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Chop's project original mk2


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Update time! been dismantling all the auto filth in the engine bay, but i need my engine crane and stand to continue with that further so i set to work in the interior.




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the auto's gear selector surround thing is different to the manuals as it has extra buttons to try and coax the slush heap into doing something, so that needed to come off. auto selector is easy enough, just 4 12mm bolts like the manual, annoyingly slightly shorter though so ill have to find them replacements.



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not the best picture i know but it was dark inside the garage at the time. the two plugs to the left there have me stumped, i suppose one is for the reverse light, can anyone tell me what the other does, and which colours do what?




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quick mock up of the manual job, needs a good clean up i know and ill do a little short shift conversion on it before it goes in properly, and maybe make some solid mounts as peeps seem to swear by them




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I also swapped the clocks over, i fitted the speedo with the correct milage into the manual cluster, itd probably have been easier to just fit the black manual facia over the auto and pull the bulbs from the centre gear indicator thing in the middle, but ah well. also chucked the plastic piping for the rear heating in, its really easy to install but the piece of the dash it plumbs onto is obviously blanked off, can the end just be removed or do i have to drill it or something, i cant tell.


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  • 5 weeks later...

Small update time as ive been busy sorting through this, taken all the pictures and then found my laptop had shat itself ffs. Got the whole front off and the engine and gearbox out, thought I might as well pull the engine and do a belts and seals job on it to futureproof it. Made it a short shifter with a bottom weighted gearstick, solid shifter mounts and bearing bushings for the selector cables that I've pinched from my white shell, along with the clutch pedal and mech. I promised myself i wouldn't pinch bits from it as its what ill be working on when this is done, knew I was lying to myself lol. pics to follow!





how do you change the titles on these threads, i cant find the option anywhere its pissing me off now!


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Couple of pics of the process of fitting the clutch master cylinder, for anyone doing their own conversion youll need an 8mm drill bit and a 30mm hole saw, and go steady as the firewall is made of like 1.6mm mild steel, you go through so fast its silly!. also, sprayed the holes with a tin of 6m6 so they dont rust. at the halfway point now, just doing some while im in there engine work, new belts and the like, and its time for it to all go back together. bottom pic is the extended shifter i made, adds a little bit of weight to the shift and should shorten it somewhat, its an extension of about 10mm.


Edited by Chops
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So i was down the scrappys as usual, and ended up trading my c63 gearbox for a corolla g6's c161 that i found lurking in a corner. Also grabbed all the metal gubbins out of its shifter to go with the box and found that the gearstick itself would go straight into a starlet with a somewhat shorter throw into each gear lol, its almost identical to my custom short shifter in length and i know thats about 10mm more than stock!

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obv the one on the right is the modified one, the corolla would need a bit of bending to angle the gearknob towards the driver but itd be an easy easy job!

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  • 4 weeks later...

It seems to me like the auto 3 plug is exactly the same as a manual 2 plug with an extra thats dedicated to the auto box. Is that the case, can i just plug in the two that match the manual ecu and leave the third plug loose, or are all the wires jumbled up? Also, is it the same shape as a glanzas three plug?post-10502-0-47032200-1464189856_thumb.j

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  • 2 months later...

Wow, its been a long ass time since i updated this thread, been slowly plodding through it, its starting to really move along now!


so i threw a load of new seals on the engine, new timing belt kit and all that good old 'while i was in there' stuff, and threw on my freshly resurfaced lightened flywheel, because why not. standard spec excedy clutch of course, and bolted my old gt's gearbox on. sorry the pic isn't the best, i took better pics of most of this then found id lost the lot and had to take more with my phone.


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i also fitted the manual pedals up properly, along with the shifter box.


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For a while after this, i mostly pottered around with other mundane boring stuff, until the arrival of my new black gt project, which sported some goodies i knew would be going straight on this green project! i immediately pulled its engine and gearbox, and decided the external lsd of this gt was a better choice than my old internal one, and created a whole new load of work for myself lol. i pulled the rear mount and offside driveshaft from the new project as both are different on an external lsd gearbox, and was amazed, look at the difference on the rear mount!


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the external lsd job is both better made and far sturdier a mount, so on the green gt it went. annoyingly the clutch cover plate that goes behind the flywheel is also very different lol, so i had to take all my carefully torqued clutch assembly straight back off to fit the correct one, so that was a kick in the face.


I"m having a lot of problems trying to fit the rear heater piping atm, has anyone else got this in their car to show me how to fit it? doesn't seem to want to go under the carpet, but itd look like shit if it was right there coming out the bottom of the centre console trim and under the front seats lol, anyone got any ideas?


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I took the cover off the og ehaust manifold the other day, was chuffed to see it hadn't cracked as so many others have. Perhaps its due to the autobox stopping less careful owners ragging the shit out of the engine, but thats just a guess.


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Finally, i got the correct engine and gearbox bolted together, and all the replacement seals that needed to go on while the engine was out and in bits on, so i was able to put the whole lot back in the car, making this now very much a manual car to be reassembled!


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Edited by Chops
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Good work dude!

There are slats in the floor to slide the rear floor heater vents into. Might be easier with the carpet lifted out.

cheers bud, ill take the carpet right back tomorrow and sed if i can find em.
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Good work dude!

There are slats in the floor to slide the rear floor heater vents into. Might be easier with the carpet lifted out.

post-10502-0-34901900-1470865993_thumb.j found em cheers, i cant believe ive never noticed em before lol, still a bit lumpy in the pic but a lot better, i can get it to sit right like that im sure. Also, forgot to get a good pic of it to ask properly but i found that box in the drivers footwell under the drivers seat, its an oem amp isnt it? Edited by Chops
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  • 6 months later...

Damn, update oclock son! so though it doesnt look like it in pictures a lot has happened to the starlet, had some ups and downs lol.


really struggled to find time to work on the thing, this wasnt even the biggest job but turned into a 'while i was in there' to end all while i was in theres, and kept getting set back. the engine is back in and running, ive been converting the little things like the automatics different radiator and thermostat housing, rewiring the reverse light plug etc, and sorting through the interior conversion, which is more involved than the avarage conversion thread would suggest, but i suppose when youre trying to literally erase any trace of auto from the car bar the vin plate the devils in the detail i suppose!



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swapping mad alloys for correct 92 spec alloys.


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jap credit card i found under the carpet. actually found two of these, havent gotten round to comparing them to see if theyre from the same owner lol.


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bay starting to look a bit better. its all offered in here, and im going to buy a new intercooler cover as theyre still available from toyota but you get the idea


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interior fiddling, with mad touchscreen dvd player because im generous like that lol. note the rear seat vents are a bugger to fit too.


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big nasty eaton m62 supercharger i got the other day for my other starlet, offered up to the bay while it looked like this to get an idea of how little space theres going to be where i wnat to fit it!


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basically how it sits now, just waiting for the last few things in the bay like the ac condenser so i can get it motd and get it off to the paint shop to have that bumper and bonnet sorted!



so i was trying to fit the 3 point brace to the towers on the rear and found this:


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the turrets only have two studs from the shocks, and i dont think theres a central fixing point either. i shat myself immediately and assumed it must be a clone or some mad cut n shut, but ive checked it thoroughly and theres no signs of any tampering, and the frame number matches the one on the vin, which confirms this is definately a factory automatic gt turbo, so i was wondering if anyone could shed any light on this new nonsnese lol. perhaps as its an early 92, this is a last of the mk1 chassis factory fitted as the first of the mk2s, as ive read in places that mk1 chassis are different in several ways.


Edited by Chops
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My 92 gt is the same way and so are the Mk1s

you sir, are a gentleman and a scholar, ive been freaking out a bit over it, its good to have it confirmed, cheers!

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  • 3 weeks later...

Got it through its mot today with only a couple of advisorys: discs a little corroded from sitting in my garage for over a year, and one of the shocks is some aftermarket thing so doent match the others and needs replacing. Pretty pleased with that, both problems easily sorted. More importantly of course, was the days insurance i put on it to drive it to and from its mot, which allowed me to take it for a spin and blow out the cobwebs as it were:post-10502-0-63165300-1490381144_thumb.jpost-10502-0-03076700-1490381174_thumb.j

Ive missed driving a starlet :D

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This car is a carbon copy of my first Gt lovly colour the green gts are

6m6 green, gorgeous colour. Id love to keep it but its too nice for dailying round portsmouth. Going in for its paint job middle of april hopefully!

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  • 2 months later...

So the paint shop finally finished with the gt, whatta you lot think! (ps i had a nightmare uploading pics, can someone slap whichever mod messed up photo uploading hard, in the face, kthx)



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Edited by Chops
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