March 13, 2017 TFRyan

Project Update: K24 AE86 Part 3

Picking back up where we left off with Part 2 of the K24 powered AE86 (If you haven’t been following along with the build, be sure to check out PART 1 and PART 2), in which we prepped the engine to be dropped in the chassis and also installed: full Crystal Body Yokohama aero, Work Meister CR01s, the Techno Toy Tuning brake kit and a few other small bits.

RAL_6872

RAL_6870

Before the engine went in, we installed new solid steering rack bushings for minimal steering play.

RAL_6899

We also removed some metal around the shifter location to make sure the F20C transmission fit up nicely in the Toyota chassis.

RAL_7133

In she goes!

RAL_6991

A custom driveshaft was necessary to mate the GTS AE86 rear end to the S2000 transmission.

RAL_6994

Trimming off some metal on the oil pan to clear the steering rack…

RAL_6993

On both sides of the block.

RAL_6997

A little more trimming!

RAL_7143

Everything is bolted up in its final place!

RAL_7413

JSP Fab K24 into AE86 header installed  on the car.

RAL_7470

Top of the freshly ceramic coated header.

RAL_7519

The Koyorad BEAMS 3SGE –> AE86 radiator, the perfect option for the K24 swap.

RAL_7520

We ran into a small problem once the radiator was installed; the space between the radiator and the intake manifold made fitting the intake piping, MAF, AND filter impossible.

RAL_7521

Too close!

RAL_7532

Our solution was to use a 90 degree elbow we had lying around, weld it onto the throttle body to give us the necessary space. Here the piece is tacked on and we were using the welder to clean off any impurities that might taint the integrity of the final weld.

RAL_9455

All done! Plenty of room now.

RAL_9841

Here’s how it looks with the radiator installed on the car.

RAL_9834

Making radiator brackets from scratch for the new Koyorad!

RAL_9837

Cool and good.

RAL_8213

Brand new fuel sending assembly for this car, we don’t want the owner to have any problems with his fueling.

TFW_8030

Custom driveshaft is done, yay!

 

TFW_7696

Brand new kouki Trueno bumper lights arrived straight from Japan.

RAL_8215

The Stance Suspension true type coilover suspension for the AE86.

RAL_8217

Starting to fabricate the custom exhaust. The JSP Performance header hangs pretty low, so we will be picking up that slack and building the exhaust as high as we can for maximum clearance.

RAL_8270

Fitting up the resonator near where the crossover beneath the driveshaft occurs.

RAL_8362

Tack tack tack!

RAL_8365

Exhaust is coming together. Super JDM photo tilt.

RAL_8375

Making our own hangers to ensure the exhaust sits nice and tight.

RAL_8384

Close up of the exhaust hanger reinforcement plate. Welding a hanger directly to the piping could potentially lead to the hanger ripping off due to impact or scraping over an obstacle, but this will give it a bit more strength.

RAL_9445

Welding on another reinforcement plate.

RAL_9491

Rear section of the exhaust finished up and sitting on the car.

RAL_9492

Hanger!

RAL_8346

If you checked back on Part 2 of the build so far, you would have seen the AutoMeter Spek-Pro gauges that were selected for this build, and here is the start of the custom gauge cluster for the Corolla!

RAL_8361

New faceplate to hold the upgraded gauges in.

RAL_8359

HUGE tachometer and speedometer to read off the high revs of the K24 and how fast this little go kart will be going!

RAL_8378

RIP to the GTS cluster that gave its life that day.

RAL_7385

Custom fuel lines for the car had to be made to accommodate the Honda heart.

RAL_7380

Bend!

RAL_9572

Fitting everything up along the chassis.

RAL_9782

All done!

RAL_9785

One step closer to the car firing up for the first time with its new powertrain.

 

RAL_9547

Right now we are tying up the remaining tasks on the car such as the wiring for the gauge cluster as well a few other things on the K24. There is plenty more to document for Part 4 of the build, check back on the blog for updates on this car as well as all of the other in-house projects going on at TF-Works!

Here’s a sneak peak of the new livery 🙂

RAL_9824

Tagged: , , , , , , , , , , , , ,