The plans

The Corolla AE92 GT-S Project

A website about my ongoing project

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The plans

On this page, I'll set out what the plans are for this car at the moment.

 

When I bought this car and started the project, the plans for it were a lot more modest. But as the project progressed, the plans started to get more and more ambitious.

Now it has come to a point that practically everything goes, as long as I like it, are willing to try it and think it's a cool addition to the car and the project itself.

 

But I must honestly say that these plans are regularly subjected to change. So what's listed here is more of a guide than a list of set plans. I'll try to update this page and the status of each part as the project goes on.

 

 

The engine

 

Toyota 4A-GZE engine

 

When I started this project, the original 4A-GE that was in this car when I bought it would return in the car again after a proper rebuild. But those plans have changed dramatically.

The 4A-GE was already rebuild and all the plans below were already marked 'completed', but then the 4A-GZE presented itself to me and I decided to ditch the 4A-GE. So now I can start over again.

 

So, a 4A-GZE then. Practically the same engine, but now with a added supercharger: More power, more torque and a cool whine from the engine bay.

Apart from a complete rebuild, I also have some other plans for this engine. I have no idea if I can realize all these plans, but for now, I hope I can.

 

Complete rebuild

Incomplete

Blueprinting the engine

Incomplete

Optimize intake

Incomplete

Replace roots type supercharger with twin-screw type supercharger

Incomplete

Replace 4A-GZE top mounted intercooler with custom Air-to-water intercooler system

Incomplete

Fabricate custom intake manifold with integrated intercooler

Incomplete

Optimize cylinder head

Incomplete

Deburr cylinder block

Incomplete

Replace exhaust manifold with Cusco Powerball header

Incomplete

Delete power steering from engine

Incomplete

Delete aircon compressor from engine

Incomplete

Fabricate new bracket for alternator

Incomplete

Place extra sensors on engine

Incomplete

 

 

The gearbox

 

Dismantled C52 gearbox

 

Again, the original C52 gearbox that was pulled from the car was destined to return to the car after a rebuild and the addition of a Quaife LSD. I already had this all wrapped up and the gearbox was ready to be reinstalled in the car.

But the new 4A-GZE engine came with a gearbox attached to it, and as that had gear ratio's that better suit the power plant and was a lot stronger to handle the added power, of course I went with the E58 that was still bolted to the new engine.

 

Dismantle, clean, sandblast end re-spray gearbox parts

Incomplete

Gearbox rebuild

Incomplete

Replace diff with Quaife LSD if necessary

Incomplete

Replace clutch slave cylinder

Incomplete

Rebuild clutch master cylinder

Completed

Install new clutch

Incomplete

 


The suspension

 

Rear hub

The suspension can be improved upon in several area's. So it will be dealt with to improve the Corolla's handling. 

 

Place KONI shock inserts into modified shock housings

Completed

Replace coil springs with upgraded springs

Incomplete

Replace front swaybar with thicker and adjustable one

Incomplete

Replace rear swaybar with thicker and adjustable one

Incomplete

Replace old rubbers with polyurethane bushings

Incomplete

Replace top mounts

Incomplete

Replace wheel bearings

Incomplete

Rebuild steering rack

Completed

Have all parts cleaned, sandblasted and powdercoated

Completed

Miscellaneous parts

Incomplete

 


The brakes

Red Corolla brake calipers

The original brakes that were on the care were sufficient to stop the car.

But again, room for improvement and it's always nice to be able to stop the car just a little faster.

 

Replace front brakes with AE101 brakes

Incomplete

Clean up all brake calipers (grind away casting burrs etc.)

Completed

Have all brakes sandblasted and powdercoated

Completed

Rebuild all brakes

Completed

Rebuild brake cylinder

Completed

Replace flexible rubber brake hoses with braided lines

Incomplete

Replace old steel brake lines with Cunifer brake lines

Incomplete

Replace brake discs

Incomplete

Replace brake pads

Incomplete

 

 

The body

 

Corolla AE92 GT-S body in rotisserie

 

The body needs the most work done to it. First to get rid of all the rust that has been eating on the car for years and second to repair the damage it sustained during an accident.

 

Replace damaged front with donor front

Completed

Weld on various brackets to the car for added parts

Incomplete

Weld in patches of new steel where needed

Incomplete

Weld shut old antenna hole

Incomplete

Weld shut old sidemarker light holes

Incomplete

Install new automatic antenna on rear of car

Completed

Move battery to boot of car

Incomplete

Replace fenders

Incomplete

Replace windscreen

Incomplete

Replace rear window

Incomplete

Reapply undercoating

Incomplete

Reapply anti corroding to inner parts

Incomplete

Replace pop-up headlights

Incomplete

Replace rear lights with JDM Levin Kouki ones

Incomplete

Replace spoiler with JDM Kouki spoiler

Incomplete

Replace front bumper with JDM Trueno Zenki one

Incomplete

Replace rear bumper with JDM Trueno Zenki one

Incomplete

Replace rear mud flaps with JDM Trueno Zenki ones

Incomplete

Place Trueno emblem on hood

Completed

Replace door mirrors with JDM folding mirrors

Incomplete

Replace door handles

Incomplete

Have windows tinted

Incomplete

New outer trim

Incomplete

Have car sanded and ready for painting

Incomplete

Full re-spray

Incomplete

 

 

The interior

 

Interior of my Corolla AE92 GT-S

 

The interior was in dire need of some attention. It was tired, raggedy and worn.

I already didn't like the cheap look of the original interior, so I was going to change a few things here.

  

Modify dashboard for additional gauges

Incomplete

Modify door cards for speakers and window switches

Incomplete

Fabricate shortshifter

Completed

Modify roof liner for sunglass compartment

Incomplete

Install sunglass compartment/interior lights

Incomplete

Reupholster dashboard

Completed

Install extra gauges

Incomplete

Install compo speaker set in doors

Incomplete

Install compo speaker set in rear of car

Incomplete

Install power windows

Incomplete

Install key ring light

Incomplete

Reupholster front and rear seats

Incomplete

Upholster arm rest

Completed

Reupholster Trueno steering wheel

Completed

Replace carpet

Incomplete

Refurbish plastic parts

Incomplete

Modify dashboard for new radio

Incomplete

Reupholster boot

Incomplete

 

Miscellaneous

 

Part of wiring loom

 

There are of course always parts that just can't be caught in any of the other sections, but they are still part of the car and they will all get done.

 

Repair/modify wiring looms

Incomplete

Integrate new with old wiring looms

Incomplete

Check and refurbish fuel tank

Completed

New rims

Incomplete

New tires

Incomplete

Have car approved by Dutch road and vehicle civil service (RDW)

Incomplete