LINDSAY Posted September 28, 2006 Report Share Posted September 28, 2006 (edited) Hello all i have finally got some pics of my work in progress , about february the 3K in my KE25 had just about had enough So i got myself a 16V 4AGE with T50 , it was all setup for RWD (plenum , thermostat , etc) and ripped out the 3K and got to work . First up me and my Dad put the engine in its place with the AE71 mounts that it came with , no go , the mounts were too wide for the brackets on the x-member so we had to get started on making up some custom ones these are the mounts the me & Dad came up with , made from 6mm steel plate . we used MDF board to get the shape of the mount pieces and used them as a template on the 6mm steel , cut the steel shapes out , then while the engine was suspended in place by the engine crane tack welded the various shapes together as these assemblies , then took them to a steel fab place and they welded them properly for me . Got the engine mounted nicely now with just enough room at the back then i noticed the mount was right inline with where the oil filter should be so i had to install a remote mount oil filter setup like this Edited September 28, 2006 by LINDSAY Quote Link to comment Share on other sites More sharing options...
LINDSAY Posted September 28, 2006 Author Report Share Posted September 28, 2006 (edited) next thing to get done was the clutch master cylinder needed to be installed , to do that i took some MDF board and made it the shape of the clutch m/cyl flange , then traced around that onto the firewall where i thought it should go and started drilling small holes around where the whole in the middle should be then chiselled between the wholes and enlarged it for the m/cyl to go through . i used an AE71 clutch m/cyl just had to shorten the push rod a bit . Edited September 28, 2006 by LINDSAY Quote Link to comment Share on other sites More sharing options...
Rolla__Boy Posted September 28, 2006 Report Share Posted September 28, 2006 Looks a bit better in the engine bay than the old 3K hehe. Nice work, keep the pics coming :( Quote Link to comment Share on other sites More sharing options...
LINDSAY Posted September 28, 2006 Author Report Share Posted September 28, 2006 i had to then finish the cooling system , basically just find some hoses that fit and are the right shape . It got a little bit hard when the bottom hose outlet on the radiator is the oppisite side of where it is on the engine , but a trip down to pick and payless found me a cooling pipe from a mitsubishi colt that i cut down a bit and looks like it'll do the job . Heater hoses needed to be re-routed with a couple of elbow barb fittings put the plenum/manifold on the other day to check if i had clearence from the master cylinder , looks fine for the moment but i think that i might have to go a dual circut m/cyl but i might leave that untill i get to the stage of brake upgrade. so this is what its lookin like at the moment Quote Link to comment Share on other sites More sharing options...
Medicine_Man Posted September 28, 2006 Report Share Posted September 28, 2006 Looking great so far, Keep up the good work and it will be running in no time at all! Quote Link to comment Share on other sites More sharing options...
TheNOBBLER[RL] Posted September 28, 2006 Report Share Posted September 28, 2006 Looking very sweet, keep it up! Quote Link to comment Share on other sites More sharing options...
Jono Posted September 29, 2006 Report Share Posted September 29, 2006 Looking good! are you reinforcing the clutch master at all? Quote Link to comment Share on other sites More sharing options...
LINDSAY Posted September 29, 2006 Author Report Share Posted September 29, 2006 Nah , i wasn't planning on it .Where it sits right now is sort of reinforced and it is very stiff there too (busted a couple of drill bits getting through)plus i'm trying to stay away from welding as much as possible , my old man has got the welder at his place and we're both pretty average welders anyways . is it an engineering requirement or something? Quote Link to comment Share on other sites More sharing options...
Jono Posted September 29, 2006 Report Share Posted September 29, 2006 a mate of mine who did this conversion years ago found the firewall flexed quite a bit. Quote Link to comment Share on other sites More sharing options...
OKE055 Posted September 30, 2006 Report Share Posted September 30, 2006 (edited) looking good, the 4A looks like it should be there. Good to see you having a go at the conversion yourself. It is very satisfying when you finish, to know... I DID THAT. Keep up the good work and keep us posted. Not a fan of chromies on old rolla's but this one looks like it works. Edited September 30, 2006 by OKE055 Quote Link to comment Share on other sites More sharing options...
LINDSAY Posted October 2, 2006 Author Report Share Posted October 2, 2006 (edited) Thanks for the comments guys , yeah can't wait to get the beast going . I got busy on the weekend on putting an unleaded filler neck in ( engineering req.) seems a bit silly when you can't even buy leaded fuel anymore . I took the filler neck of a 87-90 Mazda 929 at pick & payless a couple of weeks ago (cost me bout $15) and had to cut it down a bit to join it up to original fuel tank inlet pipe Edited October 3, 2006 by LINDSAY Quote Link to comment Share on other sites More sharing options...
Jono Posted October 3, 2006 Report Share Posted October 3, 2006 unleaded filler neck in ( engineering req.) only if you don't find a good engineer. you may have to get a charcoal canister and catalytic converter too if you use a 'by the book' dude. Quote Link to comment Share on other sites More sharing options...
LINDSAY Posted October 3, 2006 Author Report Share Posted October 3, 2006 Cat convertor is coming soon when i get the exhaust done , but the charcoal canister i hadn't thought of , do you run the fuel return line through that ? where abouts are you getting engineered at ? Quote Link to comment Share on other sites More sharing options...
Jono Posted October 3, 2006 Report Share Posted October 3, 2006 don't want to post their name up for obvious reasons, but i'll explain when you ring me about the ECU. They are maybe a little more expensive but more relaxed about things. Quote Link to comment Share on other sites More sharing options...
ca18rolla Posted October 3, 2006 Report Share Posted October 3, 2006 looking good mate will be a nice little power upgrade and more reliable! Its great doing it yourself too! Goodluck P.S My mates ke70 firewall flexes with the hydrulic master conversion but my ke35 doesn t see if the clutch always disengauges fully if not may need bracing Quote Link to comment Share on other sites More sharing options...
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