JoeCools 2ZZ Project: Fast Fun!

[JoeCool]

Nice tip, I think I might have a narrow cold chisel which will do the trick. Thank you.  s:bowdown: :bowdown: s:bowdown:

[JoeCool]

The to do list:

1) Fit Facelift headlights and tail lights.
2) Re-panel car including [strike:d8eh6tgm]front[/strike:d8eh6tgm] and rear bumpers.
[strike:d8eh6tgm]3) Replace windscreen[/strike:d8eh6tgm]
4) Fit Coilovers (MEister R's) - Done Fronts
[strike:d8eh6tgm]5) Fit whiteline ARB[/strike:d8eh6tgm]
6)[strike:d8eh6tgm]Locate[/strike:d8eh6tgm]and Fit rear refurbished arms.
7)[strike:d8eh6tgm]Locate[/strike:d8eh6tgm]and fit rear subframe
[strike:d8eh6tgm]7a) Powdercoat and fit TRD Strut braces[/strike:d8eh6tgm]
8 ) Address the torn rear engine mount.
8a) Alignment
9) Code 2nd key!
10) OIl and filter service.
11) Shakedown trackday?

Possibles:

11) Find screws to located centre console
12) Fit greenstuff rear pads.
[strike:d8eh6tgm]14) See if my mate who works at a bodyshop can respray my roof[/strike:d8eh6tgm] - Replaced instead

Hmm, I was hoping to be able to cross more of this list off. I suppose I'll just have to spanner harder.

Today:

Car started like this:


I fitted this:


TO end up with this:



I also got the front light brackets fixed to fit my facelift headlights, and put the wings and bonnet back on but it was too dark for pictures by the time I'd done that.

With the best will in the world (and a six week old and a very forgiving wife!) I dont think I could have done more this weekend. Still got to fit the lights and bumper and then do the rear suspension.

[jonty]

Fair play getting that all done with a 6wk old, I've got a 16 month old and rarely get that much done!

Your job list and mine are surprisingly similar, or at least with the windscreen, engine mount, key and track day requirements!

[JoeCool]

Forgot to add I also replaced the wiper linkage! Quite a quick job and glad I did it, mine was totally goosed.

And this tip:

Do you mean the bolts left in the arb mount points? If so get a thin chisel on the rear of the bolt/nut (the nut is tac welded in place) and smack it hard with a hammer. It will remove the nut and the broken bolt, then you can use a new nut and bolt for the new arb, and there is enough space to get a spanner to hold the new nut whilst you tighten the bolt, so the new nut does not have to be tac welded in palce like the factory one.

I've had this happen on almost every mk3 and always had to do this.

Worked a treat, and I even had bolts in stock so I could crack right on with the ARB fitment.

[MilesH]

Forgot to add I also replaced the wiper linkage! Quite a quick job and glad I did it, mine was totally goosed.

And this tip:

Do you mean the bolts left in the arb mount points? If so get a thin chisel on the rear of the bolt/nut (the nut is tac welded in place) and smack it hard with a hammer. It will remove the nut and the broken bolt, then you can use a new nut and bolt for the new arb, and there is enough space to get a spanner to hold the new nut whilst you tighten the bolt, so the new nut does not have to be tac welded in palce like the factory one.

I've had this happen on almost every mk3 and always had to do this.

Worked a treat, and I even had bolts in stock so I could crack right on with the ARB fitment.

Good to hear! Always nice when it all goes as planned!

[JoeCool]

Car currently looks like this:





Just the rear to do now. And all the other jobs. Sadly events in London mean I am working around the clock at real paid work, not driveway spannering. I really hope I get enough time to do the required work and alignment before my trip at the end of April.

[Alex Knight]

Car looks great buddy, very impressed with all the hard work you've put into it.

[JoeCool]

Another days graft on the car today. Rear end time.

Dissassembru.


My main fear was shearing any and all bolts holding the cat section of the exhaust on. They came apart fine - then I remembered it's only 18 months since it was last put together. I guess that helps. However, I'm missing one of the exhaust manifold bolts.   s:roll: :roll: s:roll:   The list gets longer.



I'm sure we've all been there.

Anyway, off with the old, in with the new:



Until: Disaster!



Of course, the ONE bolt I don't have a replacement for. Well done me. It's a tricky bolt, I can see why it snapped: 2 channels run along it to locate the toe adjustment cam. I've bodged a solution so I can get the car back together and replace it when I can get a new one.

The car as it stands now:


Tomorrow (next week? depends on spousal co-operation) is Coilovers and rear strut brace, then on to rear wings if I get the time and motivation to start drilling out bolts!

[JoeCool]

Got the coilovers on and strut brace on today. Ordered the bolt I snapped.

I need another day to get the rear wings on, but the mechanicals are (Broadly) done. Once i have the toe arm bolt I can get it aligned. I'm running out of spare time for a trackday though, so the first time this gets driven in anger could be at the Nurburgring!

TRD bits and Meister R's!


Haven't had time to do proper pictures. Haven't had time for anything really.

[hachiroku]

Feel your pain regarding knackered ARB/subframe bolts, can think of a few occasions where I'd have given my right arm for some air tools! All the hassle is worth it for the end result though...car's looking great keep up the good work.

[JoeCool]

Today was replacing rear wing day: only got one done, only got one photo half way through the process!



Relatively painless though, and the other is ready to come off. Tomorrow my missing bolt should come in stock, and with a bit of luck I'll be able to get it aligned too. Ok, A lot of luck. I'll be up at 8am spannering to get the rear end back on it though.

[JoeCool]

Just taking stock:

[strike:2w4yfm2j]1) Fit Facelift headlights[/strike:2w4yfm2j]and tail lights.Nearly done
[strike:2w4yfm2j]2) Re-panel car including front and[/strike:2w4yfm2j]rear bumpers. - Nearly done
[strike:2w4yfm2j]3) Replace windscreen[/strike:2w4yfm2j] Done
[strike:2w4yfm2j]4) Fit Coilovers (MEister R's)[/strike:2w4yfm2j] Done
[strike:2w4yfm2j]5) Fit whiteline ARB[/strike:2w4yfm2j] Done
[strike:2w4yfm2j]6) Locate and Fit rear subframe and refurbished arms.[/strike:2w4yfm2j] Done
[strike:2w4yfm2j]7) Locate and fit rear subframe[/strike:2w4yfm2j] Done
[strike:2w4yfm2j]7a) Powdercoat and fit TRD Strut braces[/strike:2w4yfm2j] Done
 s8) s8)  Alignment
9) Code 2nd key! I'I'm still to chicken to do this for fear of immobilising my car/erasing my only key  s:( s:(
10) OIl and filter service.
[strike:2w4yfm2j]11) Shakedown trackday?[/strike:2w4yfm2j]I've checked and I don't have time on any available dates  s:( s:(

Possibles:

11) Find screws to located centre console
12) Fit greenstuff rear pads.
[strike:2w4yfm2j]14) See if my mate who works at a bodyshop can respray my roof.[/strike:2w4yfm2j]No need, roof replaced with a better one

So the revised list looks like:

1) Finish fitting rear panels, lights and bumper.
2) Alignment
3) Possibly see if my exhaust is blowing/get it rectified (I think it might be at the manifold/downpipe union after ham-fisted re-fitting)
4) Polish her up
5) Oil service

Possibles:
5) Fit greenstuff rear pads - really want to get this done but time is now an issue.

Long term list:
6)Recode key
7)affix centre console properly
8 ) Overhaul front calipers (kits in stock)

And, as an exercise, I was taking stock of waht I've done to this car since I purchased it as a £350 spares or repairs project:

Engine and drivetrain
[li]Got the 2ZZ fitted at Bonsai[/li]
[li]Fitted 6 Speed corolla gearbox with LSD swapped in - also Bonsai[/li]
[li]TRD short shifter[/li]
[li]Ultimate shifter bushings[/li]
[li]MWR exhaust and intake pipe[/li]
[li]Fidanza light weight flywheel[/li]
[li]Exedy clutch[/li]
[li]New radiator and coolant hoses

Brakes[/li]
[li]New rear calipers[/li]
[li]New pagid brake cables[/li]
[li]Hel brake lines[/li]
[li]EBC Brake pads[/li]
[li]New discs[/li]
[li]Brake fluid flush

Chassis[/li]
[li]Meister R coilovers[/li]
[li]New everything[/li]
[li]New (refurbished) rear sub frame[/li]
[li]New front lower arms[/li]
[li]Whiteline front ARB[/li]
[li]New GT-4Play polybushed rear control arms inc hard race toe arms[/li]
[li]New lower steering UJ[/li]
[li]Rear camber bolts[/li]
[li]TRD Strut braces front and rear[/li]
[li]Cusco front under brace

Exterior[/li]
[li]New Hard top roof[/li]
[li]Panels all round inc Front and rear bumper from a 2006 car.[/li]
[li]Facelift front and rear headlights

Interior:[/li]
[li] Fitted Pioneer double Din sat Nav and head unit.[/li]
[li] Fitted cloth facelift seats[/li]
[li] TRD Shifter/Shifter knob[/li]
[li] Go pro mounts fitted[/li]
[li] Soft top deleted[/li]
[li] Pedals re-positioned for heel and toe.

Wheels and Tyres[/li]
[li] OZ Ultraleggera 16" 7J rims with posh black wheel nuts[/li]
[li] Yokohama AD-08R Tyres, 225/45 R16 rear, 205/50 ^16 Fronts.[/li][/list]

Frankly, that list is  sfuck fuck sfuck ing MENTAL.

[puma2]

i love all the work you do on this 2 especially as you do most of it your self  s:bowdown: :bowdown: s:bowdown:    s:bowdown: :bowdown: s:bowdown:    s:bounce: :bounce: s:bounce:  
keep up the good work and yes your subframe is sexy   s:oops: :oops: s:oops:

[manos3003]

9) Code 2nd key! I'I'm still to chicken to do this for fear of immobilising my car/erasing my only key  s:( s:(

Since you're somewhere on the M40, we can meet and I can help re-code that key of yours, I've done it twice on mine already  s:) s:)

[jvanzyl]

Dude - what's your deadline like for this? I can maybe put down one evening and do your rear pads for you if you want?

[JoeCool]

Right, what an epic day that has been today:

Start point was one wing replaced, the other to do. I also needed to refit rear lights and bumper, and get the bolt from Toyota to replace my sheared one. Toyota called at 8:30 to say they had the bolt, wife agreed to run and get it - so I could work on the car. Finally, Wheels in Motion (Black boots) actually had an alignement slot free at midday! WooooT! The race was on!

Stage one: Other wing replaced - slight issue with the fuel filler release, but sorted it in the end (It twists out from behind  the wheel arch liner, or you can pull it through with the filler neck surround, then deal with it in the light of day which is easier).



At this point, I had 35 minutes to refit the rear bumper and lights, replace the bolt freshly delivered by my wife, (none too pleased at the thirty quid bill for a bolt and a front light bracket!), put the wheels on, drop the car and get on the road to Wheels in Motion!   s:shock: :shock: s:shock:  

So I got my facelift parts on it.


Got it dropped, torqued the wheel bolts, grabbed my wallet and turned the key.... Chug chug chug. Chug chug chug. Oh god, had 4 weeks sat on stands (and testing the lights) killed it?! It always fires on the third turn over. Brraaaammmmmm!!! No of course not!!! PHEW!

So off we went the back roads way to Wheels in motion. And the car felt BLOODY AWFUL. I do NOT recommend driving an MR2 with 4 degrees of negative camber on one back wheel, and near enough a degree of toe out on both axles. Turn the wheel, and the car just keeps rotating!!! Nearly had a tank slapper during an ill advised overtake. Spent the half hour drive worrying that I'd done something severely wrong, whilst second guessing every bump and waver.

This is what 4 degrees neg camber looks like: As if you've crashed the car basically.



Absolutely terrible shot of the car on the ramp at everyones favourite wheel alignment shop.



And after an hour and a half of adjusting absolutely everything, here are the results:



She's pointing straight again, scotty!!!

Had a lovely chat with various punters at wheels in motion, as usual, and there was a nice Porsche Turbo on the ramps, but nothing as exotic as last time.

The drive home was much less eventful: Woeful handling appeared cured, but I was stuck in traffic the whole way, and also in a serious rush to view a house my wife wants to buy (And me too - it has a garage). So No opportunity to really test it, but it didn't try and kill me on my private local hillclimb, so my hopes are high. Also the exhaust sounds fine...

As for final photos..... It needs a clean first. And I need time to take them.

The list now:

• Oil Change
• Polish her up
• Fit rear Greenstuff pads... if I can find the caliper tool and I get a moment.

9) Code 2nd key! I'I'm still to chicken to do this for fear of immobilising my car/erasing my only key  s:( s:(

Since you're somewhere on the M40, we can meet and I can help re-code that key of yours, I've done it twice on mine already  s:) s:)

That would be awesome!  I can't do ding day sadly (I'm in france) so we'll have to sort a date out!

Dude - what's your deadline like for this? I can maybe put down one evening and do your rear pads for you if you want?

That's very kind - but my life from now to Nurburgring is 100% hectic.... I hope your shock fitment is going well. If I can do a full suspension rebuild in 4 days, I'm sure you can do a coilover fitment in a few evenings!

[manos3003]

That would be awesome!  I can't do ding day sadly (I'm in france) so we'll have to sort a date out

Drop me a PM anytime you have some dates in mind mate. Happy to help in any way I can   s:) s:)

[Paul1087]

Looking good Jon!

[MilesH]

I remember the first drive after fitting fully adjustable rear arms and no geo set up very well  s:lol: :lol: s:lol:  For a  few seconds it made me think I'd left the hub nuts loose until I twigged what it was!

Can I ask what you asked for when they geo'd it (road or track? Agressive or moderate?). The setting looks decent but not overly agressive and wondered how they spec'd it?

Thanks

[1979scotte]

Good work.
Well done.

[JoeCool]

Can I ask what you asked for when they geo'd it (road or track? Agressive or moderate?). The setting looks decent but not overly agressive and wondered how they spec'd it?

"Same again guv" which is basically fast road. A smidge of additional camber front and rear, and that's about it for now until I find my feet with this suspension set up. I honestly just trust them with it, they don't mess about.

[MilesH]

Can I ask what you asked for when they geo'd it (road or track? Agressive or moderate?). The setting looks decent but not overly agressive and wondered how they spec'd it?

"Same again guv" which is basically fast road. A smidge of additional camber front and rear, and that's about it for now until I find my feet with this suspension set up. I honestly just trust them with it, they don't mess about.

Thanks  s:) s:)

[JoeCool]

Grabbed some quick pictures on my way past it this morning:

[jonty]

Nice work Joe, looking good and enjoy the Nurburgring!

[jvanzyl]

Congrats on getting it done Joe!
I'm halfway removing my struts still.. basically trying to find 30 mins hear and there in the week to undo a bolt or two!