Nice build and nice fab work.
Thanks for the nice comments よしくん
So I originally was considering purchasing a poly-vee cutter for our lathe from
http://toolflo.com/cats/AUTOMOTIVE.pdf as a very close friend of ours is a Tool Flo dealer. The cutter is just over $100 but it doesn't fit any of our tool holders so I'd have to also purchase about a $300 holder (sucks!). My idea was to offer a service to the GZE community as follows: Send me your USDM pulley and I'll cut it down to ____ mm, hoping that I could get 10 or 15mm out of it .... but unfortunately the USDM magnet is just too large and there is hardly any room at all to shave material down. The JDM pulley just so happens to use a very small magnet and there is an extensive amount of material that can be turned down on the stock JDM pulley -- we got 10mm out of it without sacrificing any strength. While I could still offer my services for those who have imported the Levin engine, that is such a small market I decided to not invest in the tools and just have our machine shop turn mine down.
When I removed my original pulley and started looking at it, I was pretty bummed. I was hoping to only charge $30? $40? $50? for the service, send me your pulley, I'll return it X amount smaller. Oh well...
As for the SC RPM heat issue, from
reply #299 I am working on another homemade Water/Alcohol injection system. Earlier this week I received a new 5 quart container, purchased
from here for $16, and now that E85 is easy to get, I'm planning to pump 0.75 gallons E85 and then top off the remaining 2 quarts with water. Should be about a 50/50 mix. In the past I had to drive across town, purchase a 5 gallon drum of Methanol, store it in my garage, make a mess while trying to pour it into a container in my car. .....having the E85 right at the pump seems like a great solution.
I am fully aware that these old units are not as efficient as modern day SC tech. Bill (Sirdeuce) has both a M62 and M90 that we can play with and the city we live in is home to the 85% efficient Whipple S/C (
link). But I don't know... Just something about keeping Toyota parts excites me. With my Rock Crawler, many people like to swap out Toyota axles for full size American axles (D60 is very common) but I really dislike this because it's no longer Toyota, amongst other reasons. I have pride in Toyota, that's why all my cars are Toyota

So for me I find joy in using old, outdated tech. Otherwise I would have just swapped in a Honda K20 and gotten on with my life but then my car wouldn't have a Toyota heart.
Another thing I'll mention ahead of progress to this post is that I am going to re-install my Davies Craig Electric Waterpump (
link), so running a larger crank pulley doesn't have the big draw back of overrevving the water pump. Combined with the programmable Parallax Propeller board (
link) that I am currently installing, I will fit an alarm buzzer and blinking red LED to monitor my engine temps should they ever go over, what 50% or 55% gauge? (My car never runs over 45% gauge, so even if I set the alarm to 60% gauge ... if it's ever at 60% temp then something is definitely wrong and I'll be alerted straight away). When I used the e-water pump with my sidedraft N/A engine (
link) it worked great and should it ever stop working out on the highway, I carried the waterpump pulley and original belt in the frunk for a simple roadside swap back to mechanical driven cooling. So just yesterday I told our machinist to hold off on milling down my 165mm crank pulley. I think I am going to keep it large and somehow install a new timing pointer near the stock pointer location so the smog guy will still be able to check my timing. While R&R the crank pulley every 2 yrs for smog is not difficult, the pointer is awfully difficult as you know it is mounted to the timing belt tensioner and I have to remove my A/C bracket to get the front plastic cover off (or not install the bolts on that side of the engine).
Ahhhhhh decisions decisions. My water/E85 injection will also be controlled by my Propeller board. I plan to program a progressive (temp based) duty cycle so it can be reliable and also long lasting for long road trips (rather than using my old on/off boost switch that would cycle through my 5 qt container too quickly). Hopefully I can go a few gas tank fill-ups between water inj tank refills. Also, I'll be using the Propeller in lieu of a Grunt Box, and am going to experiment (the Propeller will also be datalogging from my wide band O2) between using the cold start injector or water/alc injector to cope with the low RPM lean-out condition.
Ahhh so much to do! Can't wait to get this all done!! First things first, I need to start with the Propeller somewhere, and the most clear choice is with the exhaust system. So on to the next update!