4AGE Rally Tercel

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Chard
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Posts: 21
Joined: Sun May 01, 2016 11:24 pm
My tercel:: 84' tercel sr5 4wd supercharged, 87' Tercel4wd 4age RTR Rallycross
Location: Kansas
Contact:

4AGE Rally Tercel

Post by Chard » Thu Nov 07, 2019 12:35 pm

Hi Guys,

I'm finally getting around to posting my tercel4wd projects in the one place that will truly appreciate them. The other one is under "Supercharged Tercel"
20191005_152133.jpg
This is my 87' 4age swapped tercel that I own specifically for SCCA Rallycross events. I did not do the original swap. After racing it for one season with a worn out engine that put down smoke screens on the course, I rebuilt the engine and tried to get a little more power out of it.

Engine build performance upgrades:
- Milled head and deck for estimated 10.8:1 compression and minimal "squish" area.
- "272 duration 82mm lift cams from ebay (Malasian)" - showed up with no cam card, and when I measured they had a total duration closer to 256, but the lift was correct. Should be better low end power than expected, which is actually good for rally.
- Adjustable cam gears - I had to adjust them quite a bit. Would be much easier with cam card telling you where to set them.
- Ported head - Mostly on exhaust side.
- Balanced the crank (didn't take much), pistons, and rods.
- Custom Phenolic space to replace TVIS system and keep the intake cooler.
- Ebay "4age tubo manifold" used for an exhaust manifold, 2.25" exhuast routed out in front of rear tire due to lazyness.
- Lightweight pulleys because I needed a new one anyways, and it was cheaper than a used one.
- Lighter flywheel - I turned about 5 lb's off the stock 3ac flywheel and drilled the extra holes on a mill. (I did not weld up the old holes, but I'm thinking there is plenty of material still there to hold everything together. And 8 bolts is better than the 4 that were on there...
- K&N cone intake filter.

Unfortunately with the stock ECU I won't be able to take full advantage of the upgrades. Maybe Megasquirt in the future.

Other modifications:
- Weight removal - estimating about 250lb without interior, bumpers, AC, and rear hatch (still need to replace with something lighter).
- 14" MR2 wheels with 1" spacers and rolled fenders to accommodate. Snow tires
- Koni Yellow Adjustable shocks in the rear
- Aftermarket rear sway bar for AE86
- 1 coil cut from springs.
- Battery relocated to rear passenger area.

Next projects:
- Light weight hood, rear hatch, and front bumber/skid plate
- Rework front suspension (probably start a thread for ideas on this) I want more caster and camber adjustment, and overall less movement.
- Stiffen up links on rear suspension (I was thinking solid rod bearings and arms from Coleman racing catalog).

I'll have to sort back through photos, but I'll add them as I can.

Here's some from the first time out at the track with none of the modifications listed above. Look at that body roll!
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Last edited by Chard on Thu Nov 07, 2019 1:24 pm, edited 1 time in total.
-Chard

Chard
Newbie
Posts: 21
Joined: Sun May 01, 2016 11:24 pm
My tercel:: 84' tercel sr5 4wd supercharged, 87' Tercel4wd 4age RTR Rallycross
Location: Kansas
Contact:

Re: 4AGE Rally Tercel

Post by Chard » Thu Nov 07, 2019 12:52 pm

Just got it fired up last night and it sounds awesome. The engine build was spaced out over a long time and I had to move garages. As a result I must have forgot the cam seals. Because its spewing oil from behind the gears. Hopefully I'll get that all fixed this weekend and get the engine broken in.
Here are some pics of the exhaust fabrication. I included one up close shot of the welds so that you wouldnt zoom in and see how bad all the others are!
20191102_125219.jpg
20191104_210930(oriented).jpg
20191008_203250(oriented).jpg
20191103_111405(oriented).jpg
20191004_173431(oriented).jpg
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-Chard

Chard
Newbie
Posts: 21
Joined: Sun May 01, 2016 11:24 pm
My tercel:: 84' tercel sr5 4wd supercharged, 87' Tercel4wd 4age RTR Rallycross
Location: Kansas
Contact:

Re: 4AGE Rally Tercel

Post by Chard » Thu Nov 07, 2019 1:44 pm

Flywheel process shots. I used ARP flywheel bolts just to be safe.
20190319_130811.jpg
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-Chard

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Petros
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My tercel:: '84 Tercel4wd w/extensive mods
Location: Arlington WA USA

Re: 4AGE Rally Tercel

Post by Petros » Thu Nov 07, 2019 3:24 pm

nice job on that flywheel. what does it weigh?

I had the holes welded up before it was machined (takes a skilled welder than knows how to weld on cast iron). I got my 22 lb 3ac flywheel down to about 14 lbs as I recall.

I think Larry McGrath found a better solution, use the 4age flywheel, cut down the outer diameter to take the 3ac ring gear. the 4age flywheel already has the 8 bolt hub of course, but the clutch is larger, and it still fits within the T4wd trans bell housing. Also, there are more options for performance clutches for the 4age flywheel. trans input spline and assembly depth are the same, so it all fits.
'87 Tercel 4wd SR5 (current engine swap project)
'84 Tercel 4wd (daily driver, with on going mods)
'92 Mazda MPV 4wd (wife's daily driver)
'85 Tercel 4wd DLX auto(daughter's daily driver)
'01 Honda Civic (other daughter's daily driver)

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NWMO
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Joined: Wed May 20, 2015 1:08 pm

Re: 4AGE Rally Tercel

Post by NWMO » Thu Nov 07, 2019 6:11 pm

Hey Richard,

Great post and pics. Most times the photos will orient correctly when they are clicked on, but not always. Somebody here may have a solution, we’ll see. Let me know when you race next summer, I can join the fan club.

Chris
Psalm 37:4 "Delight yourself in the Lord and he will give you the desires of your heart"

In remembrance of my friend ARCHINSTL:

T4WD augury?
"Oh, do not ask, 'What is it?' Let us go and make our visit."
T.S. Eliot - "The Love Song of J. Alfred Prufrock"

"Now and then we had a hope that, if we lived and were good, God would permit us to be pirates."
Mark Twain

Chard
Newbie
Posts: 21
Joined: Sun May 01, 2016 11:24 pm
My tercel:: 84' tercel sr5 4wd supercharged, 87' Tercel4wd 4age RTR Rallycross
Location: Kansas
Contact:

Re: 4AGE Rally Tercel

Post by Chard » Thu Nov 07, 2019 6:31 pm

Petros wrote:
Thu Nov 07, 2019 3:24 pm
nice job on that flywheel. what does it weigh?

I had the holes welded up before it was machined (takes a skilled welder than knows how to weld on cast iron). I got my 22 lb 3ac flywheel down to about 14 lbs as I recall.

I think Larry McGrath found a better solution, use the 4age flywheel, cut down the outer diameter to take the 3ac ring gear. the 4age flywheel already has the 8 bolt hub of course, but the clutch is larger, and it still fits within the T4wd trans bell housing. Also, there are more options for performance clutches for the 4age flywheel. trans input spline and assembly depth are the same, so it all fits.
Petros,

I cant remember. I wish I would have wrote it down somewhere. I want to say 15ish? But there was definetely more that could have been removed. I think I'd go the 4age flywheel route next time. Mostly for more clutch options.The spec stage 3+ for 3AC is almost $500. And their next option down is the stage 2 at around $300.
-Chard

Chard
Newbie
Posts: 21
Joined: Sun May 01, 2016 11:24 pm
My tercel:: 84' tercel sr5 4wd supercharged, 87' Tercel4wd 4age RTR Rallycross
Location: Kansas
Contact:

Re: 4AGE Rally Tercel

Post by Chard » Sun Nov 10, 2019 5:31 pm

Back on it's own 4 feet! It sounds pretty mean with the higher compression and cams. Now I just need to break in the new engine and tie up some loose ends before the next race in a couple weeks.
20191110_175911.jpg
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-Chard

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NWMO
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Posts: 695
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Re: 4AGE Rally Tercel

Post by NWMO » Sun Nov 10, 2019 5:43 pm

Chard,

When and where?

Chris
Psalm 37:4 "Delight yourself in the Lord and he will give you the desires of your heart"

In remembrance of my friend ARCHINSTL:

T4WD augury?
"Oh, do not ask, 'What is it?' Let us go and make our visit."
T.S. Eliot - "The Love Song of J. Alfred Prufrock"

"Now and then we had a hope that, if we lived and were good, God would permit us to be pirates."
Mark Twain

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Yaut
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Posts: 59
Joined: Thu Jan 10, 2019 5:34 pm
My tercel:: 1985 Toyota Tercel 4WD automatic, lifted 1.5", 15 inch wheels

Re: 4AGE Rally Tercel

Post by Yaut » Sun Nov 10, 2019 9:32 pm

That's great work!
'85 Toyota Tercel DLX 4WD (tan)
'85 Toyota Tercel DLX 4WD (white)
'84 Toyota Tercel SR5 4WD (red)

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NWMO
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Joined: Wed May 20, 2015 1:08 pm

Re: 4AGE Rally Tercel

Post by NWMO » Mon Nov 11, 2019 7:12 am

Hey Chard,

I copied the pics, rotated/saved and removed the others. I also removed your question about proper orientation, thanks for the great post.

Chris
Psalm 37:4 "Delight yourself in the Lord and he will give you the desires of your heart"

In remembrance of my friend ARCHINSTL:

T4WD augury?
"Oh, do not ask, 'What is it?' Let us go and make our visit."
T.S. Eliot - "The Love Song of J. Alfred Prufrock"

"Now and then we had a hope that, if we lived and were good, God would permit us to be pirates."
Mark Twain

Chard
Newbie
Posts: 21
Joined: Sun May 01, 2016 11:24 pm
My tercel:: 84' tercel sr5 4wd supercharged, 87' Tercel4wd 4age RTR Rallycross
Location: Kansas
Contact:

Re: 4AGE Rally Tercel

Post by Chard » Mon Nov 11, 2019 7:31 am

NWMO wrote:
Sun Nov 10, 2019 5:43 pm
Chard,

When and where?

Chris
Carbondale, KS on the 24th. Ksscca.org has the kansas region schedule. I think the KC region is done for the year.
-Chard

Chard
Newbie
Posts: 21
Joined: Sun May 01, 2016 11:24 pm
My tercel:: 84' tercel sr5 4wd supercharged, 87' Tercel4wd 4age RTR Rallycross
Location: Kansas
Contact:

Re: 4AGE Rally Tercel

Post by Chard » Mon Nov 11, 2019 7:44 am

It turns out I needed more timing adjustment than the new exhaust manifild would allow. I tried denting the stainless manifold by heating it up and hammering but that stuff is really tough and i didnt want to crack anything. Ended up grinding away at the distributor to make it work. I didnt end up needing to grind off as much as I did on the bolt area, but its on there and timing is set.
20191109_174515.jpg
20191110_111305.jpg
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-Chard

The Professor
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My tercel:: 1987 Tercel SR5 4WD wagon
Location: Western Washington
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Re: 4AGE Rally Tercel

Post by The Professor » Mon Nov 11, 2019 9:14 am

Yikes, that is not much clearance to the exhaust runner! I predict a melted distributor cap in your near future.
1975 Subaru SuperStar wagon
1984 Subaru Turbo-Traction wagon
1984 Subaru Turbo-Traction hardtop
1987 Subaru RX 3-door
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1987 Toyota Tercel SR5 wagon
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Chard
Newbie
Posts: 21
Joined: Sun May 01, 2016 11:24 pm
My tercel:: 84' tercel sr5 4wd supercharged, 87' Tercel4wd 4age RTR Rallycross
Location: Kansas
Contact:

Re: 4AGE Rally Tercel

Post by Chard » Mon Nov 11, 2019 11:33 am

The Professor wrote:
Mon Nov 11, 2019 9:14 am
Yikes, that is not much clearance to the exhaust runner! I predict a melted distributor cap in your near future.
Hopefully wrapping the manifold and inserting a heat shield there with be enough to prevent that. But we'll see. Its really just one big experiment and I anticipate some failure.
-Chard

User avatar
Petros
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Posts: 11104
Joined: Sun Jan 28, 2007 6:31 pm
My tercel:: '84 Tercel4wd w/extensive mods
Location: Arlington WA USA

Re: 4AGE Rally Tercel

Post by Petros » Mon Nov 11, 2019 4:35 pm

I think there should be a number of heat shields when the exhaust is on that side of the engine bay: fuel lines (or reroute), starter, steering u-joints, as well as the distributor. a header wrap should get most of it, and perhaps help keep the engine noise low.

the head pipe has to snake around the steering shaft and the rack, the distributor, and the starter motor (and the related wire bundles).
'87 Tercel 4wd SR5 (current engine swap project)
'84 Tercel 4wd (daily driver, with on going mods)
'92 Mazda MPV 4wd (wife's daily driver)
'85 Tercel 4wd DLX auto(daughter's daily driver)
'01 Honda Civic (other daughter's daily driver)

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