More goodies arrived today:

Can you tell what they are?



Tada!



So we have new OEM water hoses, brake pad pistons x3, shim kit, new pad pins and the caliper rebuild kit for the refurb of the front calipers, an ST202 throttle cable to hopefully run a shorter cable route, an OEM clutch release bearing to go with my new clutch and the belts for the power steering and the alternator.

New starter motor



New alternator



My car had an intermittent starting fault for about a year before I took it off the road, hopefully these in combination with a new battery will resolve the problem

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GT4DC Events Co-ordinator
1996 ST205 UK

From the packaging I'd say that lot came from TCB.

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If at first you don't suck seed, try drier grain.

Yep - the quantity of packaging is insane, they take great lengths to ensure your parts arrive safely.

Need to get a bigger recycling bin!

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GT4DC Events Co-ordinator
1996 ST205 UK

Picked up the last of the bits from the powdercoaters today. I've had the front ARB, OEM strutbrace, and the two front subframes done along with a load of the brackets and bits 'n' bobs from the engine bay.



I'll be putting my Cusco front brace back on the car however the blue anodising had failed in a number of places so I had the strut mounts powdercoated as well. I'm really pleased with how they've come out.



These should go nicely with my OEM look.

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GT4DC Events Co-ordinator
1996 ST205 UK

Bit more progress today.

I finished off the refurb of the front brake calipers, they started like this:



Almost a year of sitting and the pins had well and truely corroded themselves into place, as I was refurbing the calipers I decided the easiest way would be to cut the pins using a dremel and the large applications of club hammer to remove them.

On removing the pistons fortunately only 3 had corrosion on the skirt so these were replaced along with all the dust seals etc.



I then gave the front of the calipers a quick coat of black hammerite to tidy them up.

I'm going to reuse my existing Fidanza flywheel but I decided to replace the friction plate on it as the cost of the new plate is circa £55 I thought this very reasonable.

After getting the flywheel out of the car I found that the friction material did not have any significant wear but as I had the replacement anyway...

Old plate removed:



New plate fitted - also an ideal time to use my low range torque wrench as the small nuts and screws called for 5lbft:

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GT4DC Events Co-ordinator
1996 ST205 UK

Ur bob on nibbles it certainly is my workshop and yip am still there

Mikes ST205 is in there and coming on nicely, ive just sent mike a good amount of further progress pictures so sure he will be updating the thread soon.

It was good to see you again this week mike and don`t forget if ya wanna get stuck into cleaning my engine bay like youve just done to yours then ur more than welcome to it

I will try and keep myself about on here as much as I can and offer my 2p worth of advice where and when I can in future

Martin

Update time!

Work has been progressing apace since I dropped the car off with Martin. I'm really pleased with how things are moving on.

On Wednesday I set off for the long drive upto Blackburn stopping by Rugby to collect my freshly balanced clutch and flywheel from the engine builder, I was also lucky enough to get a look at TrackToyFour's car in the flesh (drooool!!).

Thursday I arrived at Martins and after unloading all the parts and having a coffee I set to work cleaning the engine bay and the gearbox.

They had both got quite grubby over the last 6 years since the engine was last out.

Before:


I used a mixture of marine clean, panel wipe, gunk, to get the grime off and then used some wax to polish the surfaces and provide some protection.

After:



The old engine has been removed and is being kept close to hand as a number of the components are required to make up the new engine.



After quite a bit of cleaning the gearbox is now in a much better condition although still not great, I might have to stick a steamcleaner down there once the car is finished.



A lot of work has been done on the engine as well but I'll leave that for tomorrow's update.

Whilst I was up at MK Auto's I also took the opportunity to remove my old Sparco Dash Display as this will be replaced with something better and to address some of the rust in the battery tray area.



Want to say thanks to Martin for accommodating my cleaning OCD and for the cups of coffee.

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GT4DC Events Co-ordinator
1996 ST205 UK

So here is the update on the engine.

I'm really pleased that I've had someone with more experience to build the engine as there were a couple of things that I wouldn't have found that would likely have resulted in the engine failing quickly.

The first was the cam cover being full of grit, possibly from a previous powder coating:





So the baffles were removed the whole thing thoroughly cleaned and then the baffles resealed and riveted back in place:




There was also quite a lot of debris lurking inside the oil pressure relief valve which might have spelled doom for the new engine:




So this was also thoroughly stripped and cleaned then reassembled:




Quite a lot of the engine has now been built up, the scraper, oil pickup, and sumps have been fitted:







Thats the bottom of the engine completed with the exception of fitting the oil level sensor - more on that later.

Further up the engine the oil pump has been split and the pump rotor lubricated ready for initial startup:



The cambelt side of the engine has been mostly finished with the exception of fitting the belt:



Also the fuel rail, injectors, water pump and thermostat housing have been installed:




The power steering pump on my old engine was found to be in quite poor condition, particularly rust on the pulley, the item that I got with the replacement engine is in much better condition although the vacuum lines have been snapped off, I'm hopeful that we can create one working unit from the two damaged one.

The last bit of update is that I plan on ditching the UK oil level sensor as it is hugely unreliable anyway, I am going to use the port to measure the oil temperature instead:



Ignore the dirtyness this isn't the sump that will be used on the car.

I managed to get hold of a plate that had already been fabricated for covering this port although the thread in it was much larger than the sensors that I am planning on using, I decided to use the existing plate as a template to make my own:




As you can see its a bit thicker and has not been drilled yet as I don't have a 1/8NPT tap available at the moment.

Due to the way in which the OEM level sensor seals some additional silicon gasket will be required on the inside of the port to prevent leaks, Dorris posted up about this a while back, (Dorris - hope you don't mind me reposting your picture!):



Given that my new plate won't have an o-ring we'll need to seal it better.

Here is a first trial fit of the plate, all looks good, I'll drill and tap the plate later once I have the tool available:



That's all for now folks, now that Martin has my clutch and flywheel ready there is nothing stopping the engine and gearbox from being assembled and fitted back into the car.

I'm heading back up to Blackburn towards the end of January when I hope we'll be onto the little bits before its finished.

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GT4DC Events Co-ordinator
1996 ST205 UK

Hi Mike,

thats some great work
drop me a PM if you sell the oil level sensor

greetz

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KEEP COOL UNDER PRESSURE

street legal?.....perhaps in tschibuti

Looking great Mike. Be great to see the finished product!





Thanks Martin, would be much appreciated

Time for another update!

Its been a month since I was last up at Martin's, I took a trip up there on Friday to deliver some parts, have a chat and do a couple of little bits on the car myself.

I've ordered some of the last bits for the build now:

After deliberating over various brake pads I thought I would just go with what I know - TRD Fast Road Pads. I have run these for a number of years now on the road and on numerous trackdays, I find them to be excellent so I thought I would not stray from what I know to suit me fine.




Next I picked up a new adapter to fit my chargecooler fuild temperature sensor.



I've decided to go for standard sensors wherever possible hence the 1/8 NPT thread which is ubiquitous.

I also picked up a couple of the sensors themselves as Martin wanted them so he can get the engine oil tight. I got the sensors from Race Technology however they are standard Bosch type so should be compatible with whatever system I finally choose for the car.




Next was some fluids that will be needed, Martin is supplying the running in oil which will be a Millers product, I ordered some oil for the engine once run in from Opie Oils, I chose the Fuchs Titan Fully Synthetic I had excellent results with this over about 70k miles of road use on the previous engine.



I also got the gearbox oil - using the same as I was previously:



Lastly for the fluids I bought some Toyota ForLife Red Coolant for the main engine and the chargecooler.



I have decided to change my dumpvalve arrangement, I was going to go for a recirculating Forge item, I picked it up quite cheap but I have since discovered that you can get an adapter to make my HKS valve recircuate so I ordered one through eBay:



Thats pretty much it for the new parts.

After being sat on the car for a year neglected my cusco strut brace and 'cooling' panel were looking really sorry for themselves, so I attacked them with a wire brush loads of metal polish and green pads and have come to a finish that I am fairly happy with:



Onto the engine front, the turbo has been fitted to the engine after first using some assembly lube to ensure its properly protected:






You can see in one of the pictures above that the exhaust manifold has also been tapped in 1/8 NPT to accept a k-type thermocouple to measure the EGT.
The main water hardpipes on the engine are now all installed and the turbo has been fitted with a brand new oil feed and return pipe that I obtained from TCB.

The turbo I am using is my existing TurboTechnics S148 hybrid with the custom exhaust housing with single internal wastegate:



The sump has been fitted with the plate to accept a sensor to measure the oil temperature:



Finally a short bit on the interior of the car, I plan to keep this much the same as I had it before which is basically OEM with the addition of some Recaro recliners. A couple of the parts such as the gear gaiter and armrest cover are looking a little sorry for themselves due to wear and my knobbly elbow!

I spoke with Simon at Hide 'n' Seat interiors - http://www.hidenseat.co.uk/ and arranged for a new gear shift gaiter and for the armrest cover to be retrimmed. Simon is active over on Celica Club and was a pleasure to deal with. I am really pleased with the results, I went for Black Leather with white stitching as this will match the Recaro recliners I already have installed:





The quality looks to be very high and the cost a very reasonable £32.

That's it for now, looking at the engine it seems pretty close to being able to go into the car along with the new suspension and subframes, I'm hoping that my next visit in a months time will see the car looking much more finished.

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GT4DC Events Co-ordinator
1996 ST205 UK

Hiya mike

Now that I have the sensors and once the new turbo return hose arrives i can fully prime the engines oil galleries before fitting and then get the engine in place

Martin

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We now have a new website

https://www.mkautorepairsandtuning.uk/

http://www.facebook.com/pages/Mk-Auto-R ... 7894641634

Excellent

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GT4DC Events Co-ordinator
1996 ST205 UK

I don't suppose you could post a picture of the Recaros in your car, please Sirius? Interested to see what the plain black ones look like.

Thanks bud

Hi,

I'll post a picture when I get home, I can't find one on my laptop.

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GT4DC Events Co-ordinator
1996 ST205 UK