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 Corolla BEAMS conversion

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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Wed Jun 29, 2011 11:00 am

Not yet mate, been busy and im waiting on some parts. hopefully soon tho!! Wink
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PostSubject: Re: Corolla BEAMS conversion   Sat Jul 02, 2011 3:00 pm

Finally got some work done on the car. Decided to do the passenger side ball joint as i had the driver side done already, good thing too cause it was in need of replacing!! Got the outer cv joint i was looking for, just one for now, still waiting on another, so at least i now have one of the hybrid shafts (driver side) ready to go Wink

First, the ball joint! noticed while doing this that the drop links need replacing. Il have to cut them off as the bottom nuts are also turning the bolt when i turn it!

Old ball joint! This was well fused with the wheel hub and i needed to take the brake caliper off and unbolt the bottom of the shock from the wheel hub so i could get a swing at the ball joint with a hammer! (<-professional tactics that is haha Wink )


Held up with cable tie so as to not damage the brake line!


Gave it 2 belts with the hammer and off it poped!


New ball joint


New one on! Took a fair bit of wrestling to get it on there. I noticed two that with these new ball joints the bolts were either slightly (about 1mm) further apart, than the distance of the holes they go in on the control arm!Before i put them on, i had to warp one of the bolts on each ball joint with a towel and hit it once with the hammer just to line then up and not damage the threads! Worked!! They were then easier to fit!


Then i emptied the rest of the Gearbox oil!


Then the drive shafts! I first took the boot off the inner passenger side cv joint on the st202 Celica shaft, to get an idea of what it looks like (never seen the inside of one before!).


Then i did the same with the corolla passenger outer cv joint and the st182 passenger side outer joint. The Corolla cv joint is smaller by a few mm, (bottom of picture) and so is the thickness of the drive shaft! (24 splines inside (shaft), 26 outside (cv joint that goes into the wheel hub)
I then had a fair idea of what i was looking for. I went to Calbro in Galway with the st 182 drive shaft and had a chat with a lad there. After a while i found the right cv joint (the st182 cv joint wasnt listed, just product numbers! so had to look through a few before finding the right one). Eventually got one with 25 splines on the inside (same as st182 celica shaft and st202 shaft) with 26 on the outside with the thickness of the cv joint only a couple of mm thicker than the corolla cv joint, where as the st202 cv joint is much thicker and interferes with the bottom of the shock and the top of the ball joint when put into the corolla hub! (the whole reason for getting the smaller cv joint!) So, that sorted, i made a start on the hybrid shafts!

This is the outer cv joint i got.
Its order code from Calbro in galway is 3235K
It fits a "Carina, Celica and Corona"
It has 25 splines on the inside and 26 on the outside and is only slightly thicker than a corolla cv joint.
Its pre-greased, comes with a rubber boot, clamps, outer nut with cotter pin and washer and costs about 88euros

The guy that did this conversion in the Philipines said he used a Corona as the donor car!

Did the Driver side shaft first. I dont have to do anything to the inner cv joint, just take the outer one off and put the new one on! I thought i might have to cut it off, but after a few belts with the hammer (again!) it came off easy enough


Cleaned it up!


Put on the boot and small clamp, and the snap ring (in that order!)


Then lined up the cv joint with the shaft and gave it a few taps with the rubber mallet! (sometimes the snap ring might not sit right, its no problem tho, just a few attempts at lining the cv joint u with the shaft and it goes on easy enough)


These cv joints are pre-assembled and pre-greased which makes them real easy to put on! I ve seen some cv joint kits that you can get where you have to put the bearings in etc... and they look like a chinese puzzle to me ! Razz

Bran new cv joint on my driver side shaft! Thats one done!!
I had an old pack of un-opened cv joint grease so i squeezed that into the boot just in case!


More when i get the parts! Wink
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miib14
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PostSubject: Re: Corolla BEAMS conversion   Sat Jul 02, 2011 7:23 pm

nice one mate

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★ 1993 Toyota Corolla Saloon  ★
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It's all about N/A Power.....
198 bhp and 148 lbft

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92fxgt
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PostSubject: Re: Corolla BEAMS conversion   Mon Jul 11, 2011 5:06 am

red tune your doing a far out job good work
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ae101ire
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PostSubject: Re: Corolla BEAMS conversion   Mon Jul 11, 2011 11:49 am

lots of work done there pal great job
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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Mon Jul 11, 2011 6:14 pm

Thanks lads, appreciate it as always Wink Waiting on parts is a pain in the arse tho, i get started and have to stop again!! bounce
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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Mon Jul 11, 2011 8:29 pm

Bad news!! Went to turn the engine pulley with a socket wrench today and it wont budge!, I think the pistons are seized!! There was some water in 2 of the cylinders at the the beginning of this project that i removed as best i could but i think they may be rusted!! Shit!!!
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ae101ire
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PostSubject: Re: Corolla BEAMS conversion   Mon Jul 11, 2011 11:18 pm

ah thats terrible, not a cheap fix either like
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92fxgt
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PostSubject: Re: Corolla BEAMS conversion   Tue Jul 12, 2011 4:34 am

gutted looks like u mite have two pull apart take the head and have a look redtune thats terrible
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miib14
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PostSubject: Re: Corolla BEAMS conversion   Tue Jul 12, 2011 5:42 am

thats awful news mate... strip it down and have a look

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★ 1993 Toyota Corolla Saloon  ★
トヨタ 花
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It's all about N/A Power.....
198 bhp and 148 lbft

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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Thu Aug 04, 2011 7:15 am

yip, looks like il be stripping her. On the upside, it means re-honing, bring the clock back to zero, new rings and maybe pistons, we'll see. Been busy. updates soon hopefully!!
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miib14
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PostSubject: Re: Corolla BEAMS conversion   Thu Aug 04, 2011 8:25 am

Yay! Its good to hear you havnt given up:)

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★ 1993 Toyota Corolla Saloon  ★
トヨタ 花
♥ AE-202 Owner ♥

It's all about N/A Power.....
198 bhp and 148 lbft

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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Thu Aug 04, 2011 8:47 am

miib14 wrote:
Yay! Its good to hear you havnt given up:)

Never!! The budget took a bit of a kicking tho! had to fork out for studio monitors!! had to be done. first love is music!! Ive let the engine sit over night with oil in the cylinders, hasn't worked so far, i have some anti rust fluid, might give that a go to free it up. getting the use of an engine crane hopefully next week so at least i will have the old engine out and fit the beams with shafts etc... so that will be out of the way, then il take it back out, scrub the engine bay and strip the beams! Wink then il say a little prayer to god, ala, buddha, and maybe even the devil himself haha!
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miib14
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PostSubject: Re: Corolla BEAMS conversion   Thu Aug 04, 2011 10:59 am

Twisted Evil

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★ 1993 Toyota Corolla Saloon  ★
トヨタ 花
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It's all about N/A Power.....
198 bhp and 148 lbft

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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Sun Sep 04, 2011 5:18 am

Hi,
Was pretty busy for a while and had to put the project on hold, plus the budget ran out but hopefully all going well, il have some cash to put into this again! Im a producer and music comes first before cars im afraid. I was busy writing an anthem for Defqon one Australia producers competition. Heres the link to the track for anyone interested.

http://soundcloud.com/purist2003/side-winder-defqon-one?utm_source=soundcloud&utm_campaign=share&utm_medium=facebook&utm_content=http%3A%2F%2Fsoundcloud.com%2Fpurist2003%2Fside-winder-defqon-one


Right so back into it. Im currently waiting on the use of an engine crane so i can get the corolla engine out and do some work on the engine bay, then fit the beams Twisted Evil
in the mean time, i started some work on the fuel pump. This was pretty easy to do.

Top of pump cover


Cover off, unplugged the wire loom and unbolted one hose and used a pliers to take the small clamp off the other one, then unscrewed the housing and pulled out the pump. Easy Wink



Here is the corolla fuel pump. At first i started to take off the float, to replace it with the celica float but realized later that there was no need, and the Corolla one sits better anyhow. So all that was needed to be done here was to swap around the actual pumps and nothing more, so that the Celica pump is sitting in the Corolla housing Wink Easy peazy!!


Here is the Celica fuel pump in three parts (all wires and plugs are the same. The corolla one tho does have some sort of relay or earth maybe (anyone know let me know) coming from the pumps wires onto the metal!) The pump is in my hand, the float hanging off my finger and the housing on the floor.


Took apart the corolla fuel pump parts. here they are side by side. The Celica pump to the left.


And here it is, the Celica fuel pump on the Corolla housing Wink


here is the size difference between the Corolla fuel pump and the celica one. You can see the whole pumps are the same size, but the metal cylinderical part of the Celica pump is a bit bigger! (Celica pump on the right)


Installing new Celica fuel pump



Done Wink


Also i unbolted the last engine mount from the Corolla engine. I had done the others before and made life a bit easier for myself this time by using a long socket wrench for torque! This is the rear gear box mount. So now the engine is ready to come out when i get the engine crane! Happy dayz



I had the car covered with a weather sheet thats not really worth a shite!! When i took it off i noticed the water, condensation and heat caused some damage to the paint work on the roof. There is some fading and small blisters!! Ah well, throw it on the list of shit do do haha


More updates soon hopefully! :thum:
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miib14
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PostSubject: Re: Corolla BEAMS conversion   Sun Sep 04, 2011 5:47 am

wow cool right up there..

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★ 1993 Toyota Corolla Saloon  ★
トヨタ 花
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It's all about N/A Power.....
198 bhp and 148 lbft

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john-905
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PostSubject: Re: Corolla BEAMS conversion   Sun Sep 04, 2011 7:05 am

glad its still coming together, unsure about the other wires on the corolla pump as from memory mine didnt have anything coming off it, some t cut will get that roof shiney again
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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Sun Sep 04, 2011 7:34 am

Thanks lads, appreciated as always Wink John, whats t cut and where can i get some?
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john-905
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PostSubject: Re: Corolla BEAMS conversion   Sun Sep 04, 2011 7:31 pm

t cut is like a cutting compound, its good for getting light scratchs out also, if you do get some just polish the roof after you will be able to get it from any local car shop or halfords
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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Mon Sep 05, 2011 1:33 am

Cool, thanks man, il look into it Wink
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92fxgt
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PostSubject: Re: Corolla BEAMS conversion   Mon Sep 05, 2011 1:42 am

hows the rebuild going redtune keep up the good work
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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Mon Sep 05, 2011 5:48 am

starting into it again. been busy with music. engine out as soon as i get the engine crane Wink
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miib14
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PostSubject: Re: Corolla BEAMS conversion   Fri Sep 23, 2011 8:29 am

any updates on this?

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★ 1993 Toyota Corolla Saloon  ★
トヨタ 花
♥ AE-202 Owner ♥

It's all about N/A Power.....
198 bhp and 148 lbft

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RedTune
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PostSubject: Re: Corolla BEAMS conversion   Fri Sep 23, 2011 11:53 am

Not yet unfortunately.
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miib14
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PostSubject: Re: Corolla BEAMS conversion   Fri Sep 23, 2011 11:54 am

ok coool..

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★ 1993 Toyota Corolla Saloon  ★
トヨタ 花
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It's all about N/A Power.....
198 bhp and 148 lbft

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