View Full Version : Adam's BIG turbo Nova WIP (lots of pics!)
This is my progress so far of my nova turbo build. Its been quite slow due to the overall cost mainly due to the fact ive kept upgrading the origional plan of almost every detail and due to shifting the location of the build for one reason or another. Hopefully gonna see 400 horses with a GT3071r.
The main thing i need to keep on top of is planning and organisation as i have the tendancy to switch tasks without finishing what i set out to do and have a load of half finished jobs all over the place, ending up in a mess!
The donor car... my converted ecotec calibra SE8
http://i195.photobucket.com/albums/z149/Adamo_jones/Advixdec06009.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/calibra.jpg
A very bare looking engine
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0358.jpg
The Newly purchased 1.2 Merit under 60K in good nik with minimal rust
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0293.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0295.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0300.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0301.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0298.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0285.jpg
Deburring block
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0540.jpg
Decided to get creative whilst waiting for bits and make a custom gauge pod nova/cally style!
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0713.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0714.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0719.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0728.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0730.jpg
Phhrrrrrr... new rods!
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0386.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0387.jpg
Cyl. head dissassembly
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0417.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0427.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0425.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0434.jpg
Picked up a nice newly honed and acid dipped block. There was such little wear there was no need to have it re-bored to achieve the 0.06 piston to bore clearance. The engine had only done 65,000KM!! (origionally from a calibra 4x4 import)
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0478.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0477.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0479.jpg
Etch primer to give a better painted finish
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0481.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0530.jpg
More Parts
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0611.jpg
More Measuring, and recording, a must for any build
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0589.jpg
Crank polished and cleaned
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0903.jpg
TXB checked for condition before going up for sale
http://i195.photobucket.com/albums/z149/Adamo_jones/TBB4.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/TXBclutchplate.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/TXBclutchplates.jpg
Poor quality pic showing the 5- angle valve seats (exhaust) from the pre-calibra conversion.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0556.jpg
And more head work
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0557.jpg
re-condition pre-calibra
http://i195.photobucket.com/albums/z149/Adamo_jones/Advixdec06003.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/Advixdec06001.jpg
Some recent diy porting (unfinished)
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0626.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0513.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0516.jpg
A shot of the quality of the a Regal intercooler. There're internal fins the entire length. Imo one of the most efficient coolers out there. I so hope i can use this on the Nova, but ill need to at least have the exit cylinders on the side relocated facing rear
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0179.jpg
New clutch
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0199.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0196.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0194.jpg
Arp's all round + Glyco bearings
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0462.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0596.jpg
Taken during trial assembly
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0922.jpg
A change of pistons was needed when i decided to go for a gt3071r turbo. These are standard -13cc from the states. Ive now had them machined to -16cc by s/boyslim and still the total cost was well below £400.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0895.jpg
Ignore my ring clip assembly method
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0917-1.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0935-1.jpg
Painted throttle body, another part now under scrutiny for an upgrade
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0685.jpg
Lighweight billet steel flywheel
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0978-1.jpg
Reducing internal temperatures is one of the most important things im considering and is key to turning up the power sucessfully. The benefits are well proven and some of the reported figures when testing even some of the most basic cooling modifictaions are amazing.
An interesting xe/let spcific mod (and results of it that are worth a look on the j-body forum) is drilling holes in the block to extend the water jacket to cover the full 360° around the top of the clylinder.
http://i195.photobucket.com/albums/z149/Adamo_jones/cool01fo1.jpg
And more buld pics. New turbo
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00667.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00677.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00668.jpg
painting the comp. housing
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0945.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0976-1.jpg
Measuring piston/ deck height. These gauges are so sensitive, having a lever instead of the standard pin to measure distances less than a mm. Mine has a range of 0.8mm
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00725.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00726.jpg
Oil gallery grub screws removed for a final clean before the first trial assembly.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0554.jpg
A present from my mam. A money-box to save for my car, she said! A hint maybe?
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0161-1.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0810.jpg
Engine dropped out of nova, pikey style!
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0818.jpg
The head had to come off to pull it under the front panel
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0871.jpg
Making progress
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0886.jpg
Bearings into rods. I got really paranoid after a couple of my glyco's were removed damaged with scratches on after a trial assembly of the crank. I thought they were getting contaminated with dirt so i wrapped them in cling film to be sure. Turns out there was a slight nik in on one of the crank journals. Doh! :rolleyes:
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0898.jpg
Damage
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0900.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0920.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0929.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0938.jpg
Another few pics of oil squirter mod in progress and head porting.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0535.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0544.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0627.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0618.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00675.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00766.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00768.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00770.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00772.jpg
I dont think anything needs replacing although the arches have seen better days i was going to just patch them up and seam weld the whole chassis.
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00774.jpg
Interior Gutted
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00769.jpg
Few of my rotating parts being balanced
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0982-1.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0984-1.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0987.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0986.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0984.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0981.jpg
Engine bits are now home. Block and head flat for Cometic gasket, bronze guides installed, big intake valve seats full rotating assembly balanced etc etc. At the cost of a severely upset bank balance!!
All done now though.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0993.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0998.jpg
Pistons, having been milled to -16cc
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0980.jpg
Well, i called the machine shop this morning, as they still have my main caps, to be told that they would have a look around and to call them back on monday, so there goes my plans to crack on with the engine assembly so i decided to plod on with some work on the chassis. Sanding & smoothing the bay was on todays menu. First with a wire brush on a mini angle grinder then will attack it by hand with ascending grades of wet & dry. Not one of my favorite tasks, but neverthless it has to be done. Made a fair start after doing a few measurements on my newly skimmed head and also measuring the sizes of the double valve springs as i still need seats and retainers so am going to see if summit racing have any of the correct size for the coscast head before i fork out shed loads for c20let specific items.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0999.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1000.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1001.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1007.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1003.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1004.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1005.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1008.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1009.jpg
cool build great pics to
keep up the good work dude
kevo16v
13-10-08, 10:05 PM
Impressive build mate, keep the updates coming :thumb:
Coming on well Adam :thumb:
Is it wrong I noticed your trousers and thought 'Nissan'? lol
and the boy drinks good lager too lol
Pistol Pete
13-10-08, 10:45 PM
Nice looking project. Look forward to more updates.
Coming on well Adam :thumb:
Is it wrong I noticed your trousers and thought 'Nissan'? lol
and the boy drinks good lager too lol
Thanks for looking
lol
Aye, that particular one was taken by my old man wanting an appropriate photo for the family christmas letter, unfortunately it just as i was about to leave for work! Never planned it to be posted on the net!!:(lol
UPDATE:
Got a little bit more done on the chassis and have to remove the last piece of sound-proffing that i had forgotten was even there.
Good news from the machine shop as they have located the missing main caps and ARP stud kit, so will be able to start assembling the engine at last.
Also spent a short while welding a bracket for the rear garage door as the latch was in easy reach if someone was to put the window through. http://www.vauxhall-sport-forum.com/phpBB2/images/smiles/icon_frown.gif
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1011.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1010.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1012.jpg
LEWI007
15-10-08, 10:20 PM
Going to be a beauty when its done, how much hp are we expecting to get then ?
Going to be a beauty when its done, how much hp are we expecting to get then ?
Read the first two lines :roll:
Looks a great build and a good amount of money is being spent. will be keeping my eye on this one
this is gonna be one fast car judging by the spec list
good progress with it too.
LEWI007
16-10-08, 10:10 AM
Just noticed it..
400 hp damn gonna be a fast one :thumb:
how much is the txb up for?
Ive just posted an add with more pics in the for sale section for TxB.
Bubba, PM sent
Small Update cleared office where the engine is to assembled and made a start by means of a thurough clean and drying of the block. Most of my time was taken up painting the floor, well, more like waiting for it to dry!
Before
http://i195.photobucket.com/albums/z149/Adamo_jones/DSC00767.jpg
After
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1021.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1024.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1022.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1030.jpg
http://www.vauxhall-sport-forum.com/phpBB2/images/smiles/023.gif
_________________
Adam
belly257
20-10-08, 07:42 AM
looking good mate:thumb:
LEWI007
20-10-08, 09:29 AM
Yea, its looking nice
nice work matey, will be watching this with interest
Update:
Another delay last weekend. Disaster struck whilst putting up some shelving i drilled straight through a wire for the wall socket. Not only that but i drilled through all 3 wires inside the wire itself (how unlucky). So after ripping half the wall out to carry out the repair i decided to put the shelving on hold for now and make do so i could crack on!
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1036.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1034.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1044.jpg
Nova conversion into temporary storage cabin
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1014.jpg
Checking everything is back from machine shop mand all work has been done as i requested and to the correct spec and tolerences:
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1006-1.jpg
I'll try to do as much of the final assembly as possible in a step by step process so it will hopefully be useful to others who are considering rebuilds.
Bottom end assembly:
Crank placed in block and journals given a liberal squeeze of assembly lube for main caps.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1039.jpg
ARP studs given a coat of loctite before being turned hand-tight (as specified) into place.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1040.jpg
Mains caps shold be tapped into place with a mallet and not by tightening bolts/nuts to force them down. I torqued the fastners to 50% of their specified torque then give each cap a couple of knocks with a hammer (not to hard). This can help relieve any tension. Then to 75%, and finally to 100% of the final torque, starting from the centre thrust bearing and working outwards. After full torque the crank should be able to be rotated with ease.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1041.jpg
A good coat of ARP's moly grease given to the threads and washers for final torque down.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1042.jpg
Void in end cap filled with silicone jointing compound.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1043.jpg
All sharp edges removed from the valve cut-outs and dish perimeter to reduce hot spots.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1058.jpg
Setting out in order to install rods into pistons using gudeon pins and ring clips supplied and then bearing shells into rods:
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1045.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1052.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1053.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1047.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1048.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1049.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1050.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1051.jpg
Personal choice of mine is to use a dry moly spray and give all moving sufaces a coating prior to assembly. Not really nessesary on the bottom end parts but IMO is vital to the cylinder head components especially as i'm not certain on the amount of time the engine will be standing dormant for while work is carried out on the car itself.
This way if the engine is standing still for any length of time it ensures that parts needing lubrication from start-up, especially those under high pressure and loads such as the contact areas of tappits, aren't left without lubrication and at least have a film of lube that will resist high temps and friction long enough for the oil pressure and flow to build up inside the engine. Molybdenum disulfate in form of a lubricant has ideal properties in this case.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1054.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1056.jpg
Rings onto pistons using a piston ring expander tool, ensuring correct gap distances around 360 degrees (poor pics).
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1057.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1059-1.jpg
And pistons installed into the block making sure bolts are correctly torqued to ARP spec using correct lube. After each piston is installed the crank should be rotated one full turn, and should be progressively more difficult to turn as each piston is connected but shouldn't take more than about 30NM to turn with all for pistons installed.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1064-1.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1061.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1062.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1063.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1066.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1075.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1069.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1067.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1068.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1070.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1072.jpg
the proper amound of sealer to be used )prior to sump gasket installation) compared to some ive seen where it oozes out the sides subsequently blocking oilways and the like (not good for turbos!)
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1075.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1078.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1076.jpg
Thats it for now!
http://www.vauxhall-sport-forum.com/phpBB2/images/smiles/023.gif
_________________
Adam
corsakid
04-11-08, 08:02 AM
lookin good mate! what power are you looking achieve
kevo16v
04-11-08, 11:22 AM
Looking good bud, keep it up :thumb:
lookin good mate! what power are you looking achieve
Hopefully 400bhp + nitrous, the engine spec is as follows;
Wiseco forged pistons (-16cc)
Forged Connecting rods with ARP2000 bolts
Lightweight billet flywheel
5 plate sprung paddle clutch LUK pressure plate
F28 6-speed box with Quaife LSD
Under piston oil squirter conversion
Glyco Mains and Big-end bearings
Full Dynamically balanced rotating assembly (crank, flywheel, rods, etc etc.)
Fully deburred internally & all sharp egdes removed
ARP flywheel bolts
ARP Mains caps Stud kit
Garrett 3071R BB Turbo
Tubular manifold
Cylinder head ported and combustion chambers matched
ARP head stud kit
Cometic 1.9mm head gasket
Skimmed head & block decked to ensure gasket seal
+1mm Intake valves
Bronze valve guides
Double valve springs
titanium spring caps
Solid lifters
Cams to match *
DTA P8 pro management*
Nitrous
Aiming for a static compression ratio of 8.4:1
*Undecided/ Uncalculated
turbojolt
04-11-08, 01:07 PM
who this will be a beast
1 question what do you meen by remove all sharp edges
such as those around the perimeter of the piston dish ( if you follow the red line ive drawn below), and casting irregularities in the block. especially for the pistons, the sharper the edge, the less material there is to heat up so the heat build up quicker and higher in one particular area which is the root cause of detonation and auto-ignition of fuel. Rounding these edges off helps reduce this.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM0980-1.jpg
turbojolt
04-11-08, 02:19 PM
thanks learn something new every day
thanks learn something new every day
Inside the cylinder block though its done for a different reason, that is to smooth out and round off the metal parting joints and casting irregularities which make them high stress risers and the the first place that cracks begin to form, especially when running with higher than stansard loads. Think of it like the corugated cake bar wrapper compared to those with the same strength wrapping but with smoothed ends and how much more difficult they are to start a tear.lol
Mboasty
05-11-08, 11:40 PM
intresting project, i like your attention to detail, im also leaning a few things for when i atempt my rebuild.
where did you buy your moly spray from?
intresting project, i like your attention to detail, im also leaning a few things for when i atempt my rebuild.
where did you buy your moly spray from?
Thanks, as i said though choice of lube is entirely preferential. But its a fact there is absolutely no alternative lubricant with such good lubricating properties at such high temps, up to 350 °C, in an oxodizing environment (apart from tugsten sulphite). Hense the reason i use it/ shall use it religeously on cam loabs, followers etc. in spray and solid form.
Dry Moly lube off ebay; not easy stuff to find
http://cgi.ebay.co.uk/DRY-MOLY-LUBRICANT-AIR-RIFLE-PAINT-BALL-GUNS-ETC_W0QQitemZ260298651863QQcmdZViewItem?hash=item2 60298651863&_trksid=p3286.c0.m14&_trkparms=72%3A1301|66%3A2|65%3A12|39%3A1|240%3A13 18
;)
turbojolt
06-11-08, 11:55 AM
Inside the cylinder block, however, its done for a different reason, that is to smooth out and round off the metal parting joints and casting irregularities which make them high stress risers and the the first place that cracks begin to form, especially when running with higher than stansard loads. Think of it like the jagged egdes of a Penguin bar wrapper compared to those with the same strength wrapping but with smoothed ends and how much more difficult they are to start a tear.:)
makes a lot of sense to be honest when you put it like that good luck withthe project im goin to keep a eye on this one :thumb:
Mboasty
07-11-08, 12:43 AM
sweet thanks for that link, i'll be purchasing some of that asap.
looking forward to more up dates on this thred.
Quick update. Been fairly slow the past couple of weeks but ive managed to get a little bit done here and there. Its not exactly the best time of year for spare cash to throw in but nevertheless as the projectr is just getting under way theres a whole host of odd tasks and work to be getting on with that doesnt require large sums of money to be spent in order to get on with them.
Last minute changes to inlet and exhaust ports.
Minimum material removal to keep original shape of ex. ports (unfinished pics)
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1094.jpghttp://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1096.jpg
Finishing inlet ports
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1162.jpghttp://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1161.jpghttp://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1147.jpg
Cylinder head assembly;
Valve spring seat in place followed by valve stem oil seal (use the std. oil seal from Nissan Micra or BMW M3 for double valve springs as Vaux ones dont fit).
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1137.jpg
I personally remove the spring before fitting the seal and put it back on once installed which is really simple as the springs are easilly dislodged when applying pressure to install the seal
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1146.jpg
dropping in double springs,
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1138.jpg
Folowed by the retainer on top.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1139.jpg
Clamped up then added a dab of grease on the end of a screwdriver to hold the half collet that gets installed at the top of the valve to hold it in place. The grease holds it in place (or should do) until you release the spring pressure by removing the clamp.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1140.jpghttp://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1141.jpg
You can see here the two half collets making a ring at the top of the valve stem. When the sping is released its held in place as the collets cant get past the retainer once installed as they have a slight angle on them. High performance retainers usually have a steeper angle (8-10 degrees) to increase holding pressure on the collets.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1142.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1143.jpg
Gearbox then got a clean;
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1157-1.jpghttp://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1157.jpg
Primed;
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1158.jpg
And painted;
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1163.jpg
Ive got some more pics to upload so will get them up tomorrow.:thumb:
nova_niek
28-11-08, 04:36 AM
Mmm nice, I like the attention to detail in this build. Following your referral to the J-body fora, I found a wealth of knowledge regarding LET's in the US. Cheers for that! :)
Niek
Thanks.
Ive seen a few things done over there that i'd never seen before on any cars over here. Its interesting to see how other countries trends in modifying have formed completely different styles to what you get used to seeing over here.
novaxe235
28-11-08, 07:59 PM
detailed thread or what. u obviously no ur stuff
nice project mate!
good luck with the first turn of the key.
fingers crossed for you, i would be sh#ting
my self with all that time and money spent.
just incase i didnt torque everything up correctly
(but it looks like you know what your doing)
nice job mate :thumb:
detailed thread or what. u obviously no ur stuff
Doing it step by step will help keep a record but doing it mainly as an aid to anyone else doing similar tasks or thinking about it in the future.
Also, i know a fair bit, but i'm still no expert and only do this as a hobby so by posting all the steps on here it also gives people the chance to spot any problems or let me know how i could improve or do something differently.
nice project mate!
good luck with the first turn of the key.
fingers crossed for you, i would be sh#ting
my self with all that time and money spent.
just incase i didnt torque everything up correctly
(but it looks like you know what your doing)
nice job mate :thumb:
Cheers!
The thought will always be in my mind. but have tried to stay pretty methodical and taken good measurements and records of everything...twice....often three times to be sure so should be good on the day. As you say when the time comes it'll still be 'fingers crossed'!!:cool:
nova_niek
01-12-08, 07:45 PM
Reducing internal temperatures is one of the most important things im considering and is key to turning up the power sucessfully. The benefits are well proven and some of the reported figures when testing even some of the most basic cooling modifictaions are amazing.
An interesting xe/let spcific mod (and results of it that are worth a look on the j-body forum) is drilling holes in the block to extend the water jacket to cover the full 360° around the top of the clylinder.
http://i195.photobucket.com/albums/z149/Adamo_jones/cool01fo1.jpg
I've seen this mod before. I suppose it requires taking out the sleeves (if that's possible in an XE) to get those nice thin slots between each cylinder. I've noticed you haven't done this mod to your block - why not, if you don't mind me asking?
Mickwilly368
01-12-08, 08:05 PM
A lot of hard work mate... Keep it Up!! Plenty of tea breaks!
I've seen this mod before. I suppose it requires taking out the sleeves (if that's possible in an XE) to get those nice thin slots between each cylinder. I've noticed you haven't done this mod to your block - why not, if you don't mind me asking?
Not at all:D It doesnt require taking the sleeves out it just needs drilled and milled out the top of the block. However i havn't got the tools to do such a mod and given the money already spent at the machine shop it was decided i didnt have the cash either as one off jobs like that can unfortunately end up costing a small fortune :(
Again been doing a few odd bits mainly prep'ing the shell for seam welding and the newly purchased rollcage.
removing all that sticky crap left over from the sound-proofing can be a real twÃ*t scrubbing off with thinners. I've found it best to get rid of any any heavy deposits first by going over it with a wire brush on an angle grinder. This kind of smears all the crap into a thin layer that can then easily be removed by dousing it with thinners followed by literally a single wipe with a cloth. This saves scrubbing to remove the heavy stuff and your fingers from aching like fcuk.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1195.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1177.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1198.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1203.jpg
Marking out for seam welds
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1204.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1207.jpg
New head studs completes the collection of ARP accessories.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1218.jpg
Having my photo unwittingly taken with the new 'in house' Santa!
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1213.jpg
Am really enjoying this thread, keep it up!
Jonny Martin
04-12-08, 08:01 AM
Just read the whole way through this thread and all i can say is, WOW. I'm very impressed, i found reading this very motivational. Great work! Keep it up! :thumb:
Roll cage is the last buy planned for a while until we have Christmas out the way. At least for now i can get on with welding; painting; and work on the chassis.
Trial assembly before i take it to the lock-up.(i know i just had to)lol
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1226.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1227.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1228.jpg
wilson_sri
08-12-08, 12:11 AM
Coming along nicely :)
Cage looks sweet.
Small update been slogging away with the prep work for a few hours the past couple of days. Vauxhall could have saved millions if they hadn't used so much f***ing glue on the interior roofing decor.http://www.migweb.co.uk/forums/images/smilies/lmao.gif Never mind, if nothing else its helped take my mind off a few problems im having in my personal life.
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1229.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1230.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1231.jpg
novaowner999
15-12-08, 11:42 AM
u no ur stuff
craig green
15-12-08, 01:10 PM
Nice to see an engine build in such detail.
Keep at it.
nova_niek
15-12-08, 06:27 PM
Small update been slogging away with the prep work for a few hours the past couple of days. Vauxhall could have saved millions if they hadn't used so much f***ing glue on the interior roofing decor.http://www.migweb.co.uk/forums/images/smilies/lmao.gif
Great stuff, isn't it? :D
Small update, will get some more pics up shortly. Not the best news to start it off. I've found a f**k off big crack near one of the cam bearings on the head, it can be welded up hopefully but cant believe i missed it when i checked the head over. Even worse though, somehow ive managed to get a small scratch right across the cylinder head face where the gasket seals the chamber on #3. Chances are it may need another skim but i'm really really hoping it doesn't as i'm already fairly high on compression at 8.3:1 and the engine almost built. we'll have to see what the machinist reckons as i dont want to take any chances with the HG seal either.
Apart from that I'm making some progress on the chassis prep while I wait for some odds and ends such as split collets and oem fasteners to finish the engine.
I havn't much experience when it comes to welding so some of the welds are bit iffy, but, we all know what practice makes......
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1232.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1233.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1235.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1238.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1239.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1242.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1245.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1244.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1246.jpg
Also, welding underneath the car upside down is a pig especially for an amatuer......so much so that... I decided to make it easier for myself lol :wtf:
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1248.jpg
looking at those welds id say you need more power mate. cant beleave youve got a fire extinguisher to hand. how boring lol
meritlover
22-12-08, 03:33 AM
yes, more amps or less feed speed.
meritlover
22-12-08, 03:37 AM
Why did you not cut back your valve guides before you put the valves in?:(
:cry:
yes, more amps or less feed speed.i would say more of both tbo as that bead is very thin
meritlover
22-12-08, 03:44 AM
less feed on that current will still give a thin weld but it wont look as thin and you'll get slightly better penetration, as well as it looking tidyer/flatter.
however, i agree that if you chose to increase the current the feed would also have to be sped up. it will also help to burn off paint and impurities.
worth trying out on some other metal first.
dhdev (Oli)
22-12-08, 09:27 AM
You also appear to have marked along the centre carpet support for seam welding (in front of the gear lever), complete waste of time welding that BTW. :thumb:
You also appear to have marked along the centre carpet support for seam welding (in front of the gear lever), complete waste of time welding that BTW. :thumb:
yeah, that has since been totally removed, was really just a guide where all the strips of spot welds are for when i do get round to welding it up.:thumb:
Why did you not cut back your valve guides before you put the valves in?:(
:cry:
I did, quite a bit just hadn't posted the pics......:D
Before finishing them off:
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1104.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1120.jpg
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1116.jpg
Slow progress as ive had a lot on and waited ages for a head gasket to come. Not to worry, heads now on and starting to take shape.
After bolting the head up I threw everything else on losely to see how the colour scheme worked, and...... IMO simple but effective.:cool:
http://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1292.jpghttp://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1287.jpghttp://i195.photobucket.com/albums/z149/Adamo_jones/HPIM1292.jpg
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