My AE86 F20C Project
 

This post isn't going to be much yet. Just some details and a couple pics.

I just purchased this 1985 Toyota Corolla SR-5 hatchback rust free, straight, anc clean title ($400):

https://i43.photobucket.com/albums/e...ighter81/1.jpg

I also have purchased this motor/tranny/harness package ($3100 delivered to my parents house):

https://i43.photobucket.com/albums/e...ter81/b4_1.jpg

I'm still in Italy, but I'll be home on leave next month, I'll be doing some minor cleaning up, and then towing it to a shop in Vancouver BC. Say all you want about not doing the work myself, because it doesn't matter to me. I'm not capable to do the swap myself, I don't have the custom fabrication and welding skills. The shop is run by a friend of mine and they are charging me $3500 for all labor, well worth it to me.

I'll be deployed in Honduras for a year, the car will be completed while I'm there, and I'll have a friend go pick it up and take it back to parents garage to wait for me https://honda-tech.com/forums/images...es/emsmile.gif

Things I've ordered for it:
AEM EMS
S2000 Gauge Cluster
Wilwood Front Brakes / AP Racing rears
GT-S rear end with KAAZ LSD
10 Gallon Fuel Cell
Lots of other misc stuff

I'm still deciding on what route I wanna go with suspension, and what size wheels I want, I'm going for the Work Equip 03's, debating between a 15x8 and 15x9.

Although the car will primarily be a weekend driver and AutoX car, I'd like to hit the drag strip every once in a while, and I'm *considering* a small Nitrous shot, either 50 or 75, with a hidden 5lb bottle. I've still gotta do more research on how well the F20C handles nitrous.

As far as motor mods go, right now I'm keeping it pretty basic, intake, exhaust, header, and some mild cams, and possibly the nitrous.

The car will be stripped completely, with all sound deadening removed with dry ice, my goal is 2000lbs without driver. Not sure if I'll be able to do it with the full cage that will also be going in, we'll see how that goes.


I'll post more pics of the car next week, my parents are gonna take more pics for me to hold me over until I get home next month. After I drop the car off the shop is going to e-mail me progress pics as things go along.

Should be a fun car when it's all done! https://honda-tech.com/forums/images/smilies/emthup.gif


Modified by firefighter81 at 1:47 PM 3/3/2006

Re: My AE86 F20C Project (firefighter81)
 

Neat project, but for as much as you spent you could have gotten a whole s2000.

Good luck, take more pictures.

liam

Re: My AE86 F20C Project (liam821)
 

awww, half the fun would be doing it yourself!

someday when I have enough spare time I want to do the LS1 into a 3rd gen rx7...

mmmmmm

https://honda-tech.com/forums/images/smilies/emthup.gif on AEM, I'm really wanting to find a deal on a used one.

Re: My AE86 F20C Project (liam821)
 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by liam821 &raquo;</TD></TR><TR><TD CLASS="quote">Neat project, but for as much as you spent you could have gotten a whole s2000.

Good luck, take more pictures.

liam</TD></TR></TABLE>

Yes, and I'm sure I'll hear that alot, but the fact is, I really don't like the S2000 that much. But I've been in love with the AE86's for the last 10 years. I can appreciate the performance of the S2000 however, and it's a great powerplant. So with some decent mods, I should pull 260hp without the spray. If I can get the car down to 2000lbs, that will be, around 1000lbs lighter than a stock S2000 (correct if me if I'm wrong on that weight).

So yeah, I'm spending alot of money, but it's a car that will be 100% mine, built how I want it, for the same price of an S2000.

stock weighs in right around 2,800 I believe?

Also, since I've been in Italy, I've been traveling around and deploying so much, that I haven't had time to spend the money on my only hobby, cars. So I've got all this money saved up, and now I wanna spend it. I know I should invest it, but not that worried about it, I've got my 401k and my military retirement plan, so I'm pretty set.

Anyways, I've considered getting an EVO IX, but I just don't wanna spend that much on a car. Even if I end up spending $20k on this Corolla, I'll be much happier in the end. I've got a decent little DD, and the Corolla will be ongoing project.

As much as I would like to do the work myself, it's just not something that I'm currently capable of, it's alot of work. Cutting out and rewelding in a new transmission tunnel, custom driveshaft, motor mounts, etc.

Yes, S2000's are at 2800 lbs. It'll be a sweet set up, once everything is tuned right. There is a BMI video (battle at 10,000, I believe?) with a segment of an AE86 w/ F20 swap. Looked pretty nice. Good luck.

Thanks alot for the good wishes guys. I really do appreciate it. It'll be torture sitting in Honduras thousands of miles away while the car just sits there waiting to be driven https://honda-tech.com/forums/images...es/emsmile.gif

Anyone got any comments/suggestions on the F20C and nitrous?

Re: (firefighter81)
 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by firefighter81 &raquo;</TD></TR><TR><TD CLASS="quote">
Anyone got any comments/suggestions on the F20C and nitrous?</TD></TR></TABLE>

N2O? Why? Is this going to be a drag car? If so, scrap that F20 idea and get an LS1.

Re: (P Nut)
 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by P Nut &raquo;</TD></TR><TR><TD CLASS="quote">N2O? Why? Is this going to be a drag car? If so, scrap that F20 idea and get an LS1.</TD></TR></TABLE>

I'm just throwing the idea around right now.

It won't primarily be a drag car, it will primarily be an AutoX/Track day weekend street driver. I just figured the nitrous would give me that little added boost when I do take it to the drag strip. That's why I was considering a small shot (50 or 75) and a small bottle, because I would seldom use it.

Like I said, I'm just researching the idea right now.

Re: (firefighter81)
 

AF member here too. Sick project. I wouldn't use N2O, but it's your car. Can't wait to see it. https://honda-tech.com/forums/images/smilies/emthup.gif

Yeah, I guess the N20 was just kinda spitballing. I'm probably not gonna do it, once the car is finished, I'll concentrate my time/effort/money into shedding pounds from her. The SR5 Corolla is 2250 stock, I figure the F20C has got to weigh a few more pounds than the 4AC, but with removal of sound deadening crap, interior, and lightweight bucket seats, I'm sure I could get down to sub 2000lbs.

Then I'll add a rollcage which will probably add back another 60lbs. At that point if I'm not happy with the power of the car (I'm sure I'll be perfectly happy) I'll look into power adders for the future.

Re: (P Nut)
 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by P Nut &raquo;</TD></TR><TR><TD CLASS="quote">Yes, S2000's are at 2800 lbs. It'll be a sweet set up, once everything is tuned right. There is a BMI video (battle at 10,000, I believe?) with a segment of an AE86 w/ F20 swap. Looked pretty nice. Good luck.</TD></TR></TABLE>

if i remember correctly they said it was like 4 million yen to complete the swap.

so i'll go ahead and do the math...$35,000

i think their labor estimate may be a little low?

That's ridiculous. The shop in Sacramento California that has done several F20C swaps charges ~$3500 labor as well. One such car was in the BMI video "American Togue" that belongs to Gabe Tyler of Techno Toy Tuning. I've spoken with him and the shop that did the swap personally, and they do the entire swap for $10k out the door, that includes parts/labor/fabbing/AEM EMS..... EVERYTHING for $10k.

There's more work involved in the swap if you have a RHD car, you have to custom fab up a new header and motor mounts that tilt the motor differently. But even then, $35k is absolutely ridiculous. Perhaps they said 400,000yen and not 4 million.


When the initial swap is done, the car should be somewhere around 250-260 flywheel hp, and weigh in at just under 1800lbs. Once I get into a little more modding and tuning the EMS, I should be around 270 or so. Sounds like fun to me https://honda-tech.com/forums/images...s/emsmilep.gif

Re: (firefighter81)
 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by firefighter81 &raquo;</TD></TR><TR><TD CLASS="quote">That's ridiculous. The shop in Sacramento California that has done several F20C swaps charges ~$3500 labor as well. One such car was in the BMI video "American Togue" that belongs to Gabe Tyler of Techno Toy Tuning. I've spoken with him and the shop that did the swap personally, and they do the entire swap for $10k out the door, that includes parts/labor/fabbing/AEM EMS..... EVERYTHING for $10k.

There's more work involved in the swap if you have a RHD car, you have to custom fab up a new header and motor mounts that tilt the motor differently. But even then, $35k is absolutely ridiculous. Perhaps they said 400,000yen and not 4 million.


When the initial swap is done, the car should be somewhere around 250-260 flywheel hp, and weigh in at just under 1800lbs. Once I get into a little more modding and tuning the EMS, I should be around 270 or so. Sounds like fun to me https://honda-tech.com/forums/images...s/emsmilep.gif </TD></TR></TABLE>

i thought it was a lot of money when i had heard it too...maybe it was the fact that it hadn't been done before and so it was all basically trial and error...who knows...i'll watch it again tonight and see if i was off...but i'm pretty certain it was 4million.

Re: (silver j)
 

Hey man.

Best of luck with your project - I am currently performing the same op on my Japanese Levin. Blew up my 4age and couldn't be spending silly money on another 180-200bhp engine that will just go pop again from constant abuse.

http://xtr2net.dnsalias.com/images/ae86/70.jpg

Hopefully it will be back doing this come summer time
https://i20.photobucket.com/albums/b...u873/don47.jpg

best of luck with your conversion man!

Re: My AE86 F20C Project (firefighter81)
 

i would have gone with an sr20det swap. Here in hawaii someone did an f20 swap into an FC but he crashed it drifting.

Re: My AE86 F20C Project (fkneh)
 

I considered the SR20 swap, but it would end up costing more due to some differences, and also, I've been a turbo freak for so long, I figured I'd try N/A. I might go forced induction later on down the road, but the first priorities are getting the swap and stitch welding done and shedding some pounds.

The car was delivered to my parents house, it's in real decent shape for $400 with a clean title. Here's some pics.

http://www.posdsm.com/uploads/images...G_0966_1_1.JPG
http://www.posdsm.com/uploads/images...G_0968_3_1.JPG
http://www.posdsm.com/uploads/images/88/IMG_0979_1.JPG
http://www.posdsm.com/uploads/images/88/IMG_0996_3.JPG

The condition of the interior didn't matter much to me, the only thing not being replaced or ripped out is the dashboard, which is in great shape. All carpet, seats, and sound deadening are being removed. A Sparco Ultra seat (maybe two) will find a new home inside. I chose the Ultra because it's the lightest seat for the money, 12lbs, $450. Lighter Sparcos are CF and $1000+.

I've ordered alot of stuff for it over the last few days:

Headlights
Corner lights
Driver's side tail light
Front grill
Upper windshield trim piece
Momo 330mm suede steering wheel w/ hub and quick release
Sparco Ultra black seat
Autometer fuel level and engine temp gauges
Konig Rewind 15x7 wheels

I still won't be home for another 4 weeks, but once I'm home I'll really get cracking on it. Gonna rent a high pressure steam cleaner and remove every panel on the car and clean the shit out of it. Entire interior except dashboard will be removed, and sound deadening will be removed with the assistance of dry ice. I can't wait to get started.
https://honda-tech.com/forums/images/smilies/emthup.gif

Now I need some ideas for a muffler for the car. I don't mind loud, but I'm trying to keep away from a fart can. Should I just get a basic Flowmaster muffler? Anyone have reccomendations on another brand?

Re: (firefighter81)
 

HKS Carbon Ti 60mm.

Re: (firefighter81)
 

t1r 70

or

j's racing 70

*shrug*

Wow, I didn't know mufflers could be so expensive. I don't wanna spend $1000 on a muffler https://honda-tech.com/forums/images...s/emsmilep.gif

That HKS Ti is a possibility, but I'm gonna have to convince myself to spend $400 on a muffler first.

Re: (firefighter81)
 

Its more like $300. My entire exhaust for an S2000 ran about $750 for a 3" single catback/testpiped setup with a 3" straight through presilencer.

First site I checked said $389, but now found a few sites at $279, so that's not too bad. Sounds pretty good? 3" seems kinda big for an N/A, or are you FI?

Re: (firefighter81)
 

It was supposed to be a turbo exhaust, but I don't mind it on an N/A car at all. No booming, low drone, deep and throaty. I recommended the 60mm for you because I've ran that setup before, and it doesn't sacrifice low end.

Re: (Slideways2000)
 

Sorry to disapoint but a local guy did this already and is making 500+ whp turbo

Re: (GDM Ap1)
 

That's irrelevant. He's doing his own project. I'm not going to stop a turbo build just because a local guy is making 600whp. Besides, he's staying N/A it seems, and he actually tracks/auto-x's his car. Leave the man to his madness.

Why would that dissapoint me? I never claimed to be a pioneer with this swap.

Are you dissapointed because there are other turbo S2000's out there? https://honda-tech.com/forums/images...es/emdgust.gif

Actually, hell I would like to meet the guy with the 500hp one, just to see how it feels. He obviously has different goals than I do with his car. My goal isn't to make alot of horsepower, it's to make an extremely well balanced car with a good amount of power. It would be nice to meet someone with the same swap who has different goals, just to see how he approached it and see if I can learn anything. I don't need to run 9's, I really don't care about drag racing. To each his own though https://honda-tech.com/forums/images/smilies/emthup.gif

Re: (firefighter81)
 

Good attitude. Back to your topic, 60mm HKS + 60mm mandrels make a great exhaust.

Yeah, I am leaning towards the HKS muffler now, thanks for reccomending it.

Re: (firefighter81)
 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by firefighter81 &raquo;</TD></TR><TR><TD CLASS="quote">Yeah, I guess the N20 was just kinda spitballing. I'm probably not gonna do it, once the car is finished, I'll concentrate my time/effort/money into shedding pounds from her. .....</TD></TR></TABLE>

the f20c comes with forged internals from the factory, and capable of making hp on a stock block that sr20's dream about. a nice 150 shot direct port setup would be more than enough when you want to smoke that guy in the corvette. especially since you have an ems, with proper tuning, that engine will run beautifully for years to come.

here's a link to the first 10 second s2000 in US. 557 hp/363 tq on a stock block with a thicker headgasket

http://www.s2ki.com/forums/ind...66290

I'll think about it still. Although as I said in an above post, weekend driving, AutoX, and light road racing are going to be the primary uses for the car. So the N20 will only come if I decide to get a little more into drag racing.

I spent today ordering new OEM parts, can anyone suggest anything else I should buy while the motor is out? Head gasket maybe?

OEM Exedy Clutch kit
Water Pump
Timing Chain
VC Gasket
Intake Manifold Gasket
Exhaust Manifold Gasket

Anything else?

edit: I've decided to go ahead and do a complete motor refresh. So rings, seals, head gasket, and all other gaskets. https://honda-tech.com/forums/images/smilies/emthup.gif


Modified by firefighter81 at 5:31 PM 3/10/2006

Re: My AE86 F20C Project (liam821)
 

L U C K Y

wow i was thinking im the only one in this forum that has a corolla well nice idea on your car man F20C is a good motor good luck hope to see it soon

Re: (put3ska)
 

good luck with the project... i wanna keep an eye on your progress.

Re: (dabullet)
 

subscribed.

The last week or so I've been doing alot of research and I've been inspired in a few different ways.

First off, the dash is coming out, along with the whole ventilation system (heater core and all) and a full FIA approved cage is going in. I'll be fabbing up an aluminum dash which should be about 3lbs when finished. It will be painted black as well.

Also, I've decided to go turbo on this car. After reading through the s2ki.com forced induction forum, I am very impressed with the F20C with a mild turbo setup (312whp and 210tq @7psi on a Mustang dyno). They can be beat on for hours road racing and take it like a champ. I don't think any of the currently available manifolds will work with my setup, they put the turbo and intake pipe too far forward. I'm in discussion with the shop doing my swap, and also another shop about fabbing up a nice manifold for me. The battery will be relocated to get rid of some that front weight that the turbo will add. The intercooler will be lightly sprayed black with radiator paint. An oil cooler will go in as well.

The stock fenders are going to be hacked out, and the fender wells are going to be beat in enough to fit 275's in the back for road course use. Bolt on fender flares will take the place of the stock small flares.

For a purely functional basis, I've decided to get a body kit. This one looks perfect because of the room for the intercooler, while still flowing air to the Koyo radiator very well. The oil cooler will fit nicely in one of the side ducts. Only $400, if there's slight fitment problems, it's no big deal, I can work with fiberglass fairly well.

https://i21.ebayimg.com/04/i/06/4d/da/f4_1.JPG

Lots of stuff going on in my brain. When the car is all done, it should do very well in all situations (except daily driving https://honda-tech.com/forums/images...s/emsmilep.gif but it's not a DD anyways).

I'll be back in the US in mid-April to start the initial cleanup process as well as ripping out the dash, complete interior, and all sound deadening. I can't wait to get home and get started!

Re: (firefighter81)
 

Looks like you got everything planned out pretty well! Hopefully your friend/buddy will adhere to the $3500 they quoted you because labor can add up fast if something goes wrong!

what diff are you going to run w/ all that power the old corolla GTS rear will break on you.if you intrested modified inc. makes carbon fiber dash case...running free is a good body kit but expensive, add on a carbonfiber drop vent hood and damn you car will be a S2000 kicker lighter and diffrent.