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Conrad_Turbo
05-15-2006, 09:07 PM
Been getting a few emails and PM's on the status of the Starlet, so I did a little writeup. :D

Well the Starlet won’t be ready for the June 6th autox event like I was hoping…the machine shop is taking far longer than I expected. I’ll also be gone for 2 weeks at the end of this month (passing through Montana/Wyoming/Colorado/New Mexico), so I won’t get my engine bits back until probably June 5th…so I am now aiming for June 18th to have the car ready.

Things I am working on:

- Transmission is 95% assembled; I should be getting it done tonight.
- Every part has been ordered to get the car up and running…the only thing missing is connecting rod bearings (should arrive in the next day or two).
- Flanges just got cut last week for the new tubular manifold as well as a new downpipe flange. I also bought all the 1-1/4” weld els at a local metal shop had in stock (they are WAY cheaper than McMaster & Carr…about 4 x cheaper). Haha. The runners are sooooooo tiny!!! Just glad I have spare block and head so I can mock things up and build a manifold while the machine shop is working on the actual block and head.
- Cleaning up bits of the engine, shaving un-needed mounts on the valve cover, removing engine pull hooks and whatnot. Basically I’m just trying to make the engine look very clean.
- The car might be the first 4k Starlet motor to have wasted spark ignition (ie. no distributor cap and fully programmable timing). The crank trigger wheel, VR sensor and coil pack were taken off a few cars out at a local wrecking yard 2 weekends ago. The spark control will be done with a MegaSquirt system (should arrive in the next day or two), in terms of ignition it has a programmable 12x12 table for rpm vs MAP pressure, so I’ll have no more distributor and full control of my timing. It also has features for launch control, adjustable rev limiter and flat shifting as well. It’s going to be so sweet! Then maybe next winter (after looking at the rules very carefully) I might fuel inject the engine and the MegaSquirt will control the EFI as well. :D

Here are some random photos I have taken around the shop in the past few weeks.

The motor when it came out of the car. (http://www.aceengineering.ca/Temp/214_1485.jpg)
Fresh Toyota gaskets for both the engine and transmission (http://www.aceengineering.ca/Temp/215_1533.jpg)
Brand new Toyota synchros’. (http://www.aceengineering.ca/Temp/215_1529.jpg)
The coil, crank trigger wheel and VR sensor (still have to be cleaned up). (http://www.aceengineering.ca/Temp/215_1584.jpg)
Flanges with a ton (although I think I might need more!) of weld els and pipe. (http://www.aceengineering.ca/Temp/215_1579.jpg)
Cool transmission bits (before final assembly) photo (http://www.aceengineering.ca/Temp/215_1570.jpg)
Yet another. (http://www.aceengineering.ca/Temp/215_1573.jpg)

Man I can’t wait to fire up the car and begin breaking in the motor! The only major flaw to the car this year is the rear end…crappy trailing arm “bushings” and no LSD is the only things that will be hindering the car (next to myself!). The car is going to be stupid fast though!!! :D

hobbie2k
05-16-2006, 12:28 AM
yes, it is gonna be stupid fast. Gonna knock heads with a few Minis, then?

Colossus20v
05-16-2006, 06:02 AM
I really love your project Conrad. Keep us posted.

Colossus20v
05-16-2006, 06:05 AM
Im considering to go with a megasquirt unit on my 7age 20v if the stock ecu has issues. We'll see.

Conrad_Turbo
05-16-2006, 03:48 PM
yes, it is gonna be stupid fast. Gonna knock heads with a few Minis, then?

Yup they’re in the same class as me…I raced against a pair of them in Red Deer, Alberta 2 years ago…Chris Dittrick was there. I was 0.3sec back in the dry from one of the Mini’s…then it rained the 2nd day and I got absolutely destroyed by about 6 seconds. Lol. I was running Kumho V710’s which are absolutely horrible in the rain, and the mini had some 12” Advan A00R’s. The car is going to be much quicker than then and much more reliable too.

Well the transmission is done being assembled and it’s stored in a few clean garbage bags until I get the motor completed. Now I have begun to plan out the new tubular manifold. :D

3sgte@daspeedof
05-16-2006, 09:23 PM
sweet build keep us updated

undecided
05-16-2006, 09:35 PM
how fast are we talkin :D

Toyota_Todd
05-17-2006, 01:42 AM
I'm glad the parts are working out for your Conrad. :bigthumbu This looks like a serious build up thats for sure. After you get done with the Super Starlet project, is the All-Trac the next one getting an extreme makeover?

You got skills boy, that is for sure....wish you lived closer to me :squint:

Conrad_Turbo
05-17-2006, 02:18 AM
I'm glad the parts are working out for your Conrad. :bigthumbu This looks like a serious build up thats for sure. After you get done with the Super Starlet project, is the All-Trac the next one getting an extreme makeover?

You got skills boy, that is for sure....wish you lived closer to me :squint:

Haha no the Celi is just a tow bitch/daily driver/"show car" (I won first place at a local car show 2 weeks back in one of many classes).

To be honest if I had another project...it'd either be a scratch built tube frame race car that I'd design...or else a tube framed mini with a 1L bike engine in it that I could daily drive. :D

As for how fast...the Starlet comes stock with 58hp at the crank brand new in 1982, last year with just the turbo on (with tons of issues that I am sorting out this time around) it made around 105hp at the crank. Now I am expecting 130-140 hp as a modest level (I know of a very few that have gone upwards of 170hp on the 4k block)...which isn't bad for a 1600lb car that can turn on a dime. :D

Thanks to Todd for helping me with sorting through tons of part numbers, multiple faxes, phone calls and emails. I truely appreciate it man! :D

Playfortoday
05-17-2006, 03:04 PM
Tood is the man!

Looking good Conrad, but I think the All-trac deserves more attention.:(

Conrad_Turbo
05-17-2006, 05:03 PM
I spent nearly $6k on the 062 Pearl White paint job on the Celi last year…it’s got all the attention it needs for a while! :lol:

Here are two pics of it at the car show (I was entered in with the Saskatoon Sports Car Club). :D

SSCC display (http://www.aceengineering.ca/Temp/stitched.jpg)
View of the rest of the show (http://www.aceengineering.ca/Temp/215_1508.jpg)

Well the MS hasn’t shown up yet…but that’s good because I’m still busy in the garage working on the mechanical bits. Started to plan out the exhaust manifold and things are looking a WEE BIT TIGHT! Considering I plan on building (as close as I can) an equal length tubular manifold.

Here’s a pic: Beginning of mockup (http://www.aceengineering.ca/Temp/216_1604.jpg)

The transmission is also 100% completed, these are some photos I snapped before I fully assembled it. :D

Outside Shot (http://www.aceengineering.ca/Temp/215_1589.jpg)
Inside Shot (http://www.aceengineering.ca/Temp/215_1593.jpg)

I’m slowly getting there!

Playfortoday
05-17-2006, 07:29 PM
I am happy for you, yet sad for the celica. The paint job is a beauty, but it need another 6K in suspense upgrade so it can be raced too.

The tranny looks so purty!

Conrad_Turbo
05-18-2006, 07:31 PM
Well I got home and found out my MS system had arrived. :D

The board is 80% assembled (stopped last night at around 2am) and should have it completed by this evening and lightly mocked up in the car. I’d have the majority of the MS stuff done tonight, but I have some work to get done for ChrisD (make sure you post pics of it when you get it Chris :D)) and another customer. Once that’s done then it’ll be back to the tubular manifold, downpipe and full exhaust. Then I’ll just be waiting on the machine shop to have my entire machine work done so I can fully assemble the engine and begin getting things back into the car.

Jay, its expensive enough modding one car…let alone even attempting to try 2. Haha.

Playfortoday
05-18-2006, 08:24 PM
Hey, Conrad... please don't make parts for ChrisD. He has sold out on his GT-Four. Bike racing and work. His car emails me nightly asking me to steal it away to put it to good use again. :(

Conrad_Turbo
05-19-2006, 04:46 PM
Hey, Conrad... please don't make parts for ChrisD. He has sold out on his GT-Four. Bike racing and work. His car emails me nightly asking me to steal it away to put it to good use again. :(

If it makes ya feel any worse...it includes putting 205 bits on his car. Haha.

ciento44
05-19-2006, 05:03 PM
If it makes ya feel any worse...it includes putting 205 bits on his car. Haha.


So you do smaller fabrication jobs, too? Hrmmm... i may have to send you a proposition in the next few weeks...

Love the Starlets, too.... always kindof wanted one.

Conrad_Turbo
05-19-2006, 10:54 PM
So you do smaller fabrication jobs, too? Hrmmm... i may have to send you a proposition in the next few weeks...

Love the Starlets, too.... always kindof wanted one.

Haha yup I've done everything from drawings on napkins to full CAD drawn components and assemblies. :D

But ya the MS is 99% done, just need to test it out tonight and add one more power transistor for the secondary coil...then it'll be put on hold since I have tons of other commitments tha have came up. No turbo mani, downpipe or exhaust till I get back on June 4th. :eek:

ToyotaSupra
05-20-2006, 11:22 PM
Hey I have a starlet. Silver with black stripes. It's just sitting at home because the fuel pump gave up on me, also tranny grinds 1st and 5th gear.

I have been wanting to fix it up, but my MK3 Supra turbo is where all my paychecks are going into for now. lol.

I'll let it go for a good offer though. :bigthumbu

Located in Portland, OR.

Playfortoday
05-21-2006, 07:04 AM
:ohsnap: Conrad is getting another Starlet! :woot:

Dr.Auto
05-21-2006, 07:51 PM
Conrad

You sound about as busy as I am. The X won't be together this year unfortunately. Ended up buying a 65 triumph spitfire already built for road racing for $150. Just had to do a few things to it becasue it's been stting for awhile. So I'm going to auto-x it this year and try to get paint on the X by fall time.

E-mail me if your headed my way here soon.

Sean
05-22-2006, 03:38 AM
Hey I have a starlet. Silver with black stripes. It's just sitting at home because the fuel pump gave up on me, also tranny grinds 1st and 5th gear.

I have been wanting to fix it up, but my MK3 Supra turbo is where all my paychecks are going into for now. lol.

I'll let it go for a good offer though. :bigthumbu

Located in Portland, OR.


I'm in Portland Oregon

Conrad, make two of every part please :D

Conrad_Turbo
05-23-2006, 07:34 PM
Conrad

You sound about as busy as I am. The X won't be together this year unfortunately. Ended up buying a 65 triumph spitfire already built for road racing for $150. Just had to do a few things to it becasue it's been stting for awhile. So I'm going to auto-x it this year and try to get paint on the X by fall time.

E-mail me if your headed my way here soon.

Bah I've been meaning to get ahold of you! Just too damn busy!!! Just shoot me an email to conradandres at aceengineering dot ca with your addy and tele number, I'm leaving for Billings tomorrow and will be staying the night. So if you're free tomorrow I'll be up for swinging by if it works for my folks.

Bah I have enough with Starlets...I've already got one donor car in the driveway, no need for 2! Besides a lot of OEM parts on the car are useless to me, if all I need for spares...it'd just be a spare transmission and engine. The rest of the car would be useless to me. Haha.

Sean, I'll be sure to post final photos and videos of the car racing this year. The car is going to be insane!

Nemesis3S-GTE
05-26-2006, 03:13 PM
Hmmm, I was unaware that the Starlet weighs half as much as my All-Trac, I could only imagine how much more fun autocrossing would be with that light of a car! I love this project Conrad, make sure to keep us updated on the progress and good luck getting it all put together.

Conrad_Turbo
06-07-2006, 04:32 PM
Hmmm, I was unaware that the Starlet weighs half as much as my All-Trac, I could only imagine how much more fun autocrossing would be with that light of a car! I love this project Conrad, make sure to keep us updated on the progress and good luck getting it all put together.

Ya the Starlet weighs nothing, and it should have 130-140hp this year...so it'll probably out accelerate the Alltrac in the dry. It already outhandles the Alltrac just due to it's sheer lack of weight, fully sorted suspension and sticky tires.

Well I got the engine back from the machine shop yesterday, finally began to do assembly and hopefully I should have the engine fully assembled by Saturday or Sunday. The MS is done and working/communicating with the computer so all is well in that regard. Now I have to:

-assemble the engine
-install rebuilt engine and transmission into the car
-finish rebuilding a spare IHI turbo
-install the MS and direct fire coil packs
-build a bracket for the VR sensor (works with the MS for ignition control)
-finish building the tubular manifold (25% complete)
-redo some of the intake and intercooler plumbing
-redo a lower rad hose (if i have time)

Then break in the engine (tune as well), trans and clutch before July 18th autox event. :eek:

Colossus20v
06-07-2006, 04:50 PM
DId you put your CelicaTech stocker on the Starlet yet?

Conrad_Turbo
06-09-2006, 03:49 PM
Well here are some updates…

Engine is back from the machine shop, everything was done correctly as required and I am very happy with their work. Assembly has begun on the bottom end and the head will be getting assembled in short order. The only thing I have left to do before the head assembly is to CC the combustion chambers, lap and beadblast the valves. Otherwise things are moving smoothly with the assembly process.

One weird thing I did find is I compared the donor (the new race engine) engine to the engine that was previously in the race Starlet…the race Starlet has a single row timing chain while as the donor has a dual row timing chain. Odd considering they’re both made in 1982… At least now I know I am going to a dual row instead of single row chain in the past.

The MS is operational (talking with the computer) and will be getting wired in once the motor and transmission are installed in the car. The crank trigger wheel was fabbed and balanced by the machine shop and now I need to fab a mount for the VR sensor and throttle position sensor. Then it’s just simple wiring after that…that won’t happen for another few days or so. Then the car will have the full benefits of launch control, antilag, flat shifting and full control of the timing in relation to manifold pressure and rpm. :D

The tubular manifold is slowly progressing; it has been slowed down due to my time focused on the assembly of the engine. The manifold is a SUPER tight fit, so it’s hard to make it an equal length manifold…but it’ll be much better than the OEM manifold with J pipe I had in the past. Instead of making it an equal length I am trying to make it so cyl #1 and #3 are as close to as equal and so cyl #2 and #4 are as close to equal length as well. In the end it all comes down to space constraints.

Other than that nothing much is going on in the garage. :lol:

Here are some photos:

Cleaned up flywheel (http://www.aceengineering.ca/Temp/Starlet/217_1732.jpg)
Nicely honed and prepped block (http://www.aceengineering.ca/Temp/Starlet/217_1734.jpg)
Partially assembled bottom end (http://www.aceengineering.ca/Temp/Starlet/217_1747.jpg)
Tubular manifold slowly getting completed (http://www.aceengineering.ca/Temp/Starlet/217_1748.jpg)

As for the stickers they just arrived at my folks place yesterday, can't wait to see em! They'll probably find a home on the Starlet somewhere. :D

ToyotaSupra
06-09-2006, 06:28 PM
Here's my Starlet. :cool:

Got the fuel pump fixed and it runs like a champ! haha. Powersteering would make it more enjoyable to drive though. And no the Ebrake isn't gone. I was changing the differential fluid.

http://myspace-692.vo.llnwd.net/00773/29/69/773129692_l.jpg

http://myspace-278.vo.llnwd.net/00773/87/20/773130278_l.jpg

http://myspace-875.vo.llnwd.net/00773/57/80/773130875_l.jpg

http://myspace-977.vo.llnwd.net/00773/77/99/773179977_l.jpg

Conrad_Turbo
06-12-2006, 03:23 PM
Very nice! Your car has a lot less rust than mine did (before I cut all of it out and welded in fresh metal). Now you’ve just to stiffen it up, lower it and get some wide 3 piece wheels. :D

As for an update…the bottom end is 99% done being assembled, the timing chain cover needs to be installed, along with the water pump and some other quick bolt on items. The head needs some material to be removed since the block and head have been machined a combined 0.020” to ensure they both have perfectly flat surfaces. Now I have to remove some aluminum to drop it back down to the factory CR (9.0:1). Then the head can be installed (valves have already been lapped and valvetrain has been prepped and is ready for installation) and the whole engine and transmission can be installed into the car and topped up with fluids. Then all that is really left is building a bracket for the VR sensor, wiring up the MS, installing the direct fire ignition setup, redoing 1 intercooler and intake pipe and redoing the high pressure oil line to the turbo.

Conrad_Turbo
06-26-2006, 06:46 PM
Woot engine is completed being assembled and is now in the car. :D

Found out the pilot bearing that I received is incorrect, so I have sourced one locally for $6, so all is good. :D Then the clutch, transmission and driveshaft can go in the car. Then it’s just doing plumbing in the engine bay and putting a whole bunch of parts back in the car…along with wiring the MegaSquirt. Things are slowly progressing. :)

Here’s a pic of the engine before it went into the car.

Slowly coming… (http://www.aceengineering.ca/Temp/IMG_1787.jpg)

Colossus20v
06-27-2006, 02:34 AM
damn. Thats a sexy engine shot Conrad. Keep us posted sir.

Conrad_Turbo
06-27-2006, 08:45 PM
Awesome, found out last night that the clutch sent to me is the wrong one... So I am most likely dropping that company (Clutchnet) and buying a clutch from Spec. I had way too many issues with Clutchnet; the clutch not fitting has been the last straw.

Last night the whole front suspension was reassembled and now the car is a rolling chassis again, after 4 months of being immoveable. The VR sensor bracket will be completed tonight along with installing the radiator and wiring of the MegaSquirt. Things are slowly progressing despite some of the setbacks. :D

Conrad_Turbo
08-16-2006, 03:01 PM
Here’s the latest update on the car. Finally got a clutch that fits the car…been a few months, A LOT of phone calls and dealing with two suppliers and then bypassing one to deal with the manufacturer directly. Frustrating…but what’s done is done.

The clutch was installed last night, transmission was installed and driveshaft as well. The MS is 95% installed, just need to tap off the O2 sensor output, coolant temp sensor and tie in the clutch switch and TPS sensor. The car just had the plates renewed so the car is now allowable to drive on the street, just need to get it running now.

The tubular manifold is being built, #1, 2 and 4 exhaust ports are complete, cylinder 3 should be complete tonight. A pic of it from 2 days ago: http://www.aceengineering.ca/Temp/img_2488.jpg Then the manifold will have to be broken apart and TIG welded together and then bolted onto the engine. Then onto the downpipe, exhaust and some minor intercooler piping work. Then some little things (coolant and oil lines to the turbo) and then the car will be topped up with fluids and started up. :D

Have to get the car ready for the big race on September 2nd and 3rd.

Trance4c
09-06-2006, 03:16 PM
Any update on your manifold? Would like to see how it looks all installed under the hood!

MrWOT
09-07-2006, 03:52 AM
And where's my article?! ;)

Conrad_Turbo
09-12-2006, 03:01 PM
Yep I am sure I can snap some photos of the manifold before the intake manifold covers it up (intake/exhaust are on the same side). I was going to get the car ready for a big race (Sept 2nd and 3rd) but the week before I got very sick…long story short it was due to a lack of sleep and I was put on antibiotics, muscle relaxants and pain relievers. Not good… Now that I am feeling well again I have been working on business stuff as well as getting back to the car. The exhaust manifold is done, the downpipe (semi-divorced wastegate) should be completed Thursday or Friday of this week. Then the car will be getting some stainless coolant lines and some oil lines routed to the turbo. The only major thing left is 1 intercooler pipe, then the car will be nearly ready to start. :D

Colossus20v
09-13-2006, 01:39 AM
Do you have any pictures of the celicatech sticker on the Starlet?

Conrad_Turbo
09-13-2006, 06:51 AM
Do you have any pictures of the celicatech sticker on the Starlet?

Haven't had time to decal the car yet! I'm sure when I find time I'll dig up my decals and plaster the car. :D

Here is a quick snapshot of the car up on the hoist with the manifold on:

http://www.aceengineering.ca/Temp/Starlet/Manifold/IMG_2702.jpg

Here is the downpipe that is currently tacked/mocked and should be fully welded by Thurs/Friday this week:

http://www.aceengineering.ca/Temp/Starlet/Manifold/IMG_2697.jpg

Any other manifold would be a simple design...but I always seem to overcomplicate things...but then it usually yields a better result. :D