Beast Build Diary

[jason_l]

*** Another Update ***

Can't believe this but i have just got an email from ToyotaGT.

They have just informed me that they have reached the previously agreed money that i am willing to spend this month. Although this sounds bad, its not! and im over the moon!

They have completely exceeded my expectations and have done what would have taken me 6 months to do in only 3 days!!!!!

They have cut the rear of the frame off and removed the rear subframe, this has been cut in half and rebuilt another 6 inch's wider and painted. They have done some welding that i asked them to do at the front of the buggy and have prep'd the frame ready for the extension. They are now waiting on the steel i ordered a few days ago to continue the build and are keen to get it back to a rolling chassis within the next week or so!

Im going up there on Saturday to pay what i owe so far and will take a few snaps while im there, can't wait for the weekend. Also going to talk with them about how i want the rear made up, i have a good idea that will incorporate some HUGE side intakes to vent air to the radiator/intercooler.

Jason :)

[jason_l]

Went up to ToyotaGT today and spoke to James.

Things are going well with the buggy and its all prep'd waiting the steel i ordered last week to extend the frame. I got mixed up the other day and when i thought the frame was going to get extended by 6 inch's i was wrong, its getting extended 6 inch's either side, so its going to be 12 inch's wider!!!! going to be slightly longer than 12 inch's as well.

Going to look well mean now!

here are a few little pics i took.

the rear is all ready waiting for the steel so it can get PHAT!!!!!

Im going up there next weekend to work on the front brakes and a few other bits. Money's going to be tight the next few months with paying for this extra work but its so worth it!!!!

Jason

[jason_l]

*** Small Update ***

Went up to TGT today and had a little look at state of play on the buggy.

Coming along nicely and now has the extra 12 Inch's added to the rear that will house the fuel cell, intercooler and radiator. Im going to be pretty broke for the next few months while i pay for all this extra work but will be up at TGT doing a few bits where and when i can.

Here are a few pics of the extension work.

I currently owe them for 3 days work and will be a couple of more days on top to get the thing back to a rolling chassis with maybe engine in :)

TGT are on holiday for 2 weeks from 19th of this month and the car will be remaining there during as not much point moving it about. Going to spend the next few weeks doing as little here and there and reading through the 280 pages of the IVA manual :(

What do people think?

Jason :P

[sparkystav]

Looks great mate.

The whole garage on holiday?

seems to be an expanding project though lol.

[jason_l]

Looks great mate.

The whole garage on holiday?

seems to be an expanding project though lol.

project is expanding, wallet is shrinking...............ALOT! :D :D

Yes all of TGT are on holiday, one guy is staying about to do a few bits i believe but the will not be open for business i believe. Can't blame them though, everytime i go up there they are working their asses off so need some time off :D

Jason :)

[Yeldarb]

They are always hard at it, kettles don't boil themselves you know.

Strange to see that ramp without my car on it

[jason_l]

They are always hard at it, kettles don't boil themselves you know.

Strange to see that ramp without my car on it

Your car was just being moved from the workshop as i arrived mate, still looking great! Mine is so small that it doesn't need a ramp, its currently sat on a table top being welded :D

Jason :)

[chrisis200]

They are always hard at it, kettles don't boil themselves you know.

Strange to see that ramp without my car on it

Your car was just being moved from the workshop as i arrived mate, still looking great! Mine is so small that it doesn't need a ramp, its currently sat on a table top being welded :D

Jason :)

Looks like they have done alot quick mate, I'd love to get into something like this one day. My funds are alot less then yours so cant even think about it yet, but cant wait to see it all done & then will pick your brains for ideas etc.

[jason_l]

They are always hard at it, kettles don't boil themselves you know.

Strange to see that ramp without my car on it

Your car was just being moved from the workshop as i arrived mate, still looking great! Mine is so small that it doesn't need a ramp, its currently sat on a table top being welded :D

Jason :)

Looks like they have done alot quick mate, I'd love to get into something like this one day. My funds are alot less then yours so cant even think about it yet, but cant wait to see it all done & then will pick your brains for ideas etc.

To be honest Chris i don't have alot of money and this project hasn't cost me much in terms of what it could have cost me.

I haven't had the chance to check exactly what i have spent so far but i reckon no more than £2500 so far. That includes everything i have spent on the frame, parts, labour through TGT and buying the Starlet. Im hoping to spend no more than another £2000 to get it finished but can't be certain.

So potentially for £4500 i could have something with lambo/ferarri beating performance!

[jason_l]

*** Phat A$$ ***

My bro went up to ToyotaGT today to check on his MR2 engine rebuild and while he was there he kindly got a few snaps for me of the buggy :D

Looks like they have been cracking on with it again this week and her A$$ is starting to get PHAT. My bro says it has almost the same wheelbase as a MR2 but looks alot smaller because there are no panels to it.

Anyway here are the pictures..............

The last picture makes it look so mean now with the extra size :)

Obviously there will be extra strengthening to be added and the chassis needs to be put back together fully but she's starting to get there now :)

What do people think?

Jason :D

[Yeldarb]

Same wheel base as an MR2!! Sure does not look like it, if so it should handle great, and with that engine go like the clappers!!

[jason_l]

Same wheel base as an MR2!! Sure does not look like it, if so it should handle great, and with that engine go like the clappers!!

Well my bro says its close to it! got to remember that the car starts and finishes in line with the wheels :) Should handle great now though me thinks, has the drag car stance as well with the rear wheels wider (6 inch's either side)

Jason :)

[richie*is200]

this should interesting wen finished. good luck wit it.

[Yeldarb]

had a look at this one on Monday, it is going to fly!! I think you should stick a 3S in it!! and stop messing around with 1.4 turbo engines

And your brothers new/rebuilt 2.2 3S looks MENTAL that turbo is something else, no room in the boot for shopping though, full of intercooler and air pipes.

I hear that the 3SGTE Starlet TGT built embarrassed an Ferrari F40 last week!!

[jason_l]

had a look at this one on Monday, it is going to fly!! I think you should stick a 3S in it!! and stop messing around with 1.4 turbo engines

And your brothers new/rebuilt 2.2 3S looks MENTAL that turbo is something else, no room in the boot for shopping though, full of intercooler and air pipes.

I hear that the 3SGTE Starlet TGT built embarrassed an Ferrari F40 last week!!

Thanks Phil :) its coming along nicely, i need to keep the starlet engine for the moment so i can get the car road legal as i have the V5 and chassis plate to prove where the engine came from.

Did you speak to James by any chance??? I just mentioned to him that im considering putting a 3S into it at a later date B)

Brothers cars getting there also, he spends sooooooooooooo much money on that car its unreal. That turbo is a work of art though, and the manifold is crafted from god himself.

I can't look at your car anymore, every time i look at it i just want it so much :shutit:

[jason_l]

*** Small Update ***

Last Saturday i managed to get up to TGT and have a little look round the car and get a few bits painted, i didn't bother painting loads of it as he still has some welding to do on the frame. its getting there though, although still a long way off! I believe he may have done some more this week but i didn't get a chance to speak to him before he went on holiday :(

Sort of looks alot more racey now and should go some when its done.

Well James is on Holiday now for 2 weeks so no more update for a little bit but i have managed to sort a few things out this week......

Firstly i ordered up some hardened 7/16 bolts for the harnesses and turned up some inserts on the Lathe that will be welded into the rear bar to secure the harnesses.

Went to my local Halfrauds and they where selling off alot of stuff, picked up a new K&N induction kit for a vauxhall corsa but its a nice size filter so will be ideal for the beast for the moment, only reduced because the box looed tatty, £15!!!!! bargain

Few weeks ago i got a few little bits at the Japanese Tunning show, Exhaust wrap and metal ties £12 and some rather nice roll cage padding, 2 metres £10 :)

My bro had some spare heat shield material lying about so he has given me the remainder, had a look and there is about 2 metres of the stuff!!! nearly £60 in value :) He is also changing his oil cooler setup so he has given me his old Setrab 10 row cooler free of charge :)

Also bought a RX7 top mount intercooler on eBay although im not sure if i will be using it yet?

Not much i can do now for 2 weeks until James is back and i have access to the buggy again.

Jason :)

[jason_l]

*** Another Update ***

Well the guys are back from their holiday so i went up there today to have a little look at the progress. Its all looking good and they have started offering up the engine and looking at fixing the engine mounts in place.

Had a little talk about a few things and got a few more things sorted out. Including the exhaust, keeping the carbon bike can for the moment and lookig at routing it over the engine rather than under. This means that it will be increadibly short, pipework will only be about 300mm long with only one bend and then the rear can :D Have a look at the pictures, i have roughly placed the exhaust where it will go.

This picture shows how short the pipework will be. Exhaust will come straight from the turbo and join onto the rear of the bike can, with no cat of cousre :)

Anyway, its getting there but bit slower than i thought beacuse of my tight funds. The guys at TGT have been spot on and have been working at an exceptional pace. However the buggy won't be ready for JAE unfortunately as its needed alot of extra work and i don't currently have the funds to fund it at the pace they can work at :(

Anyway what do people think? comments welcome as always

Jason :P

[Yeldarb]

Needs twin Zorsts.

[jason_l]

Needs twin Zorsts.

Maybe but that will add weight

*** Update ***

I know updates on this slowed off for a little while but its all back on now as i really want this thing done.

Went up to TGT yesterday and spoke with James, he was welding the engine mounts in place when i turned up and hopefully engine will be in its final place in a few days. Meaning the next stage will be to get the custom drive shafts made up :D

Had a little talk and im going back to a front mounted radiator, best option really as there is limited room at the back, even though it has been extended. Battery will be getting moved to the rear and a fiat chinqy rad will be used up front as its PERFECT size and should easily be enough to cool it. Chinqy rad will be on order in the next few days.

On my way up to TGT yesterday i stopped of at a company called Xsport racing in basingstoke and had a little talk about some custom carbon/fibreglass parts.............watch this space :P

While i was there i borrowed a fibreglass vent and checked the fitment on the buggy. Looks good and will help vent some air to the engine and the oil cooler at the rear.

I would have taken some pictures but my camera on my phone was playing up so didn't really have a chance. The second i get home it starts working again!!!! time for a new phone me thinks!

Also my new seats arrived, god they are sexual. Custom made in white as black wouldn't be very good in hot weather. These things are mega light, roughly 4.5kg per seat. Can easily be picked up with one finger. Didn't bother with the padding as im intending on making something later. They have mounting points already built into the floor so they just bolt straight in.

anyway, Will let the pictures do the talking........

Comments always welcome guys.

Jason :P

[jason_l]

*** Update Time ***

Got a few parts bought, a few on order and some to soon be on order and follow later.

Firstly got the new rear side vents ordered up from Xsport in basingstoke and they arrived early this week, need a little work but will sort these out soon and nothing too bad. These are being used to vent some air to a oil cooler and generally just cool the engine a bit.

Next came the Fiat Chinqy rad, now being mounted at the front of the car. Its only small i know but will have a couple of small spal fans added to the rear of it to help draw the air through it. Fits at the front of the car nice and snug though :D

My bro also gave me some Pajero indicators that he never used on his supra project so these will probably end up being molded into the custom front nosecone i will be making? This will mean that the arch's won't have to have the indicators mounted into them then and i can keep the nice clean lines.

Then today was spent moving the buggy to its new home for the foreseable future. TGT are moving and soon to be changing their name as they are going to start doing all Japanese cars rather than specialising in just Toyota's.

Got the buggy out and on the trailer, this is the first time any of us has seen it outside with its new fat ***** and to be honest i think it looks LOADS meaner and has a more racing look about it. Ignore the camber on the rear for the moment, the rear hasn't been fully finished yet so looks a bit low/crazy angles. Anyway, tell me what you think of the car now?

This picture really shows the profile of the car now, looks great, if i do say so myself :D

Back still needs some work, including a rear crash bar/light unit. not too sure what yet though??

Got it moved 10 or so miles down the road to its new HUGE home, makes the thing look even smaller when you see it inside the place. The glanza in the picture belongs to one of the guys that works at TGT.

Gives you some idea of the size of their new place

Buggy won't be worked on now for a little while as they have alot of stuff to move but i have said i have the money now to get back on it so engine/wiring/driveshaftwill be very soon :)

Also have ordered a Apexi turbo timer and should be here next week and will be ordering the powerflex poly engine mounts in the next few days along with a load more steel to finish off the frame.

thats it for the moment, any comments always welcome

Jason

[jason_l]

*** Update ***

Got up to TGT to measure/check a few things on the buggy. They are going to be mega busy moving premesis and getting ready for JAE so think they may not get anything done this month, can't blame them really. However it will be back on next month and i will have more cash to fuel the work :D

I have started ordering a few more bits and they are slowly turning up, first was my race tow strap. Nice and light as there is not much to it but will easily pull the buggy if i get stuck in the gravel traps :D

Started looking at making up the induction pipework and location for the induction kit, Filter will be mounted in the side compartment and stick out the side of the car. This means it will be in direct air flow so should stay nice and cool :D you will be able to see the turbo in the first pic so it should be relatively short pipework which is good. Im thinking about relocating the oil filter and a oil cooler to the other vent on the side.

Also measured up a few bits on the front and im going to start looking at parts to start fixing the radiator in place and coolant pipework. :D Here is what the Fiat Chinqy rad looks like on the front, almost perfect fitment. The hoses coming off the rad will have to bend back around as they are quite close to the edge of the car but should be ok, and before anyone says the Battery will be going to the rear of the car.

I know its not really much of an update and it will go slow for a bit this month but will be back on with more speed next month.

As always people, comments are greatly recieved. :D

Jason

[chrisis200]

Hey Jason I've not been around for 3-4 months but just catching up & the projects looks ace still, will try an pop in every so often to check how your going on mate :)

[jason_l]

*** Update ***

Well as i haven't updated this in absolute ages i thought it only fair to add a few words.

Work has been very slow on this, in fact its gone backwards its been that slow and parts have actually come off the buggy.

My Apexi Turbo timmer turned up recently and after 3 weeks wait i finally got my set up Powerflex Poly Engine mounts.

Also another set of michelin racing slicks arived last week and will soon be ordering the rear wheels. Should look so good with the deep dish wheels all round.

I have also bought a pair of Gaz adjustable coilovers for the front and these will be turning up any day now. Im converting the whole car to coilovers as the mini suspension setup is basically prehistoric. Will get pictures up when i get them :)

I got the steel delivered which is being used to make the seat mounts. The seats are normally just bolted to the chequer plate floor but i want something a bit stronger so im going to have steel box section underneath to hold the seats more secure.

JDModified (previously ToyotaGT) are soon to begin work back on the buggy after they moved premises and have expanded their workshop.

I have been talking gearbox's and it looks like the MK1 MR2 box may fit straight onto the Starlet engine. They share the same clutch so in theory should mount straight together without too much hassle but we will soon see. The MR2 box is better suited for the buggy as the gear selector mech is on the other side of the box and is designed for a rear engined car.

I have also got a quote to have the buggy shot blasted, sprayed with etch primer and then sprayed bright lime green, and it came to £300 all in. Well happy with that price and im going to be getting it sprayed sooner rather than later. Im going to get the welding done and before i start putting more bits on im going to strip it all down to the chassis and have it sprayed before the year is out :D Going to get a few more bits done at the same time. Its not any specific green, its just a green that i have chosen from their colour chart and is very similar to Kawasaki Green, just ever so slightly different.

I have also have designs i drew up months ago for a adjustable rear wing for the back of the car and as we are getting some steel laser cut at work im adding this to the job so will have that made up and test fitted very soon.

Also i got the CAT removed and have already drawn up the flange details in CAD. Im going to get some new stainless steel flanges made up for the exhaust system and look at routing this. Im making 2 systems up. One will be a standard pipework system, full stainless and will be heat wrapped. The second of the 2 will be the same style but will have a screamer pipe coming off it and will be put on the car after IVA :D

I know its not much of an update but felt i should add a few words as this has been left for far too long.

Comments always welcome people..........

Jason :D

[jason_l]

**** Mini Update *****

Well after my hospital check up on wednesday i got back to work and these arrived 10 minutes later. :D

These are the coilovers for the front of the buggy, wasn't going to buy them just yet but when people are selling them slightly cheaper than what it would cost me then i can't resist and gave in to temptation. The springs going on these are the ones already on the buggy which will fit on these a treat. The coilover kit for the rear will be on order very soon.

Also the steel that i need laser cutting for the rear adjustable spoiler design is currently being made up and should have this with me very soon.

Hopefully next weekend i will get a full day working on the buggy and actually get something done, its been far too long now with no progress so im keen to crack on with it.

On another side note, my hospital check up was not good news! I was born with a dodgy aortic valve on my heart and they have been keeping an eye on it and the check up showed that it has got considerably worse since last time. I have been told that it needs to be replaced with a carbon fibre valve soon! So after christmas i will be going in for surgery. This means im going to be off work for 3 months and not allowed to do proper work for an additional 6-8 weeks. Meaning that work i can do myself will stop on the buggy. However it shouldn't stop completely as because im not able to work or do anything then im not spending money on getting to work/lunch/going out etc. Meaning i can put some more money towards getting other parts made/ on order. Hopefully won't effect the build too much, although my health comes first of course ;D

Jason :D

[jason_l]

*** little update ***

As i posted before i was going to get up to JDModified and do some work on the buggy today but unfortunately it was not possible as James wasn't about for the day so couldn't get to the buggy :(

Instead i went to work and cracked on with a few little bits:

The metal for the adjustable spoiler arrived on Friday so i spent a few hours today getting the bits welded up and it looks like a keeper. The spoiler brackets get welded to the top roll bar piece on the back and should be more than enough to support the rear spoiler piece. They are adjustable as well so the angle can be changed to fine tune the downforce supplied to the back. I will be making something similar for the front and will also have a rear lower diffuser added later.

Here's the pics.

spoiler pieces.

inserts welded in and ground off.

pretty much there, still needs a little finishing but this will be done before it goes to paint with the rest of the car.

Here's a little mock up of what it will look like, will be using a tinted green acrylic so you can see through the spoiler and gives an idea of the level of adustment available.

Not going to order the acrlic just yet as don't want it getting damaged before i need it. Im also considering using the same tinted green acrylic for the side of the Demon so you can almost see through the car. Then having the sponsor logo's/decals etched into the panels so they are 'ghosted'.

Have also found a 40lt fuel cell that will be ordered up next month. It doesn't come with a locking fuel cap as they expect you to fit it into a car where its secure but i will need to adapt a locking fuel cap onto it. I did buy a locking fuel cap off of a Honda motorbike and it may be able to be adapted to fit the fuel cell. It is even hinged so it doen't come away from the car (as per IVA regs :D ). Keys even stay in the cap until its locked back in position, which is the other requirment if its not tethered.

I have also ordered the other 2 Deep dish Ultralite wheels that are required for the rear of the buggy and they should be here next week with any luck and will be on in 2 weeks time.

I won't be able to get to the buggy for 2 weeks now as im going to look around Williams F1 test facility next weekend :D not turning that down!!!!!

I have however now 'booked' the buggy in to have the chassis finished off, seat fixings made and the final rear roll cage parts added. This should be done within the next 2 weeks and then comes the coilover work.

As always people comments are greatly recieved and help me to work out parts that need attention so any comments/questions/concerns please ask away.

Jason :D