[Black_Sheep_xB]

Well, I got the 1ZZ-FE Tb off a 01 Corolla. I have a lot of plans for this otherwise simple swap (thanks to the efforts of crxgames and some input to me from PCH on this). A plan has been developed to include tweaks to both the TB and the WR Manifold. This will be the first update to my saga...

Phase 1: TB Port and Polish

Here is the original Tb as I received it:





After initial strip down and cleaning:



After a week of a counter looking like this:



2 raw knuckles, arthritic wrists, blowing through a couple Dremel wire wheels, hours of hours of hours of hand sanding. From 220>400>800>1000>Wet 1000 grit papers.. and finally a polish..













I did clean the outer ring, but only polished the leading lip that will be exposed to air current within the coupler to the intake.



Some pictures were flash on and some off.. it was too shiny for most angles The thing I'd like to point out, and the thing that kept me patiently working to perfect is, please note that from the outer most portion of the TB to the throttle plate is one smooth graduation with no visible levels of change. I also want to point out that I never touched the OEM throttle plate seat. So, my version of a bore here is not quite what you may think. I did shave the overall inner diameter and removed the raised areas (compare to original pics, highly visible in the "initial clean" pic), but I did not change the output diameter. In the end, I think I turned the TB into as much of a velocity stack type design as I could.

- Concludes Phase 1

[sdsnybny]

Nice work................whats next?

[Black_Sheep_xB]

Thanks.. Knife edge the leading edge of the throttle plate and grind down the protruding ends of the mounting screws.. then I will be deleting the PCV inlet.. then a little aesthetics.. then port match and polish the WR Manifold.. Then doing something niffty with the EVAP purge line.. then install.

I should add, I will be installing the TB to the manifold with OEM hardware.. but not have to grind away at the Tb to do it

[PCH]

Watching with excitement. What CAI or SRI are you going to run with this?

[Black_Sheep_xB]

I am running the Injen SRI

[crazysol]

this is awesome.
I've been watching from some of the beginning post and cant find a tb at any of my yards.

I'll keep watching and might do this later

[PCH]

On Injen SRI the PCV inlet fitting is before the MAF. Do you think it would be better to use the PCV fitting on the new TB to connect the inlet hose? This way you would have it connected after the MAF just like factory configuration. What do you think?

[Black_Sheep_xB]

You know.. that may not be a bad idea.. though I just spent $40 on the best-est (lol) aluminum filler.. but I suppose I could save that.. That would be a little slicker though.. I can cap the intake inlet and just run that line to the TB.. I guess that would help the ram of air up to the Tb as well.. no prior disturbance.. I like it. (less work too)

Edit: That is the "vent hose" not the actual PCV hose you meant.. correct? (PCV to Intake Mani - Vent Hose to Intake Inlet Port)

[PCH]

Yeah, the unrestricted air inlet into the valve cover. Not the hose from the PCV Valve that should stay connected to the manifold vacuum.
Guess the official name for the one i was talking about is Ventilation Hose #2: ToyoDIY.com

[Black_Sheep_xB]

I am in complete agreement with you on that thought... So, I guess Phase Two has dwindled down to just knife edging the throttle plate.. lol. But, really.. the thought never occurred to me on that.. great idea there... and I will implement it.

Pics of the "knife edge" soon.

Originally Posted by PCH

.. i was talking about is Ventilation Hose #2: ToyoDIY.com

lol.. I go here to look at the parts catalog. Sources, man.. sources!! ..lol

Originally Posted by crazysol

this is awesome.
I've been watching from some of the beginning post and cant find a tb at any of my yards.

I'll keep watching and might do this later

cool dude.. ebay was my friend on this one.. funny part... the guy with the part was one zip code over.

[xBtony]

Damn this is sick. im stoked to see more pregress man. and now i wanna hit up a local yard and maybe get started. lol. Can u just switch out the tb and nothing else, and still have a noticable gain? Or do u need more stuff? Lol

[Black_Sheep_xB]

just the TB is a 6mm difference in bore, that is enough, what I am doing is extra... from what i understand the sensors work as well.. but just to keep it in check, again, from what I see, the OEM sensors (TPS & IAC) screw right in.

Phase 2: Knife Edge the Throttle Plate

Phase two might seem little.. but if you notice, I am doing the things that will cause this project to fail by anything I do.. taking away metal.. can't put it back.. patience is key.

So, I am happy to say the official "knife edge" as I see it, is a success.

Knife edging the plate.. Why? Well, it comes down to air flow over the plate. I have even seen aerodynamic oriented scientist argue if it is worth it. Some say the intake never sees enough air flow to make a difference, while the other half say not only knife edge the leading edge, but the trailing edge too (according to another scientific theory). I judge it as this.. I live by the ocean, so forgive...

but.. if you have a flat front boat versus a semi V style hull.. in 3 foot seas.. both with 35 hp Johnson motors.. will you see a difference at 100 yards? Most likely not.. However, after 10 miles.. I guarantee the semi v hull is way in the lead. Same as I see this mod.. it is a positive effect, measurable by dyno..? doubt it... but positive none the less.







Is it a true "knife edge"..?
No. I had two goals.. improve the air split over the plate, and make sure the plate still seated at the OEM placement. In order to achieve that, a flat surface, at the OEM diameter, must remain.



close up of difference:

[sdsnybny]

Beveled for the win.......................watching this is getting good rep points for great DIY comming

[hotweelz4me]

watching the awesomeness that is this thread.

[xBtony]

damn. thanks fer the help and great work man. i deff wanna try this out (not to the extent u are.) but still. haha

[Black_Sheep_xB]

lol.. thanks guys. More to come.. though I am waiting on the mail for the next step.. will be updating as soon as possible.

[crxgames]

Glad to see you working on this. Definitely taking it one step further than I did. Are you going to get it dynod?

[Black_Sheep_xB]

yes, I am.. I am due for a dyno.. I have a baseline from before the Weapon R intake.. will try to get "before and after" the TB separate.. but either way, a dyno will happen.

[Black_Sheep_xB]

Crap.. I called this TB a 2ZZ for some odd reason.. it's a 1ZZ.. lol.. same size dispalcement motors but different TB's!

Sorry..

2ZZ-GE Throttle Body:



Trying to get the title fixed...

.. feel dumb, but I do that.. dyslexic

Aww.. Fixed. Thanks SAKURA!

[bBwannabe]

So if I want to do this swap & I also want a tb spacer do I have to buy the matrix spacer for it to work right?