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PDM Racing1986 BATTLE COUPE AE86 Build-up (Page 2)
 
PDM Short Stroke Struts - Up front, the entire suspension was looked after too. The stock strut stock spring perches were removed, and the struts were shortened 50mm.
- Tokico Illumina Toyota MR2 inserts were installed, along with Ground Control perches and Eibach ERS race springs. Tokico Illuminas

- Front control arms were taken apart, shot blast, and new Moog K9083 ball joints installed and Whiteline W05655 lower control arm bushings installed. Note how shiny and new looking the control arms are. After bead blasting all suspension components we intended to re-use, all parts were coated with Por 15 epoxy paint. Absolutely stunning product.

AE86 FLCAs
Moog AE86 Ball Joints
Whiteline AE86 FLCA Poly Bushings
- Front lateral rods also cleaned up, and W0205 Whiteline poly bushings installed after paint, along with KCA363 Whiteline roll center adjusters. Whiteline AE86 RCAs
Whiteline AE86 Front Swaybar - Cusco adjustable top camber plates were added, along with Whiteline BTF35Z front 6 way adjustable swaybars, and PDM race links.
Goodridge SS Brakelines - Unhappy with the stock front brakes, it was decided that a 4 piston caliper had to be added also, so a custom one-off set of Wilwood calipers was modified to fit the stock hubs, AND fit a 13” race wheel. Porterfield R4 race pads up front, Goodridge lines, and custom PDM long wheel studs for race use were installed. KVR Cross Drilled Rotors
PDM Fender Roller - For street use, the car used Konig Rewind wheels, 14 x 7 wide, with Toyo T1S 195/55/14 rubber. The rear wheel arches had to be rolled with our special fender rolling tool to fit the special Compomotive one piece 13 x 8 rims were ordered up from England, that were shod with Hooser 225/45/13 A304 R compound race tires.
 AE86 13x8 Compomotives


While the suspension pieces were being designed and installed, PDM contacted Geoff Bardal from Colt Cams, - our friend who designed our trick Nissan KADE billet cams, and we commissioned Geoff to come up with a trick street/auto-x cam profile we could use on our billets. Using his years of cam knowledge, and many dyno sessions, Geoff came up with a set of bumpsticks that produced results beyond any of our expectations.

Our main priority was to minimize torque loss at the lower rpms, which was a concern for an auto-x car, where most courses were 2nd gear. We didn’t want cams that were slugs out of the tighter corners, but gave good all around midrange and pulled right to the 4AGE’s 7500 rpm redline. What Geoff delivered were cams beyond belief. (see dyno results here!)

Not only did the cams retain good bottom end torque, but it increased mid range torque all the way up the rpm range, AND give us an additional 25 WHP!!!
PDM AE86 cams! - The power increases were unheard of from a naturally aspirated 1.6 liter motor with 150,000 miles and zero internal combustion or piston changes. Not only did this change the car’s race attitude, it made the car extremely fun to drive on the street with rocket-like corner exit and hard pull all the way through redline. The gains are so much, many disbelieve our dyno claims until they install a set of these cams and cannot wipe the grin off their faces!! 25 whp!

AEM cam gears were added to these prototype cams (production cams have the proper timing ground into them – so expensive cam gears are not necessary to see big power gains).
MSD Ignition - An MSD6AL ignition system, MSD blaster coil NGK plug wires, NGK iridium plus, and our trick Genesis sealed race battery (only 13.5 lbs) filled out the engine bay, along with a Whiteline KSB519 front strut tower bar to keep the font end taught. Genesis Battery
Stripped Interior - Interior was stripped to CACC rules, so both seats removed, carpeting, consoles and dash components, and a rear harness bar was fabricated out of 1.5” 304 stainless and bolted to the B pillar panels.
- This would allow for the Sparco Cam-lok 5 point race belts, fitted to the Sparco Pro 2000 race seat. Sparco Pro 2000
Sparco & L2 Hub - Sparco pedals, a Sparco race wheel, and L2 quick release hub. A Sparco billet aluminum shift knob finished off the race-spartan interior.
- Then looking to further decrease the Battle Coupe’s weight, PDM had Gemini Composites manufacture molds of the Toyota AE86 to make lightweight carbon fiber hoods. These are absolutely beautiful pieces, with smooth, durable clear finishes that are designed to last, rolled edges, and perfect fitting hardware. PDM AE86 Carbon Fiber Hood
AE86 Parts Pile! - In all, the Battle Coupe was a great project car, as we learned a lot about the Corolla, and had fun in the process. (just some of the parts and components that went into building up the car. A dream pile of parts for some ;)

The finished project was fast, much nimbler than what we started with, and is a very responsive car now. Flick the steering wheel a bit, and the car will turn in. With go-kart like stick, it literally flies around street corners absolutely flat out. The car was campaigned in the remaining 6 B.C. Regional Series races, with 5 1st place wins in D Street Prepared, won the 2004 Kumho Super Challenge event and proved to be the dominant car in D/SP.

Lowered on 13s - car outside the shop. Aggressive, low stance that means BUSINESS !
PDM Racing AE86
- PDM Racing's AE86 Battle Coupe powering through a sweeper
CACC DSP Champ Car