plans for Super Hellatones at this point. I like the tow strap idea and it's on my list to do... But the bumper is coming off for another job in about two months *Hint* so I can always do those then.

Cheers mate!
Good luck with your build, hope it goes as smoothly as mine has. The kit is really easy to install so you shouldn't have too much in the way of problems.

I haven't wired in my failsafe yet. That's my job for tomorrow. I'll be happy to let you know how it goes though!

Almost done! I got to hear her run today, so I'm so nearly done. I have to wire in my failsafe, finish the lines for the oil cooler, put the front bumper on, reinstate the strut bars and then I'll be on to tuning.
Progress for today included mounting the new radiator (Koyo works a charm with the AVO kit, no swearing involved or clashes with the turbo), plumbing the final bits of the turbo kit (including the AVO front mount catch can), mounting the rims and the oil cooler.
I went back and forth a little bit with the position of the oil cooler. I was tossing up a position behind the bumper where the standard intake trumpet is but finally settled on under the driver side headlight (RHD). For the moment I haven't sorted out airflow through there but we're still in winter here so the temperatures are down, the radiation will be enough to cool it for now. I've mounted the cooler on a bit of an angle to fit it under the bumper and to allow it to drain oil when I do an oil change (the ports are on the bottom of the cooler).
So nearly done! I'll be driving it tomorrow (map pending).

AVO plumbed in, front mount catch can looks just like the stock resonator box.
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Koyo Radiator. Perfect fit with the AVO kit, awesome piece of kit too.
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Oil cooler mock fitment.
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Pure wheel porn! Love how the colour goes with the car.
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Thank you. I would really appreciate any info you could share with me with respect to the failsafe. Where are you going to mount the gauge?

Dave

Have a look at the bottom of the previous page. I have a little custom gauge pod that replaces the aircon vent just next to the A pillar on the top of the dash. A guy named redline made it up for me, I'll PM you his email if you're interested.

At present all I know with the failsafe is that you wire the power into the ignition/key, the lights into the dash lights and take a T off the brake booster for the boost... Oh and you have an exhaust sensor that you need to weld a bung in to get your A/F ratio (I've got mine welded into my overpipe behind the chasis) Beyond that I'm a little stumped. But I'll figure it out in the morning.

:thanks: I would appreciate it if you could PM me the details. I am also thinking of possibly mounting it in the round vent on the front RHS of the dash. I want to keep my install as stealth as possible.

Dave

:mad0259::mad0259::mad0259::suicide:

So update for today is not the update I wanted to give... I wanted to say that the car was sitting in my garage ready to go.

But it's not.

The good news is the car is done and I got to drive it... About 500m down the road to the wheel alignment place. Only to discover that the latch cable had come a drift and I couldn't pop the bonnet... So I got to drive it back to the workshop where we had to get the car back up on the lift and after about two hours of faffing we settled on removing the intercooler to access the latch.

This was about 4pm. I left when they got the bonnet popped and the latch cable attached. with a bit of luck they will be done tonight and I'll get my car back first thing in the morning.

The other positive for the day is that the car is flashed with the AVO base map. Thank you so much to Paul from AVO for helping with that.

For those that are interested.... You don't ever want to break the cable on the latch for the bonnet. It was a nightmare to get free particularly with the turbo kit crammed under the hood.

How did you manage to open the bonnet?