K24 swap Corolla - Running an open source Standalone

[Hassan1991]

Assalam-o-Alaikum
I'm working on this car from quite a long time. Work was slow as i was a student back when i started, barely got anything to spend on it. And i wasn't sure about many things.
Anyway learned through the process and right now the car starts. I haven't drove it yet because there are some issues that needs to be resolved. For example the rack is touching the transmission. Was talking with sir Xulfiqar about it so hopefully will get it sorted out.
So the car is running on open source ecu. That was the main reason of this swap.
As i have some more with me if anyone interested. Although i will be starting another k24 on same ecu soon. That car will come on road even before mine.
I will share the details later.
Coming to this project. It's a ae80 corolla chassis. My father own it from 1989. It was used to be daily runner but after when we got a secondary daily it got parked without shade for few years. That cause the chassis to get rusted pretty badly.
I got my hands on it in 2016. Details of this car before starting the swap is on this thread....efi conversion etc.

Toyota Corolla 1986 (e80) Owners' & Fans' Club

Hello Members, This thread is dedicated to the Legendary Fifth generation Toyota Corolla aka EE80 or in Pakistan famous as CHIYASEE Corolla :slight_smile: discuss all your problems over here and feel free to share pictures and queries. :slight_smile: [image]

I'm gonna begin this thread from the day i started the swap, from 2019.
Will try to bring it to present date quickly as i'm going to drop some tuning related videos on youtube and elaborate it here as well.
You will see alot of wrong nut/bolts at different places or even enormous washers. I will change them when i will go through the complete car again.
I'm not good in taking pictures so forgive me for that. You are welcome to ask any question and disagree if you don't like it.
And let me know if you think title should be different.

Note. This car is not meant to be daily driven and wouldn't be reliable. That's what you should keep in mind before going for such swaps. The more you mess with the oem stuff the less reliable it will become. This chassis was a scrap so i used it for my learning experimentation. This car is an experimental mule.

[Hassan1991]

Engine Hoist was borrowed. That was a 5af converted to E with 4afhe manifold. Ported and polished head. This engine had really old tech ecu and 3 points tps. Transmission was C150. Sold it for 35k back then.....and bought the TIG welder and hide it inside the car.

[helper_learner]

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[Hassan1991]

I learned welding on this car. So you will see some horrible welds. Those would be my earliest welds.
Tube used for rear is 14 gauge 1.5x0.5 inch if i'm remembering right. Between it was thin if you ask me now. I was new to these things back then. Might upgrade it.

That's a 16 gauge sheet.

Kind of frame i made to support rear struts. Still need a cross between it.

Have to test it.

Painted just to keep the rust away.

[Hassan1991]

For inside i used 1.5x1.5 2mm wall thickness square tubes. ( I'm still not happy with them. I might upgrade to thicker sidewalls).
There are tubes that connects the middle frame with the fronts and rear struts.

[capsat]

@SER_GTR loop in its going to be a Total Recall
@babarhyd @dani_kk @rajaatta @nomi01 @argtr65

[Hassan1991]

After that i went for the front.
So this is the weakest chassis of corolla. I love the looks of this car but i still say that bluntly. Front wheel will start opening up if you don't put some sort of tie bar in it. And making it worse i installed 195/45R16 on this thing. Even though the fun looking tie bar was always been there but it was never enough.
The marked areas you see were cracked. Steering position use to change while accelerating and decelerating.

Don't mind the brake and clutch lines.

Denter ruined the bolt hole where control arm sits. I had to redo it.

You might have seen me sharing this picture before. That's the 4 point tie bar i made. 1.25 inch 2.4mm wall thickness tube.

The bars you seen going under the steering rack where later modified.

After all that its time to check the body flex.
I did put one more wheel and painted the underneath.

[Hassan1991]

Transmission was bought before the engine. Bought it for 75k from ISB with clutch fork and shifting cable bracket. A very good friend of mine bought it and shipped it to me.
AST5 from Honda accord CL9 6 fwd. Non LSD.
Gear ratio of this transmission.
1st - 3.533
2nd - 1.880
3rd - 1.354
4th - 1.027
5th - 0.825
6th - 0.659
Final drive 4.388
Reverse 3.583

[Hassan1991]

Engine was bought after 5 months of transmission. The time was give to the understanding, learning and parts arrangement of standalone.
It's a k24A3. Many people here don't know the differences in K24 engines. I will make a detailed thread on it. To begin with this engine has Oil Cooler and not from Japan. Bought for 78k without AC compressor and Ecu.

Cylinder 3 valve seals were weak. Recently confirmed that. Although i already planned to replace them all before buying the engine.

Oil pan had a dent. Took it out.

[rajaatta]

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[dani_kk]

Subscribed.

[capsat]

sir @Hassan1991 it is your DIY I will respectfully follow

Honda into Toyota is like watching my persian pedigreed double coat round face cat mating with a stray ginger pointer face male with respect

[suzukialtomehran]

oh khair ye sub daikh ky mujhy "hushyaaaari aa gae aa" subscribed

[Hassan1991]

Apologies ...
But sir atleast it rotates in right direction.

[dani_kk]

Haha sir apkay alfaaz cheer dete hain andar se. Cross brand pe baat aye jab. But for hasan I think we should be motivating him for this as its a very interesting project.

[Hassan1991]

After that i made this stand for the engine. Keeping in mind the center of gravity of engine and engine bay spacing.

[Hassan1991]

Then lets cut the front.
Don't worry after i'm done with it. Exterior will look bone stock will look like an ordinary ae80. I don't like messing with the exterior and oem looks.
Measurements were done before cutting. Also my friend got ee80 corolla which we swapped with 1nzfe. He lives near my house, i have taken every measurement of his car as well.

[Hassan1991]

Time to slide the engine in first time. My favourite part to do. Makes it easy. I have taken it out several times.
Also found the first issue, Transmission hits the steering rack.

[Hassan1991]

Made this front bar.
Now this is the thickest metal used on this car. That's 2x2 square tube with 3mm wall thickness.
Have to make it straight. So spend some good time before finalizing. Reference point was steering rack and strut towers.

[Hassan1991]

Bought toyota 2C motor mounts brand new. I wanted to use something that is readily available in market. Also talked with sir Xulfiqar about it.
Torque of 2c and K24 are very similar so they should work but i will replace rubber with polyurethane .
Yes one of them was EE100 mount. The transmission one.
All are local made.