Gary's Track Day/Fast Road Weekend Car (1ZZ turbo) Now 2zz Turbo

Started by Gaz2405, March 11, 2019, 20:39

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Gaz2405

Right then!

Thought I better get one of these started!

Picked this up from Facebook a couple of weeks ago. I was originally looking for a cooper S or Clio 182, but then this caught my eye. The wife had one 5 or 6 years ago and I remembered how much I enjoyed giving it a good thrashing when she wasn't watching!





Initial impressions have been really good.

£2.5k with 100k on the clock but feels like its done much less, paint work is near spotless on it in fact its nearly too nice to track.

Plans are to sort the handling, then add extra power.

At the moment its sitting on Tein lowering springs, with a TTE exhaust and apart from debadging is standard as far as I can see.

By adding extra power I intend to build a DIY turbo set up.

So far, I have or have on order the following:

T3 Turbo manifold (look like a Black Label one) Cast

TD04 15t Turbo, manifold will need some buggeration to make it fit, I've got some adaptors on order failing that chop and re-weld manifold.

Full Brace set from Megillian Motorsport

Oil Pressure, Oil Temp, Boost and Wide band AFR gauges and senders.

Intercooler pipework from a previous project.

Braided Brake Lines.

13 Row Oil cooler and sandwich plate.

New Sump.

Corbeau Leather Reclining Seats (literally just won on ebay) Bought on a wim but prefer recliners to full on buckets (for now!)

Next big thing on the list is Engine Management, its looking likely I will go down the ECU Master route on the group buy, but haven't had chance to get in contact with them yet.

With it being a weekend/track car and not a daily I'm not too fussed about over stressing the engine and pushing it to its limits as I'll probably go down the 2ZZ forged route worst case.

Forum so far has been brilliant and really useful looking forward to becoming more of a part of it. 

Cheers

Gary
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

shnazzle

Love me a project. Looking forward to seeing progress.
The king of DIY turbo builds happens to live here and goes by Dan.
He's got all the info and tips anybody could ever need for DIY turbos.
...neutiquam erro.

1979scotte

Definitely sort the handling first.
After 100k if the suspension is original it will be well past its best.
Good quality track orientated tyres are a must imho.
Consider fitting a charge cooler intake temps can be very high unless you can find room for a massive intercooler.
Forged 2zz isn't really worth the effort imho. A stock 2zz can take over 300bhp because it creates so little torque. If you want to push it harder than that the gearbox can become an issue.
Enjoy.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Gaz2405

Ahh wasn't aware the 2zz was capable of that.. interesting.

Gauges have all just turned up at work this morning.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

thetyrant

Interesting will follow as its a option for me in future.

Ian
Ex-2005 roadster  owner, i will be back :D

1979scotte

Quote from: Gaz2405 on March 12, 2019, 09:31
Ahh wasn't aware the 2zz was capable of that.. interesting.

Gauges have all just turned up at work this morning.

Also if you are looking for big power a 2gr V6 will give you around 300bhp stock but with low down torque no 4 pot can match.
Sounds better too imho.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

dan944

Ooohhh...hello.

Love a turbo build.

I'll throw my 2p in and do with it what you will.

Scott is absolutely on point as usual. My car is almost at 100k and full suspension refresh was required.

Look at Yaris wishbones. (Cheap!!)
And general revamp of all bushes. Probably poly if your going track.

Engine mount bushes are a must in my opinion. Especially with the extra torque of the turbo. Mine was unbearable without putting new ones in. I used BRD ones. (Lou Brooks). I also made a mk2 version of Caroline's head steady.

I recommend a re circ valve.

Take advantage of the Ecumaster group buy if you can. Your build will only be as good as the map.

Mine is at the "limit" of Gearbox torque at just 8.2psi. I'd like to think that means longevity will be good?

Intake temps are ok but not great. Recommend a charge cooler. There's testing that proves the cheap eBay ones are very effective (spyder Lees YouTube channel)

Get the ally sump. I went with OBX but whatever you want really. The extra capacity helps massively with engine cooling. That was proven on the dyno in 30 degree weather.

Hope this helps.
"I swear mum I did try and sell the roadster"

Silver mr2 2003 FL. Custom Turbo build 209whp. Lots of handling mods.

Honda CR-V The Work Horse

Gaz2405

Quote from: dan944 on March 12, 2019, 16:16
Ooohhh...hello.

Love a turbo build.

I'll throw my 2p in and do with it what you will.

Scott is absolutely on point as usual. My car is almost at 100k and full suspension refresh was required.

Look at Yaris wishbones. (Cheap!!)
And general revamp of all bushes. Probably poly if your going track.

Engine mount bushes are a must in my opinion. Especially with the extra torque of the turbo. Mine was unbearable without putting new ones in. I used BRD ones. (Lou Brooks). I also made a mk2 version of Caroline's head steady.

I recommend a re circ valve.

Take advantage of the Ecumaster group buy if you can. Your build will only be as good as the map.

Mine is at the "limit" of Gearbox torque at just 8.2psi. I'd like to think that means longevity will be good?

Intake temps are ok but not great. Recommend a charge cooler. There's testing that proves the cheap eBay ones are very effective (spyder Lees YouTube channel)

Get the ally sump. I went with OBX but whatever you want really. The extra capacity helps massively with engine cooling. That was proven on the dyno in 30 degree weather.

Hope this helps.

Cheers Dan.

Have looked at the OBX sump, but got for a standard one to start, do many track MR2's have issues with oil starvation? As I may go baffled.

Hopefully getting the car up on the ramps at my brother in laws garage to have a check of bushes and suspension. (Check them out on FB https://www.facebook.com/pg/speedshopuk/posts/?ref=page_internal ) They do some really nice builds!

Hmm Yaris wishbones! Straight swap? Same polybushes etc?

Yeah spotted Lee's test on the charge cooler, I've got a fairly large intercooler left from a build a couple of years ago so I'm going to see if I can make that work.

Anyone doing any Gearbox swaps or updated boxes

1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

dan944

Quote from: Gaz2405 on March 12, 2019, 19:15
Quote from: dan944 on March 12, 2019, 16:16
Ooohhh...hello.

Love a turbo build.

I'll throw my 2p in and do with it what you will.

Scott is absolutely on point as usual. My car is almost at 100k and full suspension refresh was required.

Look at Yaris wishbones. (Cheap!!)
And general revamp of all bushes. Probably poly if your going track.

Engine mount bushes are a must in my opinion. Especially with the extra torque of the turbo. Mine was unbearable without putting new ones in. I used BRD ones. (Lou Brooks). I also made a mk2 version of Caroline's head steady.

I recommend a re circ valve.

Take advantage of the Ecumaster group buy if you can. Your build will only be as good as the map.

Mine is at the "limit" of Gearbox torque at just 8.2psi. I'd like to think that means longevity will be good?

Intake temps are ok but not great. Recommend a charge cooler. There's testing that proves the cheap eBay ones are very effective (spyder Lees YouTube channel)

Get the ally sump. I went with OBX but whatever you want really. The extra capacity helps massively with engine cooling. That was proven on the dyno in 30 degree weather.

Hope this helps.

Cheers Dan.

Have looked at the OBX sump, but got for a standard one to start, do many track MR2's have issues with oil starvation? As I may go baffled.

Hopefully getting the car up on the ramps at my brother in laws garage to have a check of bushes and suspension. (Check them out on FB https://www.facebook.com/pg/speedshopuk/posts/?ref=page_internal ) They do some really nice builds!

Hmm Yaris wishbones! Straight swap? Same polybushes etc?

Yeah spotted Lee's test on the charge cooler, I've got a fairly large intercooler left from a build a couple of years ago so I'm going to see if I can make that work.

Anyone doing any Gearbox swaps or updated boxes

The stock sump is baffled to some extent. But the OBX has a massive capacity. It about 2 extra litres off the top of my head. It really is worth it. And it has better baffling

Yaris is straight swap. There's some recent threads on removing the old ones. It could be an absolute pain!! But other than that it's an easy job. And £55 ish a pair :)

The bushes may look ok but after 100k I can guarantee they're shot. Mine were soo flexible.

"I swear mum I did try and sell the roadster"

Silver mr2 2003 FL. Custom Turbo build 209whp. Lots of handling mods.

Honda CR-V The Work Horse

1979scotte

Gearbox swaps.
Our C6X boxes aren't strong we consider around 240 ftlb to be nice and safe.
You can swap in a jubu gearset which is much stronger but not cheap.

Serious power you go E153 from mr2 mk2 turbo. It won't break on a 1zz or 2zz build.
We also use the S54/51 for low power V6 builds. Not sure if anyone has ever done it for a 1zz.

If you want strong and 6 speeds you go for a modern Toyota diesel box exact one escapes me atm but its far from straight forward.

Sump.
Everyone has there own ideas if I tracked a 1zz I'd buy an elise parts sump.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Gaz2405

Interesting I'll have to look into the gearboxes in a bit more detail.

Some more goodies arrived yesterday.

AEM wideband, braided lines from Matt Lewis Racing, oil T, oil P and boost gauges.

Seats expected tomorrow, need to chase Megillian Motorsport for a delivery date on the braces.

Yaris wishbones ordered yesterday and hopefully fully polybushed kit this weekend.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

dan944

Just one on the sump, it also already has fittings for oil return. Saves a bit of faff. In my opinion removes the need for an oil cooler as well.
"I swear mum I did try and sell the roadster"

Silver mr2 2003 FL. Custom Turbo build 209whp. Lots of handling mods.

Honda CR-V The Work Horse

Gaz2405

Quick little update, parts are starting to arrive now.



Turbo is an OEM TD04 15T from Saab.

Oil lines, manifold, AEM Wideband, gaskets, filters, oil cooler, braided Brake Lines.

Also dug out all my old intercooling pipe work and gave it a clean down, should at least give me a head start on the pipe work! Couldn't find my old intercooler though, so may have to get a new one.



Also test fitted, OT, OP and Boost Gauges. (Don't worry the parrot is going!)



Found a new unopened set of 4 point harness in the garage as well from an old build so they'll get used too!
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

1979scotte

Not hanging around are we.
I'm going to bang on about a charge cooler again.
If your old intercooler has gone walkies and you've got to pay out spend a little more and reap the benefits. Fiat cinquecento rad bosch pump and an eBay cooler don't cost the earth.
I know I'm like a dog with a bone.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Gaz2405

Stating to listen in the charge cooler front now..... Just been looking at various threads on IAT's...  ;)
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

1979scotte

Quote from: Gaz2405 on March 14, 2019, 17:57
Stating to listen in the charge cooler front now..... Just been looking at various threads on IAT's...  ;)

My Rotrex is stupid cool for IAT bit overkill for a mild 1zz build probably.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Gaz2405

Searched high and low for intercooler.

Couldn't find it.

Charge cooler ordered! EBay universal special!
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

shnazzle

Quote from: Gaz2405 on March 14, 2019, 20:03
Searched high and low for intercooler.

Couldn't find it.

Charge cooler ordered! EBay universal special!
Dan I think you have competition here for quickest turbo build
...neutiquam erro.

dan944

Bloody hell!! Haha. Getting your pace on there. But I'm glad you're doing it right.

That charge cooler will make a world of difference.
"I swear mum I did try and sell the roadster"

Silver mr2 2003 FL. Custom Turbo build 209whp. Lots of handling mods.

Honda CR-V The Work Horse

Gaz2405

Quote from: shnazzle on March 14, 2019, 20:11
Quote from: Gaz2405 on March 14, 2019, 20:03
Searched high and low for intercooler.

Couldn't find it.

Charge cooler ordered! EBay universal special!
Dan I think you have competition here for quickest turbo build

Need it done quick before the wife notices the pile of parts!

Ordering the parts is the easy bit, it's finding time to work on it.

Campervan needs putting through it's Mot this weekend. Should be OK, it's only done 4k since the last one!
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

1979scotte

Quote from: Gaz2405 on March 14, 2019, 20:22
Quote from: shnazzle on March 14, 2019, 20:11
Quote from: Gaz2405 on March 14, 2019, 20:03
Searched high and low for intercooler.

Couldn't find it.

Charge cooler ordered! EBay universal special!
Dan I think you have competition here for quickest turbo build

Need it done quick before the wife notices the pile of parts!

Trust me she's already noticed.
If she's anything like mine she'll be working out how many pairs of shoes it's all worth.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Gaz2405

Few more little bits ordered today whilst I had a spare 10 minutes at work.

Fiat Cinquecento Alloy rad for the charge cooler.



Bits to do the battery relocation to the front as I'll be needing that space in the engine bay.

Rest of the oil cooler bits, some AN10 braided hose for the charge cooler to heat exchanger.

Chased up the seats, they should be here on Monday.



Got some more oil fittings to get and need to measure up for a charge cooler expansion tank (copying SpyderLee's idea)

I've chased Megillian Motorsport as well for an update on the Bracing bits.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

thetyrant

Seats look good be interested to see how they fit etc, hopefully enough room as i know when ive changed seats in other small cars like my old mx5 and boxster space was very tight!


Keep up the good work :D

Ex-2005 roadster  owner, i will be back :D

dan944

Curiosity, where do you plan on putting the rad?
"I swear mum I did try and sell the roadster"

Silver mr2 2003 FL. Custom Turbo build 209whp. Lots of handling mods.

Honda CR-V The Work Horse

Gaz2405

Yes I'm hoping the seat backs aren't too wide, look like they should work seen plenty of wing back recaro's fitted.

@dan944 planning on fitting rad behind the front bumper, obviously not all of it will get air flow. But will have a proper measure up once its hear and see what can be done.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0