Forgot to update this thread again.

I finished repairing all the crash damage a few weeks ago, got the replacement panels wrapped etc and she's now pretty much as good as new :)

http://s18.postimg.org/7bpl3rck9/IMG_8428.jpg

http://s18.postimg.org/tz4u9ws49/IMG_8439.jpg

http://s18.postimg.org/m8y24rpsp/Untitled_2.jpg

Went for a slightly different wrap on the front, with the gloss black part along the bottom centre section below the number plate. Also replaced the fog lights with the APR carbon fibre cooling ducts (which were a nightmare to get to fit even half decent).

The engine seems to be fine despite the over revving during the crash - I've done about 300 miles of hard driving since with no problems. It passed an MOT a few days ago as well, although I guess that doesn't mean much but at least it proves its not a wreck lol

Finally got round to installing the new StopTech big brake kit last week as well:

http://s9.postimg.org/4u0sdi7fz/20151107_164914.jpg

Word of warning to anyone considering these - the stock 17 inch wheels don't fit over the callipers. My 17 inch OZ wheels fit fine due to the lower offset though. Haven't had chance to drive it much yet since fitting the new brakes but first impressions are that they feel a lot better than the DBA discs and hawk pads I had before (with stock callipers).

Anyway, in a couple of weeks I'll be taking the engine out and getting the new pistons/rods/valve springs installed :) looking forward to it

Don't complain... You could live in (South Africa)... We have to import pretty much everything, and our currency isn't strong!

I'm subscribed to your channel and very much enjoy your vids. Good work so far!

I knew I recognized your car! Watching your videos reminds me I have to get off my butt and start modding my car. Loving the build!

Glad you got her all fixed up!

haha thanks, wasn't expecting anyone on here to have seen our videos but its nice that a few people are enjoying them.

And yes, get modding! ;)

Got the engine out yesterday - will be taking it down to the guy that's installing the pistons and rods next week.

http://s27.postimg.org/e1tdwta1v/20151211_154922.jpg

http://s30.postimg.org/ffzjdvki9/20151212_213211.jpg

The only bits that were a pain were coolant lines to the turbo and the larger exhaust obstructing one of the exhaust manifold bolts. Everything else went pretty smoothly (probably wouldn't have done if I'd done it on my own but luckily had some friends round who have done this kind of thing before).

Engine has now been delivered to the engine builder and he's cracking on with it :) just waiting for some new con rod bearings to arrive at the moment but here's a few pictures he's sent me so far:

http://s27.postimg.org/obwg7m6wz/Ai_...aemn43pv_L.jpg

http://s27.postimg.org/wxzps7iwz/Aix...343gln_NOM.jpg

http://s27.postimg.org/k5blsa7b7/Ao_..._DXLwxiw_A.jpg

http://s27.postimg.org/otw717lvn/Ar2..._Iz_K01_M0.jpg

Hi chris.
Nice configuration. I will fallow your story.
A question : Did you install some gauge to check the oil temp, pressure, water, afr, etc..?
I m interested by your statistics on oil pressure. ;-)

So far I've only been monitoring oil temp and coolant temp, not oil pressure. However, I've bought an oil pressure sensor and gauge now so will be installing that when we put the engine back in.

For the oil temp and coolant temp I used the p3cars.com gauge which replaces the drivers side air vent and just gets its data from the OBD2 port

ok so we use the same installation : P3Cars VIDI + Oil Pressure Gauge.
you can check my journal, I installed the Zenky oil pressure gauge.
But I didn't plug it on the P3Cars AUX wires. We plugged the electrical source behind the radio.
If you plan to plug the oil pressure gauge on the P3Cars AUX, I'm interested. ;)

Hi another Brit based in Buckinghamshire. The forum is great as there is so much variety with every conceivable mod to view.

Ah nice :) nah I'm not going to install the oil pressure gauge into the P3Cars AUX, I've got a separate gauge that I'll mount somewhere on the dash. Have you got a link to your oil gauge install? EDIT: Nevermind, found it in your signature :)

Subbed

The thing a really love on the Zenky Racing Oil Pressure Cup : alarm when the pressure drop under X bar (I have configured 1 bar, Stock It was 0.6 bar).
If you lost controle on track and shut the engine by error, oil pressure will drop at 0 bar and it will BEEEP BEEP BEEP like fool ... but I prefer that than not seeing an oil pressure falling to 0 on track because I didn't notice the warning led shining.

Engine is going to be finished in a couple of days :) here's a few more pics:

http://s9.postimg.org/h4eonk927/Ai9_...Njrg_Mx_Qk.jpg

http://s9.postimg.org/rfr1g80rj/Ak31..._IQTHkt_Q0.jpg

http://s9.postimg.org/ft6xf3dgf/At_Y...op9wf_Qo_P.jpg

Oh and also the hydraulic hand brake and 1.5 way LSD turned up yesterday :D next drift day is booked for March so at least we've got a couple of months to get everything installed

http://s11.postimg.org/dvpr5zuvn/Hydro.jpg

http://s11.postimg.org/76j7pz9jn/LSD.jpg

Engine isn't back yet, but we mounted the hydraulic hand brake (with a little bit of cutting to some of the transmission tunnel and gear shifter surround plastics, but not much). Just got to hook it up to the brake lines now

http://s11.postimg.org/gjd4vqcxv/20160110_101958.jpg

It was a tight fit but its pretty much perfect, just in the right place and just a few mm from catching on the seat or the centre console etc. As you can see though, we did have to cut a little notch out of the gear stick surround but its only on the lower half so its not very noticeable

http://s11.postimg.org/wgbwsg5c3/20160110_102011.jpg

Who's building your engine Chris?

Great to see another UK build. Very few here doing this kind of work.
What cams and valve springs did you choose?
Have you fixed the problems in the cylinder head?
Did you bore it out and hone with torque plate to fix the twist in the stock bores?
Doesn't look like the bottom end parts have been balanced as I see no machining anywhere, why is this so?
Hope the engine builder is good, i've seen some real horror stories.
Please keep the updates coming :)

I looked at quite a few build threads on here and asked a few questions about what would need doing on the engine (and spoke to 2 separate engine builders who have both done GT86 builds before) - never heard of any of those issues you've mentioned... Care to elaborate on what these problems are?

I knew a guy who was a development engineer on the Audi R8 and RS engines and then worked at a tuning company building engines for British Superbikes and various high power cars. He's now starting his own company and he's doing this engine for me for a pretty good price while he's still getting everything set up for the new business. So far he's been really helpful, seems to know his stuff, and like I said its a decent price. Obviously the proof will be in the pudding, will see if we have any problems once it is back in the car, but so far so good.

This is why i said i hope it is someone good as plenty of "engine builders" miss loads of the flaws in production engines. The bores aren't prefectly straight with the heads bolted on, the cylinder heads have a couple of major flaws, there are plenty of other little flaws too.

I know who that is as he worked for me for a while. He is not and never has been any kind of engine designer. I'll drop you a pm with my number. Just hope you don't end of with the kind of problems he left me with!

I should have said development engineer not design engineer, my bad. He seems to know his stuff... but what you say is quite worrying

No problem. I hope it works out well for you and if you do have any issues then don't hesitate to give me a call.

I gotta hand it to you @ChrisD. I saw this title, then read the first post and thought, oh great another "build thread" that is more of a dream list. But you man, are doin it. Way to go! building, tracking, wrecking, fixing and building. nice work!

Thanks :) and yeah I hate it when people have all these unrealistic plans, but once I've got an idea I tend to end up doing it lol which doesn't always work out too well... but having a lot of fun with this car so far :)

Hey Chris,


How do you intend to plumb the handbrake in? The 86 has a diagonally split system which uses the brakes to effectively give you all your driver aids. To use the single rear line and retain all the ABS/TC functionality you'll need to add a second pair of calipers.
If you're removing the ABS, then just ignore me and I'll go away..

Did you order uprated pins for the CP's? Good discussion about them here. http://www.ft86club.com/forums/showt...t=84897&page=5

Yeah we hit this stumbling block the other day... its a pain trying to keep ABS, keep stock cable hand brake, and have hydro hand brake too. The problem with mounting extra callipers is that all of the solutions I've seen for this require you to remove the cable drum brake that is used for the stock handbrake. Currently trying to find out exactly why some of them need the drum brake removing and hopefully we can find a workaround then.

Could you use a pair of VW additional calipers as these have the cable actuated on the caliper. So, you'll leave the stock caliper/abs alone and add a mech handbrake and hydraulic handbrake to the additional VW calipers??

Funnily enough that's actually what my friend just suggested as he's got rid of the drums on his VW and replaced with just one calliper that does both normal brake line and cable operated for hand brake too. We'd still have to get some kind of custom mounting bracket made for it, but its looking like the best solution so far.

http://s12.postimg.org/qe3ti7a4t/Engine_Out1.jpg

Had a few minor issues getting the engine back in, ended up putting the exhaust manifold & turbo on and taking them off again 3 times... buts its almost there now. Just got to stick the air intake back on to the turbo and route a few hoses to the catch can, then we can fire her up and see what leaks..

Looking forward to reading your reports once you get it up and running on big boost. Do you wanna buy my brand new AVO stage 4 kit Chris??


I've had these engines in and out now a few times and have always found it best to remove the manifold if coming out from the top. Keep the engine on the hoist, hanging loosely a few mm off the mounts, then you can work all the studs of the manifold/heads/overpipe together.


Still, probably too late to give you this advice now!!

This thread has gone very quiet.. what's the latest Chris??

Spent the last couple of days putting everything back in place and then went to start it up today and found the immobiliser has kicked in cos the battery was disconnected for a few weeks while the engine was out. Ugh. Guess I'm gonna have to get it towed to Toyota

Um Chris, before you take it to Toyota, double check all your connections.


My road car had no battery or engine in it for over 8 months. In the meantime I reconnected a battery and played around with the wiring and fitted a new interior into it.


Once I refitted the engine it started with no issues. I don't think you have an immobiliser issue?


Does the starter button allow you to cycle through the three steps? Acc on - Ignition on - all off?

Just had a look at the 2 ground connections that go to the chassis and they're definitely both connected and look fine.

It is behaving differently today though...

Last night when we first connected the battery back to it the green key light would flash, the red padlock light would flash, the screen in the centre console would come on, but the car would not lock or unlock.

Today, after changing absolutely nothing, the car will lock and unlock (but when you lock it it just beeps repeatedly and doesn't stop), no green key light, still get red padlock light, screen in entertainment system won't come on at all. Pressing start/stop button with or without clutch depressed still does absolutely nothing.

I've put a charger on the battery and will leave it overnight and then try again in the morning.

Chris I've no idea what I'm talking about here but would your problem be anything to do with the glove box key pad, just an idea.