omgpham…
15Jul/120

ITB Build – Part 2

Some more progress today 😀

Had a friend come over to help strip out the interior since my cracked dash and ripped carpet will be getting replaced. Also makes it easier to get out the old wiring harness. Enjoy the madness below, sorry for the lack of photos.


Seats and center console out.


Steering column dropped and dash completely out.


Everything nearly out, just need some more free time to get the wiring harness out.

14Jul/122

ITB Build – Part 1

FINALLY!!!!!!!!!!!!

Started pulling apart my car today, the head is being removed so I can get that ported. The AC, all wiring, intake, strut brace and fuse box will be removed to make way for my custom tucked wiring harness.

I was planning to port it myself but have decided to send it down to Warren Heath Performance down in Melbourne. The head will received an extensive porting job as well as larger oversized valves, stronger valve springs and re-shimmed solid lifters. The camshaft going in will be 280degree duration and 10.5mm lift.

Didn't get too much done today but photos below.


The operating table where most of the work will be done.



Bonnet off, radiator out and headers moved aside.



Valve cover off to remove the head, full port job on the way with massive cams going in.



The AC condenser removed and a pile of parts that won't be going back in.


That's all for today, covered up and put to bed.

8Jul/120

More Parts & No Progress

Blehhh not much progress lately, BUT I have acquired some more bits for the build. Also been talking with a few guys who are also doing the same ITBs and we've found a few more issues with the T3 manifold... The issue is that the TPS is located towards the firewall and hits against the clutch master hard-line. This is not an issue for all the US guys who have the clutch master on the other side of the engine bay (LHD).


So that's the problem... there are possibly two ways to get around this.


So this is a solution that I'm going to test out, it involves taking 12mm off the end and machining the surface flat. So now I can use a banjo fitting that will let me clear the TPS.


The other solution is to use a braided hose like above, not sure if it'll clear the TPS though. Will figure it out when everything else goes into the car.

So when I installed my new KG Works cluster I forgot to mention that my gauge hood also cracked. Was a pain in the ass but I was able to find a brand new genuine replacement :D. Apparently it was the last one in Australia too! Mazda have more on back order I believe.


So it looks amazing! It does't have the shiny finish like my old one but has a more smooth matte look. Will install this later on when I get a new dash to replace my cracked one.

The next part I found is a duct that is used in cars that don't have air-conditioning from factory. Since I'm removing my AC this part is perfect so that I can remove the ENTIRE AC system and still have functional air/heater.


Wasn't able to get a brand new one but Richard at MX-5 Plus was able to hook me up with this used part. Would prefer a new one but this is pretty decent.

24Jun/120

ITB Test Install

My new fuel rail finally arrived, had to replace the M-Tuned rail because it had clearance issues with the fuel rail bracket. And I was able to get myself a B6 cylinder head for free. This allows me to test fit all the parts and I can work on the fuel lines and wiring while my NB6 head is away for porting and cams.

Also did a quick test fit of the ITBs to see if there are any issues that need to be sorted out.


13May/122

ITBs muhahaha

So I'm still waiting for the paint to dry on the ITBs, going to be a long 7- days... But I couldn't wait so I did a dummy fit of the trumpets (velocity stacks) on the ITBs.

I'm so WET with excitement!


11May/120

ITB Clean & Paint

My ITBs were pretty dirty so I had them sent out to Chilton Engineering for some sand-blasting, got it all back today and they came out great! It was also recommended that I give the ITBs a coat of paint to keep them clean.

I picked up some VHT Primer Coat and Quick Coat in the aluminium finish, was considering painting them black but decided against it. Some clean silver aluminium will look spiffy in between the black adapter and velocity stacks.

Follow on after the break for my write-up and photos.



Fresh from the sand blaster, so clean. Had to mask the ITBs again to get it ready for paint. VHT Primer Coat and Quick Coat in aluminium finish.

Read more after the break...

23Apr/1210

Murdered Out

Decided I'm going to save up and get my head ported/machined as well as throwing in some billet cam shafts. So ITBs will be gathering more dust while I save up for the head work...


Most of the ITB bits... all billet aluminium and murdered out 😀

19Apr/122

ITB Strip & Clean

So my AE101 Toyota ITBs are filthy, full of grime and covered in weird corrosion stuff. I can't mentally install them without giving them a "refresh". I initially attempted to clean them by hand but to no avail, so I decided to get them professionally sand blasted.


The dirty yuk throttle bodies.



The screws holding the butterfly in are secured from factory by "mushrooming" the ends of the thread, this effectively prevents the screwd from backing out and getting into your engine. So I've had to drill out the screws to disassemble.


I then cleaned the butterflies as well as the insides of the throttle bodies, easily enough with some elbow grease a scotch-brite pad.



Because the throttle bodies use ball-bearings and seals for the main shaft, I had to tape off all openings before I take them to the sand blaster.



All the parts prepped and sorted out so I don't misplace anything, hopefully get a chance to drop it off to the sand blaster next week.

11Apr/120

GarageStar x T3 ITB Adapters

I've been a slacker... I've had my ITB parts for months now and yet to install them. Well today I've started pulling the AE101 ITBs apart to clean and possibly paint. I also took the adapter plate to Chilton Engineering, can never recommend them enough, and had them check it over to make sure everything was flat. Unfortunately, the side that bolts to the head wasn't very flat at all. This was concerning because there are water outlet/inlets on that side of the head and I didn't want to risk water leaking into the intake.

Photos below of the amazing looking adapter and the re-surface that Chilton did for me.


3Jan/122

ITB Build

So over the holidays I put some money down on a few parts for the car, will make for some great New Years Resolutions =)

Found a brand new ITB kit "second hand" off a forum, was able to get it at a very good price so I'm going to try do a budget build. Kit came with the Garage Star/Techno Toy Tuning (T3) adapter plate (black), Toyota AE101 throttle bodies, fuel rail mount, velocity stacks (black), air filters, vacuum block, Toyota TPS and various gaskets.

I've also got myself a Megasquirt DIYPNP ECU for tuning purposes, will assemble this ASAP and get running with the car as is. Will need other parts too like a new fuel rail, fuel pressure regulator, wideband O2 sensor and synchrometer to sync the throttle bodies.

ITBs will improve engine response, emit evil noises from the engine bay as well as a small jump in power. My initial goal is to have fun building/tuning the engine, but long term is to gain more power with cams, head port/polish (and maybe other expensive stuff!).

Some good info here:
http://clubroadster.net/vb_forum/showthread.php?t=39898

What it'll roughly look like when done:

Read more after the break...