Just another corolla - DIY Caterham frame 7age and ´93 Liftback RWD

Continue....

Time for welding


It´s been a drag, welding upside down Is not my favorite thing but It
was fairly easy because the body is in really good shape, had no trouble


Sorry for lame ass pictures, taken on my Nokia phone
The nut in place and ready to be tack welded


Drivers side tacked in place


Passenger side tacked in place


Welded, sanded down all the ruff spots and painted



Drivetrain bolted in place and everything painted that showed bare metal


Then came the hard part, connecting fuel filler pipe back in and the
new fuel rubber hoses damn that was a bust, took me two hours to
get them in there and they where snug fitted with style..


So couple of small things left to do in the rear be for I can start to tackle the front

Tackle the brakes, pipes and hoses, put in the shocks, find one longer strap
to strap the fuel tank in place only one of them fitted, connect the fuel tank
with the existed fuel lines (only one hose needs to be fabed with new fitting)
then connect the fuel tank to the gauge cluster....

Looking forward to next week  

More at the rear.....


Desited to tackle the brakes and shocks last night


That brake hose had a nasty scar in it


As you can see the brake pipe broke off because of rust


Brake pipe is out now making new ones


New in both sides


The shocks inserted


Tiers are on both sides


And down it goes, just test fitting


So I actually kept the 1" aluminum shock lift up kit to see how it sits
and to compare it to the front later when Im done with the engine swap


Checking the alignment of the axle this is actually not that bad
compare to my old G6 4wd the axles pointed up instead of down   


Now theres the fuel tank strap and fuel line to jump on next time...

Cant wait to begin on the engine swap thats going to be fun  

looking good man

Thanks for the comment bud   


I cant stop thinking how it will be driving this car as an Rwd so I went
out to day and moved the corolla so I could start on the front


Jacked It up and removed the bonnet, wheels, shocks and axles



Decided to switch the springs now instead of later



All done


Then started getting the engine and gearbox out



There is a storm tomorrow so I don´t think I can do much then, gonna be
with the kids and watch some movies together in our pajamas  

The day after tomorrow Im going to have the fuel line rebuild for me with
the right end to fit the fuel tank and find another strap to hold the tank in place

hope you guys like what you see?!   

did this have a 4efe in it?
shocks look good, but will they be able to handle the weight of the v6 + gearbox?

wish i could attempt a 4wd corolla swap, oh well maybe one day i will

miib14 wrote:

did this have a 4efe in it?
shocks look good, but will they be able to handle the weight of the v6 + gearbox?

wish i could attempt a 4wd corolla swap, oh well maybe one day i will

Thanks for the comment,

Yes it had the 4efe in it. My old G6 4wd had same suspension
in front for 6years never had any problems with it..

Im not doing the v6 because the gearbox does not fit the block.
Im doing 3sfe instead and if that does not go well I have 4age
on standby with 4afe engine block for the 4wd gearbox.

On with the build   

I bought fitting for the fuel line to connect the 4wd tank to existing fuel lines


Then finished removing the 4efe engine


And into the corner it went


Cleaned the floor a little bit and moved stuff away


Stood in front of the car for about 30min just thinking
over what needs to be done be for this and that


Then sanded and painted the shocks tops



Then was about to bolt them in and noticed more rust


So I sanded and painted that also


Then started on the 3sfe engine, just thinking what I need to buy for it
and what needs to be done to it so I can run it safely with or without Turbo


Got the Garrett turbine from the shelf and turned the oil and water passage


Took me a good 15min to get the ring in again


Turbine assembled  and fitted with GT4 top mount intercooler


   <- Do the Monkey dance

 

   the monkey dance...

great work though.. bit disappointed you're not doing a v6 swap now   

miib14 wrote:

 

   the monkey dance...

great work though.. bit disappointed you're not doing a v6 swap now   

Yea, I was so hoping It would fit together..

The reason I have not gone out to buy a 3vz to use instead of
the 1mz is that this build is low budget, so far I have not laid
out single penny for anything even the corolla it self..

I had stuff to sell that I got for free or in trades or with another
corolla that I have long sold and I got the money from there,
even sold the rear suspension and stock fuel tank out of the ae111
and that paid for the whole car   

The rwd drivetrain and fuel tank I got for trades for 15" Camry rims I had

I have been trying to sell couple of my 4age engines to buy 3vz from
a Camry because I want to do the v6 swap if not now then later when
the 3sfe explodes into bits from the Turbo   

I read through the thread fast, which diff and gearbox are you using?

I would like to buy a Ae101 wagoon, stock 4wd. Do you know anything about the strengt of the system?

Skorp wrote:

I read through the thread fast, which diff and gearbox are you using?

I would like to buy a Ae101 wagoon, stock 4wd. Do you know anything about the strengt of the system?

Hi

With the 3sfe 2000cc engine im using stock Rav4 gearbox E250
With the 4afe engine block with 4age head and guts im using corolla
Carib or Touring witch is AE95 AE101 wagon 4wd gearbox E57

The over all gears and differentials in both of those gearbox is Identical
I can use all of the gears in the Rav4 and put them into the E57 and
vise versa.

E57 Carib or Touring gearbox fit all A type engine blocks 3a,4a,5a,7a
E250 Rav4 gearbox fit 3sfe, 3vz, and couple more of the v6 blocks but
taken to consideration if the back of the block as clearance for the center
diff of the gearbox.

The strength of both of those gearboxes I can say is fairly good
Ive had couple of Carib Touring cars witch I made Rwd and just
trashed them but nothing ever broke. I also had my G6 4wd
ae111 with Silvertop engine and then Blacktop engine 20valves
with the same gearbox and drivetrain, one day I lunched it from
start every single time I had to stop at red light for maybe 10hours
I was cruizing the city with the car filled with people, then made it
Rwd and then 4wd again and was just trying to brake something
to see how good it was, in the end I got fed up trashing it and
started driving normal every where i went   

I also had the E250 gearbox in my Shit box Camry 1988 with 3sfe 2.0L
I made that Rwd and I really tried to brake it, I was going to use that
gearbox with the 1mz in the first place but I got such good offer on the
car that I sold it then got it back year later then sold it again for alot of
monney then bought it back again and sold it again for alot of monney
and Ive been offered to buy it again for nothing and im consitering It    
But now its dying out of rust, it does not pass smog anymore and has
to bee broke? brakeing? I dont know the right word, part it out?

If you have any more questions just ask...

Thanks for the good answer.

So would you say a RWD conversion is reliable for everyday use?
Weld center diff and drive without axles front?

On the stock AE101 is all differentials open, or are there a possibility to lock the Centre?

Skorp wrote:

Thanks for the good answer.

So would you say a RWD conversion is reliable for everyday use?
Weld center diff and drive without axles front?

On the stock AE101 is all differentials open, or are there a possibility to lock the Centre?

I don´t know how it comes from the dealers in your country, but in hours
the gearbox in the Carib/Touring, Rav4, Camry 1988-1989 4wd all come with
center differential lockers, but if your corollas don´t come with that lockers
you will have to weld the center diff and pull the front axles out to make it Rwd.

The only thing I had to do with my cars was to pull the front axles out but leave
the hubs in place and then I was Rwd, but I made little modification to the vacum
diff locker unit, I made it lock so it was allways locked, if you have it like stock
It will only lock the center when the engine is on.

I would say it is fairly easy to drive it in rwd conversion, I had two of my Carib/Touring for a year both of them Rwd and also the Camry i had was
Rwd for more then two years never had any issue with it.

If you stick around and watch my thread I will make my corolla Rwd and weld
the rear diff and play with it this summer so you can keep up with me how
well it goes and then you could do the same if you are satisfied   

It has been known in Australia that a AE95 Carib with 4a-gze engine making
300whp and was 4wd, he had broken one gearbox then swapped the gears
from C56 supercharged gearbox from MR2 with limited slip differential, If the
guy who told me about this is on this forum and sees this pleace comment   
It was back in 2008-9 and he told me about rwd ae101 camouflage with rotary
engine witch was mad!

Im trying to find the pictures of them both if I do I´ll post them here!

Hit the beat!!

Removed the subframe


Messured the 4wd subframe to the Fwd one for any differences


Started the gearbox teardown


E57 ae95 ae101 left, Rav4 right only difference is those 4 bolt holes for a rubber mount


Removed the center diff locker hub from the E57




And compaired it to the rav4, everything identical exept those
peaces that are broken off and are nowhere to be found


Decited to use the E57 cender diff complete if the bids that broke off the
E250 diff locker are somewhere in the center diff and will show up later!


Then on to the speedo swapp


My ae111 has cable driven speedo, and the speedo in the E57 is cable driven but was broken


This is making speedy progress now, or I hope!

I will follow your thread!
The only reason i really would like RWD on a Rolla is to do some rain and snow skids.

I've been looking for RAV4 mk1's aswell, is the suspension parts and everything the same as from a Corolla?
They are cheaper here than the Corollas, maybe a lowered Rav4 would be "cool"

Skorp wrote:

I will follow your thread!
The only reason i really would like RWD on a Rolla is to do some rain and snow skids.

I've been looking for RAV4 mk1's aswell, is the suspension parts and everything the same as from a Corolla?
They are cheaper here than the Corollas, maybe a lowered Rav4 would be "cool"

Thanks..

No the rear suspension in the Rav4 is not McPherson, the front is similar.

Lowered Rav4 would be cool   


I knew it, I shoulden have sayd "This is making speedy progress now, or I
hope!" because I´ve been super busy lately and been sick for three days
and my daughter got sick for another two days...

But finally I went out yesterday

Remember this?, new timing belt and cam seal


These are his bigger brothers, front and rear main seal for the crankshaft


Really oiled up timing belt and stuff


All cleaned up, changed all the seals and put the new timing belt on


In the progress of cleaning the engine I looked really carefully over every
part of the engine inside the valve chamber and exhaust and inside the
valve cover, and It got me thinking I want to destroy this engine and start
a new build up one   

This engine had so much oil burned up inside it I just dont want to
spend more monney at it, going to find replacement for it   


So I started thinking for the fun stuff, 14mm bung bolt and nut


Drilled a hole in the oilpan for the oil return line from Turbo



Welded


Testfit



Then cleaned it



Then two codes of primer, one sand and one zink


Then decided to try get the burned up oil gunk out of the head
so I had to move my Bio diesel machine to the Toyota garage along
with the e57 gearbox and the rav4 hubs


Then pushed the 3sfe out and started scraping the gunk off
going to try out burning hot water tomorrow



Its not even driven that much, 250þkm, but the gunk is way to much for my taste
This is what happens when you dont change the oil every 5-7000km


Then started on the cooling for the gearbox, this
is the cooling pipe that came on the E57 gearbox


This is the E250, it hat a small cooling radiator
behind the front bumper that I had cut away



I was thinking about using this one for much better cooling
since this is going to be really revving it´s ass off ones it´s rwd   


OK. this is not going to be a speedy progress from now on!
(just saying so I wont jinx it, 7.9.13, knock on wood)



Im having trouble finding another speedo sensor for cable driven gauge
Im having trouble finding the clutch that was on the 3sfe engine, I got so
many that look the same hahaha...
I found a 3000cc camry 188hp 1993 that has a faulty transmission and Im
trying to buy it or trade the guy the Ford Transit Van I picked up three weeks
ago, will know to morrow how that goes   

What more?..... I got swag!

the sump... is that a dent or is it like that from factory?
are you going to baffle the sump?

that is alot of gunk lol, good luck cleaning it out

slowly but surely.. like the turtle not the hare

miib14 wrote:

the sump... is that a dent or is it like that from factory?
are you going to baffle the sump?

that is alot of gunk lol, good luck cleaning it out

slowly but surely.. like the turtle not the hare

The sump had much more dent to it, this is after I baffled it like a mad man
trying to get it back to normal, exactly ,where something hit the sump
and made that dent, there is a giant metal plate inside it to stiffen it up
from factory and there is no more way for me to baffle on that anymore
than it is right now but its good enough, there is plenty of room for the
oil suck up system...

Im 28years old today.. Man Im old, and still doing this shit    fun fun fun

Happy birthday!

Happy birthday

Sorry I missed the day but Happy Birthday Brotha

Aww thanks you guys, your are so sweet...


There has not much been going on in the project, the school
is officially closed because the teachers decided to go on a strike
and now all the highschools are closed and probably will be for
the next couple of weeks so this semester just went out the
window for me because there will be no tests!!!

Ive been out there trying to find a job instead with no luck!

So I started fixing cars for others until I find a steady job
and had one to fix, automatic 1600 4afe and the auto was
not doing its job right...



I had to put me in one of the pictures for the owner  to show him I was working not playing  


Then he came to help out despite his back was killing him, TRD boys!


Then I finished that job and went home and found out that the Rav4
left engine mount fits with little modification and I just started laughing
for no reason so now there´s only one engine mount I need to fab!


Thats it for now, still trying to find parts for the 3sfe engine and still searching
for the cable driven speedo...

iv got the rav4 mount on my 3s swap.. its bolt on..

Take some good pictures when you are finished fabricating the last mount! This is interessting

I'm watchinng this with a big interest also

Thanks for the comment

Yes I will take pictures of everything I need to change in the corolla...

I woke up yesterday and got it into my head that this was taking to much time to finish
so I shuffle foot into my mouth and out I went to try do as much as I could   

I grinded the motor mount braket that bolts to the engine block just to not scratch the corolla


then changed the injectors for the lime green supra injectors



Also found a MR2 turbo map sensor and my oil feed line with a T for the oil pressure sending unit


Supra injectors in place


Put the intake back on


Then finally found this little bugger after about an hour searching for it


Its the one that bolts the gearbox to the back of the engine block


Then off to swap the power steering hoses



Decided to keep the stock fluid container


Engine up


Rear crank seal replaced


Then cleaning


Sump as new and bolted back on


Cleaned the clutch


Measured the clutch thickness (enough for summer)


All on



Gearbox ready


Gearbox on


All bolts in


Ready to go into the engine bay


Got my ae101 blue hatch friend to help me out getting it in, we lifted the body up


And rolled the engine under


And its IN!


He borrowed the engine hoist, he had just bought 4wd corolla swap
engine, gearbox and the drivetrain.. no plan for it yet..


This is the clearance, I have about 1cm, I think I need to fab both front and rear
engine mounts to have it fit 100%, "Miib 14" what did you use in yours?


Behind the intake on the power steering pump side and beside it
(rubber hose there gone now so its a little bit more room now)


Rear gearbox mount lifted up about 3cm to make more room for intake


Here is front gearbox mount and what needs to be done



Left engine mount


Right gearbox mount


Without the strap there to hold it in place the intake rubbe´s in to the firewall


Turbo back on



Then today I got an offer that I was
waiting for but the day started like this


So I swapped 31" under instead


Went to pick up my friend


And went on a road trip haulin the Ford Transit behind me



Got to the place out side of town, a Farm....


Got unhooked



And hooked the a bar to my new corolla








The offer was these two corollas saloon ae101 1300cc manual for
the Transit and a box of beer   









I only had time to pick up the green corolla now, will pick up the gray one later


Driving over a bridge in Selfoss


Glacier water


Wilderness, here´s where I go motorbiking sometimes in the summer


And here we are at my Toyota garage



With those two saloons I was thinking about renting them out,
just to start with a small renting business and see where it will lead me..

Hope you guys enjoy