Suter's AE86 Build - Lots of LONG posts and pics

[Suter]

Hey everyone, I was at the meet tonight with my friend in his stock 2011 Corolla so I thought I should join up here considering I have a Toyota haha.

Anyway, here is the build.

Its pretty long so get ready.

Hey everyone, heres my AE86.

I got it home last Wednesday, 30/11/11. The guy I bought it off spent about 2 weeks pulling everything out of the car, and had ordered parts around when the earthquake hit Japan and since they took so long to get here he lost interest in it and it just sat in his parents backyard for nearly a year. He has also tried to retrim the interior in a suede-like fabric, but I think he used cheap material and the two layers of the material separated, and the headlining didn't stick because he glued it over the old headlining.

Anyway here's the basic specs:

Engine, Drivetrain

JDM 4age. Bigport head on a smallport block

Cusco 3.7kg flywheel

JDM T-50

Kouki Rear Axle with disc brakes and TRD 2-way LSD

JDM front rotors (vented) and calipers with braided brake lines

TRD Copy extractors

2.25" Exhaust

EMS Stinger Aftermarket ECU

Came with Wiseco pistons and some forged con rods, but don't plan on rebuilding the engine yet.

HKS adjustable cam gears

KLS Short Shifter

JDM Fuel tank

Suspension:

D2 coilovers F: 9kg/mm R: 7kg/mm

D2 adjustable camber-tops

D2 adjustable panhard rod

Whiteline adjustable swaybars

Whiteline 25mm RCAs

AJPS Adjustable tie rod ends

AJPS Corona LCA's

Interior:

Full black interior

Personal Neo Grinta 350mm steering wheel

Steering wheel quick release

Bride Vios style seat

Kenwood head unit with bluetooth

Exterior:

Zenki front lip

Kouki Levin tail lights

New OEM kouki rear bar and brackets

Watanabe R-Type in 15x8.5J-6 wrapped in Maxxis MA-V1 in 205/50R15

Resprayed 3 years ago in the JDM Red which is darker than the Aus cars

Here are some pics: (Sorry for bad quality, all coming from my phone)

Before the car came off the road:

As it sat when we went to pick it up:

Edited February 10, 2013 by Suter

[Suter]

Continued...

Thursday 1/12/11

Interior after we took all the spares out:

The spare parts pile: (there is more that I don't have photos of)

Gave the car a wash, paint came up really nice, but needs a polish

Pulled the rest of the interior out to get it ready for paint:

Edited January 28, 2012 by Suter

[Suter]

Continued...

Saturday 3/12/12

We started to trial fit the interior, and started painting the plastic trim:

Headlining after we got the glue off:

Sunday 4/12/11

New dash because the old one was ruined by the glue when he tried to retrim it:

Engine:

Gearbox:

Parts that need to be painted:

Parts that still need to go in:

And finally, as the car is sitting in the garage now:

Edited January 28, 2012 by Suter

[Suter]

Continued...

Wednesday 7/12/11

Replaced the gaskets around the taillights because the left one was leaking.

Old:

New:

Thursday 8/11/11

I bought new carpet for the car and started to dye the head lining but it was too wet so I stopped.

New carpet (front half):

Rear half test fit:

Friday 9/12/11

I finished dying the interior except for the dash, which will be done tomorrow. Also installed the headlining and all trims above the doors.

Trial fitted the wheels from my KE70 to get an idea on how my planned sizes for wheels will fit.

Plan for the weekend is to fit the dash, seat belts, the plastics in the boot and maybe carpets and seats if time.

Edited January 28, 2012 by Suter

[Suter]

Continued...

Saturday 10/12/11

Dyed the dash black:

Finished the rear half of interior:

Sunday 11/12/11

Installed dash:

Finished the interior, still a few minor things that need to be sorted out but its all in:

Edited January 28, 2012 by Suter

[Suter]

Continued...

Not that much has happened this week. All I've done really is clean up the engine and the engine bay a bit to get it ready to go in.

Saturday 17/12/11

Painted the block gloss black:

Painted extractors matte black:

Painted alternator silver:

I ordered a gasket kit earlier in the week and was hoping it would arrive yesterday so we could get the engine back together and hopefully in this weekend, but it didn't arrive and it should be here on monday. Engine will be in this week if it all works out.

Edited January 28, 2012 by Suter

[Suter]

Continued...

Sunday 18/12/11

Cleaned up the engine bay and gave it a quick coat of matte black

Monday 19/12/11

Gasket kit arrived

Put the engine back together and mock fitted everything to make sure it all fits

Engine is going in on Wednesday.

Wednesday 21/12/11

Engine went in today, still a few more things to connect and figure out where they go but not much left to do.

Edited January 28, 2012 by Suter

[Suter]

Continued...

Friday 23/12/11

Finished off the wiring today and got it running :D. Still needs some tuning and a stronger throttle return spring because it isn't returning to idle when I give it a rev.

http://youtu.be/QerR_Ju72nc

Gave the car a wash today as well to get the 3 weeks worth of dust off it

Monday 26/12/11

Haven't got any pics from todays work. What we did was:

- Fixed the ignition because the key would come out when the car was turned on

- Fixed the leak in the rear quarter window

- Hooked up the fog lights

- Fixed the horn, there was a button in the cluster surround for the horn, but we got the horn button all wired up now so it works properly

- Got the rear window squirter kind of working

Still got a little bit to do before its ready blue slip but it is all just small things

Thursday 29/12/11

Pulled the master cylinder off because it was leaking. It was all corroded inside so we headed to the brake shop and they said it needs to be sent away for a stainless steel sleeve to be put in, but they're on holidays until the 9th so when they open up its getting sent off to them.

Friday 30/12/11

Painted the garnish in between the bonnet and the windscreen matte black and replaced the rubber that runs along the edge of it.

Bought new windscreen wiper blade assembly, paint stripped the arms back to bare metal and repainted them matte black.

Saturday 31/12/11

Painted the surrounds around the rear quarter windows black

Had a spare airbox lying around from the go kart so threw that on there, seems to make no difference so far.

Edited January 28, 2012 by Suter

[Suter]

Continued...

Monday 2/1/12

Made some brackets up for the grill because it was only held on with cable ties before.

Sold my corolla so wheels are being ordered next week.

Wednesday 4/1/12

Got a free 3SGE. Missing too much and too much custom work for little gain so its not going into the car.

Friday 6/1/12

Master cylinder sent away to get sleeved.

Tuesday 10/1/12

Went to Otomoto and ordered my rims.

Watanabe R-Type 15x8.5J -6 all round. Was originally going 8.5J-6 front and 9J -13 rear but after trying the 8.5s on the rear the 9s will poke wayyy too much.

The other 2 are ordered and on there way from Japan.

Going to go buy tyres for these 2 tomorrow and hopefully the master cylinder is back tomorrow too.

Edited January 28, 2012 by Suter

[Suter]

Continued...

Wednesday 11/1/12

Went and got my tyres fitted today. Maxxis MA-V1 in 205/50R15.

Rear:

Front:

I couldn't find any open ended lock nuts in the right thread so I havent seen how they fit when its on the ground yet, but they should be ok.

Haven't heard anything about my master cylinder yet but hopefully it comes tomorrow.

Gearbox has a problem so its coming out on friday hopefully.

Edited January 28, 2012 by Suter

[Suter]

Continued...

Saturday 14/1/12

Got the gearbox out and pulled it apart. Found the problem, the pin had fallen out of the selecting arm so it wasn't moving the fork and not selecting the gears. Tapped it back in and will put it all back together tomorrow.

Sunday 15/1/12

Put the gearbox back together and got it back in the car, works fine which is awesome, shifts in and out of gear good.

Monday 16/1/12

Bought some longer wheel studs for the front because the old ones were too short with the watanabes on, going to go order some lock nuts that fit tomorrow.

Brake master cylinder is coming back sometime this week but Im going on a holiday tomorrow for a week so it will but put on and bled up when I get back.

Edited January 28, 2012 by Suter

[Suter]

Continued...

Tuesday 17/1/12

Bought lock nuts and finally got to see the car on the ground with its new wheels.

I haven't heard from Ben at Otomoto yet about the other 2 rims but they should be here this week. Master cylinder is going back on tomorrow and rego some time this week if nothing else goes wrong

Edited January 28, 2012 by Suter

[Suter]

Continued...

Monday 23/1/12

Got the master cylinder back and installed.

The stainless sleeve

Tuesday 24/1/12

Finished bleeding the brakes because we had a problem with the proportioning valve yesterday.

Filled the diff up with oil, adjusted the panhard rod and took it for a spin around the block. Cylinder 2 isn't getting any fuel, won't downshift into 2nd and needs a wheel alignment.

Edited January 28, 2012 by Suter

[Suter]

Continued...

Tuesday 24/1/12

Went and picked up a splash tray

Pulled the injectors out

Wednesday 25/1/12

Took the injectors to go get tested, the injector for cylinder 2 was clogged so we got them all refurbished.

Got a new fuel filter too, put the injectors and fuel rail back in and drained the old fuel out of the tank. Will get the filter changed tomorrow

Edited January 28, 2012 by Suter

[Suter]

Continued...

Thursday 26/1/12

Took the car for a drive around the block again, goes heaps better now. Car was blowing a bit of smoke so did a compression test too, 170 on 3 cylinders and 160 on 1 so I was happy with that, the smoke has gone away now though. Also ran into the guy that lives up the street who has a sprinter. Then we found out he has two. Went into his garage and had a good look over his track car that he's building. Lots of effort has been put into it and lots of money has been spent too. Going for blue slip tomorrow so hopefully it passes and can finally get it registered.

Blue slip guy wasn't there yesterday so is going for it on monday now.

Saturday 28/1/12

Fitted the splash tray and gave the car a wax.

Tomorrows plans are to put some lighter gearbox oil in to see if that helps with the problem, otherwise it will be getting rebuilt after the cars registered, also going to take a bit of oil out of the engine to see if that helps with the smoke and add some smoke reducer stuff. Might also finally get around to heating the carpet up and moulding it.

Still haven't got the other 2 rims so hopefully they're here on monday.

Edited January 28, 2012 by Suter

[juvenile]

AWESOME So your the owner of this baby, been following that elsewhere.... You have done a beautiful job on it Ryan, ******* champion...

Glad those skirts are gone, welcome and nice meeting you tonight ;)

[Suter]

AWESOME So your the owner of this baby, been following that elsewhere.... You have done a beautiful job on it Ryan, ******* champion...

Glad those skirts are gone, welcome and nice meeting you tonight ;)

Thanks John, nice meeting you too, and the fitment on your auris is perfect. I will probably put the skirts on again once its registered to see if I like them, but I doubt I will. Needs a ducktail to finish the exterior off for now but that will come when the time is right haha.

[jeffy]

Nice build dude :] !

[69.NIX]

great little project man,

keep up the great work :)

[Suter]

Nice build dude :] !

great little project man,

keep up the great work :)

Thanks guys

Edited January 28, 2012 by Suter

[dwee.]

Awesome work! Keep it up!

[dutchie101]

Bloody Excellent! Always had a sweet spot for these... youve done a great job so far!

[Suter]

Awesome work! Keep it up!

Bloody Excellent! Always had a sweet spot for these... youve done a great job so far!

Thanks

[4ABHGE]

Awesome stuff! I love these cars, and yours is a great example of one :)

[eviltwin]

Very nice build mate! well done!