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- Other Engine Conversions - non V-8 (https://www.rx7club.com/other-engine-conversions-non-v-8-118/)

- - My 2JZ attempt: (https://www.rx7club.com/other-engine-conversions-non-v-8-118/my-2jz-attempt-957550/)

Got some interest from folks here that aren't on Supraforums, but wanted to see some of the work I've done.

I'll post the pictures here and explain some of them, but regardless there should be quite a bit of information in here for those curious about the problems and solutions for this swap.

Feel free to ask questions, and if I don't know the answer I'll know someone that does.

We'll start from the beginning when I bought the car last August.

http://img.photobucket.com/albums/v2...nt/p_00455.jpg
http://img.photobucket.com/albums/v2...nt/p_00458.jpg
http://img.photobucket.com/albums/v2...nt/p_00459.jpg
http://img.photobucket.com/albums/v2...nt/p_00451.jpg
http://img.photobucket.com/albums/v2...nt/p_00452.jpg
http://img.photobucket.com/albums/v2...nt/p_00457.jpg

Packing the car up to ship to the shop:

http://img.photobucket.com/albums/v2...nt/p_00181.jpg

http://img.photobucket.com/albums/v2...nt/p_00182.jpg

The truck, trailer, and car were just so beautiful I had to take some shots together.

http://img.photobucket.com/albums/v2...nt/p_00188.jpg
http://img.photobucket.com/albums/v2...nt/p_00185.jpg
http://img.photobucket.com/albums/v2...nt/p_00184.jpg
http://img.photobucket.com/albums/v2...nt/p_00187.jpg

Wheel the car into the shop, and start pulling stuff apart. (The white MKIII is also mine.)

Next step was to design a subframe, so I got a hold of a Tech2 frame and reverse engineered it.

Here are a couple pics of the frame and models.

http://img.photobucket.com/albums/v2...ent/REV2-2.jpg
http://img.photobucket.com/albums/v2...ent/REV4-1.jpg
http://img.photobucket.com/albums/v2...Semi-Mount.jpg

As for the mounts, I used some MIL spec hi-density UHMW stock with some 6061 T6 al stock.
If these fail, I'm going to revert to some Poly-urethanes I have at work.

After the engine and sub-frame were in, I tackled the transmission mount.
I have access to a plethora of tools and equipment, so I decided to try a formed aluminum bracket for high weight to strength ratio.

In the mean-time, I prepared my exhaust manifold for installing.

http://img.photobucket.com/albums/v2...ent/mani_1.jpg
http://img.photobucket.com/albums/v2...ent/mani_4.jpg

The first bracket came out "okay" but I wanted perfect, so I ended up making 2.
http://img.photobucket.com/albums/v2...s_brace_sw.jpg
http://img.photobucket.com/albums/v2...rans_brace.jpg

In preparation for the intercooler, I removed the front bumper cover as well as the fender liners. This FD has been in a fender bender, so the crash bar had a small pucker on the driver's side.

To mount it, I welded some .125" steel plate pads to my custom hanger brackets on the core, marked, drilled, and tapped.
Here are some pictures:

http://img.photobucket.com/albums/v2...t/IMAG0388.jpg

Collision damage:
http://img.photobucket.com/albums/v2...t/IMAG0389.jpg

Cleaning up the intercooler. (I used this cooler on my MKIII supra up to 650hp.)
http://img.photobucket.com/albums/v2...t/IMAG0403.jpg

With some small pilot holes, we hung the intercooler in a couple places with zip-ties to get an idea where it will go.
http://img.photobucket.com/albums/v2...t/IMAG0393.jpg
http://img.photobucket.com/albums/v2...t/IMAG0395.jpg
http://img.photobucket.com/albums/v2...t/IMAG0395.jpg

And here we are after welding in the pads, tapped, and bolted up:
http://img.photobucket.com/albums/v2...t/IMAG0404.jpg

The duct in the OEM bumper needs to be trimmed a little so it's not rubbing on the core:
http://img.photobucket.com/albums/v2...t/IMAG0414.jpg

Here we are with the bumper back on. (I couldn't have a better fitting intercooler for this bumper.. I'm really happy with it.)
(ps, check out my hover car!)

http://img.photobucket.com/albums/v2...t/IMAG0405.jpg
http://img.photobucket.com/albums/v2...t/IMAG0412.jpg
http://img.photobucket.com/albums/v2...t/IMAG0411.jpg

Next will be IC pipe routing, and it's got a great path.
http://img.photobucket.com/albums/v2...t/IMAG0407.jpg

Since I only get to work on the RX7 on weekend, during the week I spend some time running simulations of components I design or would like to use.

I typically design for a FOS of 2.5 or greater on something like this.
For the engine sub frame, I choose a force comparable to a of 1,000 lbs in various directions to highlight any areas of concern.
In the Tech2 style subframe, assuming an basic AISI 304 material I was able to determine a couple key areas that had zone where the stress surpassed the yield strength of the material. In an average weld, depending on the filler metal or post annealing the strength of bond can be as low as 70% of the yield strength. So I'll be keeping an eye on these areas.

Here are a couple screen shots of the calculation results.

http://img.photobucket.com/albums/v2...nt/FOS_SIM.jpg

Here shows a small buckling scenario at the weld joint near the steering rack engine standoff interface.
This was simulated at 1,000lbs static force with the car frame mounting locations restrained. (The scaling is 16X.)

http://img.photobucket.com/albums/v2...ON_SCALE16.jpg

Purchased a standard CXRacing IC pipe kit to piece together my bends.

They look decent.
We'll see how they work out:

http://img.photobucket.com/albums/v2...t/IMAG0844.jpg
http://img.photobucket.com/albums/v2...t/IMAG0845.jpg
http://img.photobucket.com/albums/v2...t/IMAG0846.jpg
http://img.photobucket.com/albums/v2...t/IMAG0847.jpg

Milled off a couple standoffs that I intend to weld to my transmission mount.
http://img.photobucket.com/albums/v2...t/IMAG0848.jpg

Some other misc. parts to fabricate the exhaust:

I got my 316 stainless reducer to make my down pipe. Currently, it's a 4" pipe with 4" v-band flange. What I would like to do for the time being, is use my GT4088 with the 3" turbine exit and reuse my 4" downpipe.

So I'll go from 3" to 4" to open dp.

http://img.photobucket.com/albums/v2...t/IMAG0851.jpg
http://img.photobucket.com/albums/v2...IMAG0849-1.jpg
http://img.photobucket.com/albums/v2...t/IMAG0850.jpg

Also got some fiberglass heat shielding wrap for whatever I'd like to insulate.
About 100' by 2" here.

http://img.photobucket.com/albums/v2...t/IMAG0852.jpg

Replaced all the brakes with new rotors and Porties:

http://img.photobucket.com/albums/v2...t/IMAG0967.jpg

New heat shield from ATP Turbo:
http://img.photobucket.com/albums/v2...t/IMAG0998.jpg

Did a little bit of work on the 7, but check out what we got one morning.;-)

http://img.photobucket.com/albums/v2...t/IMAG1001.jpg

http://img.photobucket.com/albums/v2...t/IMAG1005.jpg

Seth came for a visit today to bring me my manifold for the supra, so I took the opportunity to see what my billet turbo would look like on the. Rx7

http://img.photobucket.com/albums/v2...t/IMAG1024.jpg
http://img.photobucket.com/albums/v2...t/IMAG1009.jpg

Got the driveshaft installed, and the fuel tank drained ready for dropping.

http://img.photobucket.com/albums/v2...t/IMAG1016.jpg

http://img.photobucket.com/albums/v2...t/IMAG1000.jpg

http://img.photobucket.com/albums/v2...t/IMAG1014.jpg

Gonna put the brakes on this project.
http://img.photobucket.com/albums/v2...t/IMAG1046.jpg

Bought a new camera, so the pictures from here on out will be better:

Before heading home today, I took some scrap pieces of pressboard, sheared out 4 pieces to some dimensions I'm thinking of making a radiator to.
It's always nice to have a model to work with in the car.

I epoxied the sides together, so it's a real quick and dirty mock radiator. :)

http://img.photobucket.com/albums/v2...t/DSC_0116.jpg

http://img.photobucket.com/albums/v2...t/DSC_0117.jpg

http://img.photobucket.com/albums/v2...t/DSC_0120.jpg

Using the numbers here just to describe the percentage in change of angle ONLY, you can see by reducing the steering rack's location results in a large change in tie-rod angle:
The illustration doesn't really represent the wheels, tires or rack, but rather the difference in angle required if you lowered the rack.
Note that everything is constant, minus the location of the line representing the rack to ground (this value is known and correct.)

As long as I keep the other arbitrary numbers constant, my angle difference can be calculated.
http://img.photobucket.com/albums/v2.../RACK_DESC.jpg
http://img.photobucket.com/albums/v2...K_RACK_GEO.jpg
http://img.photobucket.com/albums/v2...D_RACK_GEO.jpg

After making a rough model of a radiator, I ordered a custom one from Griffin:

Here are some pictures.
It's a 2.75" thick core 2-row.
-17AN fittings on feed and return that will go to fittings on my water necks.
Two electric fans and an aluminum shroud.

http://img.photobucket.com/albums/v2...DSC_0115-1.jpg

http://img.photobucket.com/albums/v2...DSC_0112-2.jpg

http://img.photobucket.com/albums/v2...DSC_0114-1.jpg

http://img.photobucket.com/albums/v2...t/DSC_0108.jpg

http://img.photobucket.com/albums/v2...DSC_0109-1.jpg

Wrapped the radiator up in some cardboard and masking tape so I wouldn't damage it while figuring out the position:

http://img.photobucket.com/albums/v2...t/DSC_0153.jpg

AN fitting facing the water neck:
http://img.photobucket.com/albums/v2...t/DSC_0149.jpg

http://img.photobucket.com/albums/v2...t/DSC_0147.jpg

Expansion/overflow nipple is on the passenger side with a straight route to the stock bottle. Very clean, no hoses draping over the front of the engine bay.

http://img.photobucket.com/albums/v2...DSC_0141-1.jpg

Continued progress on radiator support design.

To validate the design in the system, I have simulated a static load of 100lbs on a radiator geometry to my bracket assemblies.
Assuming a total face to face bond in my gusset I get my results.

The stresses on the system are highlighted with the graph provided:
http://img.photobucket.com/albums/v2...AD_SUPPORT.jpg

Here is a simulation of the yield strength of the bracket alone with 100lbs of force, notice the low value.
By calculating the yield strength of the bracket alone, we can determine it's functionality in the system. With the yield of the bracket in the 33ksi range, I am confident in the design seeing less than 700psi in the system:

http://img.photobucket.com/albums/v2...D_SUPPORT2.jpg

Since I validated the design, I will now make the part:
Sheared out some AISI 304 steel and punched out some gussets:
I will attempt to weld them this weekend. Since it's been a while, I might just tack them and have them done professionally.

http://img.photobucket.com/albums/v2...t/IMAG1113.jpg
http://img.photobucket.com/albums/v2...t/IMAG1114.jpg
http://img.photobucket.com/albums/v2...t/IMAG1115.jpg
http://img.photobucket.com/albums/v2...t/IMAG1116.jpg
http://img.photobucket.com/albums/v2...t/IMAG1117.jpg

More to come.
Tacked up the brackets, etc.

http://img.photobucket.com/albums/v2...t/DSC_0171.jpg

http://img.photobucket.com/albums/v2...t/DSC_0208.jpg

Using FloWorks simulation tool, I am able to calculate some air molecule trajectories through various environments. I modeled my intercooler, and core density to the published data provided to me by Spearco. The IC pipe geometry is subject to change at this stage:

http://img.photobucket.com/albums/v2...C_CORE_GEO.jpg
http://img.photobucket.com/albums/v2..._GEO_FLOWX.jpg

30PSI Environment without the intercooler core:

http://www.youtube.com/watch?v=6Zahg-lUraM

30PSI Environment with core:

http://www.youtube.com/watch?v=JxdqLZ7b8y8 The beginning of the vacuum line system:
Thanks to my friend at McMaster, I got these goodies in 8 hours. :D

Anodized vacuum manifold with 1/4 and 1/8 NPT taps so I can tuck and hide some air lines:

http://img.photobucket.com/albums/v2...t/IMAG1210.jpg
http://img.photobucket.com/albums/v2...t/IMAG1207.jpg

Sorting through some push-to-connect fittings.
At $47 a piece for the stainless steel ones, they're a real nice piece.

http://img.photobucket.com/albums/v2...t/IMAG1211.jpg

At this point it was discovered that my engine set was a blown up paper-weight.
Rebuild was in order... big time.

We decided to take the oil pan off of my 2J this weekend to replaced the nasty RTV silicone with some toyota FIPG.

Soon as we turn the engine over on the stand, we hear rattling...
Fearing the worst, we pull the oil pan to discover this...

http://img.photobucket.com/albums/v2...t/DSC_0258.jpg
http://img.photobucket.com/albums/v2...t/DSC_0260.jpg
http://img.photobucket.com/albums/v2...t/DSC_0259.jpg
http://img.photobucket.com/albums/v2...DSC_0256-1.jpg