Pitman 188 Report post Posted February 10, 2015 Leading on from my thread here: http://www.gt86.org.uk/forums/topic/2091-plan-for-tss-2015/ there has been some progress, so thought I would start a build thread After a couple of months searching for the right base car, I finally found it at a relatively local Kia dealership A red, totally rust free, 3 door, non sunroof Mk1 Yaris It has only done 124 000 miles (so just run in) and it drives brilliantly. This engine (all 65bhp of it ) doesn't quite cut it for a Sprint car, so it is being replaced. I have bought a low mileage Yaris T Sport 1.5l 1NZ FE engine and gearbox which is currently being turned into a full blown race engine. I completely stripped down the engine, and after an overnight soak in Dichlorometane to remove all the oil and combustion crud, the head, cam cover, block and lower casting have been sent away for vapour blasting, to make them look like new. The engine spec will be: CP forged 9:1 pistons Brian Crowler forged rods with ARP fasteners ARP head, main bearing and flywheel studs / bolts JUN stage 2 cams Brian Crowler valve springs with titanium retainers Garrett GT2560R turbo Custom inlet manifold / plenum with a 1ZZ throttle body Custom exhaust manifold (equal length runners, not log type) Standard (new) valves, with the head lightly ported and polished Stand alone ECU. Whilst I would love to get a Motec, they are stupidly expensive, so my current thinking is to go with the DTA S60 (I just hope that Adrian can map it ) The aim is a safe, reliable 250whp, which, in a car with a target weight of under 750kg, should be fun to drive Suspension wise, I have bought (at a very good price I could not refuse) a 6 month old set of D2 coilovers. I know that D2s get very mixed bag reviews, but at the price I paid, I thought they would be worth a try. I have just finished cleaning and making look like new a T Sport front cross member and front ARB, and have also managed to get hold of a Whiteline rear ARB (which are now like the proverbial rocking horse poo! I have also bought a T sport rear axle assy, complete with the disc brakes, so when it arrives, I will be refurbishing it, fitting poly bushes, and then swapping it with the drum brake rear axle currently on the red monster. I am also making fully adjustable front lower suspension arms, so that the caster and camber can be optimised. The D2s come with adjustable top pillar ball mounts at the front, so there will be plenty of adjustment to play with. I have a new manual steering rack (don't want the weight and power robbing of a hydraulic power steering system). If, when the car is finished the steering is too heavy, I will fit an electric power steering unit. The interior will be totally stripped, and a roll cage fitted. I have got a 1 piece phase 2 front bumper to replace the current 2 piece one, as well as T Sport side skirts and a genuine TTE tailgate spoiler. As can be seen, it is going to be a lot of work to get the car built, so my current hope is to get it finished at least in time for the Croft round of the 2015 TSS, and then do the whole series next year. 4 Keethos, Kirsty80, Tweedbean and 1 other reacted to this Share this post Link to post Share on other sites
rob275 1817 Report post Posted February 10, 2015 Interesting! Can't wait to see this when it's done. I'll have to be at it's first event to see what i'm up against. 1 Pitman reacted to this Share this post Link to post Share on other sites
Riceburner 284 Report post Posted February 10, 2015 Nice one Dave,you would have to go turbo 1 Pitman reacted to this Share this post Link to post Share on other sites
Lauren 2259 Report post Posted February 10, 2015 Think you might need an LSD! In your position I would have gone with a MK3 MR2, put a cage in it, then you could put on a turbo, much cheaper, much faster and way better handling. Good luck with it though. 2 Pitman and Tareim reacted to this Share this post Link to post Share on other sites
Pitman 188 Report post Posted February 10, 2015 Thank you for the support, Guys and Gal I forgot the drivetrain spec, Lauren - Fidanza aluminium flywheel, Helex cerametallic 4 paddle clutch and uprated cover. T Sport gearbox with TRD LSD. I did look long and hard at the option of the MR2, but for what I want, the Yaris ticks more boxes Richard, after experiencing the boost of my 86, there is no option but turbo . I am busy putting together a bit of a shopping list for standard Toyota parts - I assume that RRG can also supply stuff for a Yaris? Share this post Link to post Share on other sites
Riceburner 284 Report post Posted February 10, 2015 Thank you for the support, Guys and Gal I forgot the drivetrain spec, Lauren - Fidanza aluminium flywheel, Helex cerametallic 4 paddle clutch and uprated cover. T Sport gearbox with TRD LSD. I did look long and hard at the option of the MR2, but for what I want, the Yaris ticks more boxes Richard, after experiencing the boost of my 86, there is no option but turbo . I am busy putting together a bit of a shopping list for standard Toyota parts - I assume that RRG can also supply stuff for a Yaris? No problem Dave send me the list when ready,and it will all be sorted as usual Share this post Link to post Share on other sites
Tareim 343 Report post Posted February 10, 2015 this will be an interesting project, looking forward to the updates Share this post Link to post Share on other sites
Mike 458 Report post Posted February 10, 2015 Looking good Dave, is this for this year or next? Share this post Link to post Share on other sites
Pitman 188 Report post Posted February 10, 2015 Mike, I won't get it finished in time for the full 2015 season, although I hope to be able to get it finished to do at least a few rounds this year, in preparation for a full go next year. 1 Mike reacted to this Share this post Link to post Share on other sites
Guest Report post Posted February 10, 2015 Glad you've announced your project Dave. No more having to watch what I say as you were wanting to keep things quiet..I think this will be a great little bundle of fun to drive and will certainly be a one off out there. Tell you what people, I've sat in this monster and that 65hp is just too much for me, it positively shakes the ground!!As for cages, have you checked out the OMP cage on Demon Tweeks, around £750?? Share this post Link to post Share on other sites
Pitman 188 Report post Posted February 10, 2015 Cheers, Nige It might only be 64bhp now (I have just checked, and found that I overstated the power output earlier by approximately 1.5% ) but wait until the 'new' engine is built and fitted . As you say, you are the privileged one to be the first forum member who has sat in the car with the engine running As far as I know, the OMP roll cage has got doglegs at the front to miss the dash (a total no-no, as we discussed on Saturday), plus that are made to order, with a fairly long lead-time (from memory, it was 6 weeks minimum when I inquired the end of last year).. I need to have a chat with Adrian @ Fensport about Cusco roll cages, to see if they have anything that meets my requirements. Share this post Link to post Share on other sites
Jamie_GRMN 177 Report post Posted February 10, 2015 Going to be an epic little beast this Dave, can't wait to see it at the TSS 1 Pitman reacted to this Share this post Link to post Share on other sites
LFA 68 Report post Posted February 10, 2015 Love it 1 Pitman reacted to this Share this post Link to post Share on other sites
Guest Report post Posted February 10, 2015 As far as I know, the OMP roll cage has got doglegs at the front to miss the dash (a total no-no, as we discussed on Saturday), plus that are made to order, with a fairly long lead-time (from memory, it was 6 weeks minimum when I inquired the end of last year).. I need to have a chat with Adrian @ Fensport about Cusco roll cages, to see if they have anything that meets my requirements.The OMP cage drops vertically down from the A post through the Dash Dave. It is a good looking cage and is very reasonably priced from DT, which is unusual!! Share this post Link to post Share on other sites
Pitman 188 Report post Posted February 10, 2015 The OMP cage drops vertically down from the A post through the Dash Dave. It is a good looking cage and is very reasonably priced from DT, which is unusual!! Need to look into it a bit more, then. I have found the right Cusco one - 7 point bolt in, CrMo steel, also through the dash. They are £415.50 from RHD Japan, the killer though, is the shipping, about £350! I need to give Fensport a ring. So it looks like it will be either OMP or Cusco then for the cage http://www.rhdjapan.com/cusco-d1-roll-bar-7-point-2-seats-through-dash-toyota.html Share this post Link to post Share on other sites
Quball 60 Report post Posted February 10, 2015 This look's like it could be a rather intresting thread Share this post Link to post Share on other sites
Pitman 188 Report post Posted February 12, 2015 Not nearly as glamorous as the pictures that Nige has been posting, but.......... 1NZ FE engine head, block, sump and cam cover all cleaned and ready for some machine work prior the the race engine assembly One nice clean T Sport gearbox ready to be taken to Fensport for a LSD to be fitted There are two parts of the 1N ZE that limit the amount of boost they will take, the 10.5:1 compression ratio (no direct injection like the GT86), and the ultra light weight powder forged con rods. Here is a comparison between the Brian Crowler rods and standard I will post some pictures of the forged 9:1 CP pistons when they arrive from the good old USA 1 Keethos reacted to this Share this post Link to post Share on other sites
Riceburner 284 Report post Posted February 12, 2015 Wow,looks great Dave,will you need a second driver for testing etc? 1 Pitman reacted to this Share this post Link to post Share on other sites
Pitman 188 Report post Posted February 12, 2015 Most definitely, Rich! Are you offering your services? Share this post Link to post Share on other sites
Riceburner 284 Report post Posted February 12, 2015 Most definitely, Rich! Are you offering your services? Certainly Dave if we can help in anyway give me a shout Share this post Link to post Share on other sites
Mark-in-Stoke 488 Report post Posted February 12, 2015 Well if the dark destroyer is anything to go by, this should be quite a beast. Regular updates please Dave, as Nigel has been a slightly irregular recently (blaming the cold) 1 Pitman reacted to this Share this post Link to post Share on other sites
Pitman 188 Report post Posted February 12, 2015 Here you are Mark, some more engine porn Brian Crowler valves and springs, complete with Titanium retainers. Should help me achieve my 8,000 rpm goals 2 Mark-in-Stoke and Keethos reacted to this Share this post Link to post Share on other sites
Neil_turbo 44 Report post Posted February 12, 2015 Seems like quite a major build Dave! Wonder if you will manage to stick to no Motec plans though!! Share this post Link to post Share on other sites
Pitman 188 Report post Posted February 12, 2015 Neil, at well over £2000 for a Motec that a £900 DTA can do (as far as what my humble Yaris will require anyway), I think the chances are pretty good. A key point will however, be if Adrian Smith will be prepared to map a DTA ecu. There is no one else I trust to map my car(s) for me. Share this post Link to post Share on other sites
Special K 442 Report post Posted February 13, 2015 Awesome, my friend.... ... really glad it's coming together... can I be second in line after Riceburner for a guest drive..? Spec K Share this post Link to post Share on other sites
