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ARO 10.1 with a 4EFTE conversion


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#41 ARO_10

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Posted 08 February 2009 - 07:31 PM

A quick update.

The Alternator wiring, starter motor wiring, thermofan, earth wiring is done. Injectors are in with new seals.

This week will have to hook up the boost switch for the water/methanol pump, also the hoses to & from the fuel rail, to the idle air control valve, brake booster, boost switch.

Radiator hoses will have to be done after the exhaust is made so i know where I can run them so they dont get to hot.

The radiator connections may have to be modified but hopefully not.

Mounts for the air expansion tank, oil air separator & water methanol pump.

Strut brace will have to be remade to clear the distributor.
The ARO that deffinately can. You'll only see the back of me.

#42 ARO_10

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Posted 12 February 2009 - 08:57 PM

ok well, the strut brace is 90% done just have to weld up one side & drill the holes to bolt in.

Brake booster, Idle air control valve & w/m boost switch hoses are all hooked up.

W/M boost switch wiring is done apart from runnint it to the actual pump which will be done once the exhaust is completed.

Also found out one of the rear wheel brake cylinders was a bit stuck. Pulled out, honed out & refitted works like new. Bled both rear brakes so I know all the air is gone.

Currently getting the front rotor hats made to upgrade to F3 DBA 5000 series rotors so it will stop as well as it'll go. Compared to the old slide callipers they are a complete waste of time unless you like your front brakes locking up all the time. Im replacing the front callipers with Daihatsu feroza floating jobies.

Dropping the ARO off tomorrow to get the exhaust done. Shouldn't take to long hopefully.

Edited by ARO_10, 12 February 2009 - 08:58 PM.

The ARO that deffinately can. You'll only see the back of me.

#43 ARO_10

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Posted 21 February 2009 - 08:45 PM

well the ARO project is very very close to being finished.

The strut brace is done just need to modify 2 bolts to fit them in.

The exhaust manifold is in progress of being made along with the rest of the exhaust.

Intercooler piping is getting there also. A pain in the butt to weld thin alloy.

The brake rotor hats are also being made next week so long as the engineer doesn't have any big jobs pop up.

Things left to do so far:
Oil lines to remote oil filter & turbo,
Radiator outlets being modified a bit,
Lead from coil to distributor,
Water methanol Tank,
Water methanol pump positioning & wiring,
Brake upgrade,
Intercooler piping,
Some wiring,
engine fuel pump,

Thats the main stuff, most should be easily knocked over once I get the beast back.


The ARO that deffinately can. You'll only see the back of me.

#44 h a n i m

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Posted 22 February 2009 - 06:49 PM

ohhh so close!! this is gonna be mean!

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92 GT Starlet


#45 ARO_10

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Posted 23 February 2009 - 04:47 PM

QUOTE (h a n i m @ 22 Feb 2009, 07:19 PM) <{POST_SNAPBACK}>
ohhh so close!! this is gonna be mean!



And a awesome sleeper. the exhaust manifold is currently being made. He has done the #1 & 4 runners so far onto the flange plate.

When I get more closer to completion pics ill post em up.
The ARO that deffinately can. You'll only see the back of me.

#46 ARO_10

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Posted 27 February 2009 - 04:54 PM

here's some pics of where the turbo will be sitting. Also how much room I havent got for the oil filter adaptor.

Also some pics of the engine compartment.









The ARO that deffinately can. You'll only see the back of me.

#47 ARO_10

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Posted 10 March 2009 - 07:48 PM

Another update on the project.

After leaving the water & methanol mix (50/50) in the plastic reservoir over 3 days it looks like it'll do the job. Eg. It didn't melt or get eaten.

Got a Blitz DCIV turbo timer rather cheaply so no more ebaying for that.

Should get the car back this week or early next week from the exhaust guy.

Then I can go really nuts.

The oil feed line to the turbo can be done by pirtek.
I can weld up the alloy intercooler piping.
Wiring for some minor things.
Fuel system to be finished, mainly pipe routing & a fuel pump.
The main thing is the Radiator botton feed line will be the only other major thing.
Oil air separator, radiator overflow is made now.
Oil filter mount plate will be bolted on once the cars back.
Sway bar to be measured & made up because of the sump shape.
Also ceramic coating the turbine housing.

Other than these things its 80% complete.

Ill take some pics when its back.

Edited by ARO_10, 13 March 2009 - 05:07 PM.

The ARO that deffinately can. You'll only see the back of me.

#48 ARO_10

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Posted 13 March 2009 - 05:43 PM

I dropped off to the exhaust guy this afternoon to see what progress he was making.

Allot by what I found. Also on another note was doing a twin turbo VY Clubsport wich will produce 1100+hpatw. The guy really has some issues.

Anyway the pics below are the manifold made out of stainless. But its a softer grade stainless so it wont crack. Like the hard 306 manifolds.

Also wrapped it to keep the heat down & just has to run the engine pipe somewhere. Kinda hasn't got bugger all room to fit it. 2.25-2.5 inch.

I won't be ceramic coating the turbine housing anymore. Just use a blanket.





The ARO that deffinately can. You'll only see the back of me.

#49 bizz

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Posted 13 March 2009 - 06:13 PM

really impressive work mate, bet you can't wait to drive her!

#50 ARO_10

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Posted 14 March 2009 - 10:04 AM

QUOTE (bizz @ 13 Mar 2009, 06:43 PM) <{POST_SNAPBACK}>
really impressive work mate, bet you can't wait to drive her!


You bet I cant. The exhaust has actually turned out allot better than we thought it would. I will be getting some pics of the manifold berfore it was wrapped next week hopefully.

Id say it a boy car as its a square shape & going to be pretty brutal on the road.

Anyone think of a name that may suit.
The ARO that deffinately can. You'll only see the back of me.

#51 h a n i m

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Posted 16 March 2009 - 09:27 AM

i'll put my name thinking hat on. its really strange seeing the engine in nth/sth position smile.gif

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92 GT Starlet


#52 ARO_10

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Posted 16 March 2009 - 09:20 PM

it's not easy getting the little bugger to fit either. Heaps of room after you swap the ends of the plenum over though.

I thought it was going to be a complete pain in the ass.

Now its only a little pain in the ass.
The ARO that deffinately can. You'll only see the back of me.

#53 ARO_10

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Posted 26 March 2009 - 05:57 PM

Ok well another update on the project. Ill be picking the ARO up tomorrow afternoon fron the exhaust guy.

Ill post up pics of the system if I can tomorrow as well.

The exhaust pipe was a bit of a pain in the ass as the steering runs behind the engine & had to allow for the idler arm movement.

Only a few things left to do as the methanol nozzle is fitted into the intercooler piping & polished.

Remembered I also have to weld on the BOV mount after I polished the intercooler piping. Just have to do a bit more polishing as I thought i would.

Bit of a bugger as I have to go to Sydney for a little while when I would rather be getting the final things done to get it closer to running.

It's so bloody close to being started its itching me.




The ARO that deffinately can. You'll only see the back of me.

#54 ARO_10

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Posted 27 March 2009 - 10:54 PM

Well I eventually picked up the ARO from the exhaust guy. Cost a bit more than expected.

System has one sports muffler & 2.25 maybe 2.5inch system. Haven't measured it yet.

Now I know the water methanol tank will fit.
The Air intake has heaps of room.
Intercooler piping fits like a dream.
Header tank if also fitted.
Oil Air separator will go next to the battery.
Circuit breaker is fitted & works. Also turned on the stereo again, oh my god I miss that thing. You can deffinately blow your ears out & maybe kidneys.
Water methanol pump now has a confirmed spot along with the radiator reservoir.
Oil filter mount fits next to the chassis. Will fit when I go back to work.
Oil feed lines will be made & fitted up later.
Boost controller temporary fitted.
BOV just fits next to the header tank.

I have a few pics of most things. If I can Ill post them tomorrow.
The ARO that deffinately can. You'll only see the back of me.

#55 4eCynos-Riko

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Posted 28 March 2009 - 12:34 AM

love your project, can't wait to see and hear it on completion! biggrin.gif

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#56 h a n i m

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Posted 28 March 2009 - 10:07 AM

sweet!!!

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92 GT Starlet


#57 ARO_10

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Posted 28 March 2009 - 10:59 AM

Here's some pics I took last night. Some are a bid dull though. sorry.











The ARO that deffinately can. You'll only see the back of me.

#58 ARO_10

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Posted 13 April 2009 - 12:07 PM

ok guys, I'm getting there a bit quicker now.

I found out one slight problem with the carbon canister though. It was hitting the bonnet. Now relocated to new spot with clearance.

Well so far the oil feed line plate on the turbo has a fitting in ti to allow a teflon braided line to be fitted.
The radiator reservoir is fitted & now also has bonnet clearance.
Oil air separator will be fitted next to the water methanol tank.
BOV mount will be welded on tomorrow hopefully. Pending on how busy I am at work.
Water methanol spray nozzle is fitted. (pic posted in prior post)
Turbo timer boost hose now has a feed line.
Everything else is just a case of little bits here & there. Mainly hoses a fuel pump & wiring the modules etc up.

Fingers crossed.


The ARO that deffinately can. You'll only see the back of me.

#59 bizz

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Posted 13 April 2009 - 12:30 PM

veeery close now mate... almost a complete engine bay!
where's the bov going to sit?

#60 ARO_10

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Posted 13 April 2009 - 05:25 PM

QUOTE (bizz @ 13 Apr 2009, 12:00 PM) <{POST_SNAPBACK}>
veeery close now mate... almost a complete engine bay!
where's the bov going to sit?


It'll sit just below the water methanol nozzle on the left hand side (looking from the front) intercooler pipe.

Should have it sorted tomorrow once I weld up the piping & attach the adaptor.
The ARO that deffinately can. You'll only see the back of me.




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