muin1331

basically this is her now...been at a new workshop for a month or so now, but hope to get her back soon...installing an adaptronic e420d and ive changed to a td0520g

Ive went with recirculating the wastegate, exhaust piping is still 3 inch, might change it to 2.5

airconditioning condenser in place

car is now at a new workshop called GP Racing, I needed to finally get her done...im pretty limited with what i can do experience wise and with the tools i have. she's in good hands now should be on the dyno within a few weeks, then ill finally see the hp i can squeeze out of her

I will post all the updates i can get when i visit the shop

the misfiring issue wasn't solved so I made time to work on the car at home for the time being. Bought sparkplug cables and a new distributor to try fix the problem...by then the car was yet again puffing smoke and using a ton of oil....couldn't really catch a break

took out the turbo and saw this....

not a good sign at all...barely 30km's on a new turbo

bought a cheap service kit to try and fix it myself

gave me a chance to put these in

found out that the suspension mountings had crumbled and got these off a guy (cusco adjustable pillowballs)

gave them a clean before putting them in

I rebuilt the turbo....fit it in and also sprayed the intercooler and piping matte black haha. I got some info that maybe the cause of the miss could be the knock sensor. I did switch the 4e for the 5e one when doing the conversion so I found that and replaced it. Car started great took her for a spin and job was done! got 0.5 bar no problem but the car never had a tune as I removed the piggyback. was pretty bittersweet as the turbo was smoking on boost but not as bad . was still very chuffed with fast that she was running properly engine wise.

So I think the best thing about living here is how the laws aren't so stricked, you can see car hanging on by a thread with gaping holes of rust still running with registration! Here there is something like an MOT, but unlike the law in UK you only have to go for the inspection when you buy a new or used car. Modification is limitless and can be sorted with some $$$ if you get into trouble haha, but the only issue is where I stay its very hard to find top notch quality work...luckily where my car is now has to be the best garage ive been to!

Anyway, I never wanted to spend the money on a tow lorry and all that had to be done was the downpipe to the turbo, along with some intercooler piping adjustments as i opted for a smaller intercooler. The car ran, but was loud due to no downpipe, neither did i have boost .

With no bumper, loud exhaust and no numberplate I risked the drive! Managed with out any misshaps just a lot of attention for passing cars

On the hoist!

Intercooler position is abit different, slightly more to the side than going for mid mouting, so the piping is more of a shorter route.

Done in a few days, was planning to have the intercooler flipped the other way so the outlets would be on top, but that can be changed in the future

job was done well for the price, then headed out back home this time with everything connected together...still the limp mode issue was still ticked off about that!

fit the bumper back on and gave her a well deserved wash!

A quick view of everything before i sent her to the exhaust shop...i did reposition the wastegate

So with the td05 there was no need for the custom intake, found my original one and modded the flange to fit the evo throttlebody...painted those black too

Fit the turbo in, it has a slight tilt so the downpipe bend isn't so aggressive

So I got Back from NZ and I was all pumped to fix the issue with the car, I had a more clear vision as to what i want my starlet to look like, responsive and can go great round a corner, that hx40 was too big so I swapped it in for a td0g 16g...I would probably have to give thanks to my Dad as he helped me out a lot when doing the turbo change

so the plan was to cut the flange off my manifold and change it to fit the td05, but then i found this cheap manifold for only RM850 (GBP 128)

It made the whole engine look 50hp faster, needed some modification to fit though

Mocked up the location to where the turbo will sit... took the oil filter relocator off aswell!

when in New Zealand I managed to snap a some pics of these

I managed to temporarily repair them, but the misfire issue was still not solved....2 months on and I had no clue, not only that but the problem messed the tuning on the management....I swapped out countless sparkplugs aswelll.

I then was working so I lost time to work on the car....had one crazy idea to swap turbos to try solve the smoke problem...I put in a Holset HX40 which is pretty overrated for a starlet . I did the swap in a few days, because I was going to New Zealand for a few weeks to see the gf....

I used v-bands to connect the turbo housing to the downpipe, It was basically a quick cheap fix to let her run before I left for NZ

Everything bolted on easily, except from the downpipe....it leaked like hell! was out of time and managed to drive her home, problem was still there with the missing, although I managed to narrow down the cause to the car going into limp mode.

Atleast I got some aweome gt turbo stickers for the side, got these in a smaller size with matte black as the colour

small details give so much satisfaction!

it was now around October of last year. With the car mostly done, I was running the KKT piggyback, no airconditioning which was not so good haha. at 1.0bar of boost on the gt30 it was laggy without cams....I loved the force it gave when on boost but unfortunately the turbo was leaking, I then developed a bad miss after 5000rpm's I had no clue what was wrong...so I stripped the car apart changed sparkplugs, and no one around knew what was wrong with the car...It was pretty devastating, smoke coming out and a horrible problem.

None the less I checked all solutions out.....until I checked the sparkplug cables and found this

the end of the connector where the lead plugs into the socket had snapped off! this was merely due to the bad quality of the cables

intercoolerpiping was done and unfortunately Iearned a hard lesson using solid mountings

I think the shortest route help with lessoning turbo lag, moved the batt to the rear, so ill show u when I can get a picture!

forgot to mention...the radiator im using was an aftermarket for a b16...not sure on the dimentions, but fits perfectly

I did put in an oil filter relocator, I had no use of it after awhile so I took it off

I bought some Bride bucket seats from a friend...I did fab up some rails, but im not 100% happy with them will buy new rails when done

installed better, engine mounting bushings got this powerflex kit from ebay

next on the list was rims.....since the evo brakes are bigger I needed to use a 16inch rim, my current 15inch one's scrapped the caliper

so I found these used Thailand te37's for rm800 or (GBP 120)

they fit nicely and never had any clearance issues...

tyres wise I was in a tight budget, got these Altenzo sports comforters haha, I am not sure how long they will last, going for semi slicks next

the dimentions of the tyres are 205/45/16....

installed a innovate afr gauge to monitor the fuel mix

I did buy glowshift oil temp and boost meters, I later changed those for something better

I recirculated the wastegate...im using a tial 38mm with a 0.5bar spring for daily use

Cant seem to find the pics of the manifold getting done but this was it when finished

it was far mounted and came out of the front!

intercooler was modified to make the shortest root of intercooler piping!

everything nearing completion

went ahead with trying to do the full works, friend of mine (Conrad) helped fab the plenum, manifold and exhaust

mocking up

went with a evo 4 throttlebody

got a hold of some evo 560cc injectors serviced them too!

parts!!

So I did the head, port and polish. can't seem to find the pics of the process, but with help from my brother and Dad we lapped, did a port and polish then assembled everything back together!

by this stage it was already almost 3 months into the build

one thing I had to do since the 4age arp studs are larger in diameter is port a little off the part the holds the buckets in on the head

so got the engine in for a quick mock up...removed it the next day to final fit everything in

Over here airconditioning is a must, its really hot over here haha

well this was the finish result of the paintjob, arch looks pretty sweet and I chose to go back to the stock white, although ill probably change the colour in the future!

Looking good dude

thanks Maddox!

So I got everything in....all torqued down, I did infact lose an ARP stud which cost me ordering a new box

So everything was coming together well....this was all a trial and error project, no experience at the time haha....so now I have more knowledge thanks to some guidance! (note, the missing stud )

the went on the the engine.....clearences were on spot, pistons and rods were assembled....

the crank in place, as all the fellow 5efte guys you have to redrill the flywheel bolt pattern to fit on the 4efte one!

I want to ask if any of you have experienced when your oil rings are too big for the pistons.....I did trim down them to fit, but im not sure if that is a safe way to do it?? ive never had compression issues but I have not pushed the car over 1bar!

So I tried my best to take apart the gearbox, ive always had a problem with shifting from 1st to 2nd.....somehow while just sitting there the whole jammed, I could only get 3rd and 4th

Got the cover off and this was as far as I got, the C- clip came off and when I tried pulling off the gears it was in there for good.....with help from my dad...he manage to play around with the linkage and get it working again . Even though the gearbox was fixed, still isn't 100% fully functioning

i think i like this project

thanks jiggaman lots more to come!

more pics of her during paint

I cut out the grill so the intercooler could get some more air

Ive always wanted to go for a clean 'sleeper' look, so I got them to remover the vents from the rear bumper, looks really good and am chuffed to bits with the job!

nice update bro, keep them coming.

will do man, still have tons!