altezzaclub

Have you got some specs for how efficient those filter pads are? They should get down to 10micron at least, but then with their small area they will block up quickly. If you can feel the dust it is gritty enough to chew your motor up, so fine clays feel smooth between your fingers and silts feel gritty. Just google "micron efficiency car air filter" for some background, these sorts of thing- http://www.aftermarketsuppliers.org/Councils/Filter-Manufacturers-Council/TSBs-2/English/04-3.pdf http://www.donaldson.com/en/engine/support/datalibrary/073667.pdf http://www.hollingsworth-vose.com/Documents/Product%20Literature-Filtration/Automotive%20Air%20Filter%20Media%20Applications.pdf The main reason I have the agricultural airbox on The Girl's KE70 is that I don't trust foam socks and the airbox runs a full late-model Corolla air filter. When I took it off a few days ago the carbs were dead clean in their throats, while the rally car has fine dust in behind the socks. With your lack of room I can't even think of a way to run an airbox with a filter somewhere else. Even some tapered fibreglass box would be hard to squeeze in there.

Sell'em... fit quad Keihins.. The bike carbs are small and aim upwards. Upright the motor, that gives a whack more room right where you need it. Make your own manifold, two separate ones that aim one forward and one backwards away from the turret. Use twin throttle cables. Use twin inch & 1/4 SUs, they're also shorter. They aren't working very well just like that even, they want more than a choke diameter clear air in all directions at the entry, so cyl 3 is getting squeezed.

I thought about replacing the little diamond-shape insulators with thiicker plastic, but they were Lexan and my replacement piece was a lower melting point Perspex so I did away with them altogether. The new version starter motor heatshield took the form of a polished stainless steel sheet bolted to Hardiplank and hung on the extractors with stainless wire. This sits hard against the bellhousing at one end and will reflect the heat away from the motor. I re-wrapped the extractors at the top where they were still painted blue, that will stop some of the heat going up through my alloy heatshield and into the carbs.

hmmm... Well, its a Celcia and there's no use WASTING it at a wreckers..

Arrgh! Forgot about toyodiy! Star man! Same part numbers! cheers

The Girl's KE70 has a split in the top of the passenger's rack boot, but KE70s aren't listed in the parts book the shop has, it is all AE Corollas. Does anyone know if the rack boots are the same on the AE86 & the KE70?? I can't see why Toyota would change them, but there are differenmcs in the racks aren't there?? Thanks

Not specifically, but I'd assume you soak the PCV valve in petrol then spray it out with Brakleen or similar. Inside is a spring and a piston valve The little piston inside should move up and down when you tip it upside down, and it should seal so you can only blow through one way when it is horizontal. The rest are just hoses as far as I know.

Nice! What's it like around town and at traffic lights... that annoying "under 3000rpm" driving?

Well, its been a few years with many experiments, and now I can see what has worked and what hasn't. With the drama on the orange rally last weekend (How not to build a rally car) the exhaust started sounding like a tractor.. I thought the special stage work with a loaded car had torn the pipe off the extractors, or the extractors had been cracked at the head. But no, something I've never seen, they were acturally melted out of shape and when cool one pipe had cracked. I don't knowe how long they have been mis-shapen, with the fibreglass wrap on you can't tell, but I do remember they got red-hot coming up out of Bathurst way back in the early days when we bought the rich needles. The Girl was flat-out going up the hills when I said to pull over to swap needles, and as I opend the bonnet at dusk the pipes were glowing pnk. So I assume my lean running up to Walcha and back has had them red-hot much of the time, the metal is heat-spalled over quite an area. Anyway, a 6km walk downtown and back carrying a set of extractors, and a $20 donation to the welder's beer fund means they should work. Other problems- Two of the diamond-shaped insulators I cut out of a sheet of plastic have broken, I assume they got brittle and the gasket paper half-stuck to the inlet manifold and half to the carb. I'll need new paper gaskets too. The throttle cable is frayed where it comes out of the outer cable- I folded the carbs back over on themselves when I took them off, which certainly didn't help. The rack boot on the passenger's side is split on top, not something you can see without taking off the exhaust. and I already knew the Corona LCA balljoints were worn so Id better get them done too. I'll toss up a separate topic on heat-wrapping extractors- http://www.rollaclub...ors-or-headers/

These have been running on the KE70 for several years, beautfully wrapped in the fibreglass cloth they sell for the purpose. The rowdy sound of a pipe cracked off the manifold means I pulled them off, and got quite a shock. They have been red-hot and soft enough for long enough to flow into a new shape. While the obvious place for them to get hottest is right by the head, you can see that the paint is still fine at the ends, it is only where the pipes join together that is has over-heated. I could wrap each pipe individually for the first part, but then had to wrap around all four at once, and that is where the metal got really hot. I assume the pipes were transmitting heat to each other, rather than passing it on. The exhaust guy said the metal was OK where he welded the crack, even though it has re-crystallised several time. I won't be wrapping them all this time, just the parts that are still blue with paint. I have a heatshield above them to keep the heat off the carbs and seeing is only a sheet of alloy I don't want to melt it. I'll try to fit one below them to keep the heat off the starter motor. I thought of boxing them, but there is not enough room so I'll hook up a cold-air tube from the radiator panel to blow cold air on them generally. I assume this is from running the carbs lean on cruise, I suppose the way to find out is a webcam under there again! Anyone seen this before??

:POSTPICS!: The stock KE70 manual pedal box is an auto one with a bit welded on, so it might just be like that. or did they weld on a fitting to take the hydraulic rod??

You are SO lucky- I've got the carbs and extractors off the KE70 so you can actually see what is there. The solenoid activator wire is black & white, it comes from the igntion key. The three fusible links may not be the same in your KE30, they burn out when there is a short circuit, like a fuse does. Mine have a screw-junction added and are taped together as they fracture from old age and are irreplacable. The wiring diagram is KE70 too, so while the overall layout is the same, some things may not be in your KE30.

There you go! Put a filfrederick 4AGE head onto your cross-plane crank and you have a real flyer still using a K block!

The amount of choke it delivers is adjustable. I've never played with this particular carb but it looks like most of its generation. There is a choke idle screw that will need a touch up where the choke mechanism works on the throttle to hold it open at cold idle. Just screw it in a 1/4turn and see if that is enough. There will be a series of steps in the steel quadrant that holds the idle open in the various stages of warming up. Usually the black plastic cover on the back of the choke in that photo can be turned when you undo the three screws. It has a bimetallic coil inside that unwinds as it gets hot, so you just need to put more tension on the coil spring to close it slightly more. Make sure it comes back to completely vertical when warm.

Does it have an automatic choke or a manual one?

otherwise strip and check the alty- the diodes burn out and the brushes wear out.

I'd given up turning around and was reversing down by now, and was asked to go down and move the ambulances, at which time Ashley's face lit up with glee and she piled in for the ride down. We were all set for racing ambulances but found Steve and a couple of 4WDs had dragged them out of the way and were clearing the little space as a helicopter was due in. He had left the 2-way radio from the rally car up at his crash site, which was just a little further up passed the bad one and wanted to go up and get it, but I figured if we didn't get the truck out of town we would be loading the rally car in the dark. So he hitched a ride up in a 4WD and we went down to Pete. He had moved the radiator hose so it wasn't kinked and filled it with water and it ran fine while the water dribbled out. While we were deciding whether to drive a very rolled car back through the center of Orange or go and get the truck, Steve phoned and said he had the radio and was waiting for a lift down, We had left when the medic heli was circling the stranded ambulances trying to find a landing path in, but he'd actually stood there and got pictures! Back up the hill and I met him coming down in one of the 4WDs, and when we got back Pete and Ashley had driven the car into town. The control said they had cancelled stage 5 because of the crash, and then had to cancel stage 6 as the First Responders had all gone to the crash site as soon as they found out... so we had done all the stages... but hadn't handed in the road book to be counted as a finisher! We finally loaded it in the dark in the almost-deserted showgrounds, & I stopped to talk to the Clerk of the Course (Event Director) as he was packing up. He said we might be able to get out times accepted if we hurried into town where the scorers were working flatout. Then Pete came over to see what was happening and said he had got Ashley to hand our card in when they arrived just as she was meant to!! So we rolled AFTER the rally, seeing that stage never counted! We never got time to take revenge on Leichty, and of course he will rag Steve for years about rolling. Give us a clean run and we will whip his ass, its just a matter of time. Steve came 14th overall, after two dud stages with the puncture and the slower car, and the 10th place in a stage was great. There is a 2minute gap in the results between 9th and 10th, and that is where he should have been. However you need a clean run to do it... We found TRDKE70 and Steerfast at the prizegiving, they came down from BNE & won awards for coming 4th and 5th in their KE70 and RA65. It was great to finally meet people off the forums here, especially such great guys. There was another white RA40 Celica there, an immaculate one the driver said had been built twenty years ago and not touched, they were 16th. The Celica GT4 we have run up against before came 17th, a Levin was 26th an MR2 30th, and a KP61 Starlet was 31st, so Toyotas were there in force. Amongst the non-finishers were an AE86 and and RA23 Celica. So we have some chassis pulling to get done, a lot of welding in of structural engine bay panels, a roof panel-beaten, another radiator support front nose welded in, and we need new doors, new front guards, new bonnet, & new windscreen. It was all just a stress test of the welding a lot of people thought was crap- our strut spring bases, our cross-strut bar (saved the whole driver's side behind the turret from collapsing over) our seat mounts, our chassis welding (the actual box section chassis is fine, all the damage is above it) ..and my rustic farm-spec roof vent made from the Valvoline oil tin got destroyed before I got a decent photo of it! We picked the truck up this morning and stripped a mudguard off to see how bad it is underneath, and made a plan to move forward. Chassis-pull it, or cut it off and fit a new front, or get another shell and build that, or change to a KE70 now instead of being stuck in Celicas...

Straight into stage 5, the repeat of two, and I had the camera at the end for photos... but no, he rolled it up in the top of the hills. So we waited to see what eventuated and the following guys helped tip it from its side onto its wheels and stop it blocking the road. They were the same guys he was furious with for holding him up earlier in the day.. kama always strikes! He'd come to some nasty drainage humps that the road was full of, gone over one sideways and the front wheel dug in on the second, so it rolled over onto Ashley's side while sliding, then must have got almost airbourne and landed heavily on the front driver's corner and ended up lying on his side. The Recovery 4WD were going to go and get him as he was blocking the road, then the crew that helped arrived and sorted it out. It was vaguely OK but losing coolant, so I poured 10L of fuel into the Corolla and zoomed off to find a creek or a puddle to fill up the jerrycan. He drove it out with the radiator leaking and we were looking at it when the recovery 4WD went up anyway as they couldn't match the number of cars at the end control and the start control. We were standing there when they came racing back down and said to get it the car and follow them to give a hand, a car had vanished miles down the cliff. So Steve and Ashley & I left Pete with the bent Celica and we raced up the mountain in the KE70, once again doing stages in the road car. A 180B Datsun that had gone before Steve had slid off a yump on a downhill corner and just continued over the edge into the trees down the bank. Apart from the tyremarks if you knew where to look, it would never be seen, it was a good 20M down and upside-down against a tree. The navigator wasn't bad, but the driver had spinal injuries and had trouble breathing. They couldn't get him up the hill without 10guys in a firefighters line who climbed from the bottom to the top after they passed him onto the next guys. I didn't think they would ever get the car out of there, but we saw it later that night after prizegiving. anyway- The lady from the recovery 4WD met us 50M down from the crash site and asked us to go back down and guide the ambulances up, she was road control as they wouldn't let her near the wreck. We were to tell anyone else coming up to turn around and go down to keep it clear. So Ashley volunteered to stay with her, two woman are always better then one, and I managed to turn the car around on a narrow muddy steep pine forest track with a 45deg bank down one side and a 45deg drop down the other, both side covered in trees. Steve and I went back down to Pete & when two ambulances arrived they followed us up, but got stuck in the muddy section. So Steve jumped out, we emptied the Corolla and the ambos grabbed their packs and all piled in. I took them up the first gear track to the crash site. The first girl in said “How can you get this car up these roads,?” Then said “well, you're older than me I'll trust your driving!” They got to work and I was asked to go back down and bring the firies back up, so it was the 5-point turn and back down for the firies walking up, as the ambulances were blocking the road and their fire truck was only 2WD too. So I hauled the firies up The next were the Police walking up and I was asked to run them up before I'd even got down to the ambulances, so I turned back up and called out “taxi”. The girl got in the back, looked a the mixture display and said “Oh, I see the meter is running already!” When we got to the top she got out and told the guy “you pay the driver”... he said “We'll take if off his next ticket!”

Now, Leichty is a sly old fox who has been rallying since the 70s with Steve's Dad Pete. He's seen (and probably done) all the tricks I've seen over the same time, and a lot have nothing to do with holding a steering wheel.. On Thursday Leichty was talking to Steve's Dad Pete and asked him how Ashley, Steve's navigator, was getting down. She was meant to be coming with Leichty but hadn't formally asked him so there was lots of phonings and carry-ons between the four of them before it was settled. We left Walcha at 7am Friday morning with time to hit the wrecker and get the 3SGE motor out of the early FWD Celica down there. While Steve was in the KE70 with me following the truck, Pete rang him and said Leichty had just phoned and they were waiting to leave Port Macquarie but there was no sign of Ashley, so Steve better phone her. When he did her father answered and said there was no Ashley living there, then asked him who the hell he was, and what did he want with his daughter, then said she was freezing standing outside waiting to be picked up. So more phoning around and back to Leichty, who just burst out laughing and said he'd got Steve good! They had left with Ashley & Ben hours before and he was bored, so he set up the whole prank with Ashley's phone. So Steve and I spent the next couple of hours planning counter-attacks on Leichty! Anyway, we hit Orange about 2pm and started at the wreckers. That was as bad as feared and three hours later they were about to let the dogs out and go home even if we weren't finished. Finally, we ripped it out with the forkhoist and put it on the truck. We checked in at the Bowling Club HQ and did the paperwork, but could only get scrutineered at 7am Sat morning at the start. We got up Saturday 5.30am to leave at 6.30am and I noticed the canvas on the back of the truck had been moved. Some prick had stolen the 50 litres of rally car fuel in the plastic containers! So much for this being a safe area. When Pete jumped in to take the truck to the start, the diesel had been siphoned! There is a puddle of that on the road by the gutter. ...and of course when I had raced off to get rally car fuel we found they had siphoned the rally car dry as well. Anyway, they made the start and off they went. We followed them up Mt Canobolas, the same stage as last year that drops steeply to the right near the summit, and found everyone waiting as someone had already gone off a couple of Km in and they wanted to clear the car first. So we went all the way around to the Cadia road and just missed them at the end of One, and caught up at the end of Two- with a puncture, which destroyed the first of the set of gold mags off the spares car. We changed that and sent him off to the 15min refuel at the showgrounds to buy another tyre from the Dunlop truck while I stopped at the wrecker with Pete to get Corona rims. 4 for $40, to hell with alloys now! (we've gone from $100 mags to $25 mags to $10 steelies now...) They had dropped position for stage 3, a 36Km all around the back of the mountain, and got caught behind someone slow that they couldn't get past, so when he got off the stage he was furious. Then a lunch break so we bought two new steer tyres for two steel rims, and he had 4 new tyres on the car when they repeated stage one. He moved from 17th place on the stage to 10th place, taking 50seconds off. It also took the smile off Leichty's face as he'd got a couple of minute up on Steve with the puncture and slow driver.

I meant to get some detailed photos but it was getting late, so we loaded the car and I spent the rest of the time loading tools, then reversed the truck into the woolshed for a fast getaway. If just fits.. at the front then overhangs the spare 18RG at the back. and you can't walk down the side- So we were all go for 7am-

What a weekend! Where did I get to? Right- the car was always full of dust, it really vacuumed it up as Steve would drive with the windows down. They would open the rear 1/4 windows to get airflow out, but last rally the nav's side one fell out and was hanging by its clip. So a roof vent was needed! I found an old Valvoline oil tin in one of the other sheds and grabbed the grinder. Being razor-blade thin it shaped nicely into a wedge, and the grinder made short work of the roof. I slipped it into the hole and drew the curve of the roof along each side, then transferred that line onto a sheet of paper. Cutting the paper gave me a curve to put on a bit of timber, and a hacksaw gave me a roof curve. I made two of them, clamped the tin edge between them and bent a couple of flaps that matched the roof. A couple of rivets and a reinforcing strip of metal underneath finished the basics. In case of rain while on the back of the truck I cut the rest of the tin into a front cover that neatly read "Valvoline" and it clipped over the opening. Inside a took the grinder to a 20L drench container and made a vent that directed the air to the back instead of freezing the crew. If it gets too hot in summer I'll cut holes in that and make some adjustable gizmo to direct the air to each seat.

We've got $40 ones from Shitcheap or similar, and the lift height is always too low. The trouble is, to get good lift height they are both expensive and made for lifting too much, so too heavy! I'd love a cheap plain one that lifted 600kg 600mm high. Sadly to get 600mm its made to lift about 3tons! Anyone want to start a sticky'd thread about what garage equipment you need for working on Rollas?? Jacks, stands, welders, grinders, sliding hammers, port-a-power panelbeating stuff, a hoist, engine stands, parts washer, chassis straighteners, lathe, mill,...

That will probably be the wire that activates the solenoid on the starter, so you will need that connected to its tab on top of the starter by the big wire.

There were more things done, but I have to go to bed as there is yet another 6am start tomorrow... and we have to find Steerfast and TRDKE70! We watched the local news on TV tonight where they were talking about the rally and dang! There goes the red and white Celica across the screen! So we're famous already! More updates Sunday!

The maths is simple- the 4mm bend in the wood on each side gives 8mm to add to the back measurement, then subtracting front and rear gives toe-in or out over the length of the wood. My timber was 1500mm long, compared to the rim at 360mm. I measured 1780 & 1790, whch became 1798 with the timber bend. So I had 18mm of toe-in along the timber, which is 4mm over the rim. Then you adjust the toe in as needed (the painful part) and push the car forward again a couple of metres to settle the steering. Repeat the measurements until you get what you want. I made it 2.5mm of toe-in after this.