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Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

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motorklasse
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Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Fri Mar 23, 2012 7:54 am

Hello!!


This forum has been greatly helpful building our race cars, so I would like to share our project. :)
We are located in Korea, and my friend and I have been building two IS200 race cars since Nov. of 2011.

Since Lexus IS200 were one of very few FR import car that were imported officially thru Lexus Korea since late 90s, it was one of cheapest FR cars you can buy in Korea market.
(For those who wonder, RHD JDM Altezza was NOT officially imported.)
As you know IS200 is pretty sad car with 155hp I-6 & 4-speed auto. :(

So we planned to swap the 3S-GE engine with 6-sp. :cool:
Due to displacement regulation of the league we are attending, we didn't bother with 2JZ.
2JZ would also increase the running cost this car in our country much higher due to its displacement.

Overall, we are building amateur club race car that won't break the bank.
Also car has to be driven on the street time to time.
(mostly on the way to the track)


Here are specs of the car we planned.
We are aiming total of US$35k for each to buy/build the complete race car.
(The budget is extremely subjective since we are located in Korea)

-. 3S-GE w/6-sp swap.
-. 6-point welded roll-cage.
-. Stripped Interior.
-. The car has to be "street-able" since we have to drive the car to track. Has to retain AC/Audio.
-. FIA approved front seats.
-. FIA approved 6-point harness
-. Wheel/Suspension work to be run competitive time in our class.
-. Reliable/low-cost running race car for at least next 5 years. (Maybe I will buy used FT86 later. ;) )
-. Tires : Radials (no slicks). Our class has spec tires, so we have to run Hankook R-S3 or TD.


[COLOR="Red"]I will be posting/updating the thread periodically as we proceed.[/COLOR] :)



1. Buying IS200 from used car market.
It only costed us about US$5,000 to pick up MY01 IS200 with 100k miles on it.
It's extremely low price considering high price import car market that Korea has. (for example, brand new GS350 goes about $65k+)
Both cars(Grey-mine, White-friend's) were extremely clean condition.
Front end had some minor accident.(no frame damage) which is expect-able for 10+ year old car.
White one had been riced out by previous owner with LED tails and replica wheels. lol

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2. Take it to track.
I know it's lame to take IS200 to track, but I had a chance to take it to track the day I bought the car. lol
I was also very fortunate to run the car in F1 track in Korea.
I didn't have a chance to take good pictures of the IS200 running at track.
This is only one picture I got right before I get into track.
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Although the IS200 was light and nimble around the corners, it was seriously lacking power esp with 4-speed auto.
Also the steering pump was over-heat very quickly. 1-2 laps were enough to make PS whine.





3. Planning...
As I expected, engine swap with some diet on weight will make this car very competent in our class.(2.0L NA, 1150kg, No-VTEC)

I have started to order goodies such as engine, suspension, etc from US, Japan, Italy, HK, Taiwan, UK. :)
While parts are being delivered, I have planned to start taking interior apart for roll-cage work.

The 1st race is being held on March 11th.
So the car needs to run by end of Feb.


Here are last pictures of the car in "stock form" lol
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Last edited by motorklasse on Mon Mar 26, 2012 2:29 am, edited 1 time in total.
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

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mlcoolj
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Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby mlcoolj » Fri Mar 23, 2012 8:57 am

so it's been past march 11 now.. is the car done?? Nice project!
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motorklasse
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Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Fri Mar 23, 2012 9:22 am

mlcoolj wrote:so it's been past march 11 now.. is the car done?? Nice project!



Yup the car is perfectly running all good. Got the 2nd place on the track day.

I will keep posting the update daily.
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

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mlcoolj
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Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby mlcoolj » Fri Mar 23, 2012 10:52 am

throw up some pics!
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motorklasse
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Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Sat Mar 24, 2012 7:57 am

4. Tint Removal.


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Both cars already had tint on window.
We heated the glass with heat gun for easy removal.
It's critical to do right temperature, or you will melt the film.

Have to very careful on rear back window, because you can easily damage the heat wires while removing 10 years old film with adhesives.

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Nice and clean, tint-film free glass!
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For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

DBX
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Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby DBX » Sat Mar 24, 2012 5:05 pm

Nice, + i like the wheels on the white one ! also a korean spec IS200 its strange to have USDM front / rear bumpers with side lights, i know this as i seen some other photo of korean IS200 with these bumpers, you got photo of the 3S-GE engine ?

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mlcoolj
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Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby mlcoolj » Sun Mar 25, 2012 1:00 pm

some video of the cars in action would be great too!
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motorklasse
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Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Mon Mar 26, 2012 2:26 am

DBX wrote:Nice, + i like the wheels on the white one ! also a korean spec IS200 its strange to have USDM front / rear bumpers with side lights, i know this as i seen some other photo of korean IS200 with these bumpers, you got photo of the 3S-GE engine ?



Yup, I will post up the picture of the engine soon. :)
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
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Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Mon Mar 26, 2012 2:26 am

mlcoolj wrote:some video of the cars in action would be great too!



Don't have a vid yet, but I will take some! :)
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
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Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Mon Mar 26, 2012 2:27 am

Part 5 : Removing interior


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Now time for removing interiors of both cars.
We are going to put some interior back(Dash and etc) after welding the roll cage in, so we need it keep the parts well.

Obviously, it seems like white car's driver was female.(many long hairs!! eww)
The grey car driver had kids. (small toys, stickers. lol)



Dis-assemble time!! ;)
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Since we moved the sunroof, we needed temporarily solution until we get it sealed. :cool:
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Now it's time for grey car.
We only had time/space to work 1-2 hours per day, so we had to work few days to dis-assemble interior + moving parts to storage.
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Yup it's Toyota, you only need 10mm/12mm to loosen most parts! :)
We only used very basic tools to remove the interior.
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We put little more effort on making temporarily sunroof cover. lol
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Dash is off!!
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We kept track of the weight of each parts.(kinda gave up mid-way. lol)
IS200/300 does have much sound deadening due to it's "luxury" position of the brand.
It was not hard task to saving much weight from simply removing interior.
I would guess at least 200lb+ saving for what we have done so far.
But there are still tons of parts we can remove.
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For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
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Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Mon Mar 26, 2012 2:28 am

Part 5 : Removing interior(Continues...)




We used the traditional "dry-ice" method to remove the floor sound deadening material. :)
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Hey, we gotta feel the weight savings of these 155hp IS right?
Took out for a drive and WHOAA!! what a difference!!
Can't wait until we put 3S-GE in!

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For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

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mlcoolj
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Joined: Tue Oct 20, 2009 8:14 pm

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby mlcoolj » Mon Mar 26, 2012 7:34 am

I thought you already put the engines in? nice progress... I didn't know about the dry ice method? could you tell us more about it?
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motorklasse
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Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Tue Mar 27, 2012 2:48 am

mlcoolj wrote:I thought you already put the engines in? nice progress... I didn't know about the dry ice method? could you tell us more about it?



Yes, we did put the engine. I am just going to post up the process one by one. :)

Dry ice method works pretty well, but we still had to use heat gun to remove the left out parts on here and there.
With dry ice, you can just pop the material. So there won't be scratches and etc.
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
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Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Tue Mar 27, 2012 2:49 am

Part 6 : ROLL-CAGE!!!

Yup, now it's time for the roll-cage.
Since we are NOT professional welder/bender....I got help from my friends.
We moved our cars to my friend's race shop for roll cage.



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Since these cars will be running spec radial tires(Hankook R-S3) + running time trial, we only needs minimal roll-cage to pass the regulation.
BUT we do take seriously on minimalism, meaning even if it is minimal 6-point, it has to be welded correctly.
So there won't be crazy roll-cage which adds much weight. :)



Time to work!!
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Used the paper to make the roll-cage support base mount template.
It's critical to make base mount rigid to dissipate the stress of the rollcage thru the chassis.
Not only the rollcage protects the driver,but it also adds much rigidity to chassis.
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Now time for white car. :)
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Since all the base mounts are done, now time for some piping!
We wanted to put the A-pillar piping more towards to front, but we wanted to keep the wiring harness + steering column in stock position(without modifying it).
We had to make compromise to current position.
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Main piping are finished! :)
Now I started to see some "race-ness" of the car.
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For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
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Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Tue Mar 27, 2012 2:51 am

Part 6 : ROLL-CAGE!!!(Continues..)




Some pictures from outside.
It's nice to see some roll cages thru the window. :)
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Now we moved back to the shop for engine swap + etc.
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We also added extra two bars(rear strut bar & harness bar)
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After we paint the roll cage and interior, we will do engine swap.
For those who have not seen 2.0L I-6 engine look like...
Here is the 155hp hopeless 1GE-FE engine!
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The engine room will look like this soon...(my friend's JDM Altezza) :cool:
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Begging for new engine. ;) I will update more this week!
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For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.


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