Malecrod's 3rd Gen 3SGTE Swap, Documenting a JDMGuy Garage 3rd gen 3SGTE Swap Options

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Hey All,
A Month or so ago, I got a PM from Eli (Malecrod), asking me if I was interested in doing a 3rd gen swap for him.
We exchanged a handfull of PM's discussing the in's and out's of getting it done for him, and settled in on a plan of action.
I went over the details of what he wanted to do to the engine as far as mantinence and what not, he let me know that he wanted to get everything done while the motor was out, just to make sure everything is fresh and ready to go when he picks the car up after the swap.
So, I made a list of all the mantinence parts we would need, and set him up with an engine set thru Jim.
I am currently waiting on the motor to arrive, and in the mean time, have been ordering and gathering all the parts to get the motor ready to go in.

His car currently has a 2nd Gen 3SGTE Swap, that was done by dr. tweak back in '06, using the stock S54 tranny, with a front mount intercooler, ect.
The one "issue" he had with the car is that for some reason, he's gone thru several clutches. He explained that for some reason, he kept spitting out the springs on whatever brand disk he tried. (spec, comp, ect) He is currently running an ACT 6 puck sprung disk clutch that he has had good luck with so far, but noted that it did have a heavy pedal feel, and that he was open to suggestions on which brand to go with.
Other than that, he said that the car runs just fine, he just wants to update the motor, and go to the cleaner 3rd gen intercooler setup.

So, for the Clutch, I suggested a Clutchmasters, with an unsprung 6 puck disk. I installed one in my cousin Joes 3rd gen swap last year, at the suggestion of the guys over on mr2oc and aaron @ ATS racing.
The pedal feel on this clutch is REALLY good, not nearly as heavy as the ACT, and the engagement on it is amazing for an unsprung disk.
I talked to my guy, and Clutchmasters will do the 3sgte disk, with the S54 spline, no extra charge, no problem, so that is what I ordered.

His Exhaust system is currently a 3" downpipe, into a 2.5" b-pipe, back into 3" after the crossmember.
For some reason, his exhaust guy couldnt fit 3" piping over the crossmember, so I will be making him a new 3" b-pipe in 304 stainless. I already ordered and recieved a U/J combo bend, 3"X6" flex pipe, and 2 3" flanges.

I also ordered and recieved a bunch of Toyota parts from Aaron from lithia toyota, just about everything I needed, he had in stock, the only thing he didnt have was the spark plug wires, but I have another source for those anyway, which is great. (thanks steff, your the best!)
Here is the list of parts:
Complete Gasket Set
T-Belt and Tensioner ( I will get the idler pully locally)
Oil and Water pumps
Distributor Cap and Rotor (plugs and wires locally)
Fuel Filter
PCV Valve
and some FIPG to do the Oil Pan
Axle Seals
T-stat is being picked up locally thru steff as well

The rest of the small stuff (coolant, oil, gear oil ect), will all be picked up locally when the car arrives.

And here is the kicker of this whole deal... He lives in MN, and will be driving the car to me in MA to perform the swap for him! Awesome!

According to Jim, the motor will arrive next week some time, so for now, here are a few pics of the stuff that has arrived so far:

The Clutchmasters Clutch setup (I still need to measure the disk, i want to verify that it is in fact a 3sgte disk.)



the Exhaust stuff:



and the Toyota parts:



Lots more to come over the next couple weeks once the motor arrives and I start tearing into it.

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a couple pics.

old 2nd gen setup, out.



new rear main seal installed:



the 3rd gen, tranny installed and just about ready to drop in:



it goes in later today.

here is somthing i noticed when i pulled the axles, his passanger axle is thicker than a normal s54 axle, i havent had a chance to ask eli about it, but ill try and get more details.
the drivers side is normal.

his passanger axle is the bottom one, the top one is a old one i had in the garage.