Project Add power to make Sith - waiting for new home 8/20

Talk about your project car here

Postby justjoe » Sat Jul 12, 2008 4:02 am

I did have some Nylon nuts and good bolts, unfortunately they were the exact size of the bolts.. and if I did that, I wouldn't have been able to move the calipers out another 2mm or so..
So I ended up using some bolts that were smaller than the hole.. but I didn't crank on the bolts.. and thus they came loose.. loose enough to make the whole caliper move down.. part of the caliper was rubbing on the rotor and the caliper was also touching the wheel!!! I had to fix that right away. So, as I said before, they are bolted on VERY well now, and they are not coming off anytime soon.

I did end up sanding the pads just a little.. there was very little if any imperfections about the pads.. but make sure that I sanded everything down again.. it should be better when we go out tonight and see how everything is feelin. We will do a writeup on the setup soon.. with lots of pics.
Members don't see the above ad. Register now - it's free!
justjoe
89 AW11 MR2 Hardtop SC Swap <-- w00t!
90 ST185 Celica All-Trac
99 Camry Grocery getter..
Image
User avatar
justjoe
Club Member
 
Posts: 340
Joined: Tue Nov 22, 2005 1:06 pm
Location: Dallas, TX

Postby darthripley » Mon Jul 14, 2008 1:18 am

after bleeding the brakes for the 3rd or 4th time mostly due to having to take the calipers on & off that many times to get them secured on .. the brakes are finally coming into their own.

the brakes were put through their paces this past weekend on some twisty roads around Austin with the guys from 6gc.net

they stopped a million times better than the old brakes even thought about & kept us from rear ending one guy who thought it was a good idea to brake really really hard at the crest of a hill :x

i am working on a detailed step by step write up with pics so i should have it done by this week & will post it in the brake section so everyone can see it who might be interested.
Image
86 RN66 Hilux 4x4 Turbo Truck "Falcon" 22RTE
87 AW11 MR2 "Super 2" 4AGZE
90 ST185 Celica AllTrac "Vadar" 3SGTE
99 SXV20 Camry "Maul" 5SFE
Female Moderator
User avatar
darthripley
All Trac Goddess
 
Posts: 4110
Joined: Sat Mar 25, 2006 8:09 pm
Location: dallas, tx

Postby Nitro_Alltrac » Mon Jul 14, 2008 1:36 am

I'm really looking forward to this write up. This will be really good info to have out there.

Glad to here that the meet with the 6g guys went well. I hope you didn't embarass them too bad! :)
Mike

92 All Trac - Daily Driver

Image
User avatar
Nitro_Alltrac
Gold Member
 
Posts: 1990
Joined: Mon Jun 26, 2006 9:13 pm
Location: Nitro, WV

Postby darthripley » Mon Jul 14, 2008 2:10 am

Nitro_Alltrac wrote:Glad to here that the meet with the 6g guys went well. I hope you didn't embarass them too bad! :)


we did get to go first in line going back on the twisty road since everyone knew the alltrac was made for that kind of spirited driving 8)

one guy who was behind us - w/a 5sfe i think - was able to stick to us closely in all the twisties.
he was a good driver with a good suspension setup.

i can only think/imagine how Vadar would have handled if we had the GAB struts, JSpeed springs + whiteline rsb.

with an old COMPLETELY stock suspension on Vadar with only a 205 Torsen LSD to help Vadar actually held up pretty well.

the heat was the real enemy with saturday being the hottest day we have had so far this summer - a high of 102*
we got sunburned & overheated & unfortunately so did Vadar on the way home.
the temp gauge got all the way to HOT and we pulled over & the coolant boiled out of the overflow.
we let him cool him cool off & added more premixed toyota red coolant we brought along & the temp gauge moved to the middle again.
Vadar started right up & stayed at middle on the temp the rest of the way home.
everything felt ok after the overheating.
AFR's were normal & boost was ok too.
i'm thinking the thermostat may be toast ... we have been hearing coolant boiling under the rad cap just after spirited drives in the evening when its not so hot.
i don't think the headgasket blew or anything like that ... he had this overheating problem happen when we first got him & were driving him home from Cali ...we turned on the heater & it cooled him off (nowhere to pull over)
so like i said i am leaning towards the thermostat being the culprit.

the 6gc guys were cool to hang out with & they had nothing but love & admiration for Vadar which made both of us feel like proud parents :D

here's a link to the thread on 6gc.net w/lots of pics (vids to come later):

http://www.6gc.net/forums/index.php?sho ... 60209&st=0

-edit added more info
Image
86 RN66 Hilux 4x4 Turbo Truck "Falcon" 22RTE
87 AW11 MR2 "Super 2" 4AGZE
90 ST185 Celica AllTrac "Vadar" 3SGTE
99 SXV20 Camry "Maul" 5SFE
Female Moderator
User avatar
darthripley
All Trac Goddess
 
Posts: 4110
Joined: Sat Mar 25, 2006 8:09 pm
Location: dallas, tx

Postby robolt » Mon Jul 14, 2008 11:55 am

Watch out with nylock's they will not work around heat. They could get warm and the brakes could heat up the fasteners and they could work loose. Try flexloc, spiralock, splitpin or safety wire. Something that is made for the possible temperatures as rotors radiate a LOT of heat You never can be too safe around brakes.
'90 CS conversion
240Z, Super 7, + others...

You are in a maze of twisty little passages, all alike
User avatar
robolt
Club Member
 
Posts: 74
Images: 2
Joined: Mon Mar 06, 2006 1:44 pm
Location: California, Long Beach, SF Bay Area, Foothills USA

Postby darthripley » Wed Jul 16, 2008 8:42 pm

thanks for the suggestions robolt.

i'm making a list here of what i need to pick up for & install on Vadar for his big fall maintenance/overhaul coming up.
i'm doing this so we can both stay focused on what needs to really get done.
(x) in front of each item = completed/installed on car :D

* Suspension:
(x) KYB Dust boots + bump stops & OEM Strut perch insulators
(x) GAB struts + JSpeed springs
(x) Front Swaybar poly bushings
(x) SuperPro Front control arm poly bushings
(x) Whiteline RSB + SuperPro poly bushings
(x) Tworus rear endlinks

- install SuperPro rear trailing arm bushings
- buy Eibach camber bolts
- perform an alignment after all suspension work is completed
- high quality JDM 17" rims in a nice width/offset (long term)

* Transmission/Driveline
(x) install 205 tranny
(x) install C/F ACPT driveshaft
(x) install Exedy Hyper Single fw/clutch/pp
(x) install Technafit SS clutch line
(x) Speed Source extended slave push rod
(x) fill 205 tranny with toyota super gear oil
(x) install TRD 2-way clutch type rear LSD & fill with Kaaz fluid

*Engine
(x) install straight intake + Apex-i filter w/adapter
(x) install custom Grounding Kit & re-do some wiring + add better terminals
(x) install ST205 WTA I/C, pump, lines + heat exchanger
(x) install larger 15mm Carbing oil catch tank
(x) install new Innovate Wideband O2 sensor
(x) install HKS Silent Hi-Power cat-back exhaust
(x) install Cusco rubber exhaust hangers
(x) install Wolfkatz Side Feed Fuel Rail w/cleaned stock injectors
(x) HKS Adjustable Cam Gears
(x) install heat protective stuff to insulate underside of hood
(x) install heat protective stuff to wrap bottom & sides of WTA I/C core
(x) install custom c/f "sticker" for WTA I/C
(x) install Spal slim fan on radiator for more room + less weight - mount w/brackets
(x) install all aluminum Ron Davis radiator
(x) install HKS S-Type Rad cap
(x) install Project Kics magnetic oil drain plug
(x) install heat protective wrap on throttle cable
(x) install TRD low-temp thermostat
(x) install new alternator heat shield w/gasket
(x) install new alternator heat shield

- install 165 PS reservoir (in progress)
- install HKS Fan Controller
- order & install 1 step colder iridium spark plugs
- gut TVIS, install ATS Phenolic Spacer, clean intake manifold
- adjust HKS cam gears
- install Denso Supra TT Fuel Pump
- replace o-rings in a/c lines
- recharge a/c soon
- relocate oil filter & install ATA oil cooler w/SS lines & fittings

Parts Left To Order or Find:
- long term for Apexi PFC: MR2 MAT

Ordered, Awaiting Arrival:
- nothing for now

To Do:
(x) properly flush coolant with motor out
(x) replace water pump, gasket & o-rings on the backside
(x) replace HFH #3 on the backside of the motor
(x) replace camshaft seals
(x) replace oil pump seal & gaskets
(x) rebuild dizzy
(x) replace timing belt, #1 & #2 tensioners
(x) replace timing belt cover gaskets & paint covers black
(x) inspect spark plugs
(x) clean ST205 tranny
(x) replace old heater hoses w/new OEM ones
(x) steam clean engine itself
(x) with engine pulled, steam clean engine bay & treat rust on battery tray
(x) sand & polish valve cover + replace squished washers
(x) remove ABS brick + lines & p-valve, replace with non ABS lines & AWD p-valve & 3 way
(x) replace rear main engine seal & gasket
(x) replace a/c fan w/slim spal fan for more room & less weight
(x) replace a/c hose that is leaking
(x) bleed brakes again w/new Motul
(x) bleed clutch w/Motul
(x) refill power steering fluid w/new OEM ATF
(x) replace old rubber vac lines w/silicone hose
(x) weld on Random Technologies hi-flow cat
(x) install new rear hatch struts

- reinstall underbody panels, cut for ST205 WTA pump + lines & RC bumper



*Interior
(x) install new alarm
(x) install 7th Gen Celica Steering wheel + airbag
(x) make C/F Gauge cluster surround + install chrome trim rings
(x) install 7th Gen Celica/IS300 OEM pedal set
(x) install pair Recaro SRD seats w/Bride rails
(x) sort out gauge display cubby under radio

- shampoo carpet, clean floor pan underneath
- locate correct rear floor mats
- locate better looking sunvisors
- locate better looking glove box

*Exterior
(x) paint & install rear mudflaps
(x) paint & install RC front bumper, crash bar + foglights
(x) install GT-Four badge on rear hatch

- full Zymol wax treatment


* Take to a 4 Wheel Dyno after all upgrades/clutch break-in is complete
* Weigh at truck scales for kicks

this list should complete our stage 1 for Vadar.

Stage 2 upgrades after we have a house w/garage:

*Engine
- order GT3071R turbo kit
- order larger injectors Sard 800cc
- order HKS, JUN or Toda 264* intake/exhaust camshafts
- order 2zz shimless buckets
- order JUN head studs
- order JUN knockoff intake manifold (would prefer real JUN manifold)
- install adjustable Sard FPR
- install Denso Supra MKIV Fuel Pump
- install Ingalls engine torque dampner
- go standalone install Apex-i Power FC (gathering parts for Gen 3 electronics switchover)
- possibilty of full build w/forged internals + 5sfe crankshaft for a 2.1L stroker
- install FiberImages CF RC/CS hood with OEM ornaments, hood spoiler & taller squirters

i know i'm forgetting some things, but this is a good start that i can come back & edit for personal reference.
Last edited by darthripley on Tue Nov 03, 2009 9:25 pm, edited 62 times in total.
Image
86 RN66 Hilux 4x4 Turbo Truck "Falcon" 22RTE
87 AW11 MR2 "Super 2" 4AGZE
90 ST185 Celica AllTrac "Vadar" 3SGTE
99 SXV20 Camry "Maul" 5SFE
Female Moderator
User avatar
darthripley
All Trac Goddess
 
Posts: 4110
Joined: Sat Mar 25, 2006 8:09 pm
Location: dallas, tx

Postby ST185pinjo » Thu Jul 17, 2008 11:43 am

Big list!

A lot of work!

happy tinkering. :D
Image
ST185pinjo
Club Member
 
Posts: 819
Joined: Mon Aug 15, 2005 4:55 pm
Location: The Netherlands

Postby WarTowels » Thu Jul 17, 2008 4:09 pm

^Wow. Really taking Vader to the next level.

EDIT: I'd be interested in a write up on eliminating the AFM... hate that thing.

-Towels
Last edited by WarTowels on Thu Jul 17, 2008 5:50 pm, edited 1 time in total.
2003 S2000
1985 300TD
User avatar
WarTowels
Gold GTfour God
 
Posts: 6443
Joined: Tue Aug 17, 2004 4:30 am
Location: I live in a garage.

Postby Nitro_Alltrac » Thu Jul 17, 2008 5:01 pm

This will be the point when Vader goes from apprentience to Master! :evil:
Mike

92 All Trac - Daily Driver

Image
User avatar
Nitro_Alltrac
Gold Member
 
Posts: 1990
Joined: Mon Jun 26, 2006 9:13 pm
Location: Nitro, WV

Postby darthripley » Fri Jul 18, 2008 12:57 am

lol well said Mike :D

well, i was trying to pick up a KP61 Starlet, but it didn't work out (for the best) and after getting to drive Vadar more, we both realized how much fun he truly is to drive.
he would be more fun with a bit more power - nothing too tits out - just something more "Sith-y" with a "real" turbo.

I'll get a KP61 someday when we have a bigger driveway & a garage, but for now, why not aim towards making Vadar the Dark Lord of the Sith he should be :D 8) :smokes:

205 front brake pics & write-up coming up below.
Image
86 RN66 Hilux 4x4 Turbo Truck "Falcon" 22RTE
87 AW11 MR2 "Super 2" 4AGZE
90 ST185 Celica AllTrac "Vadar" 3SGTE
99 SXV20 Camry "Maul" 5SFE
Female Moderator
User avatar
darthripley
All Trac Goddess
 
Posts: 4110
Joined: Sat Mar 25, 2006 8:09 pm
Location: dallas, tx

Postby etantshi » Fri Jul 18, 2008 1:30 am

darthripley wrote:- nothing too tits out -


wow... didn't really expect you to say something like that lol I guess you're picking up the AT.net potty mouth. lol
-----
André B.
1991 ST185 (down but not out)
1990 ST185 (lost, but not forgotten)
1996 RZN140 (the daily)
2004 Yamaha R6 (needs a battery)
etantshi
GTFour God
 
Posts: 5749
Joined: Fri Sep 03, 2004 1:05 am
Location: Augusta

Postby Nitro_Alltrac » Fri Jul 18, 2008 1:42 am

etantshi wrote:
darthripley wrote:- nothing too tits out -


wow... didn't really expect you to say something like that lol I guess you're picking up the AT.net potty mouth. lol


Hang around here long enough and it happens.
Mike

92 All Trac - Daily Driver

Image
User avatar
Nitro_Alltrac
Gold Member
 
Posts: 1990
Joined: Mon Jun 26, 2006 9:13 pm
Location: Nitro, WV

Postby darthripley » Fri Jul 18, 2008 2:23 am

Everyone does the 205 front brakes differently, so please just consider this a basic guide.
I'm not responsible for anything that may happen to your car or you if you attempt to do this - brakes are obviously an integral part of the safety of the car and in turn yourself.

Before purchasing ST205 brakes, you must have a minimum of 16" rims & you better make sure you have rims that can clear the calipers.
16" stock 7th gen rims will not clear the calipers.
I know that 16" SSR Competition rims will & our 16" Speedlines also clear with plenty of room.

The Rear ST205 brakes are a straight bolt on for a ST185.
The only mod necessary will be you can either cut off the dust shield or bend/massage it out of the way for the rotor.
The rotor can retain the original diameter of 315mm and the 2 pot calipers bolt on with original ST185 hardware.
No fuss no muss.

Now onto the front brakes.

First we had the rotors milled down 9mm, so now the front rotors have an overall diameter of 306mm.
You could still have 1-2mm of rotor that could be milled off without having the brake pad hang off the rotor.
A lot of it depends on using different sized bolts to move the back half of the caliper further out to the rotor.

Image

We also had the front rotors turned for a new surface to use with old pads which we later sanded down to avoid any high spots forming.

You will have to use a spacer to allow the rotor to clear the lower ball joint.
We chose to use an Ichiba 5mm spacer and we had the diameter of the spacer milled down 4mm so it would fit inside the rotor hat.
The machine shop was kind enough to bevel the edge for a perfect fit.

Image

We also used extended studs which are an absolute pain in the arse to get into the hub.
After struggling getting 1 stud in the hub, we realized that putting oil on the threads allows the extended studs to go in much smoother.
(we don't have a press - hence the ghetto operation pictured)

Image

and for those of you wondering - yes i really do help work on Vadar, even the tough jobs.

Image

unless you take apart your hubs and a set of 205 hubs to use the 205 dust shields, you will have to do something about the 185 brake dust shield up front since it is in the way.
we chose the easy route which was to cut off the dust shield :)

to fit the caliper on and get it to center onto the rotor, you must grind off 2-3mm. basically you have to compensate for the spacer so hence the grinding. you can see here in the pic below where joe ground the caliper on the "ears" and how the ST205 calipers "split" in half.

Image

since the hub is 54.1mm on an ST185 and 55mm on a ST205 we again used a little metal ring on the inside of the brake rotor to keep it on the hub nice and snug.
here are the extended studs on along with spacer & just enough space to clear the rotor.

Image

just enough space to clear the lower ball joint:

Image

we used technafit 185 SS brake lines which work perfectly with the 205 calipers. at full lock there is a tiny bit of stretch in the line, but nothing to be concerned about.
here is one side all installed along with new ss lines:

Image

the caliper on one side is only a tiny bit off center, but close enough for govt. inspection ;)

Image

installed completely with pads & hardware:

Image

we used Motul brake fluid too which helps immensely :)

Image

do not forget to torque the calipers down to 75ft lbs ... this was 1 of the causes of the problems we encountered.

also use good bolts and fasteners so the calipers will not slide down and wear the inside of your rim, which also happened to us.

Finally, here is a comparison before & after.

ST185 stock brakes before:
Image

ST205 front brakes now:
Image

was it worth it upgrading the brakes?
DEFINITELY!

excluding performance mods & the short shifter, this was one of the most important/most noticable mods we have done so far.
we put the brakes through their paces on some twisty roads in the hill country in Austin and they performed very well.
they did something the old brakes didn't do, which was STOP!
without going through the floor pan to stop fred flintstone style either.
the 205 brakes have also done something the old brakes never did ... there is brake dust on the rims for the first time -- amazing! :twisted:

yes, the 205 brakes are much heavier, so just like any BBK you will add weight & take away from the whp of the car.
however, i feel it is worth it for the safety aspect as well as any track events we may want to do in the future.
not only that i feel with performance pads, the brakes can support the amount of hp & tq we will hopefully be making in the future.

for the final price - everything cost to do the entire brake project - it was about half the cost of a brand new Wilwood 4pot setup for the fronts only.

for those sticking to a tight budget, this is an inexpensive oem BBK that not only looks amazing but performs head & shoulders above the oem setup which is lackluster at best imho.

i may have left something out, so please feel free to ask any questions.

Now, Vadar has proper stoppers more becoming a Sith Lord 8)
Image
86 RN66 Hilux 4x4 Turbo Truck "Falcon" 22RTE
87 AW11 MR2 "Super 2" 4AGZE
90 ST185 Celica AllTrac "Vadar" 3SGTE
99 SXV20 Camry "Maul" 5SFE
Female Moderator
User avatar
darthripley
All Trac Goddess
 
Posts: 4110
Joined: Sat Mar 25, 2006 8:09 pm
Location: dallas, tx

Postby darthripley » Fri Jul 18, 2008 2:27 am

Nitro_Alltrac wrote:
etantshi wrote:
darthripley wrote:- nothing too tits out -


wow... didn't really expect you to say something like that lol I guess you're picking up the AT.net potty mouth. lol


Hang around here long enough and it happens.


LOL :lol:

i'm afraid i've said tits & other naughty words long before i ever came here lol
they used to say it ALL the time on some of the honda forums ... if anything was cool, all those guys would say "that's tits!" or "totally tits!"
Image
86 RN66 Hilux 4x4 Turbo Truck "Falcon" 22RTE
87 AW11 MR2 "Super 2" 4AGZE
90 ST185 Celica AllTrac "Vadar" 3SGTE
99 SXV20 Camry "Maul" 5SFE
Female Moderator
User avatar
darthripley
All Trac Goddess
 
Posts: 4110
Joined: Sat Mar 25, 2006 8:09 pm
Location: dallas, tx

Postby etantshi » Fri Jul 18, 2008 2:38 am

I actually noticed the weight difference to be slightly negligable. The st185 calipers and brackets are iron and are extremely heavy. The st205 caliper is aluminum needs no bracket and thus is lighter, however the rotor is heavier on the st205 vs the st185. I personally don't think there are many if at all downsides to this mod aside from having to get front pads from only a handfull of places (and not being able to run my OZ rally racing wheels...).
-----
André B.
1991 ST185 (down but not out)
1990 ST185 (lost, but not forgotten)
1996 RZN140 (the daily)
2004 Yamaha R6 (needs a battery)
etantshi
GTFour God
 
Posts: 5749
Joined: Fri Sep 03, 2004 1:05 am
Location: Augusta

PreviousNext

Return to My Project

Who is online

Users browsing this forum: No registered users and 1 guest