Despite a few niggling issues to start with after the 3S-GTE upgrade, the car passed the 1000km mark without any problems and had its first oil change. About 300ks later we played around some more with the TPS, ignition and idle control valve and the car is now running a lot better - especially up to 5k rpm.
So, tonight, after a few light runs yesterday taking the revs up to 6k, went for a decent blat along some lovely country roads with a fellow GT4 WRC owner as a passenger.
All I can say is "Holy ****". With boost still 'restricted' to a maximum of 8psi, even my mate had to concede that the car felt faster than his 4 which has some 220bhp @ wheels with 17psi and an Apexi Power FC. It is almost frightening to think what the car will be like when it's been fully modded.
The engine has been totally transformed with the 20cc larger capacity, 8.7:1 CR, HKS 264 cams and fully worked head. It feels so tight and smooth and keeps pulling all the way up to the red line with no noticeable drop off in power. It just keeps pulling and pulling. I am looking forward to getting the new ECU and upping the red line to 8k

I'd also been telling Frank how much better the car was handling too with the new front uprated ARB. To say he was gobsmacked was an understatement. This was also the first time I'd been able to really put the car through its paces and its road holding ability was unbelievable.

Frank had a turn at the wheel and I literally had to prise him out of the seat with a crow bar at the end. He wasn't looking forward to driving his 4 back home

So, all in all, at this stage of proceedings I am a very happy man. And if anyone is rebuilding their engine, all I can say is spend the $ and get it done properly. It really does make all the difference between a good engine and a great one!
Gary

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1994 Toyota Celica ST205 GT-Four Group A WRC - running in rebuilt engine....

Nice one mate, glad it's going so well, nice to hear the more pleasant side of Four ownership

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'92 GT-Four RC - Project Rufus - something of a mover.
'05 Audi A3 3.2 V6 Quattro S Line - not bad for a daily.

This is good news for the rest of us with modified Gen3 engine builds under way or planned

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

2000ks now and all still looking good. Slight downside is that there is a niggling little oil leak which I'm going to have to pull the sump off to investigate, but other than that all is as it should be.
Even better news is that an Apexi Power FC ECU is currently on its way to me as I type which means a revisit to the dyno to get it set up properly.
Also, driving up a motorway on ramp over the weekend with a mate in his GT4 WRC following saw something interesting. I'm currently running a maximum 8psi while Frank's car has 17psi with a TOMs panel filter, high flow turbo (Modded CT20B), 2.5" exhaust with custom DP and dyno tuned Apexi Power FC. However, at WOT going up the on ramp, he couldn't close the gap on me (while I wasn't pulling away). Goes to show what a difference a properly built motor can do with a few mods even if it is running half the boost pressure
Gary

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1994 Toyota Celica ST205 GT-Four Group A WRC - running in rebuilt engine....

Doh! I know you have a really good handle on things Gary, but are you sure it's the sump?

With all the gunk that is applied to the sealing faces I'd be very surprised to get a leak there? Or did you go for the minimalist approach when applying the sealant?

Interesting comments on the performance comparison

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Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
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Turbocharging - the replacement for displacement

It's at the gearbox end of the sump. It's definately not the gearbox and am 99.9% confident that it isn't the crank seal - but appears to be coming from that area. Pulling the sump off is the only way really.
Gary

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1994 Toyota Celica ST205 GT-Four Group A WRC - running in rebuilt engine....

Gary - did you fit ARP mains studs?

There is a fitment issue with these

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Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
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Turbocharging - the replacement for displacement

Kris
No. I opted for OEM in the end.
Gary

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1994 Toyota Celica ST205 GT-Four Group A WRC - running in rebuilt engine....