All good and well, but what is the point to this whole project? Just a nice car? A well tuned monster? Loud audio in the boot?
What is the whole idea behind the car?
It's not going to be my daily driver, but a car just for fun! It's going to be car I can take to shows, club meetings and can just take for a nice drive when I feel like it.
The Corolla will probably meet some track asfalt aswell.
On this page I will tell you what the plans for the car are and tick them of when they are completed. That way, you'll have a nice overview of what has already been done to the car.
There will probably be some changes while the project is running. But that will be updated here aswell.
The engine
At first I meant for the original 4A-GE engine from this car to return to it's rightfull place under the hood. It was already completly overhauled and ready to be installed in the car again. But a few years into the project, there was a slight change of plans...
I already had a 4A-GZE engine lying around for a other car I had standing by for a project. But I had to sell that car because the body was getting to bad to restore again. But I still really wanted to use that 4A-GZE engine, and since I figured that a engine like that would do justice to the coupé it will find it's way to this project.
The 4A-GZE is basically the same engine as the 4A-GE, but now the engine has been fitted with a roots type supercharger. In stock trim this 1600cc engine will produce a whopping 165 hp. But I do think that there a number of things that can be improved on parts of this engine. So I'd like to experiment a little with this the try and improve/change a few things and try to get a bit more power out of her. That should be relativly easy to do with this engine, but I think 200hp is a nice figure to drive around with in a car like my coupé.
The short list below are things I'd like to do now. But I'm not quite sure if some things are really possible or might even be just to damn expensive. So this list may change along the way and when I start working on the engine and find out if things a really do-able.
Complete overhaul Still to do
Blueprint the engine Still to do
Optimize the throttlebody Still to do
Replace the Roots type charger with a Twinscrew supercharger if available Still to do
Replace stock 4A-GZE TMIC Intercooler with a Water-to-Air intercooler system Still to do
Fabricate my own design intake manifold Still to do
Optimize cylinderhead Still to do
Deburr cylinderblock Still to do
Replace the exhaust manifold with the Cusco Powerball Still to do
Remove Power steering system Completed
Remove Airco system Completed
Fabricate a new custom bracket for the alternator Still to do
Place extra sensors on the engine Still to do
The gearbox
I think that with a lot of other projects, the gearbox is a often forgotten part. But it is a vital part of the car of course. That's why I didn't forget it and overhauled it.
I've done all the work to the gearbox myself.
Dismantle the gearbox, clean,
sandblast and spray it
Completed
Overhaul the gearbox
Completed
- 2 New bearings ingoing shaft
- 2 New bearings middle shaft
- 2 New bearings outgoing shaft
- New synchromesh first gear
- New synchromesh second gear
- New synchromesh third gear
- New synchromesh fourth gear
- New synchromesh fifth gear
- Reshim the gearbox
- New gasketset C52 gearbox
- Sandblast and spray several small parts
Replace the standard open differential
with a Quaife ATB LSD Completed
New slave clutchcylinder
Completed
Overhaul main clutchcylinder
Completed
New clutch
Completed
The plans for the gearbox also changed when I chose for the 4A-GZE engine. That engine delivers quite a bit more power, but what's even more important for a gearbox: A lot more torque! More than would be healty for a C52 gearbox on a long term basis. So the much stronger E58 gearbox that is mated to the 4A-GZE will stay with the engine and find it's way into the car. But not before I had my way with it of course!
The suspension
The suspension could use a little up-grade to improve the moderate handling of the Corolla. Only the sandblasting and powdercoating is being done by a proffesional. I'll be doing the rest myself.
Adapt existing shocks to receive adjustable yellow Koni inserts Completed
Replace standard springs with new -35mm lowering springs Still to do
Replace front swaybar with a adjustable, stiffer one Still to do
Replace rear swaybar with a adjustable, stiffer one Still to do
Replace all busings with polyurethane bushings Still to do
Replace topmounts with new ones Still to do
Overhaul the steeringrack Completed
Clean, sandblast and powdercoat everything Completed
Replace or clean, sandblast en powdercoat several small parts Completed
Brakes
The standard brakes of the Corolla sufice for normal road use. But they could use a good up-grade. Except for the powdercoating, I'll be doing everything myself as usual.
Replace front brakes with AE101 brakes Completed
Clean up all the brake calipers Completed
powdercoat all the brakes Completed
Overhaul all the brakes Completed
Overhaul main brakecylinder Completed
Replace brakepads with Ferodo DS2500 ones Still to do
Replace brakediscs Still to do
Replace flexible brakelines with stainless steel ones Still to do
Body
I won't change much or do any drastical things to the body of the car.
So there are no fat bodykits, spoilers or other things like that in the plans. But there are some small things I can try to improve.
All the rust will be removed of course, very rotten pieces will be replaced. Clean up the whole car and respray it in slightly different colours.
Because cleaning up the body and respraying it is very specialistic work, I'll let someone else do it for me. I'm also going to let the windows be tinted and if possible, I'd like to reproduce the stickers. I'll do everything else myself.
Replace rusted body parts with new weld in parts Still to do
Weld old antenna hole shut and replace antenna with telescopic one Completed
Drop sidemarkers and weld holes shut Still to do
Replace front fenders Completed
Place gasshocks on the hood Still to do
Tint all the windowd Still to do
Replace windshield Still to do
Replace rear window Still to do
Clean up car and respray it Still to do
Replace moulding in bumpers Still to do
Replace doorhandles Still to do
Replace headlights with clear ones Still to do
Replace other lighting on the car if damaged Still to do
If prossible, reproduce stickers Still to do
Recoat the underside of the car Still to do
Coat hollow parts of the body with tectyl Still to do
Sandblast en spray several small parts Still to do
Replace front bumper with JDM Trueno Zenki bumper Completed
Replace rear bumper with JDM bumper Completed
Replace rear spoiler with JDM Kouki spoiler with LED brake light Completed
Replace rear lights with Levin rear lights Completed
Interior
The interior was one of the few parts of the car that was really worn out.
That is not necessarely a bad thing, because I really don't like the boring interior
Redoing the interior is very specialistic work aswell, and since I can't really handle a sewing machine it's also going to be done by a specialist.
Reupholster the roof headlinig (maybe skai?) Still to do
Reupholster the front and rear seats with black leather Still to do
Replace the carpet Still to do
Replace the steeringwheel with a 'Trueno' wheel Still to do
Adapt the doorpanels for new speakers Still to do
Build compo- speakers in the doors Still to do
Build compo- speakers in the rear Still to do
Clean up the plastic interior parts Still to do
Repair the armrest and upholster it Still to do
Adjust 2-DIN space for new radio Still to do
Build a shortshifter Still to do
Everything else that I haven't foreseen yet Still to do
Fit power windows to the car Still to do
Fit ignitionlighting to the interior Still to do
Adapt the dashboard for extra meters (oil temp., oil pres., boost, clock) Still to do
Reupholster the dashboard Still to do
Others
There are always things that can't really be catagorized. Here are some things I can think of. This list may grow a little with time.
Repair the damage to the wiringloom Still to do
Adapt new wires into excisting wiringloom Still to do
Conserve the fueltank again Completed
New rims Still to do
New tires Still to do
Get the car inspected to get it road legal again Still to do
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