Worlds first 2gr-fe Mk1

[Woodsport]

You guys appreciate a good Mk1 engine conversion so i thought i'd share pics of the worlds first 2gr-fe Aw11.... we are just at the hanging stage but its now fully mounted. It has taken one week from having the fire damaged 4a-ge in it to get to this stage, and the engine bay has needed to be massaged in a few areas to get the clearance. These engines are unbelievably powerful and pull like a train in the Mk2's we have built so god only knows what this will be like. (same engine as the lotus Evora has)

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0132-1.jpg

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A view of the torque mounts, which have been substantially strengthened as has the chassis mounting points....

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http://www.mr2mk1club.com/images/imported/2010/03/DSCN0142-1.jpg

Ok not quite as radical as my Mk1 V8, but we expect this to pull tree stumps out :)

[mr2mk1chick]

the engine bay has needed to be massaged in a few areas to get the clearance.
LOL
PW Massage parlour
:twisted:

looks quite a snug fit, will be interesting to see how the plumming side of things go. are you going to use the same rad as your v8?

[Woodsport]

LOL well if by massage you mean getting whacked repeatedly with a lump hammer until you are flat then yes!

Yes this one will get the same alloy rad upgrade as my mk1 v8. :+:

[Woodsport]

Well today saw the fidanza fitted, ACT clutch installed and the LSD gearbox fitted, then the whole lot refitted into the fresh engine bay...

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0168-1.jpg

Some things are just meant to be, this left side radiator hose is the stock 4a-ge one, and it fits perfectly, no trimming or adjusting, it just fits. I also added the heater hoses, fuel pressure regulator and worked out the placement of a few other things, we have loads of room in this bay surprisingly.

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0169-1.jpg

An overview of the bay as it looks now... personally i think we should leave the back window out permanently :)

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0167-1.jpg

[Woodsport]

More Mk1 2gr madness from today, i found a 1mz camry expansion bottle is the perfect size and shape for the job...



http://www.mr2mk1club.com/images/imported/2010/03/DSCN0178-1.jpg



Also made the first part of the induction pipework with MAF mounting boss on it...



http://www.mr2mk1club.com/images/imported/2010/03/DSCN0175-1.jpg



The supported shaft needed its bearing relocating towards the diff as do all 2gr swaps...



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The view from underneath...



http://www.mr2mk1club.com/images/imported/2010/03/DSCN0177-1.jpg



A reminder of just how good Marcs mounting kit is....



http://www.mr2mk1club.com/images/imported/2010/03/DSCN0173-1.jpg



So the engine is now totally plumbed up, clutch line adapter made, gear cables modified at the stick and speedo cable routed....all we have left to do is...



Driveshafts

Frankenstein Motorworks rear hubs

Exhaust

Battery relocation

Wiring

Brakes

Engine lid

WS alloy rad upgrade

Boot access panel

Refit rear window,bootlid,side panels

Tacho correction

Wheels

[mr2mk1chick]

fast work
i love how other jap car parts come inot use and fit where needed :+:

[Woodsport]

Yeah that is the one thing i really love about Toyotas, so many parts are useable from other cars, it's almost like Toyota wanted this to happen :D

[Woodsport]

Today saw 90% of the wiring completed, this corner is where the ECU is going to live, i still need to make brackets for it etc but it's a nice dry corner away from the engine bay heat.

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0198-1.jpg

The ITG air filter now fitted...

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0196-1.jpg

Engine bay overview...

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0197-1.jpg

Here is our chosen exhaust for this project, a Mk2 HKS system, it is the only one that satisfies all of Dirans requirements, has a low key look about it (ish!) , good silencers on it so shouldn't be too loud (fingers crossed) and has the smallest tips i could find (DM hates big bin lids).

It has a 2.5" inlet on it, which has been our only concession, i know it should be 3" to take full advantage of the 2gr but i could not find anything 3" that ticked all of the other boxes, so this system is the best compromise. I am going to remove the cut out from the drivers side valence and respray it so it looks equal both sides.

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0199-1.jpg

[Woodsport]

Today we got the Frankenflanges fitted with new wheel bearings and seals, Marc has done a great job here, this is the hub fitted and complete Mk2 turbo driveshaft inserted....

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0216-1.jpg

Also today we managed a bit of a first, we did talk yesterday about the possibility of using the camry torque mount shock absorber on an Mr2, well it turned out to be easier than i thought. The shock itself only works in a "pull" fashion, so it has hardly any resistance compressing it like a regular suspension shock, it's resistance is all when pulling it, so it has to go on the front torque mount to do its job properly.

Here it is tack welded in situ, i have adapted the camry top mount onto the Mr2 torque mount bracket and modified the aw11 lower mount with a braced bolt and mounting tube. I think this is great and could end up being the next big mod on all conversions.

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0204-1.jpg

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As you know by now this is just the tack welded mocked up stage, it needs removing and painting. I also need to make a nice aluminium heatshield for it because the exhaust will run nearby.

There are a lot of first time mods on this car but it really is coming together now.

[Woodsport]

Today saw the WS TD lid painted, still needs a flat and polish but this is one lovely colour.... we also meshed the vents, which will be done black.

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0222-1.jpg

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Also today work started on the Woodsport Aluminium rad upgrade, this is the same kit i developed for my Mk1 V8 and when i have worked out all of the details will be available as a kit for homebuilders. It's 50mm thick and held my V8 at 90* with very little fan use and no air flowing through it.... a thing of beauty in my opinion.

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0218-1.jpg

[Woodsport]

Spent a few days making the downpipes on this one, i can get a much cleaner sweep on the rear bank on a Mk1 2gr swap, and as a result a better Y pipe in my opinion...

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0282-1.jpg (http://smg.photobucket.com/albums/v624/paddy1970/woodsport3/?action=view&current=DSCN0282.jpg)

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0284-1.jpg (http://smg.photobucket.com/albums/v624/paddy1970/woodsport3/?action=view&current=DSCN0284.jpg)

Then fitted to the car....

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0287-1.jpg (http://smg.photobucket.com/albums/v624/paddy1970/woodsport3/?action=view&current=DSCN0287.jpg)

Can anyone spot anths contribution?

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0285-1.jpg (http://smg.photobucket.com/albums/v624/paddy1970/woodsport3/?action=view&current=DSCN0285.jpg)

[Woodsport]

The worlds first 2gr-fe powered Mk1 Mr2 is now running...

http://www.youtube.com/watch?v=mZssEbM-o2E

[Woodsport]

today saw the car rebuilt, the WS TD lid polished and fitted, new back window put in... boooo! and everything finished off in the engine bay 100%.

So as soon as we get the brakes fitted this thing is ready to rock...

http://www.mr2mk1club.com/images/imported/2010/03/DSCN0306-1.jpg

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If only people knew what lies beneath!!

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