Project Elephant: DeeCee's GT4A

deecee

New member
Hi,

I'm Dave/DeeCee and I am a GT4-A owner from New Zealand.

Been browsing around for the last couple of years and thought i'd finally join up. I belong to too many forums being an internet whore, so it really wasn't that much of a priority to join, though i've managed to read through a lot more material here recently due to joining and seeing the extra areas available :)

Anyway - thanks in advance to all those who have posted tips, tricks, diagrams, provided useful advice / pictures / video and whose love for celica make the car still a popular vehicle to have :)

I thought I'd chuck this in as well as I had already written it for st18x.com when the admin asked "why did you choose a 5th Generation Celica?"
Note: a lot of references to New Zealand local places and content, but i think you'll get the drift ;)

-----------

Interestingly enough, I fell into Celicas by accident.

Around 6 years ago, I was looking for a hatch, mainly Civics and the like as I always enjoyed whizzing around in the smaller hatches.
Unfortunately at the time, I couldn't find any within my price range and was desperately needing a car so when I was around in Miramar looking at cars on the side of the road, I happened to notice a ST182 Black Celica GTR for a half decent price.

The GTR was selling for 3300, and had to be sold that weekend as the owner was leaving for Aus. So I had a test drive and negotiated down to 3000, but also bought some of the sounds installed as well so that increased the price a little.

Considering that I had only driven 1600s up till that time, driving around a 2.0L was a bit of difference!
In the end, the curvy bio design got me hooked and for the couple of years I had it, it was low maintenance and a good runner. And as all things go, I ended up doing some little mods here and there, mostly stereo stuff.

In the end, I found that the GTR was just a big wallowing pillow compared to the GT4 I was about to own!

A friend of mine was selling his GT4A (3 years ago now). Now this GT4 he claimed was a RC model, but in fact was a standard GT4 but just A spec. I took for a test drive and man... it was fast, it handled well (at least compared to the GTR) and it was straight as.
Little things such as the factory widebody got me hooked and knowing that my mate was actually a nanna driving it just made the decision better and better knowing that it had had a pretty good life.
Also: he didn't like driving it in town, his wife drove in town; he didn't fang it cos he isn't a driver and he'd get scared when he'd put the foot down; the car was garaged all its life; he has all 90% of receipts; car had turbo rebuild in the last year at the time.

So after doing some research (which is now a sticky on toyspeed) and finding out that it wasn't an RC, I still bought the GT4A, but just negotiated down and ended up buying the GT4 for $6200. Yep, it may have seemed overpriced, but considering the history of it, I was very happy paying that.

Old GTR
deecee_celica_0002.jpg


New GT4A
deecee_celica_0001.jpg


Subsequently over the last couple of years, I haven't had a chance to do many major modifications, but more recently over the last year, I have made numerous purchases to increase the potential of my GT4A incl wheels and braces and suspension and RC intercooler and engine components.

As of August last year this was the car:
elephant.jpg


At this stage, I had removed the AC and cleared out the underside of the dash for my big audio install. I had also got some brand new 18" wheels in the pattern that I wanted and had installed some king springs and some new KYB shock absorbers. The celica was looking tight!!!

Then someone dinged me on the front guard on my first night out :cry: god that fucking pissed me off! you can notice it in the front guard on the above picture

Anyway I had gone to VTNZ for the warrant near the end of August and expected the car to fly through (esp since the mods were very cosmetic and nothing much more..) and was knocked back by the inspector saying that an oil leak in the car had oil all over the underside of the engine and was just impossible to tell if the car was mechanically sound!
I knew that the engine had a slight oil leak but never thought it was that bad!

I talked to my mates mechanic and he was talking about replacing all the hoses etc and potentially pulling the engine to get everything fixed up which was going to cost 1k - 1.2k and that really got me agonising over decisions. Don't get me wrong, he's a good mechanic, but some of the figures he was talking about at the time were a lot of money. He suggested that he clean up one hose that was the obvious leak, he'd slap a warrant on it and we'd sell it on and look to a diff car.

So here I was with a car that I'd just chucked 2.5k worth of wheels, tyres and suspension onto only two weeks earlier and was now talking about selling it!!

Around 1 week after talking to the mechanic, I killed the syncro gear hub on number 3 and with that, I agonised over what I should do with the GT4. Um.. i can't exactly sell the car with a dead gearbox now! I was planning to off load the car and everything with it and go buy a turbo altezza, or even supercharge the 3sge, as another friend and his dad were using a supercharged beams 3sge in their race car.

After talking with my work colleague who had recently done some engine work on a couple of his cars, he made something along the lines of this statement (note: he's an accountant, so the whole cost/benefit ratio comes into play):

If you buy that Altezza:
a) you'll have a debt to pay. The interest on that debt is money you are giving away.
b) you don't know what has been done to that "new" car. Have the belts been done, has it been thrashed or had an accident etc.
c) if you fix your car, then it you know what has been done and know what should be next in terms of maintenance instead of something of the unknown that could happen.
d) its cheaper to fix your car instead of going out and know what has been done to it instead of buying that other thing which you will want to modify and giving away money while you pay back the loan + interest on a car you don't know the history of.

In the end, the accountants words (sage old man..) hit home and I called Miles Udy gearbox specialists and quizzed him over things to be done and a quote on the work. In the end, it cost just under $3k to remove the box, and replace the cracked syncro hub and all the syncros in the box. I also got him to remove the engine so that I could fix up the leak as well.

Now, you may say that what I get done is expensive, but then again, I know that its been done once and its been done right!

So that is where the project currently sits. I have the engine on a stand / gearbox on the floor of garage. I continually buy parts here and there (most recent was the Tein adjustables I purchased) and I'm still focussed on re-engineering the celica to what my dream car would be.

Most people who know me, constantly ask when the Celica will be back on the road as a joke, but they also know that I'm a very busy person who is starting up a couple of businesses as well as working full time. Understandably, projects like this take time as I want to do as much as possible as I can to ensure that the costs are lower and to ensure that certain areas of work are done to my level of expectations.

So, i'll stick with my GT4 until I'm finished as it will have all my dream car bits and pieces and it will be as original as I want it to be.

The Bio design has actually endured a long time in terms of looking modern on todays roads. It never ceases to amaze me that it can still look reasonably fresh compared to more modern cars and this is after 18 years.

My mate said yesterday (after I mentioned that a rally light pod for the hood was for sale..) that he wished I'd gone for the rally look, and after watching a Celica dvd I downloaded, I can see where he would get that idea. I still have some mudflap material in the garage lol..

Thats my Celica story in a nutshell :)
 

deecee

New member
Parts and Mods to add to the GT4A:

Cusco Braces - Front / Rear
Tein HA Coilvers
CS Bumper
ST205 Engine
WRX seats
ARP head bolts etc (coming soon)
JUN adjustable cam gears (coming soon)

my list used to be longer with c one camber plates, ct20b, st185 W/A intercooler, 540cc injectors, manifold and dump pipe, but I bought a turnkey ST205 engine with full intercooler setup, turbo, harness etc for $2750NZ a couple of days ago.

I think I might be selling some stuff hahaha
rc intecooler setup anyone?

-----------

Plans for the car:

Initially I wanted to turn my GT4A into a streetable show car.
1. Big custom kit (I f/glass ;) ) with 7th gen lights and custom lights blah blah; redesign the front bar so that you get a Audi R8 look with lights that go straight into the bumper air vents

2. Big audio install (my main hobby is car audio and i'm starting up an online shop soon..) and rebuild the interior to suit a SQ (sound quality) install + add some SPL gear in the back for giggles. I am looking at replacing the rear seats with 2 x RE MT18 woofers.

3. Only 300 - 350hp at the wheels. I don't want to play power games as I don't have a big money tree like some people. I was debating 5sgte under square, but too much hassle for me. I'm not that mechanically inclined.

Overall I wanted to do the majority of work myself, but I've found over the last 6 months with the car off the road, the engine on a stand, gearbox on floor of garage and parts in boxes, that my IT contract work + other external projects have not allowed for the time to spend on the celica. (i was coordinating SQ competitions around NZ as well as being a SPL/doof doof competitor.

With the prospect of opening an online car audio shop as well as my other projects and the realisation that i definitely should not move with trends in show vehicles, I have decided to cut the above plans by.. hmm.. maybe 25% off?

This got me worked up the other day:
217.jpg


218.jpg


awesome hill climb car with pumped guards - thats all i want really :D
Something a little more staunch and aggressive without being rice and is reduced work to do with the potential to hold its look for ages :up:

So i'll pump the guards on mine and keep it smooth all over, do the CS bumper and add a custom lip and do custom skirts and a rear bumper with diffuser and i think that should be the body side.

I may do some lighting things, but only for the car shows and removable for daily/standard (hey, i gotta market my shiz at shows and stuff.. gotta have the lighting effects unfortunately, but i got tasteful designs in mind ;) )

Audio/interior will stay with the same plan - i love my audio and the car will be a promo vehicle for my store.

Engine - with the new turnkey, its going to be a lot easier to reach my power goals, as the mark is not that high and i'm starting off with a better foundation (oil system, h beam rods, bigger intercooler, larger throttle body, bigger injectors etc).

I might still rebuild the engine and chuck in a couple of lumpier cams, td05/6 hybrid and run it all off a link/linkplus ecu. Upgrade to a walpro and i think we're nearly there haha

Anyway, that's me and my GT4A in a nutshell.

If you need any help audio wise, let me know.
I do both sound quality and spl and have worked with a wide variety of equipment of the years.

I'll chuck up my battery relocation tutorial soon which should help some people :)

Cheers and catch ya around :)

Dave

Edit: i've just been offered some 880cc injectors for $550NZ - 1 day offer.. so tempted but so many other things need my attention money wise :doh:
 

Sal

New member
thats an awesome GT4 you got mate!
That Yellow celi looks like a narrow body? Also looks like an RX7 IMO. Looks really light indeed!!!
any more pics of your ride?
cheers
sal
 

deecee

New member
the white car is mine :)
the yellow car is a photo i found that is giving me some inspiration at the moment.

no other pics. The gearbox syncro hub shat itself a couple of weeks after i added the mags and lowered it.

here is my cracked syncro hub
deecee_celica_0139.jpg
 

deecee

New member
I haven't installed the WRX seats as of yet.

The cool thing with the WRX seats is that you can unbolt the seat rails off the seats and can mount to other rails.

Unfortunately, you can't do that to the celica seats as the rails are welded to the seat frame as far as I can remember.

When I measured the difference in width between the celica seat rail width and the bolt holes on the wrx seats, I think (if I remember correctly) the width difference was about 10mm.

I will either remove the rails off the old seats and a) weld them to the WRX seats, or b)get an engineer to make some brackets to weld to the rails and bolt them to the WRX seats.
 

deecee

New member
The WRX seats cost me $250NZ dollars.
They are much lighter as they do not have the heavy mechanicals in the drivers seat and they are very comfortable as they are bolstered and have good lateral support.

Of course, the standard st18x celica seat is excellent with adjustable supports, but overall, you can feel the spring through them and I just want something different.

With the WRX seats, i'll be adding some more foam to provide a bit more support as they are older, and then recover them to match my new interior.

Overall, they are a pretty good seat from factory, and they are cheap here in NZ :)

Here is an example of the seats:
52975752_full.jpg


Mods - could you please move this to the project area? I'll rename and will do a full project thread there :)
 

deecee

New member
Updates: 5/4/08

I've just ordered my Jun adjustable cam sprockets - they should arrive in a couple of days.

I've also had a cursory look over the loom that came with the engine.
It has the MAP sensor, the ignitor, resistor blocks, ecu, full fuse blocks etc etc. Seems that everything is there and it shouldn't be too much of a hassle to get the engine in the car and started up to meet the warrenty requirements.

What I may do is clean everything up and just chuck it in the car and run the car for a hit. I've been without the Celica for over 6 months now so i'm getting withdrawal symptoms from not having a decent car to drive around :(
 

deecee

New member
Okay - time for a big update.
Over the next three weeks, I'll be intensely involved in the Celica as I'm working on my business from home.

I unwrapped my baby after 6 months of not looking at it. Thats right, I've been too busy for over half a year to look at the car. It was still polished and waxed and looked the hotness 8)
deecee_celica_0164.jpg


Its like its got a lift kit without the engine in it!! Go teh monster truck!
deecee_celica_0165.jpg


3SGTE in one corner of garage - st185.
Gearbox rebuilt by Miles Udy Automotive - top chap and knows his shit! (and I bought that extra st205 gearbox cos it was too cheap to pass up haha)
deecee_celica_0166.jpg


3SGTE in other corner of garage - st205
deecee_celica_0167.jpg


The mess to still clean and sort tonight
deecee_celica_0168.jpg


RC Bumper from Gonad / Alex - I forgot it had foggies and the water sprayer!
deecee_celica_0169.jpg


Things to do:
1. clean up the garage and sort out all my tools, equipment and space I have to work with.
2. identify all hoses and wires off the st205 engine. Remove and measure to replace with silicon and braided hoses and fitments
3. remove current loom and engine parts/sensors in the engine bay and formulate plan on where I want to mount new radiators, reservoirs and where I will route lines and loom extensions.
4. remove suspension parts and start to strip back paint, grease and grime from under body and in engine bay.
5. Assess current brake and fuel lines and formulate plan on rerouting various lines to present a cleaner engine bay.
6. clean engine and gearbox and paint
7. remove suspension and rear subframe and replace items that are worn. Powder coat or paint as required.
8. clean underside of car, weld in nuts for custom undertry/diffuser and coat in hippo liner.
9. Remove dash and remove excess wiring and make way for Link G3 Ecu and custom gauge setup
10. Weld bolts to firewall internally, block and fill excess holes in firewall and engine bay.

That should keep me busy for a week lol

Parts ordered:
HKS Silent Hi Power Exhaust
ASI Aluminium Radiator
Oil Pump, water pump, inlet and exhaust manifolds
Speed source engine mounts, stainless clutch lines, clutch pushrod, crossmember mounts, cable bushings
TWM Performance short shift kit

Parts to assess and potentially order:
Braided hoses and fittings
Silicon hoses and joiners
Catch cans / reservior tanks
Oil, gearbox, power steering cooling kits incl radiators / adpators
Clutch

Cheers

Dave
 

deecee

New member
Hey hey,

its only the start haha.
There is so much to consider and do!

My friends know that I'm serious so are keeping me on a firm course and knowing them, they'll say that I have to concentrate and focus on one thing at a time to achieve my goals.

I'm busy selling stuff, buying stuff, sorting out distributors, building websites, sourcing equipment etc etc etc.. so busy!

Back to the garage for me!!
 

deecee

New member
Of note, I will be working with hacker_720 / Steve to create a widebody kit. First on the computer and then hopefully in practice later in the year ;)
 

deecee

New member
Okay - so I've been doing a bit of work recently and taking a couple of photos here and there as well.

The gearbox is fully painted in red engine enamel. I took my time in cleaning up the transfer case and box to ensure that I had the best surface to stick to. I can't be half assed as my expectations are high and my friends would constantly give me shit if I didn't do the job properly from the start.

Understandably, there is a sense of high expectation as the boys have some very nice cars to compare with.
That and judging show cars for 3 years, you tend to notice where shortcuts have taken place and/or things could have been done better, so my mind is always thinking what is the "right" way of doing things.

I started on the box and case on Friday night. My friend Nish came around and we talked a bit on engine bays, Link LEM G3 options and wiring and he did a little bit of work on the box cos he felt like it (hey, I'm not going to complain if someone helps me out).

I used scotchbrite pads and a lot of degreaser and sometimes even paint stripper. Nish suggested the paint stripper as the paint stripper brings up grease and grime really easily and doesn't affect the aluminium (he works for bostik international - chemical product people so I could trust his knowledge) but I just made sure that I spread the paint stripper on large areas.

Of note, after removing the grease and grime build up, I found stress fractures and cracks here and there in the gearbox and transfer case. Can't expect too much after 18 years, but I'm confident that there will be no troubles for daily driving.

I ended up finishing cleaning up the box and case on saturday night at 4am after 3 days work cleaning up, removing 17 years worth of grime and built up grease on the transfer case. The box wasn't too bad as the team at Miles Udy Automotive put the box through their parts washer, but there were still areas that needed to be cleaned up.

I thought that I may as well spray at the time as I really really needed to get things underway with the build. I went over every part of the box and case with the wax and greaser remover and then I balanced the gearbox and transfer case on my work table, covered all the necessary areas in tape and proceeded to shoot up the first coat at 4.30am lol. (BTW, if you balance the box and case like I did, just make sure you don't bump the table. Its a pretty precarious position to balance up, though it sits quite nicely)

The next day I got woken up by my mate Jonno and felt like shite as I'd been pulling some late late nights (or early early mornings) and subsequently got back to work after talking some options with placement of catch cans and reservoirs to clean out the engine bay. I also got him to shoot a layer on the box as he is a better sprayer than me.

In the end, I believe around 5 coats have been laid down haha. This was between the normal household chores, and mowing the lawns on Sunday.
In the evening, I rested the gearbox right side up and shot the areas that were missed while on its angle. I did a couple or 3 coats on the areas missed while dismantling the engine.

As to the engine dismantling, a methodically removed all nuts, bolts, hoses, brackets, parts etc etc while documenting using a log book/photos and labelling everything that came off and storing the bolts etc in plastic ziplock bags. I finished up at 2am last night with still a bit more to go.

I rounded off one bolt on the turbo flange, so I had to stop.

Today I've been recovering and getting back the feeling in all my muscles and finger tips - sanding and scrubbing a bitch and I really went to town on the box and case as it was the start of the project. Something small to sink my teeth into lol.

There are a couple of runs, but nothing that can't be taken out with a bit of a wetsand.

It actually seems like everyone is willing to help at the moment. They all know that I'm dedicated to this build and my standard is high so they know that I want to do things right the first time. I have access to cabinet sandblasters, a wide range of tools and the advice of racecar builders, so I'm very very lucky as most things are a 5 - 15 minute drive from my place.

I was just around at Kat's place and borrowing tools and asking questions of Kat and his Dad.
I walked away with rattle gun, snap-on impact wrench bits, rounded nut removal tools, brake/fuel line flaring kit, pulley balancing/puller kit etc and asked a bunch of questions and was answered and advice provided (in the normal straight and very blunt approach of Tom with a bit of shit thrown in lol).

If you want to know the shit.. basically it was "why didn't you just send up the engine to Kevin, spend 7k and get a race engine in a crate in 3 weeks cos its a lot less hassle instead of pissing about with what you say is a better engine" hahaha. Gotta love the constructive criticism.

Basically i had the option with the old engine to send to a race car/engine builder 600km away and get a full rebuilt engine with all forged internals, overbore etc etc and not mess around with stuff.

But then again, the st205 engine has the upgraded oil pump, better cams, turbo, better oil system (i did seriously debate a dry sump, but since I'm not racing, it was like whats the use of that..) etc etc so I'm still happy with my purchase, though I will get unremmitant grief from Tom of not getting the engine rebuilt.

So now, its just a matter of a quick clean up of the garage, getting the flywheel off, getting off pully wheels, removing old engine off stand, putting new engine on stand, removing other stuff and figuring out what can and can't be removed.

Then its simple green in the engine bay with degreaser, removing lines and ancillaries and then removing the dash and old wiring and prepping for the new wiring and possible some other little things as well.

Apparently I'm going to be spraying my own engine bay :eek:

Jonno and I were talking options for the car over lunch and apart from rerouting all the lines and hidding reservoirs etc, I talked about the seam sealer in the bay and cleaning up, or going reasonably hardcore. I am now going hardcore..... oh shit! haha

Cleaning up the bay, deleting holes and filling them in etc etc. Use etch primer, then lay down new seam sealer and look at shooting my own engine bay.... Looks like I'm going to be rather busy!

That and I'm on a Link group buy, so that will be in a couple of weeks and I'll be hardwiring up the link as I'l be running seperate gauges and minimising a wide range of electrical connectors and stuff in the bay.

Speedsource bits arrived in mail the other day. Exhaust I need to rearrange delivery for as I missed the other delivery. I believe the shortshift kit from TWM is at the post office to be picked up. ASI radiator arrived last friday.

Still need to order a bunch of things - new oil and transmission radiators, hoses and braided pipes and fittings.
Pictures up later, I have to remove a flywheel, clean the garage and move engines around the place :)

Laters

Dave
 

deecee

New member
Of note, while i'm replacing and rerouting lines, I'll use the old transmission radiator as a power steering radiator.
The old power steering lines circle through to the front of the AC radiator for cooling and since I'm deleting the AC, replacing the AC radiator with a W2A radiator and upgrading the gearbox radiator, I may as well use the old gearbox radiator for something :)

Apparently this is rather excessive, but i don't want the old PS lines in there, so out they come and in place is the old radiator :)

I also have to figure out more of the loom as I'm thinking that it there is a lot of extra crap that was attached to the engine when I received it. Oh the joy. I can't wait for the wiring.. thats going to be really really fun!
 

deecee

New member
Mon Jun 09, 2008
Gearbox Pictures

As you can see, a whole bunch of grease, grime and work to be done. Some of the build up was 3mm thick
deecee_celica_0170.jpg


Nish cleaning up an easy part lol
deecee_celica_0171.jpg


As you can see, he didn't do much.. like a 50mm x 100mm patch haha
deecee_celica_0172.jpg


Progress getting made!
deecee_celica_0173.jpg


I had to orientate the gearbox on all sorts of angles to be able to clean it.
deecee_celica_0174.jpg


Some of the micro fractures in the metal and some casting crap
deecee_celica_0176.jpg


Cleaned up with a dremel nicely though :)
deecee_celica_0177.jpg


More cleanliness
deecee_celica_0179.jpg


Balanced amazingly
deecee_celica_0180.jpg


More micro fractures and a crack in the diff case. It "should" be okay *fingers crossed
deecee_celica_0181.jpg


Ready to spray
deecee_celica_0182.jpg


All important bits covered up
deecee_celica_0183.jpg


Jonno the next day shotting a layer in the morning before lunch
deecee_celica_0184.jpg


deecee_celica_0185.jpg


Looks good in the light :)
deecee_celica_0186.jpg


Covering up in preperation to spray over the missed areas.
deecee_celica_0187.jpg
 
Top