Fuppylodder's '97 ST202 2GR-FE swap Options

[Fuppylodders]

Hey, I'm a frequent member over on CCUK, but here is where I first found out about the 2GR-FE swap, I'd seen that njccmd2002 was one of the first to have one, and after reading through some of his Beams thread (photophuckit ruins it ), his Vert thread, and the thread titled 'never satisfied', I wanted to let him see what he helped inspire, as I was originally looking at a 1mz/3mz swap.

I have already had the Celica for about 3 years now, and 2 of those it has been in a body shop and engine shop. I work away 9 months of the year, so don't have the time (nor space nor know-how with regards to electrics, or welding capability/capacity amongst many other things ) but the job afforded me to make it happen anyway. So I still had the vision!

Well, the project itself is not far from being complete already.

Bodyshop to carry out:

• Full strip down of the car-Done
• All rust removed/welded up- eh, sore subject, was done, have had to get the body shop to revisit this
• Full respray-about 98% done
• Rebuild car with all new parts/fully refurbished parts-about 97% done
• Merge GT4 front bumper with Tom's Lip-Done
• Merge rear lip with rear bumper-Done
• Remove glass sunroof and replace with a fabricated metal panel that works in its place so the paint job can be applied to it while keeping sunroof functionality (not to be confused with transparency)-Done
• Interior reupholstered-door cards and rear quarter cards covered in leather too-Done
• BC racing coilovers fitted-Done
• GT4 front and rear caliper conversion-called off (I wasn't happy with shaving off near on a 1/3rd of the lug mating face material for safety reasons)-instead bought a full set of PB Brakes: 330mm disc, 6pot front set up and 4pot rear calipers and I forget the size of rear disc, but is smaller. I think 304mm or thereabouts.

• Woodsport to carry out the 2GR-FE engine conversion. For those that haven't heard of them, they mainly deal with MR2's, Beams, gen4 3SGTE, 1mz, 3mz, 2GR conversions for all 3 gens of the MR2. Also some bodywork/custom fabricated stuff, and erecently the Hapers hatch for the mk1 MR2. Anyway, moving on! Nearly done-fully installed, but required car to be finished off at bodyshop to be road worthy to set up and road test engine. That'll happen hopefully next week.
• Exhaust-Dual exit either side sitting inside the rear lip-Done.

Me to do:

• Chrome door sill strips to be converted to light up the word 'Celica'-Passenger side-Done.
• Modernise the rear center brake light-Nearly there. Chrome internals done, just have to attach it inside the stock holder. Custom resin cast clear and diffused pattern removed-nearly done, just got to work some bubbles out to perfect it. Current progress looks promising.
• Customise rear lights. Something completely different and more modern looking-In progress.
• I have someone working on working out if/how to get a 7GC set of dash gauges working for a 6GC so I can then modify them into the dash. I like the LED section
• Modify the 6GC dash to fit the 7GC round air vents in place of the rectangular ones. Then get it recovered in leather to fit with the rest of the interior.

Points of note for the 2GR-FE swap, The engine was hitting everything and in the way of everything. So it was lowered down about an inch (front subframe modified and reinforced), moved to UK passenger side an inch, and moved forward an inch or so. The sump is now sitting rather low so I'll be making an undertray to at least be some sort of first impact point for it should any rogue bumps get in the way

(EXTREMELY Picture heavy incoming)





















Chrome door sill tread plates customised:




























Center Rear Brake Light:

Some random ebay rear middle tail light for some random vehicle






Poured in resin to smooth it out. Next attempt need to do 2 thin layers rather than one thick.


Intention of making rubber seals too, but the one I used was seriously dry rotted and didnt take well to the silicone. It failed... Will try again though.






I've actually produced about 6 of these, each progressing with lessons learned until I swapped to a longer curing resin, which gave me much clearer result, but never really cured properly so is always slightly tacky, and I learned another lesson why I still get big bubbles on the lens. Another silicone moulding method will be attempted to combat that issue. I WILL succeed!



Current best result: Could be acceptible, if only seen from a distance, don't look too close But I'm a perfectionist and it's not acceptable to me... Especially if I'll be making them to offer for other people if wanted.




Custom rear tail light units:
First inception came because I saw an aftermarket center side/brake/reverse light unit for a 2015-2017 Mustang on google while looking for inspiration. An idea instantly popped in my head and I paintshopped a pic to see what it could potentially look like:



Very happy with that! Wasn't sure on length of the light unit though, so I went ahead and ordered two. My next leave would be interesting!
Research on angles of visibility required:


Removing the LED unit from its casing-this would be as small as I can get it apart.


Testing the lights at work-they're nice and bright!


Rough plan on how I'd fit them in the JDM rear light housing:


On leave-it's close, but looks like it could fit?


Cutting up to fit the LED units in:


Testing in the light housing, looking good so far:


Now to start on the indicator. I wanted 2 sets of sequential LED arrow indicators next to each other, with a relay enabling them to be sequential as though they were one, but I was having issues with providing enough power through the relay to light the indicator arrow, so binned that idea, and went with one smaller arrow that is a simple on/off, and one sequential to the outside of that so it looks like it emanates from the on/off arrow. Wanted to make a cover plate out of perspex to sit the arrows into so they weren't sunken in, and the rest of the room could be used for something else! Expanding foam to shape some perspex over with a heat gun.


Started the cover:


An awful lot of filing and test fitting and heatgunning later, its done!:


Perfect fit too! Coincidentally, the perspex was the exact same thickness as was the small lip that runs all around the indicator section, so sits flush:


What's this? fiber optic tubing to make fiber optic LED side light for behind the indicator (further round the side). Trying to make my own lights has turned me into a bit of a light nerd and I've really ended up looking into different lights, and commonalities with modern day vehicle light designs. One thing most vehicles have in common nowadays is the side light can be seen from... the side. I wanted to replicate this, with a fiber optic tube light. Ordered some straight tube from ebay/china, arrived mega fast, from a distance of around 30cm and very carefully (after first attempt bubbled a piece) bent the tube to test bending capability. It worked out as below:


Made a new piece, bent it specifically to fit where I wanted it to go, attached 2 of the LED lights-one on each end, and this is the result:


The black cover plate will be bent in so it shows more of the tube and stops being able to see behind the cover plate. Will possibly put a reflector on the empty spot of the cover plate as I've no idea where else I'd want to put a rear reflector on the Celica's rear end.

That's where I'm at, at the moment!

This post has been edited by Fuppylodders: May 3, 2019 - 11:56 AM

[Fuppylodders]

Well, a small update.
Finally got the car finished with at the body shop, and got to drive it all of 3 miles to the audio install place at about 30mph the whole way so didn't get to really feel what it's like.
I spent about 3 hours trying to get the rear roof spoiler fitted, what an absolute pain in the arse that was! It's like, the clamps would sit too wide and hit the frame of the car when closing the trunk/boot lid if I had the front of the spoiler just rearward so the black trim was just about lined up with the forward edge of the hatch. Got it fitted but I'm not truly happy with it as it's kinda squished up on the left side to prevent the clamp hitting the chassis so will address that on my next leave.

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Also made some slight progress on the custom rear lights. Started hacking up the left side while I still have access to visually see where I had cut away to make the light holder fit. Worked out well and got it done pretty fast compared to the first one. Next to do is to make the indicator cover plate for the left side, make the led tube side light for the left side. Make some mounts for them so they sit firmly in place. Modify both cover plates to fit the indicator arrows. Then time to fix the main light holders in place with expanding foam, some fiberglass pug over that, smooth it, then fix the clear lens on (hopefully if I get that finished good enough)


Speaking of clear lens, I made a start on that too.
Getting one vacuum formed will cost a few thousand due to requiring metal moulds to ensure the lens remains spotlessly clear while using durable acrylic so I'm kinda out on a limb having to try and form my own. Not easy to do by any stretch due to compound curves...



Need to flatten it more, so will probably have to fill the housing with expanding foam, cut back and shape it to what I need, then try heating up and forming the lens over that to finish it up rather than just on the oem lens as I did previously, as its too curved at the edges at the moment




Rear center brake light turned out OK. The one single lens I'd managed to cast that had a slight bit of fogging isn't as bad once it's fitted.
Looks oem too!







Also started and finished the driver side tread plate (although accidentally chain drilled through part of the letter 'A' I didn't want to, but managed to salvage it) so now I've a full set of tread plates ready to fit and wire in on my next leave!


Audio system will have been fitted by my next leave, including the boot build, so the rest of the interior will be put in and it'll be all finished!
Roll on October....

This post has been edited by Fuppylodders: Jul 23, 2019 - 1:29 PM