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 Post subject: St205 - Black WRC #2627
PostPosted: Fri Mar 30, 2012 4:20 pm 
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Joined: Thu Jul 07, 2011 9:41 pm
Posts: 197
Car Model: ST205
Appologies for the obvious copy and paste :wink:

...



St205 - Black WRC #2627

Thought I would start this thread to keep track of work done/needing to be done, seems like a good idea. I got this car a month or 2 ago down near Bournemouth. Its taken 4-5-6 "claying" sessions to get the salt/sand out of the paint but think it’s finally about there lol. Managed to get a few little things that have been bugging me, sorted. Fuel gauge now fixed, fitted new fuel sender. Lagged the charge cooler with me old man. Truly is turning out to be a ST205!


Current mods/Work done

--- Engine/Drivetrain
* JSP 4" SAI Lagged
* JSP Ventilation Relocation (VR) KIT
* Blitz decat down pipe
* Varley Red Top 25 Battery (relocated)
* Charge cooler lagged
* Lower temp thermostat (76°C)
* High pressure radiator caps
* Samco hoses
* Forge re-circulating dump valve
* Blitz Nur Spec R stainless exhaust
* Aisin Clutch kit
* REDLINE LightWeight ShockProof Gear Oil 75w-90
* JSP Precision Shifter Bush Kit
- Poly Gear Linkage Bush kit
- Solid Shifter Base Bushes

--- Chassis/Suspension
* Ultralite Atec 7 Spoke 17" Alloy Wheels
* Front shocks
* KYB rear shocks
* TRD top mounts
* -25mm TRD spring kit
* Front wheel bearings both sides replaced (08/2011)
* Polybushes Lower arm 2 (Banana arm) (built in crush tubes)/Rear full set
* Camber Adjustment bolts replaced (08/2011)
* Cusco front and rear strut braces
* Whiteline adjustable rear anti roll bar fitted
* TRD front discs
* Red stuff pads all around

--- Interior
* Greddy boost gauge
* Greddy temp gauge
* Momo Millennium Evo steering wheel
* TRD gear knob
* Hyper A pillar twin 52mm
* Hyper sports floor mats
* Aircon regassed - (05/2011)

--- Exterior
* Genuine TRD adjustable Spoiler
* 4mm Mud Flaps (MSA reg's)
* Aerial removed
* Spree LED side lights
* Black TPI XR steel wheel nuts & locks
* Clear side repeaters
* Late spec rear lights

--- ICE/Electrics
* Apexi Power FC ECU (Mapped by Ryan @ 2Bar tuning 08/08/2011)
* Greddy boost controller
* Kenwood 8" KFC TC200 Speakers (front)
* Alpine 6" x 9"s SXE69C2 (rear quarters)
* Clifford Concept 650 alarm
* HKS turbo timer

This maybe a slow progressing thread but hey :P

Here be some pics - Probably too many in fact

http://img801.imageshack.us/g/img0428a.jpg/

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post 2

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post 3

SMALL UPDATE - aims with the car :)

Well after a few weeks of thinking this and that, I think I know ish what I’m aiming for :). Got a few quotes,

£250 to sort out the rather large dent in rear alloy and refurb/re-spray the set.

£1000 to sort out front and rear bumper, bonnet, hmm, passenger rear side arch, few other little niggles from past accidents/track excursions lol, and highlight wings and spoiler
OR
£2800-3000 for a full re-spray

Given this is my daily driver I’m leaning toward the cheaper option :)

After seeing the "get flocked" stand at Chavfest... I now want that on me dash and doors!

Maybe refurb seats with fitted leather covers or so.

After that lot I think it will look pretty mint. I went to the effort of spending many hours creating a real life representation of what my car will look like, if you want to know what programs I used please give me a shout! :)

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I think I’m now going to go with white as appose to the green ( thought it looked good on the Norris designs evo but think it’s a bit too 16 year old kid sort of thing on mine lol)

So, best I get saving :)

post 4

White lipstick inside and out...

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post 5

A small update..

JSP SAI
Forge dump valve
Varley red top 25 battery, relocated
Some stickery bits from Mook
and a couple more white bits (Wing mirrors), just spoiler and door handle surrounds togo :)

O and pics of yesterdays dyno run

Also I pulled back the carpet couple of weeks back, turns out I dont have a Blitz access ecu lol

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post 6

A little update, couple of exterior additions, some universal 4mm rally mud flaps (size is for protection not looks! Although I think the skewer stickers looks cool :)), and a TuRD spoiler.

Also went ahead with the seat removal idea, dog seems fine with a few blankets :thumbsup:
A few pics..
http://imageshack.us/g/13/img1070ay.jpg/

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post 7

Another update..

Got the apexi power fc from nokia_aid a couple of weeks back. Had the four remapped by Ryan from 2Bartuning, at Surrey Rolling Road. Basically I've only gained 15-20bhp, but a fair chunk of torque which has a huge difference through the whole range. With any joy a few mpg too! A better way of gauging the increase (I think) from the stand alone ecu is, it made 290bhp (3bhp more) at 0.8bar then it did 2 months ago at 1bar. Apparently the only thing holding this back from 340bhp ish is the fuel pump, seems mine has topped out just over 300.

The last two pics are comparisons from a couple of months ago.

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So after that I dropped in to say hello to Johny and drool over his car and tyres! and of course Erin's beast :D Then dropped the car off at TGT in Basingstoke for some bits. Should have it back on the weekend so I'll update the thread then.

post 8

The money pit just swallowed some more cash! and she’s still hungry for more!! (where did it all go wrong?! lol)


So had TGT do
Poly bushes on front banana arms/full set on rear
Dump valve setup as recirc
Front wheel bearings
and a couple of minor bits which have escaped my mind

It definitely feels more "tight" in the corners, however I still have the knocking. So now drivers side rear top mount (guess I'll need to do both as I cannot tell if I have TRD or standard top mounts) and that lovely expensive front lower arm (drivers side again), the straight one, both need to be replaced.

Also got the alloys booked in for the HUGE dent removal and a refurb in a couple of weeks.

Just to add to the mix I started getting that crunch from 3rd to 4th so took a punt on the Redline oil as recommended and a full set of gear bushes from JSP. Got the oil changed over this afternoon. Finished fitting the new gear linkage bushes this evening, really cracking guide! Took it for spin to ease it in, not sure if it's essential but seemed to make sense in my head lol. Initially the changes feel to be "tighter" obviously thanks to the bushes. Slightly less of that crunch feeling but of course taking changes nice and easy. So, fingers crossed I don't need a new box !

Still need to sort a cold air box as I recently started looking at air intake temp on the apexi commander, getting temps around 40° even at speed so can be improved ;)
I knocked up a cave man/Halfords style cold air feed which is not worthy of pictures! lol but it did take a couple of ° off so heyho!

post 9

After another member asking a few questions regarding intake temps with SAI, I started watching the air intake tempt a little closer. I didn't realise at the time but the temp on the fc commander I was looking at, was a combination of air intake temp and another sensor on the inlet manifold somewhere. Regardless it was getting hot and sucking in hot air. Spool up was fine.

It became really apparent a couple of weeks ago driving back on a hot sunny afternoon from Silverstone, going 40-50mph with little flow the temps got up to 45-50+°c on the commander. Put my foot down in 3rd and there was just so little punch there. So after that and seeing Fawb's motor, I put my "U" grade in Design tech from 10years ago to use!

The first design (if I can call it that lol) worked perfect, about 10-15°c lower temps on the commander, also as a result oil temp seemed 5-10°c lower. The only problem was spool up. I was waiting ages to get up to pressure, was fine when up in the revs, seemed to benefit from the cooler air.

So I moved the cold air feed to where my fog light use to be, took a panel (chicken wire :D ) out and removed some of the lagging to expose the wing area behind the fuse box to give it a little more flow whilst trying to keep it cool obviously. And it worked.. Spool up is back to normal and temp inside the box is between 14-21°c (I think the 21 may have been as the sensor was in my pocket previous to going in the box lol).

Here's a bunch a pics of my cold air feed and box. I do appreciate it makes blue peter look like artisan's :D
All jokes, comments welcome, like to think I'm relatively hard to offend :D


http://imageshack.us/g/546/img1140ak.jpg/

post 10

Time for another update........

Ok, well as some of you may have seen my car at rally day it's been stickered up. A HUGE thanks to Mook as they really do look great! Just wish I had him fit them ;). Finally got the fitting issues sorted, well, compensation, Mook will be correctly fitting some of the decals which were.. not fitted so well. Pics of how it is at the moment are below. Heres a couple of pics of how f***ing ace it looks with the refurb'd white wheels (thanks to Mook again as I was actually against the idea lol). Managed to write one of those alloys off last Saturday morning but I'll get to that lol.
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The Signbuilder in Melksham fitted, or attempted to fit the stickers, I have been told they will not be taking on anymore jobs of this nature but just in case someone is tempted to get such a professional job done by them, see following pics ;)

This is a link to the pictures from the day after I believe, maybe two days after...
http://imageshack.us/g/819/img1355ah.jpg/

and this link is to the pictures from approx 2-3 weeks after fitting..(spotted a load of marks on the sunstrip, hard to get it to show though)
http://imageshack.us/g/717/img1405ac.jpg/

So should soon be able to draw a line under that mess and have a nice long lasting set of decals that look ace :thumbsup:

For the last few weeks the four has been off the road after breaking it (knocking, guessed diff mount) on a track afternoon and then stock piling some bits lol. So got it back Friday just gone complete with
RTP front/rear braces
Poly diff mount/diff bushes/subframe bushes
New lower arm
TRD rear top mounts
and a new bolt for the diff as one had corroded away (which was causing the banging-not the diff mount)

So then went for a drive the following day, Saturday just gone, going down an A road, overtook a car, as it was still a little dark I managed to miss a huge stone sat in the middle of the road, so as I pulled out to overtake the offside front hit it smack in the face. At first I thought it was maybe a bad pothole - new bushes giving it a harder feel, then was going down a bumpy road so it felt a little off anyway. Within 1mile I had to pull up, the last 75-50meters the tyre delaminated and made pulling up interesting. So that’s a fresh set of refurb'd alloys all set for the track afternoon probably useless lol! As well as probably needing a couple of new front shockers as the offside one was dented by the tyre when it detached, it now squeaks a lot, getting it checked out tomorrow.

O then just for giggles thought sod it and made it down for the last hour for Keevil track day with the old man and failed the sound test which I passed 3 weeks before with the same equip lol, massive difference in temperature mind but still, was 4-5db out and didn't take the silencer so :no:

O and and and went to get the tracking sorted and he couldn’t adjust the rear camber bolts even though they are new so they are like 11mm out on the rear which I hope is a mistake as the readings changed with no play in anything, so that’s on the "to sort" list tomorrow as well!

Still could be worse lol :D

Just keep thinking ..... " O how nice it will be when it's all sorted " lol

http://imageshack.us/g/402/img1458a.jpg/
(album)


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post 11

Right a few pics and vids of the recent abuse...and a new filter :D

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Combe
http://www.youtube.com/watch?v=JTP8wZXL ... re=related

Henstridge
http://www.youtube.com/watch?v=PKAjy51bF68
http://www.youtube.com/watch?v=I0yaQWL525o
http://www.youtube.com/watch?v=BBoVuvi8Ies

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Next on the list is used gearbox, clutch, flywheel, new rad + hoses and full belt service :D

post 12

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8)

post 13

Aye indeed, at looong last. Been building bits up for 6months :lol: ;)

Few pics and little update where I am..


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Done..

* Fit driveshaft with new boot

* Cam belt - (Full belt service)
Alternator belt
Alternator belt Tensioner pulley bearing
Idler bearings
Power steering belt
Hydraulic Tensioner
* water pump
* Large cam cover gasket
* Small cam cover gasket
* Front crank oil seal
* Rear crank oil seal
* Oil pump shaft seal
* X2 Camshaft oil seals

* Underseal front

* Fit shortened throttle cable

* Remove ABS

* Fit fuel filter

* New plugs - standard copper ones - last replaced 03/12 ------ 04/11

* Fit Gearbox, clutch, flywheel (Recently balanced (white marks)), standard release bearing, clutch line

* Fit TRD front shocks with current springs and top mounts


------------
To do..

* Sort non abs pipework/bias valve

* Fit Downpipe support bracket/ New exhaust gasket

* Fit fuel pressure regulator

* Replace front grill with mesh

* Fit TRD Front anti roll bar

* Fit radiator +
- 2x Spal fans VA10-AP10/C-61A (12", 12V pullers)
- 8x Mounting brackets 30130011 (Override on switch?)

* Fit header tank and swirl pot - http://www.gt4oc.net/forums/viewtopic.p ... t#p1306663

* Repair Battery mount/relocate for fmic?

* Fit 13 row Mocal Oil cooler setup (90degree opening temp not 80) + HKS Hybrid oil filter

* Fit UK spec gearbox oil cooler

* Fit FMIC - Evo 7 core, TD pipe work, clocking bracket,(Ford throttle clip for actuator).
51mm Outer Diameter Hot Pipe
63mm Outer Diameter Cold Side Piping

* Fit addition fans on intercooler + switch? - X2 9" Slim line fans

* Sort fmic charge cooler error code ? (Resistors)

* Active chargecooler rad/intercooler spray bar (on switch?)

* Fit fuel pump

* Paint rear callipers

* UNDERCAR SERVICE AND SEAL!? Rear

* Sort out rust under boot lid

???????? - Extra bits...

* Both footwells seems to be leaking a little, intermittent?


* 4W Laser Alignment
* Remap with Ryan £140-150 (2 weeks notice)


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 Post subject: St205 - Black WRC #2627
PostPosted: Tue Apr 10, 2012 11:31 am 
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Joined: Thu Jul 07, 2011 9:41 pm
Posts: 197
Car Model: ST205
Well, a huge thanks to Nibbles for a massive amount of help!

The car is running and technically moves by itself, could hear the lovely rattle of a twin plate clutch as well lol. So would seem successful thus far.

Didn't have time to do all bits on the list so will hopefully will drive it away next weekend now :D

List now reads ..

-----
Done..

* FMIC - Evo 7 core, TD pipe work, clocked turbo

* Power steering relocated with copper lines using Old Jap spec oil cooler

* 13 row Mocal Oil cooler setup (90degree opening temp not 80) + HKS Hybrid oil filter

* UK spec gearbox oil cooler/ pipes

* New front drop links

* 2x Spal fans VA10-AP10/C-61A (12", 12V pullers)
- 8x Mounting brackets 30130011 (Override on switch?)

* ABS removed - non abs bias valve/new copper lines

* New exhaust/ downpipe to turbo gaskets

* Offside inner cv boot replaced with stretchy

* Cam belt - (Full belt service)
Alternator belt
Alternator belt Tensioner pulley bearing
Idler bearings
Power steering belt
Hydraulic Tensioner
* water pump
* Large cam cover gasket
* Small cam cover gasket
* Front crank oil seal
* Rear crank oil seal
* Oil pump shaft seal
* X2 Camshaft oil seals

* Underseal front

* Fit shortened throttle cable

* Fit fuel filter

* New plugs - standard copper ones - last replaced 03/12

* Used Gearbox, clutch, flywheel, standard release bearing

* TRD 4-way adjustable front shocks


------------
To do..


* Cold air box

* Fit fuel pressure regulator

* Replace front grill with mesh ?

* Wire rad fans+ (Override on switch?)

* Fit header tank and swirl pot

* Repair Battery mount/relocate for fmic?

* Sort fmic charge cooler error code ? (Resistors)

* Fit fuel pump

* Paint rear callipers

* UNDERCAR SERVICE AND SEAL!? Rear

* Sort out rust under boot lid


* 4W Laser Alignment
* Remap with Ryan £140-150 (2 weeks notice)

-----


few pics

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 Post subject:
PostPosted: Tue Apr 10, 2012 12:59 pm 
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I'm not happy with the FMIC pipework as it's ended up.
It appears to have been designed to fit very low at the front, under the fog lights, and would require the intercooler to hang down below the front nose. Fine for a flat track, but asking for trouble the first big bump the car hits when used in off-road events.
We struck a compromise with the FMIC just below the level of the front chassiswork but still above the bottom of the nosecone.
The pipe from turbo to intercooler is still hanging well down further back (as shows in picture) but cannot come any higher as it hits the bottom of the washer bottle.
I'm wondering if the WRC has a larger washer bottle than standard ?

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PostPosted: Tue Apr 10, 2012 2:01 pm 
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Car Model: ST205
The WRC does indeed have a larger washerbottle. It has a little extra bit that comes out of the bottom.

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PostPosted: Tue Apr 10, 2012 2:20 pm 
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 Post subject:
PostPosted: Tue Apr 10, 2012 5:36 pm 
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Location: Camberley, Surrey
Car Model: ST205
:D

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 Post subject:
PostPosted: Tue Apr 10, 2012 10:56 pm 
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Location: Perth, Western Australia
Car Model: ST205
Sirius wrote:
The WRC does indeed have a larger washerbottle. It has a little extra bit that comes out of the bottom.
LOL....that's the WRC Homologation water spray tank and pump - non operative of course!

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1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
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2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp


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 Post subject:
PostPosted: Tue Apr 17, 2012 11:53 am 
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Well, it's up & running and driven home last night :)

I'm concerned about the header tank / swirl pot setup as it's completely sealed with no pressure relief / pressure equalisation facility. It just needs the slightest weep through head gasket and the system will just pressurise until a pipe bursts - or on a cold morning, all the pipes could be sucked flat.
Has anyone come across a fully sealed setup before, or should we be looking for a valve to stick in the top of the tank ?

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 Post subject: St205 - Black WRC #2627
PostPosted: Wed Apr 18, 2012 12:32 pm 
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Car Model: ST205
Indeed it is up and running :D

Couple of minor leaks from power steering cooler at the front and engine oil cooler which is under investigation :wink:

Temps are great, haven’t managed to get oil over 100° (yet :lol: ), water sits at 79-80° under a fair load.

Air temps on the Apexi commander have been about 25°-30°, max temp I've seen is 45° (heat soak pulled up).
Under similar conditions the charge cooler setup would typically be 35°-45° with a max of 55° ish. But of course when its got that hot it will only drop to 40° or so after that. Whereas the fmic drops right back to 25° :)

Gearbox seems to have a little hesitation when changing at high revs, I'm hoping it's an old box which needs a little settling as appose to me regretting taking OpieOils advice on the fully synth oil :?
If it persists I may have to try the mineral route.

Clutch, I was almost regretting it the drive back home lol. But the morning after it was a lot more forgiving and after a couple of lessons from Chris I'm getting a lot better at giving the throttle a little blip on down change which lets the revs match nicely, just doesn't seem very fuel efficient lol.

Performance wise, with the same settings on the boost controller it's now boosting at 1.15bar on low which was previously 1bar and 1.25bar on high which was previously 1.1.
I've of course left it on low as it's enough of an animal. I have it booked in with Ryan on 8th of May so will be interesting to see what the limiting factors are (I think reliability :) ).There is a small amount of lag, isn't quite as responsive as it was but still nowhere near as laggy as the old mans hybrid :lol: :wink:


A few pics...


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 Post subject:
PostPosted: Sun Apr 22, 2012 4:39 pm 
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Hows it going dan


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 Post subject:
PostPosted: Mon Apr 23, 2012 12:04 am 
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Location: Perth, Western Australia
Car Model: ST205
Nibbles wrote:
......I'm concerned about the header tank / swirl pot setup as it's completely sealed with no pressure relief / pressure equalisation facility. It just needs the slightest weep through head gasket and the system will just pressurise until a pipe bursts - or on a cold morning, all the pipes could be sucked flat.
Has anyone come across a fully sealed setup before, or should we be looking for a valve to stick in the top of the tank ?
The header tank should have a pressure cap fitted. If it doesn't then the coolant will find the weakest part of the system to expand into. The worst case scenario is the head gasket could blow and that could be quite expensive :oops: Please tell me you've fitted a pressure cap somewhere in the cooling system?

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1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp


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 Post subject:
PostPosted: Fri Apr 27, 2012 9:01 am 
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* Could some admin maybe stick my first post on page one then following posts on page 2 please? Some idiot posted too many pics :lol:



Funny you should say that Don :wink:
Chris said the same as we were installing it. As a short term fix I was releasing the pressure every day or two.

Until I went up to the Lake District and forgot to release it. So after a few hundred miles of motorway, bit of spirited driving and just as I caught the rest of the party up after a 15mile blast, ( for other reasons the lead car could not stop as I stopped for fuel lol) with almost perfect timing as I arrived in view of the others, it went pop lol. Turns out the top end tank on the rad was the weakest link.

So after a call to TCB had 10l of forlife and a new rad arrive at the camp site the next day.

As a even more safer temporary solution we have taped down the lid with about 3/4 of a turn so it's not pressurising (which means it will boil at 100° I think) but highest it gets to is 93° sat still.

So back to planning how to retro fit a pressure cap/valve to the lid or top of the header tank.


Other than that car was fine, temps good, tyres brilliant. Getting a lot better at blipping throttle and matching revs. Still need to sort the above prob and a small power steering leak over the weekend, then should be good for mapping 8)


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 Post subject:
PostPosted: Fri Apr 27, 2012 1:34 pm 
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Joined: Wed Jul 13, 2005 12:14 am
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Location: Camberley, Surrey
Car Model: ST205
Sorry I'm not sure the post can be split like that over different pages. I will have a look in the settings though.

Remember that although the water isn't boiling it will still be evaporating so keep an eye on the coolant level!

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1996 ST205 UK


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PostPosted: Fri Apr 27, 2012 1:48 pm 
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Location: Bournemouth
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One thought I've had Dan - scour the scrapyards for a small resevoir tank with a conventional pressure cap and a single outlet at the bottom. The ST165 had one.
You can then put your 2 air bleeds through a Y piece (available from halfords) into a single port on the header tank and feed the other port on the header tank to the expansion bottle.

e.g.

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If at first you don't suck seed, try drier grain.

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PostPosted: Fri Apr 27, 2012 2:19 pm 
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Location: Bournemouth
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or a bike breakers

http://www.ebay.co.uk/itm/RADIATOR-FILL ... 1c256fda63

http://www.ebay.co.uk/itm/1989-KAWASAKI ... 5188dd69d1

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If at first you don't suck seed, try drier grain.

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