[ ZEROGÔKI : 零号機 ]

[boganbusman]

1988 Toyota AW11 MR2 hardtop
Australian-delivered

Why is it called Zerogôki? Because I'm an EVA geek.

Engine: 4A-GTE
1.6L DOHC 16v EFI
Trans: C-52
5-speed manual

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Current list of upgrades:
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Engine:
- Full rebuild; bored to 0.5mm over, crankshaft balanced, block and head decked on CNC machine, 9.6:1 compression ratio
- Cometic 1mm head gasket
- ACL Race Series bearings
- OEM 4A-GZE 'smallport' pistons
- ARP fasteners (head studs, main studs, connecting rod bolts)
- TechnoToyTuning adjustable cam gears
- TechnoToyTuning lightweight single-row crank pulley w/ 36-1 trigger wheel
- Upgraded valve springs
- Garrett GT2860RS turbocharger w/ .64 A/R turbine housing
- Speed-Source stainless turbo manifold
- Removed TVIS mechanism from intake manifold

Fuel Delivery:
- 550cc SARD fuel injectors
- Walbro 255lph fuel pump (in-tank)
- Aeromotive 13109 fuel pressure regulator w/ Speco liquid-filled pressure gauge
- AN-6 stainless-steel braided feed lines

Engine Management:
- MegaSquirt III PCBv3.0 running MSX code
- TechEdge 2J1 wideband oxygen sensor controller
- Bosch LSU 4.2 7200 wideband oxygen sensor
- Ford EDIS4 ignition system
- J&S Safeguard Vampire 2-channel knock controller
- Bosch knock sensor
- GM open-element air temperature senor

Intercooling:
- Frozenboost.com 600hp water-to-air intercooler
- Frozenboost.com aluminium heat exchanger (radiator) 24"x12"x1" w/ two 10" fans
- EMSPowered electric water pump (75lpm @ 0psi loss)
- 3/4" copper pipe and heater hose to make up the rest of the system

Transmission:
- Second-hand 4-puck sprung centre clutch (unknown brand)
- ARP flywheel bolts
- Relocated starter postion to the intake side, using a 4A-GZE starter motor

Exhaust:
- 3" from turbo back, mild steel. One straight-through muffler and a Magnaflow catalytic converter.

Suspension/Steering:
- Custom Bilstein inverted-damper coilover struts with Swift Springs (12kF/7kR)
- TechnoToyTuning camber-adjustable spherical-bearing strut top mounts
- Prothane urethane bushings (full kit)
- Quaife quick-ratio steering rack (2 turns lock-to-lock)
- Stainless steel rear tie-rods
- Removed both sway bars

Brakes:
- RDA slotted brake rotors, front + rear
- Goodridge stainless steel braided brake hoses, front + rear
- Porterfield R4S brake pads, front + rear

Wheels/Tyres:
- Rota Grid-V 15x8 +0, bronze
- Hankook Ventus R-S3 225/45R15
- Full-size spare wheel replaced with space-saver

Exterior:
- RPM Racegear bonnet pins on the front
- Gas-strut for engine bay lid
- DIY sleepy-eye mod (thanks to Jon)
- Custom number plates

Interior:
- CAMS-certified half cage from Meridian Motorsport
- Kirkey aluminium race seat
- RPM Racegear 6-point FIA approved harness
- Racetech and Prosport gauges for boost, oil temp, oil pressure, intercooler water temp and AFR
- Speedhut Revolution GPS speedometer
- Speedhut Revolution tachometer
- Moved battery location to the front boot, using an Odyssey PC680 battery
- JonO short shifter w/ RSe drop plate
- Speed-Source aluminium shifter base bushings + brass shift cable bushings
- New leather shifter boot
- TRD Duracon shift knob
- Modified driver's side power window circuitry to enable auto-up
- Replaced green dash cluster illumination globes with red LEDs
- Darkest legal window tint from Tint-a-Car


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Stuff to do next:
- Get the engine run-in, and then tuned on the dyno
- ZG fender flares and wider wheels
- Replace the clutch with something better because it slips under high boost which sucks balls
- Install Bilstein SW20 coilovers. Need to get them adapted for the AW11 +rebuilt +revalved +resprung

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Future plans:
- If the gearbox or driveshafts break then I will probably upgrade to an E-58 or E-153 (after crying)
- Limited-slip differential (TRD clutch-type or Cusco RS-type)
- New steering wheel?
- Straighten all panels and respray


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Pics:

[xHaZxMaTx]

Win. Lovely exhaust, as well.

True-blue sports car straight outta the '80s. *Thumbs-up!*

[speed_man]

Nice exaust

[Zero260]

The Rota RBs look freakin' sweet!

And duct tape on muffler ftw.

[boganbusman]

Oh that's not duct tape, it's just the label that was on the muffler which now has silver paint on it.

Anyway I'm glad you guys like my ghetto exhaust

[RedCarDriver]

Sweet; it's a shame about the damage to the back though (actually, I'd recommend putting at least some money into fixing that before basically anything else )

Also: wow, the entire exhaust system? Now that only leaves me with one question: does / would the EPA chew you out or is the system pretty good, emissions-wise? Either way, you going to post a video soon?

[boganbusman]

I'd recommend putting at least some money into fixing that before basically anything else

I would like to, bit it's not just a matter of 'putting money into it'. I need to find parts, which is a slow process.
The damaged area is not leaking or rusting and I can still get into the boot so it will be fine for now.

Also: wow, the entire exhaust system? Now that only leaves me with one question: does / would the EPA chew you out or is the system pretty good, emissions-wise? Either way, you going to post a video soon?

Nah not the whole system, just cat-back. As for the EPA, it doesn't really worry me. Being in the trade means I can get dodgy/free certificates or whatever

Edit: as for video . . . I dunno. I haven't got a video camera

[Grez~Supra_RZ-S]

Looks absolutely awesome, love it!

[Carcrazy]

Actually, that looks pretty nice. Love the color.

[boganbusman]

Cheers, glad you all like it

[baumaxx1]

Hella yeah!
(WTF? that was freaky... I had a typo... but the typo was the whole word spelled backwards!)
Cool car. Would be fun to drive on a track or some twisties. Handling's received some good attention. How's the power though? It's quite a light car still.
Cool old school rimmies, lol.

[boganbusman]

Would be fun to drive on a track or some twisties. Handling's received some good attention.

Yeah the upgraded parts give it awesome feedback in the corners, but like I said the shocks let it down a bit. At least it's comfortable, so I can't complain.

How's the power though? It's quite a light car still.

Hasn't got much power really, but it loves to rev and the engine response is brilliant.
Also AW11s aren't really that 'light', compared to something like a CRX.

However a 2ZZ swap would help in both of those departments

[baumaxx1]

Haha! One day... one day.

[TheStig]

A 2ZZ swap would be nice, then you have a even more rev happy engine, driven a Celica and a Corolla with the 2ZZ-GE engine and have to say It's a lovely engine, there isn't loads of power low down but once it get's around 6K it's getting a real boost.
And in a small car like this it should be fun

[boganbusman]

Yeah it's lacking a bit in the bottom-end, so that's why I want to stroke it out to 2.0L as well Add ITBs and extractors and a few other little goodies and it'll be crankin about 250hp.



*keeps dreaming*

[TheStig]

Isn't that a expensive process?
I know there are supercharger kits for the 2ZZ. for instance from Blitz or TDR/TTE ok they're not cheap eighter and won't reach 250 bhp (between 220 and 230) but they also give more low end torque. and sound cool

But then.... getting a engine is the first priority, I have no clue how hard it is to get it in a AW11, and how expensive a 2ZZ is.

[steelsnake00]

Yeah it's lacking a bit in the bottom-end, so that's why I want to stroke it out to 2.0L as well Add ITBs and extractors and a few other little goodies and it'll be crankin about 250hp.



*keeps dreaming*

You'll be lucky, unless your thinking of running a stand-alone ECU

[boganbusman]

Well yeah I think it's mandatory for completing this swap . . . along with a full custom wiring harness and one custom engine mount. The rest is plain sailing (apart from finding enough moneys).

[boganbusman]

The huge dent on the back of my car has been bashed back into shape, and I put my new (red!) bumper on there, and the right-hand side light was also replaced..

I'll get some pics this week. Here is what it used to look like up until now:






This photo makes me cry!

[Grez~Supra_RZ-S]

Thats a hell of a dent!

[RedCarDriver]

Well, at least it's fixed

How much did fixing it run you?

[boganbusman]

The bumper and new light cost me about $150, but the panel beating was free. Then there is the paint which was $20, and I'm getting that sprayed on soon, again for free.
Well when I say "free", it's more like the guy owes me one becasue I gave him my old wheels and tyres.

Anyway being in the trade has it's perks

Still need to get those pictures . . .

[Carcrazy]

Dag, what did you run into? (Or did someone hit you?)

[boganbusman]

I spun at an intersection and slid backwards into a Ford Falcon.

The cause was a combination of poor tyres and lack of concentration, completely my fault. At least my car came out better off! The Ford was busted up big time.

[Carcrazy]

Ouch, liability insurance FTW.