Really? Mine had some punctuation marks removed so a few bits didn't make sense.Quote:
Originally Posted by 8valve-craig
writer? Or editor?
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Really? Mine had some punctuation marks removed so a few bits didn't make sense.Quote:
Originally Posted by 8valve-craig
writer? Or editor?
Writer. I'l find it one day.
update
The rest of the engine got removed and stripped down, a trip to visit Philip so he could sort out the overbore to 87mm, crank check(which then got polished) and the block had a light skim.
http://i193.photobucket.com/albums/z...pswkeuptjr.jpg
He did give me some bad news in regards to the omega pistons I had bought second hand, which was that white metal was once present across the gudgeon pin, putting wear marks into the piston. New gudgeon pins may have been fitted but a light tapping in the engine may occur, I wasn't too happy with this so I then bought a set of new 87mm wossner pistons.
http://i193.photobucket.com/albums/z...pslkurabhf.jpg
Following the instructions provided with the pistons, I gapped the rings and then got the pistons fitted to the rods.
http://i193.photobucket.com/albums/z...pssu7sc2c1.jpg
http://i193.photobucket.com/albums/z...psovovrb8o.jpg
Crank and rod bearing clearances got checked with plastigauge.
http://i193.photobucket.com/albums/z...ps1fpnjlxz.jpg
The block and crank then got washed off ready for assembly with new bearings.
http://i193.photobucket.com/albums/z...psauzrzpie.jpg
z20leh/vxr oil pump fitted, with the original oil cooler sandwich plate from the c20let. For reference, the front crank seal needs to be fitted with a c20let seal.
http://i193.photobucket.com/albums/z...psk6ejzjue.jpg
New 8v baffle and a z20 to c20 oil pick up pipe fitted.
http://i193.photobucket.com/albums/z...psyzzvl7sj.jpg
Pistons slipped in.
http://i193.photobucket.com/albums/z...ps3a0kqtt4.jpg
Various other parts fitted, starter, alternator etc.
http://i193.photobucket.com/albums/z...psbuillzs4.jpg
Alternator had a freshen up before fitting.
http://i193.photobucket.com/albums/z...psevhak864.jpg
Gave the lifters a clean out.
http://i193.photobucket.com/albums/z...psc70swwgw.jpg
Head on and torqued, manifold, cambelt etc.
http://i193.photobucket.com/albums/z...psdaaasggf.jpg
Jonlem had pointed out over on FB that my idler was the wrong way around. I have since checked all the times I've built the motor up and it's always been this way. Never the less, I did correct it.
http://i193.photobucket.com/albums/z...psgopopuvf.jpg
The inlet I made is now also on.
http://i193.photobucket.com/albums/z...psr0m4wvgn.jpg
Rose jointed alternator adjusted worked a treat.
http://i193.photobucket.com/albums/z...psyuxuqwji.jpg
Before I made my inlet I read a couple of WIP threads with how they managed to still use the 3rd outlet of the 3 way hose. I'm unsure if it would cause an airlock or higher engine temps, but if it was there from factory then i thought it would be best to have it.
An inch to 10mm adapter was sourced and fitted.
http://i193.photobucket.com/albums/z...pskaxaeosp.jpg
A shiny heat shield was made to stop some heat going to the rad.
http://i193.photobucket.com/albums/z...psrsiv6817.jpg
The engine complete, awaiting to be fitted.
http://i193.photobucket.com/albums/z...psva6jq968.jpg
One empty hole.
http://i193.photobucket.com/albums/z...psjvzixwnb.jpg
Thanks for looking.
Brucer
That thing is mint, the engine bay looks alot like Benn's
Looking well!
Au contraire, Benns inner wings are smoothed down to the chassis legs and his wiper motor recess is taken out to name but a couple of differences.Quote:
Originally Posted by LEWI007
Cheers geezer!Quote:
Originally Posted by torquey
Shiney pistons!!!!!
I would earth strap the alternator, I had issues with arcing across my rose jointed adjuster!!
wow its out !!! I need to look on here more often.... I love this little blue beast :thumb:
Has already fitted one off a stud on the back of the alternator. :thumb:Quote:
Originally Posted by House
Cheers Kev, it's also back in too. :dQuote:
Originally Posted by kevster
What was your deck hight with the pistons pal . im running the same pistons n had to have my piston crowns skimmed . they had 27thou pos deck hight
update
I trailered the nova over to work (with out the blue tarp Stuart) so I could set about slipping a certain motor into a certain hole.
http://i193.photobucket.com/albums/z...psxlht9uju.jpg
Flywheel and clutch fitted.
http://i193.photobucket.com/albums/z...ps7wldejpz.jpg
Gearbox man handled on.
http://i193.photobucket.com/albums/z...ps20jglshy.jpg
And eventually it went in, it took a bit longer than normal due to my new inlet hitting the brake reservoir. Which meant I had to remove some fitted items to get it down and in.
http://i193.photobucket.com/albums/z...psv0bueb5m.jpg
A new 90mm inletted air filter fitted to the 90mm MAF, makes it more of squeeze to sit above the gearbox. I will at some point get a different inlet pipe made up and maybe a intercooler to top hat pipe. See below for the temporary IC pipe.
http://i193.photobucket.com/albums/z...psujics2oi.jpg
Oil cooler filled up with oil and sat on top of the intercooler atm. I need to move it over to the middle more as the grill doesn't really fit now, it just needs a longer line which I will add to the 'to do' list.
http://i193.photobucket.com/albums/z...psggslwvqm.jpg
http://i193.photobucket.com/albums/z...psen8c5tm9.jpg
Temporary pipe fitted, as my one original pipe wasn't long enough I extended it. As above, I would like to get possibly a one piece top hat down to the intercooler.
http://i193.photobucket.com/albums/z...psr7rrysoi.jpg
So time came to try fire it up, I had to change the map in the ecu to a standard z-let one and leave the MAF disconnected. I turned on the fuel pumps and checked for leaks, which I did have. The injectors are leaking on the O rings. Balls!!! :tard:
As I had my old fuel rail about, I fitted it backwards (due to the feed pipe fouling the inlet) and added some spare hose to it so I can then try to start it again. Which it did.
http://i193.photobucket.com/albums/z...psuxxfyd90.jpg
Once running I let it run a for a couple of minutes then drained out the 10/40 I put in and filled it up with some running in oil and a new filter. I did the first fill with normal oil so any small particles that may be there would have a chance to be flushed out, instead of running the motor in with them still in there.
http://i193.photobucket.com/albums/z...psosbzjyt2.jpg
Once running a again, I checked it all over to notice I had a coolant leak from the inlet gasket. The nuts were nipped up and it seems to have stopped, this will be checked upon again.
http://i193.photobucket.com/albums/z...psuocwcfwr.jpg
And a small test drive.
https://www.youtube.com/watch?v=NpL0xlgN36c
Things to do before mapping:
Geometry
Swap out my boost nipples to longer ones
Move the oil cooler, make a bracket for it and tie it into the slam panel.
Sort my fuel leak on the purple rail
Plenty to do with only 2/3 months before the first event (excluding the spring action day that is)
Thanks for looking.
Bruce
Loving this engine looks wicked.
Stealing this ideaQuote:
Originally Posted by brucer
I cant remember off the top of my head what it measures at, but apparently it isn't uncommon to see 0.4-0.6mm above the deck. It depends on what head gasket you use too, a z-let one compresses to 1.2mm.Quote:
Originally Posted by total_vauxhall
Thank you.Quote:
Originally Posted by torquey
It then bolts to a manifold stud. :thumb:Quote:
Originally Posted by House
https://uploads.tapatalk-cdn.com/201...cc0cdf357c.jpg
Like this?!? [emoji6]
Quote:
Originally Posted by House
Exactly like that.
update
The Z20LET Lovers Race Wars event that I'm doing in may requires the car to have a valid MOT just to say its road worthy.
Que me slipping on the number plates and sorting out a few niggles with the lights.
http://i193.photobucket.com/albums/z...psmd2lgmi6.jpg
Emissions all good for an MOT, as it hasn't been mapped yet there is quite a bit of unburnt fuel.
http://i193.photobucket.com/albums/z...psszza4kzd.jpg
Headlamp aim all good.
http://i193.photobucket.com/albums/z...pshxvjulle.jpg
Generally the whole car was all good. I didn't realise how many times I've had it on and off the trailer in 4 years. lol
http://i193.photobucket.com/albums/z...pshmbc5vo0.jpg
A few more things got sorted too, longer boost nipples as I was afraid of my hoses coming off the small ones.
http://i193.photobucket.com/albums/z...pse8hbgwu0.jpg
Some super fat nitrile 70 'o' rings for the injectors which has solved my fuel leak on the rail. These are 7mm ID with a 4mm cross section.
http://i193.photobucket.com/albums/z...ps9ci6e9b2.jpg
I wanted to label the switches on the dash that aren't doing their original job now, so I painted the faces satin black.
http://i193.photobucket.com/albums/z...psee5qlb4a.jpg
Stickorzzz sheet.
http://i193.photobucket.com/albums/z...psdw2subhc.jpg
We have fuel pumps, override for the fan, boot solenoid and standard rear frog.
http://i193.photobucket.com/albums/z...psnqmop2f9.jpg
Oil cooler is now in the centre after buying a longer hose for it. The grille now fits thank god!
http://i193.photobucket.com/albums/z...psomhgddeh.jpg
And a tarty shot and another small video for y'all.
https://youtu.be/YCq7omBMFXs
http://i193.photobucket.com/albums/z...pszeijuo1v.jpg
Bruce
An amazing car !!
I wish. lolQuote:
Originally Posted by kevster
What a shit car, bloody terrible colour, awful engine and what a waste of time...
... you know I'm talking bullshit, bloody love it ;)
HAHA, thats more like it.:pQuote:
Originally Posted by Southie
Update
I kept it quiet that I was taking the nova for mapping as I was uncertain if it would come back in one piece. Lol
It was a 4 hour drive down to see Rabbid Remaps, he set about working his magic on the car so he could put a ‘tune’ (American voice ‘toon’) in the ecu.
http://i193.photobucket.com/albums/z...psb76rbaqq.jpg
http://i193.photobucket.com/albums/z...psi2sysitp.jpg
As I fitted the 875cc injectors the night before, it rendered the car immobile as the map currently installed wouldn’t let it start. He added a file to the ecu to accommodate the larger injectors and the 90mm MAF, this allowed him to start it and get it onto the rollers.
http://i193.photobucket.com/albums/z...pstj4he5sl.jpg
http://i193.photobucket.com/albums/z...psguhx2mxi.jpg
http://i193.photobucket.com/albums/z...pswj5htrdz.jpg
A test run to see how well the engine was working along with all the sensors, at 10psi which was gate pressure gave me 259bhp at the flywheel. Not too shabby.
http://i193.photobucket.com/albums/z...psamtnzqlo.jpg
A bit more fettling
http://i193.photobucket.com/albums/z...psb5anxrkq.jpg
http://i193.photobucket.com/albums/z...psoxasxtdt.jpg
And the final figure for the day was 308bhp and 300lbft @ 1 bar of boost. I was a little disappointed as it appears that either my actuator is faulty or the penny valve isn’t sealing correctly not allowing the turbine to make any more boost. Nether the less it’s a good starting figure and there will be plenty more to come later on in the year.
http://i193.photobucket.com/albums/z...pshkxnkfu2.jpg
Although I wasn’t grinning like a Cheshire cat, once I parked it back in the garage and gave it a rev it soon made me go ‘oh my dayzzz’. The poppin’ and bangin’ on lift off is a great noise, this made my day. Lol
http://i193.photobucket.com/albums/z...psybzndx5g.jpg
Here’s a couple videos of the last session on the rollers.
https://youtu.be/fpJA_QZ9m8c
https://youtu.be/ZaKM_yV3A-E
I had noticed that I was getting blue smoke on overrun, I think the stem seals may have gone hard sucking in oil under vacuum. This will get addressed at some point, as for the lack of power I think I may just use it for this year and try and fix the fault later on. If I alter anything now then theres a good chance id have to take it to be mapped again.
Thanks for looking
Brucer.
Nice run mate love this car
Just read through start to finish, what a machine, remember reading this back in about 2012 when I was actually working on mine, toyed with the idea of the same blue for my loon but I never got any further, great to see how far it's come since then ��
Cheers palQuote:
Originally Posted by carls nova sri
It's for ever evolving in some way, the bodywork stays the same though. lolQuote:
Originally Posted by Phil_d
update
Few things have changed since the last update, I bought a standard actuator rod to fit and to double check all the internals of the actuator.
I found the internal piston had actually come loose from the rod, in turn undoing any preload on it. I have now loctited it in place. :d
I also forgot that I had the strongest actuator spring forge make inside it, the red spring is rated 17.5 - 20psi of gate pressure.
http://i193.photobucket.com/albums/z...psuthpxvt0.jpg
http://i193.photobucket.com/albums/z...ps1pknbyno.jpg
Actuator fitted with half a hole of preload.
http://i193.photobucket.com/albums/z...psn3bff2or.jpg
After inspecting my actuator fault I found that the plastic sheathing that I used on the lambda and crank sensor wiring had melted due to its close proximity to the turbo/manifold, I bought some heat resistant sheath that should be upto the job.
I used lock wire to hold it in place.
http://i193.photobucket.com/albums/z...pspq4shfu1.jpg
I also did the headlight wiring across the top of the radiator and a few other bits of wiring close to the manifold.
http://i193.photobucket.com/albums/z...pshrxpjxcf.jpg
Since I have the roll cage and the electric sunroof, ive never had a rear view mirror. I was unsure what model of car to get one from, but a corsa b one looked like it would do the job.
I got some sticky pads from a windscreen company (which turned out to suck balls) to fit the mirror in place. (no pics of it fitted yet)
http://i193.photobucket.com/albums/z...psgsewwkxq.jpg
http://i193.photobucket.com/albums/z...psct6trkfu.jpg
When the car was on the dyno I noticed it had a small oil leak, which I thought was from the dipstick tube, but it turned out to be the dizzy blank. I had previously put sealer on the seal as it was past its best, but this obviously didn't work. Que a new seal, this was listed for an e16se dizzy.
http://i193.photobucket.com/albums/z...psrvhzo4yf.jpg
Head checked for tightness, this was just the final stage torque of 70lbft IIRC, all were fine and none moved at all.
http://i193.photobucket.com/albums/z...psqk2pbclr.jpg
As the hawk eye four wheel alignment threw up dodgy readings last time I checked (out of calibration which has now been fixed), I wanted a way to check my camber/caster in my garage instead of having to take it to work. Ok, it may be crude but atleast its a reference point.
So I bought one of these.
http://i193.photobucket.com/albums/z...psm1xzt3mo.jpg
And then I learnt a friend had this.
http://i193.photobucket.com/albums/z...psgyrukggk.jpg
I tried the sealey one first as it had the caster already on there without having to turn the wheel and mess with nobs, but it wouldn't fit between the wheel bolts so this was made redundant.
I then calibrated my one to be level.
http://i193.photobucket.com/albums/z...pstrhaepqe.jpg
And then mounted on the disc to check for camber, which gave about 1 and 1/4 degrees.
Next onto the caster, I made a very very very rough calculation of 20degrees with some card. Turned the wheel 20degrees one way, mounted the gauge and set it t 0. Then back the other way with the steering 20degrees to get my caster reading. As I imagined from a previous go on the hawk eye, I have little caster on both sides. Not good. :( I think i'll have to invest in a rose jointed setup to get some extra adjustment.
http://i193.photobucket.com/albums/z...psxoqio62m.jpg
http://i193.photobucket.com/albums/z...psk8iyafnx.jpg
http://i193.photobucket.com/albums/z...pshndl1u8p.jpg
I'll be taking the car to work on Thursday to give it the once over again and give it a clean as its filthy!
I have another mapping session on Friday and Race wars on Saturday (mile long drag/top speed run). All being well it should be a productive week.
http://i193.photobucket.com/albums/z...pswpxe1loh.jpg
Thanks for looking.
Brucer
update
Thursday
Prep for Z20let Lovers Race Wars.
At work Thursday bright and early.
http://i193.photobucket.com/albums/z...pstnxvrkgj.jpg
I began by getting my 6th cesaro painted to match the other 5.
I bought another pair of yoko ad08's for any wet occasion that may arise, as the weather looked a bit bleak it wasn't a bad idea to have a back up pair of tyres instead of the a048's. These 2 went on my spare wheel and now this 6th one.
http://i193.photobucket.com/albums/z...psvbkwoi2y.jpg
Also, my a048's were second hand when I got them, still having 3.8ish mm of tread, I spun them up on the balancer at work to notice they wernt quite true. As I planned to do 140+mph with the nova, I didn't want to take any chances.
So a new pair got fitted to the front wheels.
http://i193.photobucket.com/albums/z...psarwgnyml.jpg
When I weighed the car at the quarry last year, I always wondered if that was the true weight. (940kg no spare wheel) My boss had bought a set of scales for his own race cars, so a perfect opportunity for me to get a correct figure for the nova.
http://i193.photobucket.com/albums/z...psmr2hehoh.jpg
Car on all corner scales.
http://i193.photobucket.com/albums/z...psewqmrapm.jpg
no spare wheel and 25-30L of fuel. 930kg
http://i193.photobucket.com/albums/z...psfj2fp7de.jpg
http://i193.photobucket.com/albums/z...psfbs8xczi.jpg
With me in it.
http://i193.photobucket.com/albums/z...pslnpqt80y.jpg
http://i193.photobucket.com/albums/z...ps16g37dbf.jpg
Pretty happy with the outcome as it was a little lighter than I first thought.
After all prep was done (fluid levels, visual check of components and most bolts checked for torque), I then spent the afternoon washing, polishing, waxing etc.
http://i193.photobucket.com/albums/z...psvb9xtn4p.jpg
http://i193.photobucket.com/albums/z...psv6pijyum.jpg
And then it rained, the tarp had to come out as the spray that comes off the Vectra ruins the front end of the nova.
http://i193.photobucket.com/albums/z...psqtkjnahy.jpg
friday
Drove the 4hours to Rabbid Remaps again for him to work his magic and get me all the power I can have, I was feeling confident after fixing the actuator fault that I could see well into the 300+bhp.
On the rollers the car looked much more alive, when it came on boost (around 3500rpm) it sounded powerful and started to lift out of the rollers. :)
We went and had a ponder out side to which he followed shortly and said it looks like the actuators playing up again. After some visual inspection, I couldn't see anything wrong. He got a pump and put it on the actuators nipple, bad news was that it wasn't holding pressure. The diaphragm must have popped causing boost issues.
A little peeved, nothing could be done without changing the diaphragm. He mentioned that I could still use the car at Race Wars, with roughly the same power as the original map he done. This one had a little less boost and more ignition.
We left there and made our way up to Leicestershire to stay in a Travelodge the night ready for the next day.
Saturday Race Wars
Arriving at endrew Barracks all nervous and excited to use the car, its first use in four years
Being greeted with astra upon astra. All the folk were friendly and it was a cracking day.
The morning sessions were timed runs, which we got 3 goes each. The cars got fitted with a camera and a GPS box to measure top speed, 0-60, 0-100 and quarter mile times.
Each car had to do a sighting lap with a marshal to make sure we were safe, this was a good exercise as it got me used to the car and how it felt. I planned to make my first run a slow one, but this sighting lap got it out the way so I could concentrate on going flat out on all 3 runs.
First run- Launched off, car felt good. Pulled super hard from 3rd onwards, my speedo wasn't working so was unsure what speed I was doing (although it only goes to 120mph). I got into 6th at 6200rpm and then backed off 2-300meters before the line. The usb stick was taken into the building to watch back and see what top speed I got, what I didn't know was that the figure that counts is the one across the finish line, not the top speed anywhere within the mile. Boo!
I did 151mph, but 101mph across the line. :cry: But I did get a 5.39s 0-60.
Second run- Now I know the score, ill just got flat out! So I did just that, except 100meters before the line I heard a pop and the engine cut out. Rolled to a stop and the car wouldn't start up, looked under the bonnet and all was ok, looked under the car and a boost pipe had come off. Slipped it back on to get back to the pits to fix it.
I did do 155mph, but 146mph across the line
Third run- All or nothing now, launched off, again 3r gear and onwards it pulled hard all the way across the line. 6th gear at 6500rpm.
This netted me 157mph across the line!
The next half hour was nerve racking, is it enough for a trophy in my class? (250-400bhp)
The answer to that is yes! YES IT WAS!
1st place too! :d:d:d
http://i193.photobucket.com/albums/z...shjydkppa.jpeg
http://i193.photobucket.com/albums/z...scisunvpe.jpeg
I was over the moon, the cars first outing, an incomplete engine setup and I got me a trophy, my first ever trophy!
Here are the videos from the day.
https://www.youtube.com/watch?v=EvI9MLiKQ1Q
https://www.youtube.com/watch?v=K6j00HtUJl8
And some photos.
http://i193.photobucket.com/albums/z...pse3rq8x9v.jpg
http://i193.photobucket.com/albums/z...psafysxhmx.jpg
http://i193.photobucket.com/albums/z...psneisvtwy.jpg
http://i193.photobucket.com/albums/z...ps0lmsklza.jpg
http://i193.photobucket.com/albums/z...psmfrefybs.jpg
http://i193.photobucket.com/albums/z...psualdcaev.jpg
http://i193.photobucket.com/albums/z...psd8szicqs.jpg
http://i193.photobucket.com/albums/z...ps0fc4bmbb.jpg
http://i193.photobucket.com/albums/z...ps6hw27b1k.jpg
http://i193.photobucket.com/albums/z...psvos2y1uj.jpg
http://i193.photobucket.com/albums/z...pslgfa8axz.jpg
http://i193.photobucket.com/albums/z...psikyvg88m.jpg
Next steps are, fix my actuator and get it back down for mapping before PVS next month.
Thanks for looking.
Brucer
Good going congratulations on the trophy too
Sounds awesome that looks quick aswell.
Wipers don't like over 150 mph lol.
Mmm people slate a single wiper, but really...
Lots of action & updates Bruce; great to see. That white Corsa is what like 600BHP?! You can see it truly hook up as it goes into third :O I mean your car with 300BHP is fast, but that thing must be like a French trebuchet.
Only thing I would say about the power curve is; looking at it, the design of inlet isn't far off but physically needs to be bigger to get it feeling like it wants to rev.
Thank you, it was a balls out move to hold it flat out. I'm quite surprised how stable it felt at that speed, more to come hopefully!Quote:
Originally Posted by carls nova sri
I'm pleased with how it goes, the turbo spools up pretty quick with minimal lag, must be the twin scroll and titanium turbine wheel. Once I've sorted the actuator issue out and been for another mapping session it should perform a lot better, boost was fluctuating between 14 and 19psi.Quote:
Originally Posted by torquey
Quote:
Originally Posted by BRoadGhost
The corsas on another level! Each engine has I think 475HP, the owner Adam is a top bloke.
Thanks for the input, the plenum was all I had about at the time and I didn't want to buy something else as I was unsure if my fab skills would end up with a complete manifold. I will in the future get one custom made, but in the mean time it has to be better than the standard manifold that's designed for a 150hp N/A motor.
As for the power curve, it hasn't got a decent tune in it yet due to the actuator faults. When it gets sorted and mapped again then we can see what it really should be.
The more you post the more I love this car, just caught up with the videos and it sounds brilliant, you must be very happy but what's your future plans with it getting to such a top end rasper;)
Well done on the class win :thumb: looks like it goes very well! looks brilliant too :)
Cracking car mate, just watched the video and your wiper arms made me laugh. That happened to us years ago in an old GTE lol
Top end rasper? lolQuote:
Originally Posted by Southie
Thank you, it moves pretty quickly. There should still be 50-75hp to get out of this turbo yet.Quote:
Originally Posted by bazzap8389
Quote:
Originally Posted by Balley
A bit scary moving at speed isn't it. lol Was a bit unsure what do when they started lifting, I'll probably keep them off with more events coming up.