The plans
On this page, I'll set out what the plans are for this car at the moment.
When I bought this car and started the project, the plans for it were a lot more modest. But as the project progressed, the plans started to get more and more ambitious.
Now it has come to a point that practically everything goes, as long as I like it, are willing to try it and think it's a cool addition to the car and the project itself.
But I must honestly say that these plans are regularly subjected to change. So what's listed here is more of a guide than a list of set plans. I'll try to update this page and the status of each part as the project goes on.
The engine
When I started this project, the original 4A-GE that was in this car when I bought it would return in the car again after a proper rebuild. But those plans have changed dramatically.
The 4A-GE was already rebuild and all the plans below were already marked 'completed', but then the 4A-GZE presented itself to me and I decided to ditch the 4A-GE. So now I can start over again.
So, a 4A-GZE then. Practically the same engine, but now with a added supercharger: More power, more torque and a cool whine from the engine bay.
Apart from a complete rebuild, I also have some other plans for this engine. I have no idea if I can realize all these plans, but for now, I hope I can.
Complete rebuild |
Incomplete |
Blueprinting the engine |
Incomplete |
Optimize intake |
Incomplete |
Replace roots type supercharger with twin-screw type supercharger |
Incomplete |
Replace 4A-GZE top mounted intercooler with custom Air-to-water intercooler system |
Incomplete |
Fabricate custom intake manifold with integrated intercooler |
Incomplete |
Optimize cylinder head |
Incomplete |
Deburr cylinder block |
Incomplete |
Replace exhaust manifold with Cusco Powerball header |
Incomplete |
Delete power steering from engine |
Incomplete |
Delete aircon compressor from engine |
Incomplete |
Fabricate new bracket for alternator |
Incomplete |
Place extra sensors on engine |
Incomplete |
The gearbox
Again, the original C52 gearbox that was pulled from the car was destined to return to the car after a rebuild and the addition of a Quaife LSD. I already had this all wrapped up and the gearbox was ready to be reinstalled in the car.
But the new 4A-GZE engine came with a gearbox attached to it, and as that had gear ratio's that better suit the power plant and was a lot stronger to handle the added power, of course I went with the E58 that was still bolted to the new engine.
Dismantle, clean, sandblast end re-spray gearbox parts |
Incomplete |
Gearbox rebuild |
Incomplete |
Replace diff with Quaife LSD if necessary |
Incomplete |
Replace clutch slave cylinder |
Incomplete |
Rebuild clutch master cylinder |
Completed |
Install new clutch |
Incomplete |
The suspension
The suspension can be improved upon in several area's. So it will be dealt with to improve the Corolla's handling.
Place KONI shock inserts into modified shock housings |
Completed |
Replace coil springs with upgraded springs |
Incomplete |
Replace front swaybar with thicker and adjustable one |
Incomplete |
Replace rear swaybar with thicker and adjustable one |
Incomplete |
Replace old rubbers with polyurethane bushings |
Incomplete |
Replace top mounts |
Incomplete |
Replace wheel bearings |
Incomplete |
Rebuild steering rack |
Completed |
Have all parts cleaned, sandblasted and powdercoated |
Completed |
Miscellaneous parts |
Incomplete |
The brakes
The original brakes that were on the care were sufficient to stop the car.
But again, room for improvement and it's always nice to be able to stop the car just a little faster.
Replace front brakes with AE101 brakes |
Incomplete |
Clean up all brake calipers (grind away casting burrs etc.) |
Completed |
Have all brakes sandblasted and powdercoated |
Completed |
Rebuild all brakes |
Completed |
Rebuild brake cylinder |
Completed |
Replace flexible rubber brake hoses with braided lines |
Incomplete |
Replace old steel brake lines with Cunifer brake lines |
Incomplete |
Replace brake discs |
Incomplete |
Replace brake pads |
Incomplete |
The body
The body needs the most work done to it. First to get rid of all the rust that has been eating on the car for years and second to repair the damage it sustained during an accident.
Replace damaged front with donor front |
Completed |
Weld on various brackets to the car for added parts |
Incomplete |
Weld in patches of new steel where needed |
Incomplete |
Weld shut old antenna hole |
Incomplete |
Weld shut old sidemarker light holes |
Incomplete |
Install new automatic antenna on rear of car |
Completed |
Move battery to boot of car |
Incomplete |
Replace fenders |
Incomplete |
Replace windscreen |
Incomplete |
Replace rear window |
Incomplete |
Reapply undercoating |
Incomplete |
Reapply anti corroding to inner parts |
Incomplete |
Replace pop-up headlights |
Incomplete |
Replace rear lights with JDM Levin Kouki ones |
Incomplete |
Replace spoiler with JDM Kouki spoiler |
Incomplete |
Replace front bumper with JDM Trueno Zenki one |
Incomplete |
Replace rear bumper with JDM Trueno Zenki one |
Incomplete |
Replace rear mud flaps with JDM Trueno Zenki ones |
Incomplete |
Place Trueno emblem on hood |
Completed |
Replace door mirrors with JDM folding mirrors |
Incomplete |
Replace door handles |
Incomplete |
Have windows tinted |
Incomplete |
New outer trim |
Incomplete |
Have car sanded and ready for painting |
Incomplete |
Full re-spray |
Incomplete |
The interior
The interior was in dire need of some attention. It was tired, raggedy and worn.
I already didn't like the cheap look of the original interior, so I was going to change a few things here.
Modify dashboard for additional gauges |
Incomplete |
Modify door cards for speakers and window switches |
Incomplete |
Fabricate shortshifter |
Completed |
Modify roof liner for sunglass compartment |
Incomplete |
Install sunglass compartment/interior lights |
Incomplete |
Reupholster dashboard |
Completed |
Install extra gauges |
Incomplete |
Install compo speaker set in doors |
Incomplete |
Install compo speaker set in rear of car |
Incomplete |
Install power windows |
Incomplete |
Install key ring light |
Incomplete |
Reupholster front and rear seats |
Incomplete |
Upholster arm rest |
Completed |
Reupholster Trueno steering wheel |
Completed |
Replace carpet |
Incomplete |
Refurbish plastic parts |
Incomplete |
Modify dashboard for new radio |
Incomplete |
Reupholster boot |
Incomplete |
Miscellaneous
There are of course always parts that just can't be caught in any of the other sections, but they are still part of the car and they will all get done.
Repair/modify wiring looms |
Incomplete |
Integrate new with old wiring looms |
Incomplete |
Check and refurbish fuel tank |
Completed |
New rims |
Incomplete |
New tires |
Incomplete |
Have car approved by Dutch road and vehicle civil service (RDW) |
Incomplete |