Here's what I've based it on.
KP60's always had a budget suspension set-up from day one. No rear panhard rod or rear anti roll bar. The front anti roll bar also maintained castor due to no tension rods. I built a kit basing it off T3's and other kits I have seen like VHTRacing and a number of Japanese track cars. I also decided to fit a rear anti roll bar and panhard rod.
Here's what I've based it on.
Bought AE86 lower control arms, front and rear sway bars, some steel etc.
Offered the KP60 and AE86 sway bars up to each other. They are a pretty close match regarding dimensions.
Got to work fabricating a bracket to mount the new front suspension. It bolts on to the chassis in ten factory locations.
I then made some in situ adjustable lower control arms from AE86 units. These included mounts for tension rods and drop links. I purchased a load of rose joints, misalignment spacers and more.
Gusseted the underneath for more strength.
Made up droplinks and mounts.
The 2 holes allow for a large amount of track/camber adjustment.
Next I moved onto the rear suspension. The rear AE86 sway bar is the perfect width for mounting off the rear chassis legs. I made up droplinks and brackets for them which will be welded to the chassis leg.
These brackets are welded to the chassis leg. The droplinks attach here.
These brackets fix the sway bar to the rear axle. They also get welded on.
Here's the bracket which will fix the panhard rod to the chassis.
This bracket will mount on the axle and take the other end of the panahrd rod.
I bought some rosejoints, misalignment spacers, CDS tubing and more for fabricating the panhard rod.
I also picked up some few bits to tidy up the engine bay. Braided stainless hose, anodised fittings, protective wiring covering, new coil, lumention kit etc.
Painted up the full kit I made. All ready for fitment here.
Picked up some 13x8 ET-12 wheels! Painted them a dark metallic grey. Must get 2 more for the front yet.
GRP 1 wheel studs
More updates shortly once I fit everything!
EFI dash console with RPM guage,
Deep dish steering wheel,
Ancient Pioneer cassette player,
Pionieer 6'' speakers
Battery relocated to boot,
Assortment of Magic Trees!
Standard with bump-strips removed,
Full respray in Toyota 391 Red,
New light surounds
Rebuilt Bluetop 4 A-GE,
CBR 900 Bike Carbs,
Silk Road 4-1 exhaust manifold,
4k dizzy with custom adapter,
Stainless heat shield,
NGK Performance 8.5mm leads,
Replica T3 engine mounts,
MSD ignition coil,
5.5 Kg Flywheel unknown brand,
Custom Water lines,
Omex Rev limiter
Custom 2'' stainless exhaust to 5Zigen Boarder backbox
Stainless flexi brake hoses,
New copper/nickle lines,
Wilwood Dynalite Calipers,
Drilled and grooved Honda Civic EG 262mm discs
'02 Fiesta Front calipers fitted on rear
Mintex Fiesta Disks
Front AE86 struts converted to coilovers, strut shortened 40mm, rally design conversion kit, 180lb springs, TRD blue short stroke 6 way adjustable dampers,
Cusco camber adjustable topmounts,
T3 adapter bushing,
T3 steering knuckles,
AJPS extra lock spacer,
New tie rod ends,
Gaz 13 Way adjustable rear coilovers, 160 lb springs.
Ford Type 9 Gearbox
Leadwith bellhousing Adapter Kit
Custom gearbox mount and heavy duty Ford Sierra rubber isolator
Helix paddle clutch
TRD pressure plate,
Toyota carrier & spigot bearings,
Ford Anglia English axle
Trans-X 2 way LSD,
Custom GRP 4 propshaft
Wheels and Tyres:
Black centred Revolutions, 13x7,
Front: 185/60/13 Toyo R888 Proxies
Rear: 185/60/13 Budget
25mm rear spacers
It's not alone building cars, I also enjoy drawing them. Here's a few examples. They are only a photo of the drawing so they don't look near as well as they do in person!
I have developed a facebook page for the Starlet build. Please give it a like and don't be afraid to comment!
4A-GE Starlet Build
Bought this 60,000 mile KP60 in 2009. It was a completely standard 1.0L. Both the body and running gear were in good order. My initial plans were to tidy it up, fit a 4k engine, a set of wheels and lower it slightly. Thing slowly spiraled from there. The car no longer has any of the original Toyota running gear, had a full respray and has been lowered 80 mm!
Shortly after buying the car I decided to strip the underneath to bare metal and rust proof it for the Irish weather! Any rust repair needed as carried out. All work was done in house by myself. The car was zinc primed, seam sealed, 2k primed, stone chipped and finished in 2k red.
I didn't just go ahead with my idea of fitting a 1300 cc 4k engine, that also spiraled and I ended up building with a bit of a screamer. Block was honed, crank polished, all new bearings, rings, gaskets and seals, fast road spec high lift cam, shimmed, ported and polished head, stiffer valve springs, new valves and guides, new oil and water pumps, custom bike carb manifold and old school CBR 600 Jelly Bean carbs (never got her running right on those!), Martelius 4-2-1 exhaust manifold, 5 kg flywheel etc. As well as all other components new or refurbished, distributor, coil etc. Again all work was carried out by me. It was not just the standard 1300 I intended it to be! It had great poke for a 1300 in such a small car. However I wanted more!
After deciding the 4k didn't have enough power for me I decided to fit a 4A-GE. I got a good deal on a fully rebuilt engine and went for that. Fitted it on bike carbs with a custom manifold, got a Silkroad 4-1 exhaust manifold, lightened flywheel etc.
I decided to fit an AE71 K50 gearbox, they are the same as the Starlet gearbox but with a bellhousing to match the 4A engine. Swapping the rear section of the box allowed the gearstick to come out in the original position, I was able to use the original prop shaft, and gearbox mount. Just had to get the clutch disc from the AE71/AE85 4AC engine.
Because I was running the car on carbs the wiring was pretty basic. Again, all work was carried out in my garage.
Porting and polishing inlet manifold.
New jets for the carbs!
Adapter plate to run the 4k dizzy in the 4A-GE to eliminate the need for an ECU.
Dizzy gear from 4A-GE dizzy fitted.
New condenser and points for the dizzy.
Custom engine mounts.
Corolla K50 gearbox with the tail section of the Starlet one.
Brakes rebuilt and new lines.
AE86 Corolla brakes.
Negative Camber Roll Centre Adjusters
T3 AE86 Corolla steering knuckles for extra lock, CBR 900 bike carbs and Gaz rear coilovers.
Made custom coilovers from AE86 struts using TRD blue shocks, 190 lb springs and cusco camber adjustable top mounts.
Cleaned up all the bits of running gear.
Fitted a TRD 2 way LSD
Made a custom 2'' stainless exhuast to a 5zigen Boarder backbox.
Picked up some Recolution wheels and some Toyo R888 tyres. Fantastic tyre for fast road and track driving!
With all the new bits fitted I had to paint the engine bay to complete it!
Removed brackets to make the bay more flush. Relocated battery to the boot too.
To complete the car it needed a fresh lick of paint. Most of it was in good order despite a few small dings and dents you expect after an old lady owning your car!
Some minor rust repairs!
All the paint prep carried out by me with the guidance of a friend.
Too Much Power
The K50 gearbox couldn't cope with the power of the the 4A-GE. I decided to fit an AE86 T50 gearbox. These originally ran a hydraulic clutch so I had to convert it to cable
Lengthened Starlet clutch fork to work with the T50.
After numerous breakages in the rear axle I decided to upgrade that also. I went for a Ford Anglia English rear axle as its width suits the KP60 better than an AE86 one or anything else. While I was up rating the axle I also fitted a different gearbox, clutch, brakes and more! I fitted a Ford Type 9 gearbox with an adapter plate to use the T50 alloy bellhousing. That way I kept my original cable clutch system.
My aim was to have running gear that could take the abuse of a bit of drifting comfortably without worrying about breakages!
I made up a jig with a standard Starlet axle and used that to make new mounts and line them up for the English axle.
Numerous broken half shafts and a bust pinion gear!
The English axle ready to fit to the KP. Notice the 2 sets of holes on the outer triailing arm mounts are to eliminate the need for traction brackets.
Brackets for brake calipiers and lines. For calipers I am using front calipers from a '02 Ford Fiesta and the disks to match. Since there's no mechanical handbrake mechanism on them I run a hydraulic handbrake. I had to get the flange on the half shafts paired down 2 mm for the disc to slot over too.
The diff is a Trans-X 2 way LSD. Far bigger than the KP60 item!
The bellhousing adapter plate from Ledwith Racing
Helix paddle clutch to suit the Type 9 on a 4A-GE
Grp 4 Type 9 to English axle prop shaft vs the small vulnerable KP unit!
Type 9 ready for in!
Rosejointed quick shift.
Custom gearbox mount.
Putting a Stop to it!
Even with running fresh, rebuilt AE86 front brakes I decided I wanted more.
There's numerous company's doing Wilwood brake kits including T3 and GRP 4. I decided to make my own kit. I used Wilwood forged Dynalite calipers, Honda Civic EG 262 mm front disks, custom braided lines and custom brackets.
Up against an OEM AE86 disc!
With the larger brakes all round I had to replace the brake master cylinder. The small 3/4'' KP unit wouldn't be up to the task. I did't want to get too big a bore as yes you get more volume but you lose pressure at the calipers due to fluid dynamics against popular belief. So I picked up a 7/8'' master cylinder from an AE111 Levin which even bolts straight up to the brake servo and needs no modification of the hard lines.