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Toyota Corolla Trueno Battle Ready - AE86 (Part 3)

6/6/2014 2:29:08 AM
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The True no base car is actually one of Phil’ sold AE86s that he’d not long sold. He originally bought it as a slightly rusty project for the road but it turned out to need a lot more work than originally thought. “From a distance it wasn’t too bad,” he let on, “but the moment we started poking around underneath we found some horrors. The sills had gone and even rusted up into the A-pillars in places. Sections of the floor and the usual rear pockets were bad. The arches were nonexistent. In fact, doing all of the repair work has probably saved it as it was one step away from the scrap heap. A lot of the original repair work was done by a friend, ‘Steve O’, before it was passed on to Craig at Dyno Torque.”

AE86 Toyota Corolla Trueno interior

While the Driftworks boys began stripping the AE86 of its running gear, Craig was next door doing the same to the ASCAR, piling up every potentially useful component in the corner of the workshop. By the time he’d finished, all that remained was a cage, which in itself was a work of art. So much so, that it became an abstract ornament and was hung from the ceiling of one of the warehouses.

With so many customers wanting V8conversions, Craig always has a spare LS block on standby, purely to help work out mounting points and measurements. Believe it or not, fitting the engine was the easy part. It was getting the huge 10” Winters Competition rear axle in place that proved difficult. “One thing Craig and I don’t quite see eye-to-eye on is how low a car should run,” laughed Phil. “He would regularly shake his head at me, but my one of my main stipulations throughout the project was that if it didn’t go low enough, it wasn’t happening!”What this effectively meant was that a section of the rear floor pan would need cutting out and the axle essentially mounting inside the car! Only that way would there be the correct ground clearance whilst still enabling Phil to run the AE86 on the deck.“We’ll just use the chassis rails as bump stops,” Phil joked in one of his early build thread posts. The knock-on effect was that a completely new, raised transmission tunnel was required. Craig already knew this would be the case because he had the monstrous four-speed Jeri co transmission sitting on his workshop floor.

Description: http://i664.photobucket.com/albums/vv4/WRXbrian/ae1.jpg

AE86 Toyota Corolla Trueno engine

Always conscious of adhering to FD and BDC regulations, Craig trimmed the bulkhead and floor pan and set the dog box in place. This allowed him to take his measurements and begin fabricating the required tunnel panels. These were then TIG-welded together and welded into the cabin. To make surgery to the underside simpler and less neck breaking, the AE86 was set on a spit and spun over. This not only made addressing the chassis’ rot issues much easier, but also meant that Craig could make further custom adjustments, like lowering the floor to allow Phil’s seats to be mounted lower down in the cabin. Yes, as well as liking his cars to run low, Phil also likes to sit low!

AE86 Toyota Corolla Trueno on road

With the bulk of the structural welding complete, the AE86 shell was whisked off to Nickson Motorsport for its extensive T45 roll cage. Phil was more focused on achieving excellent safety than he was on fitting a minimalist, lightweight setup. “The AE86 is an old car at the end of the day,” Phil remarked.“So we wanted as much additional strengthening as possible, especially in the door areas because you’re travelling sideways most of the time. The ASCAR bars fan outwards meaning if there is an impact, at least there’s some distance between me and the wall. The other thing worth noting is that because it’s such a small car and I’m not exactly… well… small, we asked Nick son to keep the cage as tight to the car’s body as possible. This was to help with visibility and also to give me a little extra space inside.” Also included were additional support bars to protect Phil’s lower legs and feet, as it’s not unheard of for a wheel to come through the cabin on impact. Plenty of gussets provide yet further structural rigidity and safety meaning that by the time Nickson Motorsport was finished the shell didn’t look too dissimilar to the ASCAR setup.

 
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