2AR-FXE Lexus Hybrid Synergy engine swap project.

Started by threepot, November 4, 2022, 22:59

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threepot

#50
I need a manifold, but there isn't a huge selection of 2AR-FXE Hybrid nx400h Lexus exhausts on the market  :)) There is one for sale, in the USA, on the Frankenstein website here https://frankensteinmotorworks.squarespace.com/shop/2ar-fe-header

But I'm sure I can do far more jankie bodgeness than anything like that! I've never actually fabricated a manifold before, nor do I own a mandrel pipe/tube bender, and I can't TIG weld. So everything is on my side for a premium finish. So I came up with this scheme, bought an el'cheapo manifold for a similar engine, and it did sort of fit with a bit of redrilling of the flange... for testing purposes.



And then today, I took a grinder to it, and turned that lovely 4-1 manifold into this clutch of components...



When you add up buying elbows, the lambda boss and that 4-1 collector etc, it's far more cost effective to do this, and you actually get some nice bends that are just perfect for the application.

Then I've drawn out a proper flange that will actually fit the cylinder head correctly... I did cheat a bit, I took the Toyota gasket, cleaned it up then painted it matt black, then put it in my flat bed scanner. Bit if photoshop and into a drawing package... trace bitmap to vector drawing... imported that DXF into CAD, then modified the drawing to have proper round holes and some other little changes here and there. After that I've now got a proper CAD drawing of the flange, which has been sent to the Laser cutters, so a new flange will turn up in a weeks time, then I can attempt to weld this exhaust back together.



threepot

Exhaust manifold will resume fabrication soon, but in the meantime Mr Marc Frankenstein has posted up a new video about the beans on toast 2ar-fxe global budget build. Running the exact same config (single VVT, intake cam in the exhaust spot, nothing fancy) he has posted this power run:-



That flat 180 ft/lbs straight across has to give good response. Keep in mind those are wheel figures too! Given a guess of 10% trans losses that's about 260bhp peak  :o

LeEdFollow

#52
Cool thread  8)

Looking forward to seeing you pull this off as I've already been following the Frankenstein Racing videos on this.

Would be good to see someone in the UK get one of these conversions done.

threepot

This engine conversion will certainly be completed, but at the moment I'm having way too much fun just with the 2zz. There is quite a few track dates I'm aiming for between now and easter (weather watching dependant), so I don't want to disable the car for a month.

Buying power is not greater than learning driving ability - first I want to get some more seat time with the 2zz before I become carried into a straight line hero! I set my goal at 2:00 consistent laps round Oulton, so it would be nice to find that in me.

That is unless the Gods chooses otherwise e.g. if the engine or gearbox goes kersplat, then I might as well get this done.

But certainly over the next 3 or 4 weeks the gearbox will get built up, and the manifold completed. Next the counter balance shaft need to be removed, and the oil hole in the cam needs bunging.

To install I need to fab up 3 engine mounts, and sort out the gear change linkage bits.

Mark A

How much would a flange for the 2AR be I might be interested in one if not mega bucks

threepot

The flange cost me £60 to get cut by a local place as a Saturday cash job.

If you know someone in the laser cutting game they would probably do you a beer money job.

You are welcome to the DXF cad file that anywhere will cut for you. DXF attached.

Fractory will cut and deliver 1 for £90 even 3 is still for £90 !


I've been trying out stainless wire in the MIG welder over the weekend to do this manifold, but it isn't happening at all. It's going to be mild steel welds on stainless tube.


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