mk1 cortina with 4age install

[64sam]

hello all...

i've been a member for a while now but haven't had a chance to let you know what i've been upto.

i've got a 1964 pre airflow consol cortina 4 door.

it was a 1500 deluxe orientally but the engine and box are now gone to make way for a 1600 16v straight 4 toyota 4 age from a AE86 along with a T50 gearbox to bolt straight on.

anyway enough words here are some pics of what i've done so far...

starting at the start...

this soon broke down and a plan was hatched for a rice powered rwd toy so some toyota bits were bought...

with the help of my friend and his engine hoist the old unit was releived of it's duties

we then did a trial fitment of the the new engine and box

then to make room for the toyota box which isn't much bigger than the ford item but just didn't fit in the tunnel without dragging it's ass on the floor

then uni got in the way and it was the end of play till i was able to get the car home for the summer. this happened eventually after managing to borrow a trailer of a friends uncle and towing it back with my limp wristed passat... 300miles in one day with a 20 odd ft trailer was defiantly an experience when i'd never towed before

anyway with the tina home safe it was time to get the engine home for good so i bolted on the plates that i had designed and had fabricated in the shop at uni

then my dads friend came over with his mig and welded these to the pinto chassis mount kit that i had butchered as well as some 3mm strengthening plates onto the chassis rails.


he also plugged up the hole i'd made in the transmission tunnel with a plate i'd bent and cut to shape.

then with the aid of the old engine mounting bushes the gearbox too had a home for life

this pretty much brings us up to date since this all i've done is bolt a few things back onto the engine such as the 44 mikuni carbs

atm i'm being held back by being stuck in birmingham at uni and the car being 150 miles away in suffolk

atm my main problem other than needing to get the wireing sorted is the distinct lack of a radiator. i have the toyota one to go with the engine by this is too big to fit in the tinas bay and have sold the tinas original one because i need one with inlet and outlet on the same side. i've got a fan that bolts to the waterpump and would like to keep that to make the wiring as simple as possible but don't know what modern radiators fit the tina bay. any ideas? i know polo ones a popular among you escorts boys so do these fit in the tina bay just as well?

look forward to hearing what you guys think.

[banhambuilt]

gonna make a nice reliable ride

dave

[DazaV8]

cool project nice work

[wildo105e]

Looks good you have done well to get a complete AE86 setup that will have made life a lot cheaper and simpler.

Used to have a GT Coupe brilliant car and cracking engine

[seventynine]

[turbo m]

Love it will you be up grading to a turbo later???

[neilm]

We have a nice manifold for that very application










It mates straight to our Cortina system and is priced at £235+VAT and we have a couple on the shelf

[neilm]

We can modify your standard Cortina rad to have an uprated core and move the outlet to the other side to match the 4age if you like

Be about £140+VAT with a fanswith in the bottom tank, £120+VAT without.

[neilm]

Oh and we could do your prop too, but will need to know if this it's a 20 or 22 spline T50 you have.

[64sam]

turbo m

i shan't be turboing it anytime soon as i don't plan of running with much of an interior so shouldn't need any extra power.

neil

i already have a manifold from Ashley (money talks) and shall be making my own side exit with 2" pipe i picked up while there.

will probably be getting a polo rad as its 100 notes cheaper and i got £17 for the old one will probably be interested in getting a prop from you tho... i've spoken to you on the phone about this before but can't remember what other dimensions i need to order one?

[neilm]

Problem with a polo rad is you need to run a header tank, which we do on the Anglias, which adds to the cost.

You may want to look at the 3 series BMW rads as they come with a header tank on the side of the rad but I am sure the outlets will be at the wrong end.

The Ashley Corolla manifold wont fit, you will need to seriously modify it as the Retro Ford boys had to do on Project Potter to get it up and running before we did the new stainless one.

Good luck

Prop we just need diff flange to gearbox oil measurement, the real fun and games will start if you have a 20 spline T50.

[64sam]

ok i've had a look for 3 series rads and the outlets wouldn't work because they are on opposite sides

this view is from the driving position.

a polo one would work tho if i turn it upside down as long as i have the room and i'm not fussed about running a header tank if i can pick up a radiator for 30-45 notes

or

the AE86 Ashley manifold i have fits fine (sorry no pics because i took it off to fit the starter) it doesn't foul on the chassis rails, floor, inner wings

i'll get counting and measuring when i'm home next for the prop. are the 20 splin fixings a nightmare to get hold of then?

[gpcmatric]

Very nice mate,like it may well go this route with my tina.

[neilm]

Yes 20 spline is a real problem, 22 spline is readily available.

[muckerbarry]

Neilm is right about the corolla manifold, it definitely won’t fit in an escort as I found out yesterday, the Toyota engine bay must be lot wider than a fords, it would need serious hacking to make it fit.

I have a brand new janspeed manifold which is way ahead of the Ashley item in terms of quality that’s no good to me. Arse.

Neilm, ill be in touch….

[oddy]

thats strange, my janspeed fits in a escort engine bay, what ignition system are you going to use?

[warrenk85]

Nice project you've got going there
I'm in the process of building a Mk1 Escort...
With a 7AGE Toyota Motor and 2T TRD Gearbox.
I'll be using a Mk1 VW Golf Radiator as the exits are sitting on the same side... I'll fit the header tank in the wing..
Are you running Luminition Ignition?... i cant make it out in the one picture.
TNT Exhaust here in SA makes a RWD branch manifold for the 4AGE motor for fitment in the Datsun/Nissan 1200/1400 range.
They go for about R850... which is about 65GBP... I'll get one and make it fit...
Good luck with your project... you're alot further than i am

[64sam]

warrenk85 and oddy the ignition system is standard but with a box of tricks that does the job of the ecu that the previous owner binned when they put the carbs on.

think it's called wacko but can't remember for sure... will check next time i get a chance to go home and work on it. basically turns it into a full blown dizzy and produces a decent advance curve and everything...

i think that neil at 105speed can supply something similar tho.

[64sam]

today i had the first chance to work on the car in months so got rid of the headlining because knowing there are sound deadening pads up there adding weight has been playing on my mind.

one little yank and this happened and there was no turning back


even the worst of the rust looks like a few hours with the wire brush then coat of kurust and paint will have it licked


have been working out how to solve the clearance issue with the clutch master cylinder/ trumpet looks like i'm gonna buy a shorter master cylinder rather than try and move the pedal box or relocate the cylinder.

also been getting my head round the wiring but since this is the first time i've done anything electrical since high school it's all a bit over my head.

[64sam]

oh for referenced this is clearance issue i have with the clutch master cylinder

and the ignition system is by wako technical company and is called a LA-700 FX
it must have been fitted to the AE86 the engine came out of in japan before it was imported here.

this is the installation diagram i have to work from

[gtir303]

fair play to u mate looking good good to see people putting reliable engines in fords lol

i have put a nissan ca18det in mine

[gpcmatric]

Great project mate can you get the ignition system over here?

[64sam]

i've been looking for a uk supplier to ask for a copy of the wireing diagram but all i've found online are japanese websites so i'm guessing no. but i'm sure there are loads of systems out there that will do the same thing.

[neilm]

Great project mate can you get the ignition system over here?

There are not loads of systems for this conversion unfortunately as it is much cheaper than getting into ECU's and mapping etc.

There is a module available from a guy in New Zealand, he sells them on e-bay and they are currently at £145. Its called a Hyperpak and its what Ben has on the Retro Ford Project Potter Anglia.

Works very well.

[gringo!!]

looking good... im a big fan of jap engines... they love to rev, and reliably too... keep it up!!

[eliters]

looking at that diagram,the box has an earth,and live feed from ignition,a 2 pin plug which goes to the dizzy,so plug and play,and a wire that goes from box to coil negative terminal,you then run a wire also from ignition live via a supressor to the positive on the coil,hey presto.

The problem i think you will have is identifying which is coil negative output and which is live input from ignition switch on the box?
The earth on the box should be a relatively short wire possibly with a ring terminal on it,and the dizzy is plug and play from the diagram.
Edit;just thought,the coils negative wire from the box may have a spade terminal on,which would then leave one wire which should be pos ignition input.
if any of this is of any use,let us know what colour wires you have or post up a pic and will see what i can do.

If i can be of any help drop me a pm,ive been a mech for 13 years and my speciality is wiring,altho i cant read japanese very well,lol.
cheers neil.

[64sam]

bit of an update of what i've got done in the last few weeks... it's been pretty slow progress because christmas and new years has kinda got in the way of things.

in no particular order:
sorted out fuel lines with return, pump and filter
4216148965_cf688c1f55_b.jpg
got a new 1.6 polo radiator here it is alongside the original toyota one
4234743356_a8484856b8_b.jpg
put it in place and measured up for mounts
4241145513_8c85b042f3_b.jpg
4241145527_ba750d1f68_b.jpg
then designed the mounts on catia so i can get them made up at uni next term
4241972500_9a555818e9.jpg
also with a heap of advice from eliters i made a start on the wiring
4241145495_f940e56588_b.jpg
also found out that i must have shifted the engine over slightly before i made the mounts because my manifold now knocks on the to of the TCA... also waiting on news from 105speed about a prop.

that will be it for now as i'm off to uni tomorrow so won't get to work on the tina till at least easter

[127 Boy]

really nice project Sam!!!

Keep the good work!!

[seventynine]

can't beleive i've missed out on all of this, should check here more often . my boys all growned up

[gringo!!]

looking good mate.. keep at it...

[64sam]

hello here are a few pictures of what i've managed to get done in the last few days.

first up i fitted the replacement clutch master cylinder after a slight bit of fettling

this solved the clearance issue that i was having with the original one.

then i decided to get the radiator mounts i'd knocked up at uni...

... and attacked them with my mates welder (be gently i've only ever used a tig before)









i have tidied it up a bit and it all seems fairly sold so then it was time to get the grinder out to sort out the ill fitting ashley manifold


i'm really happy with how it is going because it feels like it is starting to come together and resemble a functional engine bay.

[justinveal]

very cool project and diffrent, its good to see that your finding routes round problems with the manifold and radiator etc

[GAZZAMK2]

Looking good now, starting to take shape.

If you get down a decent scrapyard or ebay there's loads of expansion tanks knocking around off new cars. Mines a Clio one on my zetec conversion...fiver

[M11rf]

Nice work...

Is that originally a RWD engine? I ask because if you fit the viscus fan to the FWD engine, it will destroy the water pump.

It should go well with that engine ... incidentally how much did you pay for the package?

[64sam]

thanks for the positive comments.

justinveal
i'm glad that i haven't had to do all the body work that you have on your scort.

Gazza
i remember reading your feature and the bit about a clio expansion tank didn't look out of place in your bay and convinced me not to blow a load on ally one. i have an expansion tank from a mk3.5 golf cab but think i left it up in birmingham so will have to fit that when i'm back from uni in the summer.

murf
the engine is original from rwd corolla (AE86) engine and i saw it running before it was taken out of the car with the viscus fan so should be no problem.

i paid just under 500 for the engine with the carbs and ignition module whch isn't bad for a rev happy rwd engine.

[M11rf]

Cheap Engine!!!

[Jon]

If you are struggling with the wiring for the ignition still let me know I have a mate who is from Japan and sure he will be happy to translate it for you ;-)

[seventynine]

Gazza
i remember reading your feature and the bit about a clio expansion tank didn't look out of place in your bay and convinced me not to blow a load on ally one. i have an expansion tank from a mk3.5 golf cab but think i left it up in birmingham so will have to fit that when i'm back from uni in the summer.

still in my boot

good to see the progress mate

[64sam]

If you are struggling with the wiring for the ignition still let me know I have a mate who is from Japan and sure he will be happy to translate it for you ;-)

you have no idea how long i've been tryinhg to find an english version of the wiring diagram. if you could get this translated that would be super amazing.



i'm scratching my head over what the resistance the resistor is and what effect that will have on my coil. i think that it is just a balsat resistor so isn't a biggie to sort.

lath

must have taken it out of your boot and then put it back again. please take it out before you sell it

[64sam]

decided to put the exhaust back together today... these are the only two pictures i took:

welding up the outside:

i only managed to half weld the collector to the rest of it before i ran out of gas will try and get some tomorrow and finish it off