The $2008 Grassroots challenge build-up thread

skipbarber

2008 Grassroots Challenge
Mar 26, 2008
134
0
0
Rockville-ish, Maryland
update on page 21!

Meet our $2008 Grassroots challenge car..
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first, a little info on grassroots challenge for those of you who are unfamiliar:
Yup, we’re doing it again. The $2008 Challenge will be held October 3-4 at Gainesville Raceway in Gainesville, Fla. Registration will be on October 2 at the host hotel.

For the ninth consecutive year, we’re challenging our readers to buy, build and race a car on a budget. A tiny budget. Keeping with tradition, we’ve increased the budget by one dollar, so get your wrenches and calculators working, because you’ve only got $2008 to work with.
http://grassrootsmotorsports.com/news/012008/2008-challenge.php

This year, myself and two of my buddies decided to take on this challenge with a '91 MKIII turbo. The idea is that you buy a car, modify it and compete in 3 categories: drag race, auto-x and show, all with a budget of $2008. A friend of mine was selling this pretty MKIII that needed work for $1500. After doing a few jobs on one of his other cars and letting him keep some of the parts from the supra, we worked him down to $950 and brought the car home. The car came with, what i consider, a huge list of choice parts. Koni yellows at all four corners, H&R springs, brand new OEM brakes all the way around, including e-brake shoes that I had installed for him the previous month, a staggered wheel setup, MSD ignition wires, NGK iridium plugs, BIC DDP that hadn't even been installed, a glove box full of OEM hoses and gaskets, Koyo radiator, Greddy radiator cap, a replacement fender (right side is damaged) and a sparco harness.

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The car ran, but it didn't like to, so we towed it to my house where it slept for about a week before we started work on it today. It had horrible misses and leaked everything from pretty much everywhere. Took it to my shop this morning where we immediately got to work. Put it up in the air, removed the entire exhaust (turbo elbow was a complete bitch to remove).
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installed the DDP. We pulled all the plugs, a few of which were swimming in oil. started stripping the interior, removed the cruise control and EVAP components. Ran a compression test..
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impressive numbers considering the way it ran the first few times we drove it around. We were surprised how many hoses and couplers were completely dry rotted and leaking, the car had so much unmetered false air, it was no wonder it was running the way it did. after an .82 cent investment and the parts we had in the glove box we replaced the majority of the failed hoses and couplers and took her out for a spin.. 9psi and a BLAST to drive. we're all extremely impressed and very excited to continue working on this project. We havent decided on too much yet, but we know for sure we want a full cage in the car with as little interior as possible..some inspiration:
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it doesnt compare...but it's certainly a start..
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we're also thinking about a side exit exhaust, ARP head studs and some type of piggy back engine management (for the sake of remaining within budget). keep checking back as i'll update this thread as we make progress. My name is Edwin, mechanic and automotive electrician (with honda roots, dont hate) my team is Avi, master welder and complete toyota nut that spends entirely too much time with his 88 celica all-trac, and David, he's also a mechanic and our veteran racer, and if it's japanese, he's owned it, built it and sold it (240sx w/sr20det, 1G eclipse, 2G honda integra race car, 8th gen civic Si, blah blah blah). We've all gained a ton of info on the MKIII and 7M-GTE from this site and this is how we will give back. Let us know what you think...

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don't mind the flat on the trailer, we fixed it before we left.

EDIT 4/1/08: short vid from yesterday http://media.putfile.com/33108-Supra-fun
EDIT 4/3/08:
skipbarber;978479 said:
Aight sooo, more pics!

Looks pretty good so far I think. Still not washed and waxed. I think our whole team agrees, go before show. But she is looking hot! Soooo fun on the road too! between her style and the open downpipe, She's a real head-turner! I really need to get on that side exit exhaust though, fumes aren't so much fun :aigo:
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We've started stripping out the interior and sound barrier, some of which came out in big chunks. For the rest I think we will need the dry ice method.
Of course we also left the Targa top holders in place, cuz who doesn't wanna drive with the top off:naughty:

Also, Edwin and David want to get rid of the carpet, but for some reason, I (Avi) can't seem to want to part with it... I know it's a race car and all. Someone want to put me back to my senses, or does anyone agree with me? I guess it comes down to this... How much are guys willing to pay for a complete grey carpet? :icon_bigg

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We've also got a little rust goin on below the quarter window. From other pics I've seen, I'm assuming it's a common problem?

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Lastly we have the Sparco 4-point harness that came with the car. We mounted it up, but feel that it might be inadequate for our uses. Currently looking for a 5-point with compatible lightweight seat.

*edit* I just also wanna add real quick that yeah, we know this isn't the right way to mount a harness. Seeing as how there was no seat belt receiver for the drivers side though, this was our only option

I think we also just made a (sorta)decision about the tuning system. (David if you read this before I talk to you, then me an E want your input, haha) So it looks like we will be goin with the Megasquirt. It was between that and the MAFT. The Megasquirt seems to have a lot more capabilities, and best of all it's cheaper. If anyone knows where to get a Megaquirt kit 3.0 for less than $189 let us know! Thats the cheapest we found so far. We're still probably a few months away from needing it, so we have time to shop.

Next big step will be removing the HVAC system, of which the most difficult thing i think will be routing the hoses under the hood. I know we can figure it out, but any tips/suggestions?

EDIT: 4/4/08

skipbarber;980451 said:
First off, sorry for the pic quality, I forgot my camera so my phone had to do the dirty work today.

This afternoon I stopped by the shop where Edwin was taking care of some small issues. A missing rear wheel stud was replaced, and the tire was patched from the inside where a screw had punctured it. The car has had some sort of popping issue issue when you get on it real quick. Sounds almost like hitting the rev limiter, but at lower RPMs. We were thinking that maybe it has something to do with running rich and having the open downpipe, so we are hearing a noise that would normally be muffled? Does that sound right to anyone?

Anyways, I checked the ignition timing and it was almost 3 degrees off. I don't know how much of a difference 3 degrees makes, but I adjusted it back to stock specifications, and the popping seems to have moved higher up the rpm band. We have yet to perform a simple tune up, (plugs, fluids, etc.) So we'll see what that does to help.

So besides what was done, it was taken out for a quick test drive. I guess it was overdue for a problem, so the heater hose decided to blow off. It wasn't so much the hoses fault, the problem was the fitting on the actuator broke:

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Soo yeah. We wanted to bypass the heater anyways, because we are removing the whole HVAC system. Although this isn't really a bypass, this was our quick fix solution

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Should hold for a while.

After we put the fitting on, E attempted to start the car but it wouldn't start. We deduced that an ignition component must have gotten soaked, so a plug wire was pulled, and our problem was obvious. Although it is cleaned in this pic, the whole spark plug area was swimming in coolant

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So a lot of time was spent cleaning the engine bay and components

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Well, that's all I got, stay tuned!

-A.

BUDGET SHEET
$875.00 - original vehicle purchase
+$0.82 - few inches of vacuum hose
+$65.00 - used ARP head stud kit
+$1.59 - wheel stud
+$6.11 - 5/8" 90 degree nylon elbow union and 2 hose clamps for heater core bypass
-$1.28 - loose change found under carpet
+$52.04 - Grant steering wheel + hub from Super.Secret.Supra.Club and hardware
+$65.00 - used walbro fuel pump and new install kit
+$65.99 - sparco seat slider from ebay (retail price ftl)
+$162.50 - used sparco race seat to replace heavy stock powered leather seat
+$57.99 - a set of inner and outer tie rods to replace the stock seized units and get a GOOD alignment..
+$20.00 - 19 feet of power cable to move battery to trunk
+$253.00 - intercooler kit with pipes, couplers clamps and a knock off greddy BOV
-$240.00 - recycled stock cats (2)
-----------------------------------
TOTAL:$1383.76
REMAINING:$624.24:nono:

the budget sheet isn't quite accurate right now, we've sold a few stock pieces and haven't included random costs of a few materials we've purchased such as paint and prep supplies.
 
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skipbarber

2008 Grassroots Challenge
Mar 26, 2008
134
0
0
Rockville-ish, Maryland
Dude...you're not kidding. But when we told him what we wanted to do, he just wanted us to win. Besides, he knows no one is going to take care of this car like we will. My teammate said it the best "we're going to do with this MK3 what every MK3 owner wants to do, but can't because it's a daily driver."

EDIT: 4/9/08
So, today we pulled the dash and started tearing out stuff that we were never going to use such as the heater core, ac unit inside the car and miscellaneous crap that shouldnt be in a racecar.

We also started cutting some of the harness to clean it up a bit and to get rid of some plugs that we dont need floating around to confuse us. We also looped the coolant lines going to the heater core and started taking all the tar up in the car and ripped out the carpet.

Now there is about a three finger gap in the rear where as before it was tucking. Interior looks like crap for now until we get the rest of the tar up and sand everything down and paint it. We are also trying to decide what we want to do with the dash. We may chop it up a bit or just leave it, we'll see. Also we are considering seam/stitch welding the chassis but that might be a bit redundant once the cage goes in. Anyway enough blabbering on with the pics......

dash out...
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still a long ways to go...
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rack o' interior parts...

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edwin at work....

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front bar out....

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trying to yank everything out at once....obviously didnt work but it eventually came out individually...

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carpet out...

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never realized it was two layer with insulation in between, no wonder it was so quiet...

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carpet...

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tar removed...

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Everything pulled out...

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Wheel gap..boo!

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just to add..i think we started working on the car around 11 am today, took an hour lunch break around 3:30, lost day light and packed it up to go home at 8. solid day of work :) the only thing we havent torn apart yet are the door panels. All three of us like them too much to hack them up. So we're probably gonna gut the doors as much as we can, and leave the panels on. We're willing to deal with the weight..the remaining crap, i mean, parts, will be for sale really soon, so stay tuned for a link to the for sale thread.
 
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skipbarber

2008 Grassroots Challenge
Mar 26, 2008
134
0
0
Rockville-ish, Maryland
we plan to, we didnt even have the seat at first. it was first a cooler, then a spare G35 rim i had in my back yard, it wasnt until this morning that we got the OEM seat. we're just looking for the right race seat for the right price.
 

americanjebus

Mr. Evergreen
Mar 30, 2005
1,867
0
0
37
wa.
Link up a for sale thread with all the parts your looking to get rid of. We can support by buying the stock pats you sell off instead of tossing them. I believe that is within the rules right? You can sell parts and the money made from parts wont count against you?

I'm a grassroots fan so I definitely want you to win. I believe a blue/gray rx7 won last year and broke so they had to push it around for their photo shoot.

The rims look amazing on the car, any more pics of that red caged interior?
 

skipbarber

2008 Grassroots Challenge
Mar 26, 2008
134
0
0
Rockville-ish, Maryland
can't sell stuff on the forums with less than 50 posts, but we've got a TON of stuff to sell. We can sell whatever we want as long as it doesnt exceed what we paid for the car.

americanjebus - last years winner was a twin turbo corvette, followed by a turbo honda civic. no more pics of the race car..ive been looking for days now.
 

skipbarber

2008 Grassroots Challenge
Mar 26, 2008
134
0
0
Rockville-ish, Maryland
Hey everyone, it's Grassroots team member Avi posting...

Thanks E for getting this thread started. Also, thanks guys for all your comments. We will definitely try to keep you guys updated to our progress. Of course we are scouring the forums for info, but seeing as how we are new Supra/7M-GTE owners, any tricks to working on them, common problems, interchangeable parts, and low budget mods you can think of, please let us know. We want to make the Supra community proud!

So anyways, my main reason for posting... I took a quick video of the car after we got it running last night, and I'm sure you all can appreciate the scenario. Just did some maintenance, wet parking lot, open downpipe :naughty:

This being our first Supra, we are definitely excited to see her perform. An WOW, just listen to that turbo spool and ignore our stupid comments, haha.

Enjoy!

Supra parking lot fun



CryoSlash - White ST165, right? Fancy meeting you here! haha. Shaggz00 on alltrac.net



And to satisfy the putfile gods:
Upload at Putfile
 

adampecush

Regular Supramaniac
May 11, 2006
2,118
3
38
Edmonton
skipbarber;975956 said:
americanjebus - last years winner was a twin turbo corvette, followed by a turbo honda civic. no more pics of the race car..ive been looking for days now.

a tt corvette? do stolen cars count as being free or something?
 

skipbarber

2008 Grassroots Challenge
Mar 26, 2008
134
0
0
Rockville-ish, Maryland
adampecush;976149 said:
a tt corvette? do stolen cars count as being free or something?

Team member Avi again:

Haha, I wish... not that we would stoop so low :evil:

The only way to understand what was really going on with that car is to check it out at the GRM website
http://grassrootsmotorsports.com/news/102007/2007-challenge-videos.php#more-1661

They used some junkyard turbos at first, one of which I think actually came out of a Corvair. The build team was entirely composed of engineers, and they came up with some crazy vacuum/suction device to help keep the car on the track. They have a build diary online, too. where you can check out all the costs associated with the build. Pretty cool stuff.

BTW, adampecush I just finished going through your entire resto-thread. Amazing work!
 

GrimJack

Administrator
Dec 31, 1969
12,377
3
38
56
Richmond, BC, Canada
idriders.com
That should leave you about $1k to spend, right? And you don't have to figure in labor, just raw materials / parts? Of course, I have no idea how much of that you want to put into show, and how much into go, but nonetheless...

Car already has an intake and exhaust - fab up something that goes from the DDP back for next to nothing.

Manual boost controller at this point will put you at fuel cut. You can build one of those for $10 in parts.

To get around the fuel cut, you have a couple options. The best way is to find an AFM housing from a Lexus 4 liter V8 and swap your AFM electronics into it, then source some 550cc injectors - preferably really cheap from an old Rx7, which came with compatible injectors for a while. The Lexus AFM flows 25% more air for the same airflow readings, and the 550cc injectors flow 25% more fuel, thus balancing each other out for the most part. Scaling the AFM signal like this gets dangerous eventually (it doesn't allow for any timing map changes) but at this point you should be fine.

Now you need some better air cooling... this might cost you some money, but it's probably worth it to find a better intercooler and have your welder fab up some intercooler pipes out of steel.

At this point you should be able to tune it to run at just shy of 400crank hp, and I bet you won't be out more than ~$400.

Taking the engine much past this without cracking it open to check it's condition AND running a standalone ECU for complete control is risky.
 

GrimJack

Administrator
Dec 31, 1969
12,377
3
38
56
Richmond, BC, Canada
idriders.com
Oh, I forgot - better plan on spending some money on a clutch, because the chances of the stock unit holding for long at that level are pretty slim. :)

If the pressure plate / flywheel is still in decent shape, just pick up a puck disc and put it in, that should hold long enough for the race!
 

skipbarber

2008 Grassroots Challenge
Mar 26, 2008
134
0
0
Rockville-ish, Maryland
^ Grimjack, we were actually contemplating picking up a used MAFT pro for engine management. We can get RX-7 injectors and I can probably find a GM MAP sensor and from what we've been reading, it seems like the MAFT pro setup is significantly better than a 400 AFM and injectors alone. We're going to pull the motor out at some point and check everything and replace the head bolts with ARPs and we wont be limited to $1000. Once we start selling stock parts, we can put that money towards more mods as long as it doesn't exceed what we paid for the car. Anyone here running a MAFT pro? and as far as an intercooler, we've already got something in the works.