House's ITB XE build and re-build

[paddy235]

Coming along nicely, well done

[House]

Few more engine build pictures

[House]

[House]

Engine out today, was going really well, only took us about an hour to get it on the floor and split from the box. Preparing the new lump to go in and had a quick look in the bay to do some cleaning and checking we weren't splitting apart at the seams.

I should have known not to expect miracles from this car, found seam sealer all over the alternator chassis leg mod, poke it with a screwdriver, as you do, and a hole appeared, the hole grew and grew 100mm long and 40-50mm wide in places.

It appears that when cutting the chassis to allow room for the alternator someone has simply cut a slot in the leg and beaten it with a hammer, then used seam sealer as a filler to make it look ok!!

I really don't get this car, there are strengthening plates that have been fully stitch welded in place, the engine mounts have all been fully seam welded too but the alternator mod has been bodged!!

Anyway, Nuno and I both agreed we weren't happy leaving that, cut an oblong into the leg and welded a 5mm plate in there with a kink to help it meet the chassis leg properly. It's not the prettiest of jobs but it's about functionality, it's never gonna be a show car!!

Enough talk, some pretty pictures









Also added a tube into the dipstick to return the separated breather oil back to the sump, again just test stuff, not the finished article



Working away for the rest of the week but Nuno the Portugeeza is gonna drop the engine and box back in for me and get it all plumbed up for me to start it next weekend.

[Benn]

Alt cut out is tidy enough.

[House]

Alt cut out is tidy enough.

Is now Benn!! I've possibly got a new shell coming so I'm beginning to view this one as a mock up.

I know for a fact I've got some rust inside the rear arches that will need me to cut big bits out to sort, so I'm tempted just to re-shell into this new one that has been dry stored for 7 years and is I'm told, by someone I trust, "box fresh"

I might just store the new shell myself, it's still a complete car, and when this current one really dies I can do a little swapsie!!

On another note, this one will be fun to just kick the butt out of and plan and play around with. Although after all the effort I'm beginning to like it and would like to keep it going!!! We'll see where things take me, Once I get in my new house and garage I'll be able to weld and play around a bit more and do all the little jobs I want to do, my mind might change again yet!!!

[nova_niek]

More worryingly was the gold coloured flakes we found in the fresh 30 mile old oil!!

Good thing you checked the oil, at least your engine didn't throw a rod and caused some unwanted big style havoc. Good luck with your fresh engine!

[Benn]

Falling in love with the old girl then..l i'd get the other shell nd keep it safe incase you need it....
Use this one till the end then swap.

Funny i was told by a guy building engines that that first oil change will be full of bits....
After that i learnt he knew f**k all and there really shouldn't be.

[House]

Good thing you checked the oil, at least your engine didn't throw a rod and caused some unwanted big style havoc. Good luck with your fresh engine!

I always knew it was coming, the old engine just never felt right!!

Benn, I so very nearly got rid of it and bought a '03 plate RS6 but there's is nothing I can do with that in the new garage!! Reading thought some of the other build threads, notably Liam Poulton's has made me realise what I can do if I put the effort in!! I'm gonna store that new shell myself and when it's needed I'll have it ready!!

One great thing to come out of this weeken is that we borrowed my best mate's kids for 2 days, as she was off out on the lash and we worked out that a wife, 2 kids, a dog and all the associated stuff do not fit in our '56 plate Mini, so my good lady has agreed that an RS6 would be a very suitable family car for when the Mini isn't big enough!!

This is a result!! I'm on the lookout for one now!!

[House]

Today was engine in day!!

I don't have any during photos cos I was doing it alone and up against time!!







Plenty of room for the alternator now!!

Just need to get it on the RR now cos it runs but not very well, it's too rich and the compensation maps are completely wrong!!