Coming along nicely, well done
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Coming along nicely, well done
Few more engine build pictures
http://i27.photobucket.com/albums/c1...4C2E338E87.jpg
http://i27.photobucket.com/albums/c1...CFF31E6E20.jpg
http://i27.photobucket.com/albums/c1...2D754245BD.jpg
http://i27.photobucket.com/albums/c1...D04D1CACA0.jpg
http://i27.photobucket.com/albums/c1...133942F415.jpg
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
http://i27.photobucket.com/albums/c1...B35ED5C053.jpg
http://i27.photobucket.com/albums/c1...14CA426A3C.jpg
http://i27.photobucket.com/albums/c1...DC5E5935C8.jpg
http://i27.photobucket.com/albums/c1...66C8568276.jpg
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
http://i27.photobucket.com/albums/c1...978BB9C55B.jpg
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.
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!!!
Falling in love with the old girl then..llol 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.
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!!
Today was engine in day!!
I don't have any during photos cos I was doing it alone and up against time!!
http://i27.photobucket.com/albums/c1...CBF5F506D1.jpg
http://i27.photobucket.com/albums/c1...E556E3B52F.jpg
http://i27.photobucket.com/albums/c1...DB71D5595B.jpg
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!!
Looks great like it was made to be in there.
Thanks fella,
Didn't manage to get the quick rack fitted as I didn't receive the new tie rods but that's easy enough to do, next thing will be rolling road.
I've tried playing around with the fueling but can't get it right!! Easier to let people that know what they're doing sort it out, i'll get them to run it in on the rollers aswell, that way we can monitor the AFR and make sure it's running right while running in, last thing I want to do is bugger this engine up!!
Little update,
Had a few hours spare this afternoon, so unwrapped my new seats and made a start on the passenger seat, after a bit of playing around, got it mounted to the original subframe, so it slides back and forward which I wanted to be able to do, without spending £80 on subframes specially made. Got the seat as low as I could, pretty happy with the seating position and height, will work well for the drivers side when I find 5 minutes to do that one, shouldn't be so tough now I know what's gotta be done.
I'll be honest I nearly gave in and ordered some but the finished result is worth it!! and I saved £160 notes!!
http://i27.photobucket.com/albums/c1...50B9738E7B.jpg
http://i27.photobucket.com/albums/c1...F50F227359.jpg
Just the belts to go, gonna mount them onto the bar between the rear shock towers, need some spreader plates and need to weld it in but apart from that small snag it's fine. Can't do the driver seat until the belts are ready.
http://i27.photobucket.com/albums/c1...CDEBAE7DE4.jpg
Just draped the belts over to see what it looked like, then remembered I hadn't taken a picture but I'd already locked up so snapped a crappy one through the window!!
Engine looks good!
I was supposed to be in Lutterworth today but woke up at 2am with a wisdom tooth trying to eat my gum, couldn't eat or drink, so decided to sack work off and get to the dentist, could only get an appointment at 4.15 so instead of wallowing in bed I got my butt to my mate's garage and got on with a few bits.
Fitted the drivers seat, after doing the passenger one yesterday this was a breeze, straight in, I've decided both seats are too high but will rectify this over the winter when I can make some direct mounts in my own time. Got the belts all fitted aswell with some eyelets and spreader plates.
I've been struggling with high inlet air temps due to the exhaust running directly below the throttle bodies.
Knocked up this little heat shield to see if it makes a difference.]
http://i27.photobucket.com/albums/c1...47047938DB.jpg
It does seem to make a difference. but I think I'm going to have to make some sort of sealed inlet plenum that feeds directly to cold air, inlet temps of 60 degrees don't help make power!!
Next on today's list was to sort the mapping out, I've got it booked on the rollers on 12th September so not too long to wait but in the meantime I've been hearing some substantial pinking under light throttle load at around 3000rpm. After studying the map it was easy to see why!!
http://i27.photobucket.com/albums/c1...nitionmap1.png
After some effort on the phone with my mate Matt from United Motorsports we managed to end up with this.
http://i27.photobucket.com/albums/c1...nitionmap2.png
It's far from perfect but atleast we know it's not going to blow holes in pistons while I'm running it in before the rollers.
Got the fuel played around with aswell, managed to get it to lambda 1 +/- 0.05 which again isn't perfect but we know it wont melt anything before the guys at Track and Road work their magic.
http://i27.photobucket.com/albums/c1...g/fuelmap1.png
Next major job will be sorting the inner rear quarters as they're rusting away merily, also need to sort out the roof where the helmet that had the car before welded in a sheet of steel to cover the sunroof hole and then added 15mm of filler. Has anyone ever re skinned a roof??
Helmet. Reskinning a roof is piss easy ;) good spot weld drill amd an aitr drill or battery drill that you can drill alow andateady on. Takes about 1.5/2hrs too remove once screens out :)
Can you write that in English not Northern please Phillip? Cos I can't understand your accent!!! ;)
would it make sense just to heat wrap the manifold and first part of the system? to reduce the temps.
Got home a little earlier than planned today.
I'm moving soon and have had this tailgate in the workshop for ages, finally got it on tonight.
http://i27.photobucket.com/albums/c1...E31F954CF7.jpg
Although it's not a perfect example of a tailgate it fits the "rat" theme quite well.
Few things to do this Saturday before rolling road next Friday, somehow I've managed to put the ARB too far forward so the front brackets don't actually hold it!! Can here it rattling up and down when driving!!
im going to attempt something with the roof before I go down the route of roof skin replacement. I have purchased a new roof skin but after reading Benn's thread about it, I'm being a girl about it and don't want to tackle it!!
Also going to fit the corsa "quick" rack, not technically quick but at 2.7 turns L2L it's better than the standard one!!
Need some SR bumpers, don't like the black ones!!
Fitted the new rack today, it has completely transformed the car!! The steering really feels so much more positive.
On the downside, chipped my windscreen on the way home from a 150 mile running in trip!!
Need a new screen, any suggestions where to source one?
Looking good mate! Will keep an eye on this.
Helmet lol
Haha
So decided to have a go at the peeling fillered sunroof mod carried out by the previous owner yesterday.
It had cracked in multiple places and the water had got in to rust the plate underneath and pop the filler, got the scraper out and peeled that off until i got back to solid filler.
http://i27.photobucket.com/albums/c1...21D43C20ED.jpg
With all that done set about fitting the 1.5mm ally packer plate to the car, drilled and countersunked bolts with nyloc nuts. No pics of this cos I forgot!!
Onto filler and sanding. I've never so much as filled a dent before, I watched a you tube video and just got stuck in.
This took me the best part of 5 hours, in the end I decided it was as good as I could get it.
First fill
http://i27.photobucket.com/albums/c1...478EF29C20.jpg
Sanded
http://i27.photobucket.com/albums/c1...65B17F3A63.jpg
I put another coat of filler on and sanded it back again but can't find the pics of that!!
Here in filler primer.
http://i27.photobucket.com/albums/c1...3A6714C0E1.jpg
Picture looks better than real life, I wasn't entirely happy but after 5 hours I was aching and ready for the next bit!!
Wont be to a lot of peoples taste but I'm no sprayer so thought this would look ok, better than rattle cans anyway.
Before being cleaned
http://i27.photobucket.com/albums/c1...A75BADDA0A.jpg
Clean
http://i27.photobucket.com/albums/c1...29D21596_1.jpg
http://i27.photobucket.com/albums/c1...CF7CD2C77A.jpg
http://i27.photobucket.com/albums/c1...A4A22CC6_1.jpg
The only bit I'm not happy with is the bottom of the picture where it folds round to the screen. I couldn't get the hair dryer out as it was getting late but will do it in the morning, there are no kinks or creases in the actual roof vinyl, it's just where it's folded at the front.
Overall I'm pretty please, can still see where I fitted the ally sheet but I'm ok with that, it's a story to tell!!
Not really to my taste, but fair play to you for giving it a go.
Better than all the clag, cause Christ that is sh*t. Wrap looks better, just a shame about the creases on the corner.
it looks good :p i love the carbon texture :)
http://i27.photobucket.com/albums/c1...D162FEF0CA.jpg
http://i27.photobucket.com/albums/c1...28B01228AD.jpg
http://i27.photobucket.com/albums/c1...349979342B.jpg
Fixed this morning mate, not perfect but better than last night!!
Bit better, ouch at the sunroof marks tho... See why you wanna reskin it.
Yeah to be honest mate it's the photo!! It doesn't look quite so sad in person!!
Still needs a re-skin, which I will get round to. Just fancied having a go at it really, I would have been better off with a 3mm ally plate instead of the 1.5 that I used but you live and learn!!
Yeah, photos show alot up. It's good enough, means you can use it ok..
Decided to start work on my switch panel today, before everyone tells me how crap it looks it is mock up only, I've got some DPDT toggle switches for the windows, had to mount the original switches back in cos of RR tomorrow and needing the windows working.
http://i27.photobucket.com/albums/c1...DD963BAB5E.jpg
Mounted a 4-way fuse box on the back side of the centre console to supply power for the cigarette lighter and interior light along with the windows once the proper switches arrive.
http://i27.photobucket.com/albums/c1...B843A1AC24.jpg
Mocked up in place, got the windows and the cigarette lighter working to charge the laptop on the way to the RR tomorrow.
Doesn't look too sad in place.
http://i27.photobucket.com/albums/c1...14FBE6E5B7.jpg
Wires under the steering wheel to be tidied when the whole lot is re-wired, I'm constantly adding to that wire run so there's no point wrapping it yet.
So, it's been a while.
Quite a bit has gone on, after fitting the Jenvey throttle bodies the original 20XE the car came to me with developed more leaks than a Norfolk leak farmer in high season. Both crank seals, sump, 5th bearing cap, it was a mess. I took the decision (as I was incredibly busy with work) to have an engine assembled for me by a well known someone else.
This engine was a standard engine with a bit of head work, nothing major. Got this engine built for a reasonable price, got it back to mine and in the car, running well, got it to the rolling road, start to map the fuel and ignition, as soon as we dial in the ignition we get some serious big end rattling. At this point I believed it to be an oil pump failure, so parked it in the garage and pretended the car didn't exist, after spending 3 months in the garage as I was rather brassed off having wasted £350 on a useless RR session, I finally decided to get the engine out the car and have a look at what was going on.
http://i27.photobucket.com/albums/c1...707F33CCF4.jpg
Standard shells clearly 000
http://i27.photobucket.com/albums/c1...D10930A1EA.jpg
Clearly an undersized big end. Big ends should be 48.970 - 48.988. quite clearly 0.22mm too small for standard shells. suspiciously close to a 0.25mm big end grind.
Anyway, after a bit of soul searching I quickly decided that you can't trust anyone, no matter how good they claim to be, the only way to do anything in life is to do it yourself.
So, got my original engine apart, cleaned, inspected, new shells, rings, gaskets, back together.
http://i27.photobucket.com/albums/c1...F32719F896.jpg
http://i27.photobucket.com/albums/c1...1AF0548B6E.jpg
http://i27.photobucket.com/albums/c1...6AF555F21E.jpg
http://i27.photobucket.com/albums/c1...6BA49233A9.jpg
http://i27.photobucket.com/albums/c1...8CD803C64A.jpg
http://i27.photobucket.com/albums/c1...832A4EB30B.jpg
http://i27.photobucket.com/albums/c1...61A736A579.jpg
http://i27.photobucket.com/albums/c1...B7F3BE0420.jpg
So with this built, I slung it back in the car, got it running and up to Jim and Steve at Track and Road in Essex.
http://i27.photobucket.com/albums/c1...60CE07C7F2.jpg
http://i27.photobucket.com/albums/c1...A10811C4AD.jpg
4 hours and 3 cups of cold tea later, this is where we ended up.
http://i27.photobucket.com/albums/c1...A88A68E8_1.png
http://i27.photobucket.com/albums/c1...EDCB4BD44F.jpg
Dialling out a bit more ignition we got it up to 187.1 BHP and 149.5 Ft/lb of torque, I need to up the rev limit to 7400 rpm and we should see another few BHP as the power curve is still rising as the limiter comes in at 6800 rpm. I need to fit the ARP's I've got in the garage, I didn't fit these during the engine build as I wasn't sure on the chamfering, I now know what to do and will get onto it within the next week. Might see 193 BHP with a slightly higher limiter.
https://www.youtube.com/watch?v=FZOjXrAToTk
Just so no one points it out the green power figure on the screen is power at the wheels, with run down transmission losses calculated the RR said 187.1 BHP as shown on the graph, the pictures above and video were taken from an earlier run while we were still playing with the ignition advance a WOT.
So in summary, you want it done right, do it yourself, trust no one!!!!!
how come you never went further with the engine that failed? surely its the guys fault who built it with wrong size bearings?! i'd be cheeses off if he didnt pay for it all!