BosoMKII's project! 56k cut your head off

BosoMKII

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Thanks all the for the compliments and encouragements.

Still so much work to do! Had some set backs lately, but getting the car sorted out bit by bit.

Took the car out for a drive today, and nothing went wrong! This must be what the Twilight Zone is like....


 

BosoMKII

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Crap video I know, but just out having some fun. Car isn't too loud which I like.

[video=youtube_share;7d7tx-aO1Cc]http://youtu.be/7d7tx-aO1Cc[/video]
 

BosoMKII

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Small update today, cleaning up the engine bay

Sourced a factory PCV metal pipe so I could route the hoses properly. Doing so cleaned up the engine bay quite a bit.

Also, installed a Nismo adjustable fuel pressure regulator. I've had this thing sitting in my parts bin since when I had my S14 turbo. Bought the part, never used it. Hope it's still good.

Additionally, I used an aluminum drinks bottle as a coolant over flow tank, so I no longer have that ugly hose going to the windshield washer tank.

 

BosoMKII

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Onwards with the fuel upgrades. Today, the pump.

The little Bosch pump I got off eBay for $40 isn't enough for the new turbo engine.

So I ponied up for a Bosch 044 and threw it in a few weeks back. Super loud! Plus, the fuel pressure shot up to 50psi as the pump totally overwhelmed the stock fuel pressure regulator. So the little Bosch went back in the for time being while I worked out a plan.

I figured an OEM style pump would be ideal for keeping the noise down, so I searched for cars with big engines that use inline fuel pumps. Turns out 993 Porsche 911 Turbos use an inline pump. I reckon the pump used in a 400+ horsepower turbo Porsche ought to be enough for my modest 7M-GTE. So I got an OEM replacement for $70 shipped.

The Porsche OEM replacement next to the Bosch 044. Bosch on the right




Bosch on the left, with the larger inlet and screen filter.



Next to the old pump I removed!



I got the wrong fittings for the fuel rail, so the install is delayed for a bit
 

BosoMKII

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Fuel pump upgrade done! Got the fittings, plumbed in the Nismo adjustable fuel pressure regulator, and set the pressure to 38psi.

The pump is LOUD

Going to have to do something about that.

Also done is the intercooler upgrade! The tiny, Mazdaspeed MX-5 factory intercooler is out and replaced by something much better. I painted the end tanks black, then just gave a light dusting to the bar and fins. Looks dark, but it's just a light coat on the front to hide the intercooler. With the grill back on, the intercooler disappears.




With both these upgrades, the car really moves! Revs smooth, feels powerful. Super fun

Also, I moved where the BOV gets its vacuum source from the intercooler pipes to the intake manifold. That made a huge difference, as the BOV no longer flutters at all and sounds better. I'll try to get a video up soon
 

BosoMKII

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Loud fuel pump solved!

I had bought a roll of sound deadening off Amazon a few weeks ago. Had intended to use it in the front, but that changed real quick after hearing the fuel pump.

Step one, clean



Step two, apply. I borrowed my wife's hairdryer to heat the metal and insulating material. Makes a huge difference in how it molds and adheres



Any leftover scraps I placed wherever



After all this was done, I took the pump out and put rubber bushings between the mount and the chassis. Now the pump is only a bit louder than the old small one.
 

BosoMKII

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Not much to update lately, mostly just enjoying driving around when I can.

The car has been running really well, and feels fast.

Just yesterday though, the idle suddenly stuck at 1500rpm. I tapped on the Idle Speed Control Valve and the idle settled down to 950rpm, so that's likely the problem.

Major problem though, transmission is really loud. 5th gear sounds like it's going to fail any time. 3rd gear loud too, but mostly only when hot. Figure I'll just replace it.

In the mean time, I finally got tires! Found a set of white walls for super cheap. Haven't even cleaned them up yet, and I am really happy with the look.

 

BosoMKII

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Thanks! I cleaned the wheels and tires today, much improved.

Small update today, I found a permanent home for the check engine light. Previously I had it tucked next to the aftermarket gauges, and it was blue.



The unused pull-switch ports are the obvious spot, and the 1/2" light I bought couldn't fit better.

Installed


 

BosoMKII

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Not a lot going on lately. Put some shorter springs from an older Corona in the front, along with shocks from a 1968 Chevelle SS. Lower, but not dumped. Looks much better without the ridiculous wheel gap I had before




Just had a nice Borla muffler installed, plus new tips for a little bit of flair. The new muffler isn't much louder than the old Magnaflow, but sounds much better

[video=youtube;LsLO0dnL_BE]https://youtu.be/LsLO0dnL_BE[/video]
 
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BosoMKII

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I bid super low on this and forgot about it, not really thinking I would win. No one else bid, so I did. "EVC" isn't all that descriptive to me, so I put some stickers on to remind me of the function of this device. Mounted in the glove box.

 

BosoMKII

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The car has been giving me lots of problems, all electrical I think. Given how crappy all the temporary wiring I did in the beginning just to get the car going was, I'm not surprised.

The two serious issues: code 52 (knock sensor) and severe hesitation under acceleration once the engine was warm.

When the hesitation occurred, I often also got code 11 (ECU power interruption)

This prompted me to finally get around to fixing all shoddy wiring I had done.

I started by fixing the brittle and cracked Camshaft Position Sensor wires by soldering in new terminal wires



Then I started on the big rat's nest by the alternator where I had several in-line fuse holders wired in with crimp barrels and the battery circuit ties in. You can see how messy it all was.



Soldering big power wires together neatly is easy if you know a trick. Start by pushing the two wires together, inter-weaving the strands.



Then use a few strands from another wire



And wrap the connection



Before connection and soldering, don't forget the heat shrink



Work in progress, using a nice fuse holder



I had previously used a drink bottle as a coolant over-flow, hoping it would look cool and rat-rod like. What it ended up looking like was that I had used a drink bottle as a coolant over-flow. Crap.



Wiring coming together, ignitor moved and less conspicuous, fuel injector resistor moved and almost hidden. Also used the OEM diagnostic port mount and attached it to the intake manifold. Looks almost like it could be factory




Other side of the engine was a mess too, with a big wad of tape and unused wires on the OEM harness. I bought a few feet of that old-fashioned asphalt-coated fabric loom and cut out unused wires and re-wrapped everything for (what I think) is a cleaner look.



New coolant overflow tank, actually for a MKIII Supra



And the overall look, contrasted to how the engine bay looked when the car first ran




Still lots of work to do, but the I'm making progress bit-by-bit.

Test driving, I think the engine hesitation is gone but got code 52 again. I'll figure it out eventually….
 

schmuckingham

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Sorry, I don't follow

Your Brawndo sticker is an Idiocracy reference, correct?



If so I am quoting the scene when the mother is trying to buy food for her kid from the Carls Jr machine. It is their slogan haha



I thought maybe it was an Ohio saying or something that hopefully isn't popular.. lol

No, thankfully not
 

schmuckingham

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OH right

Sorry I'm slow

Also it's been a while since I watched the movie last

:thumbup:

Its ok, I have a knack for remembering lines from movies and it drives my wife nuts.




I am digging this build btw, reminds me of my build but with a lot more progress.
 

BosoMKII

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Ok so now the car won't run. Stranded me the other day with several odd symptoms.

First the car had the severe hesitation come back, then just died. Kept blowing the main power fuse. After some time, the car just fired up again.

Didn't last long, because I ended up getting towed home.

The car will fire up, and maybe run for a bit. But the engine just very suddenly stops. Fuel pump still running, all power lights still on. Then the car won't start for a while after an episode.

No idea. So I'm re-doing the ECU power wires that were my next project anyway. All sorts of messy




The carpets are coming out and getting re-done

Also, got a new horn button. I like this one much better. The button is much more subtle, and matches the conservative old Toyota interior better. I'm very happy with it

 

BosoMKII

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Continuing with the wiring clean-up project.

When I first got this car running, I ran extra wire lengths and used crimp connectors for quick working. Crimp connectors work well in the short term, but I don't want to leave them in. I've read crimp connectors can cause reliability issues and strange electrical issues over time.

Pictured below is the main power plug for the ECU harness. I cut this off a junkyard car to have a nice OEM connection, and as you can see there are many wires I don't need. I de-pinned the whole connector save for the few wires I'm actually using.

Before


After (with power wires for gauges and etc tied in)



Copied Whit and mounted the ECU under the parcel shelf



In progress, getting things cleaned up. Wires under the dash now incased in the asphalt coated fabric loom to ensure long life



And done. Before, the parcel shelf was a mess of wires. Now, sitting in either driver or passenger seats you can't see much of anything. All wires tucked up out of the way.



Still work to do before I drive again, but I'm really happy with my work so far.
 

BosoMKII

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Still working on the interior. Printed out new labels for the boost controller, and still didn't manage to put them on straight.



I'm sure a few of you noticed how ratty the carpets I put in last summer looked. I hadn't ordered enough carpet for the whole car, and ran out when doing the fronts. So I ordered some new carpet to re-do the front area.



Start with more sound-deadening material for the floors.




Didn't realize that I purchased from a different supplier. New carpet has much more exaggerated loops. I like it much better. Too bad I had already glued-down the rear before realizing I had two different carpets!



Bar mats for the rear



I did my best to cut and shape the carpet as well as I could. Much, much better than my first attempt. Still not perfect.





The sharp-eyed among you will have noticed that in previous photos, my boost gauge was stuck in vacuum. No idea what happened to it, just stuck that way.

Options for mechanical, 2 and 5/8th inch, white font with a white indicator needle boost gauge are about two. So I went with the Autometer



Still work to do, but the car should be back on the road this week. Not so much time these days, thanks to this little guy



My first son, he's a bit over two months old now!
 

BosoMKII

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Finally drove the car again today! Has been about a month and a half since the car stranded me and was towed home.

Wiring, carpets, patched a flat tire, and a few other details all done at last.

Turns out the problem was in fact the Cam Position Sensor wiring. I swapped the CPS, and put a new OEM connector on the harness side to match the new terminals and that did the trick.

Car drove great! Felt better than ever. For a mile or so....

Knock sensor code came back and ruined my boosty fun, but now I also get code 42 and code 51.

I'll fix the problems eventually. But for now I'm happy that all the re-wiring seems to have been done right, the car is quieter thanks to the sound-deadening, and nicer to be in thanks to the carpets.


 

BosoMKII

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Not having 5th gear relegates a car to a local-only around town car. 5th gear in my car was super loud, so I never drove far. Never mind the constant little problems, the transmission has been the big issue.

Finding a W58 or R154 transmission is difficult, never mind an affordable one. Finally got one a few months back, and at last found some time to do the swap.

Three days of hard work in a heatwave really did me in! But the job is done at last.

Really not a lot of bolts actually, but the three at the top of the transmission are so hard to get to, I had to take a lot of other stuff off first.



You can see here the turbo elbow has been leaking. I think because the flange isn't flat. I put a second gasket in and that seems to have sealed up the leak. No more exhaust leak noise and soot on the turbo



Working on this surface with the car only 18" off the ground is terrible. I use a camping roll to keep the rocks from chewing me up too bad, but it's still hard work



Thanks to some help from my brother, the transmission is finally out! Old transmission with the longer shift housing at top is from a MKIII Supra non-turbo. Replacement W58 at bottom. Not sure what car it's from, hopefully it is actually a W58 or I got ripped off!



Replacement in at last. Very hard work for two guys to bench press the thing into place in such a small space under the car



New shifter further forward, and actually in the correct place for a Corona! Good thing I only cut and peeled back the metal underneath, so returning the trans tunnel to stock will be easy.

Need to change the angle of the shifter though, too close to the dash now.




Test drive didn't go well. Firstly, the new transmission is really noisy. Has me VERY worried. I realized though I put 75w80 Redline synthetic in, when Toyota calls for 75w90. Could that be why? Also, the brakes are doing this super annyoying thing where they gradually apply force as they warm up, until they are on and dragging fully, making the car un-driveable.

Hopefully this weekend I can fix the brakes and put the proper fluid in the gearbox and take a real test drive.
 

akito

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Your break booster it self is probably on it's way out. But before replacing I'd check all the vac line to it first. This happened on my other car and it was not drivable nor fun dragging the brakes :(
 

BosoMKII

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Your break booster it self is probably on it's way out. But before replacing I'd check all the vac line to it first. This happened on my other car and it was not drivable nor fun dragging the brakes :(
Thanks for the advice. I just put this remanufactured booster in a few weeks ago. I hope it's not bad. Finding things that fit/work on this old car isn't easy.
 

BosoMKII

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Success!!!

Fresh oil in, brakes fixed, and went for a drive.

First, the brake problem was just free-play adjustment at the booster. I cranked down on the actuator rod to shorten it, and problem solved.

The transmission was still noisy, but seemed to get quieter as I drove. Not sure if that's just in my head and I was getting used to the noise or if the old box just needed a few miles to get the fresh oil worked in.

Did a few miles on the highway, and the car was great! Very exciting.

The car gets a bit of attention too, because it is an odd-looking and rare old thing. I imagine people are asking themselves, "What is it?"

Today was a good day.
 

BosoMKII

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Been a while since I updated, just in case anyone is still out there.

Still working on cleaning up the engine bay. Wrinkle finish black helps make pipes and things look maybe passable as factoryish.



Also recirculated the BOV. Even with the anti-stall valve, I just couldn't live with the driveability issues. At part throttle under load, the BOV would vent boost making the engine run super rich and bog. All fixed now. Drives like a stock car. The pipe-forest is a little much, but at the time I had the BOV flange welded I didn't think I would need to recirculate. Oh well.



Also found an intact timing cover and a coil-pack cover. The Coil-pack covers are getting rare. This one came from Australia.

I'm really happy with the look.