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  #1  
Old 17-01-2010, 11:58 PM
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Default My Project

My big ends were on my way out so i have decided to take my engine out and try and rebuild it myself... As the engine is out i am going to turn it into a little project. Just got the Inlet manifold back from being powder coated red.

Photo's so far..
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File Type: jpg SDC11019.jpg (96.7 KB, 53 views)
File Type: jpg SDC11035.jpg (96.5 KB, 61 views)
File Type: jpg SDC11036.jpg (93.8 KB, 50 views)
File Type: jpg SDC11037.JPG (66.5 KB, 54 views)
File Type: jpg SDC11028.jpg (95.1 KB, 53 views)
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1.6 Terzo........ Non turbo.............http://www.surreyscoobies.co.uk/foru..._vehicle&id=87

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  #2  
Old 18-01-2010, 12:09 AM
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On order.
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Old 18-01-2010, 12:15 AM
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Looking forward to following this one.
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Old 18-01-2010, 01:45 AM
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Looking forward to following this one.
Cheers mate, i'm looking forward to have my car back in working order
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Old 18-01-2010, 08:59 AM
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Good to see someone else home brewing
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Old 18-01-2010, 10:01 AM
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Good to see someone else home brewing

Thanks CJ....
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Old 18-01-2010, 10:02 AM
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Looking good mate

Will be keeping an eye on this thead, looks a goodun
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Old 18-01-2010, 10:15 AM
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Looking good mate

Will be keeping an eye on this thead, looks a goodun
Cheers Chunk, this is the first time i have done anything this serious so lets say that i am taking my time....
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Old 18-01-2010, 10:19 AM
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At least you are having a go. Loads of people on this site who can lend a hand
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Old 18-01-2010, 11:04 AM
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Good to see someone else home brewing


Good luck with the build and many thanks for posting on SES

Never get tired of threads like this
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  #11  
Old 18-01-2010, 11:32 AM
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At least you are having a go. Loads of people on this site who can lend a hand
True, plus it is a hell of a lot cheaper.... :thumb:
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Old 18-01-2010, 11:36 AM
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Good luck with the build and many thanks for posting on SES

Never get tired of threads like this

Thanks MR X..... Should have the heads off weekend, depending on how it goes......
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Old 19-01-2010, 12:46 AM
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Instead of gaining on power i seem to have lost quite a few horses. I have done it all backwards, from 240hp i seem to only be on 1mp
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Old 19-01-2010, 12:50 AM
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I see you got it on here before I did....
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  #15  
Old 19-01-2010, 12:54 AM
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I see you got it on here before I did....
Had to Stiggy.... i don't want no surprises now...
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  #16  
Old 19-01-2010, 01:14 AM
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Can't wait to see the end product of this.

I wish I had the knowledge to do this kind of thing, hats off to you mate
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Old 19-01-2010, 01:28 AM
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Can't wait to see the end product of this.

I wish I had the knowledge to do this kind of thing, hats off to you mate
Cheers worzel, i can not wait to drive my car again.....

This is all new to me i have only ever done this sort of thing on mopeds, i have basic knowledge but this is all new to me!!! Fingers crossed though...
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Old 19-01-2010, 03:13 AM
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Originally Posted by Tyler T 299 View Post
Cheers worzel, i can not wait to drive my car again.....

This is all new to me i have only ever done this sort of thing on mopeds, i have basic knowledge but this is all new to me!!! Fingers crossed though...
Full respect then sir, I would like to do more on mine but I just have not got the equipment and time to do it, what are the piston pack you have pics of and where did you get them from please buddy, and whats the benifit? sorry about the many questions, but doing my homework for later this year
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Old 19-01-2010, 10:09 AM
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Full respect then sir, I would like to do more on mine but I just have not got the equipment and time to do it, what are the piston pack you have pics of and where did you get them from please buddy, and whats the benifit? sorry about the many questions, but doing my homework for later this year
Cheer's matey..... The piston pack is off ebay and the Pistons are CP Forged pistons, the conrods are Manley conrods (lol), from what i know (which is not alot by the way) the forged pistons are stronger then the originals i think they are solid compared to the originals and the metal's used are stronger, i think the set comes with top end bearings, locking clips, piston rings and ARP2000 bolts for the conrods, i still got to get the Big end bearings which i am having a little problem finding....

The pistons and conrods i have ordered have been tested upto 700bhp according to the company, obviously that is with the supporting mods, also once out i have a tool to Glaze bust the bores, which i have been advised to do. I will post up Pics as i do most of this anyway so it makes sense... I hope this makes sense to you and is correct, i am sure if i am wrong some kind person will set me straight.....
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Old 19-01-2010, 07:07 PM
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looks good so far mate, keep up the good work, look forward to updates
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  #21  
Old 20-01-2010, 10:19 AM
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Cheers Andy.
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Old 20-01-2010, 03:46 PM
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Tyler, random question...

Where did you get that uber tent from!? i want one very much so!
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  #23  
Old 20-01-2010, 04:31 PM
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Quote:
Originally Posted by Tyler T 299 View Post
Cheer's matey..... The piston pack is off ebay and the Pistons are CP Forged pistons, the conrods are Manley conrods (lol), from what i know (which is not alot by the way) the forged pistons are stronger then the originals i think they are solid compared to the originals and the metal's used are stronger, i think the set comes with top end bearings, locking clips, piston rings and ARP2000 bolts for the conrods, i still got to get the Big end bearings which i am having a little problem finding....

The pistons and conrods i have ordered have been tested upto 700bhp according to the company, obviously that is with the supporting mods, also once out i have a tool to Glaze bust the bores, which i have been advised to do. I will post up Pics as i do most of this anyway so it makes sense... I hope this makes sense to you and is correct, i am sure if i am wrong some kind person will set me straight.....
If you need and machineing done Steve at Roland L. Alsop otherwise known as SMG is your man and will also sort you out with any gaskets , seals ,bearings & cosworth parts you could ever need . Used him for mine and very happy with the prices .To deglaze/ hone block & resurface heads and block £95 +vat
Their in Chobham Tel 01276 858073
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Old 20-01-2010, 05:32 PM
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If you need and machineing done Steve at Roland L. Alsop otherwise known as SMG is your man and will also sort you out with any gaskets , seals ,bearings & cosworth parts you could ever need . Used him for mine and very happy with the prices .To deglaze/ hone block & resurface heads and block £95 +vat
Their in Chobham Tel 01276 858073

You read my mind CJ that was going to be my next question, i am going to Glaze bust the bores myself, but like i said i was having problems finding decent gaskets and big end bearings. Do they do high performance bearings and gaskets?
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Old 20-01-2010, 05:44 PM
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Tyler, random question...

Where did you get that uber tent from!? i want one very much so!
Spooky there is a place on the A22 in Godstone, it is the main road to eastborne, it is a big camping shop loads of tents outside... This one is a 5 birth tent, set my old man back around £400, but that was a while ago.. I think now they go for around £250-£300...

Hope this helps.
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Old 20-01-2010, 07:07 PM
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Originally Posted by Tyler T 299 View Post
You read my mind CJ that was going to be my next question, i am going to Glaze bust the bores myself, but like i said i was having problems finding decent gaskets and big end bearings. Do they do high performance bearings and gaskets?
Yep i got the following from them

ACL 11mm stud kit
ACL race bearing trust & end
Mahle low silicon forged pistons
1.5mm cosworth head gaskets
Cosworth kevlar cambelt
Cosworth cambelt guide
Cosworth baffle plate
All seals for bottom end build
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Old 21-01-2010, 10:48 AM
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Originally Posted by C. J. View Post
Yep i got the following from them

ACL 11mm stud kit
ACL race bearing trust & end
Mahle low silicon forged pistons
1.5mm cosworth head gaskets
Cosworth kevlar cambelt
Cosworth cambelt guide
Cosworth baffle plate
All seals for bottom end build
Cheers CJ, i should be calling him on the weekend....
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Old 21-01-2010, 11:30 AM
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sooner the better as there is normally 6 to 12 week wait !
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Old 21-01-2010, 12:18 PM
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Will do, cheers matey..
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Old 27-01-2010, 01:09 AM
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Latest update, it has been a slow process, just waiting for the parts to come now, have only got one piston out so far, just need to get one more out, so i can hopefully split the block easier..... Fingers crossed....
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File Type: jpg IMG00019-20100124-1852.jpg (95.3 KB, 28 views)
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  #31  
Old 27-01-2010, 09:12 AM
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What parts are you waiting for?


Keep up the good work, both on the engine and posting up your progress
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  #32  
Old 27-01-2010, 01:18 PM
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I have on order CP Forged pistons, Manley H beam conrods, stage 2 bc cams, titainium valve springs and retainers, ACL race bearing kit, ARP 2000 head studs, and a performance head gasket kit.

Cheers for the support though.... It is needed because sometimes it gets depressing seeing the engine like that..
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  #33  
Old 27-01-2010, 04:01 PM
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sounds good mate are you changing the turbo too?
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Old 27-01-2010, 05:40 PM
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You're a braver man than me pal and kudos to you for it

I've always figured the best way for me to have a nicely uprated engine is to buy a spare and work on it rather than oink my current one out....that way, if I really fubar'ed it I'd still have a car

Keep those updates and pics coming
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Old 27-01-2010, 06:28 PM
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all this excitement is getting me thinking as i have a spare jdm v3 sti lump in my garden it has top end damage could be the start of operation wagon me thinks
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Old 28-01-2010, 11:01 AM
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all this excitement is getting me thinking as i have a spare jdm v3 sti lump in my garden it has top end damage could be the start of operation wagon me thinks:sm:

hurrah!!
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Old 28-01-2010, 04:57 PM
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Andy i will be getting a bigger turbo when i get a new job and save up for it...

Scatz if i had the money that would of been my exact action, i am only doing it myself as money is tight, but to be fair i am enjoying it and i am looking forward to putting the new toys in......

Willis if you have the funds and space to do it, go for it, it starts of daunting, but once you have boxes to put parts in and a tyre pen to label parts nut's and bolts it is not to bad.... Go for it!!!!!!
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Old 28-01-2010, 06:32 PM
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Sounding good mate

Keeping an eye on this thread, looks interesting
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Old 08-02-2010, 10:46 AM
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Cheers Chunk...

Finally got the block split yesterday night, have not been working on the car that much as have been fixing other cars (not through choice) There was a hidden 12 sided bolt hiding behind the remainding ac bracket. Latest pic so far.
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Old 22-02-2010, 07:16 PM
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It's christmas again, my presents have arrived.......
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Old 22-02-2010, 07:42 PM
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Look good mate NOW stop dribbling and get to work on it, you have meetings to attend
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Old 22-02-2010, 08:03 PM
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Will it be in for the weekend !
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  #43  
Old 22-02-2010, 08:04 PM
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Very nice matey.
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Old 22-02-2010, 08:11 PM
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Stiggy believe me i want this done asap...

C.J i would love to have it all in for the weekend but i need a crank as mine is no good, i have spoken to Stew and i am waiting for my mate to get back to me as well, plus i need to pay for my ecu from Simon, also need to get the shims.. Hope to be done within 2 weeks dependant on if there are any more issues... Is there a meet this weekend?

Cheers Worzel..
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Old 04-04-2010, 02:58 AM
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Haven't been able to do much to the engine as i have been preping my bike for the Isle of Man run, but Yesterday i managed to fit the conrods and acl big end bearings as well as the main bearings, crank conrods and seal the block back together. I have also fitted the titainium valve springs and alliminium retainers. Just need to sort the shimes out. I would of had the piston's in today but the cer clips for the wrist pins were to big. So i need to get them tuesday.
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File Type: jpg IMG00020-20100403-0922.jpg (90.7 KB, 29 views)
File Type: jpg IMG00023-20100403-1208.jpg (72.0 KB, 23 views)
File Type: jpg IMG00025-20100403-1210.jpg (89.1 KB, 26 views)
File Type: jpg IMG00026-20100403-1257.jpg (91.9 KB, 26 views)
File Type: jpg IMG00028-20100403-2008.jpg (92.1 KB, 28 views)
File Type: jpg IMG00021-20100403-0922.jpg (95.2 KB, 23 views)
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Old 05-04-2010, 12:32 AM
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I have lapped in the valves, fitted the valve stem oil seals, titainium valve springs and alliminium retainers. I also have torqued the cam caps ready for measuring the shimes.
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File Type: jpg IMG00081-20100313-1407.jpg (96.5 KB, 17 views)
File Type: jpg IMG00082-20100313-1419.jpg (94.4 KB, 19 views)
File Type: jpg IMG00080-20100313-1042.jpg (88.7 KB, 18 views)
File Type: jpg IMG00083-20100313-1519.jpg (94.7 KB, 19 views)
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Old 04-05-2010, 11:10 AM
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It has been a slow process with a few problems on the way but i managed to get the engine in, by myself, i had problems with the engine crane. Managed to sort it out and fitted it in myself... Lets say that there was a few horrible words said in the process but i managed to get it all in. It is all bolted up now pretty much, just need to buy some turbo bolts which i have managed to loose and a turbo oil feed banjo bolt. I am also having a problem putting that release bearing hydrolic thingy majig ontop of the gearbox.... Not good..
Attached Images
File Type: jpg Bores.jpg (90.2 KB, 29 views)
File Type: jpg Engine with one head on.jpg (92.8 KB, 29 views)
File Type: jpg Engine first put together.jpg (92.1 KB, 28 views)
File Type: jpg Engine timed up.jpg (97.5 KB, 30 views)
File Type: jpg Engine just landed.jpg (94.7 KB, 31 views)
File Type: jpg Car out of tent.jpg (99.7 KB, 29 views)
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1.6 Terzo........ Non turbo.............http://www.surreyscoobies.co.uk/foru..._vehicle&id=87
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  #48  
Old 04-05-2010, 11:51 AM
worzel
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Cracking job mate
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  #49  
Old 04-05-2010, 12:23 PM
Spooky Spooky is offline
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Nice one T! Imagine you're going to be nervous when you first turn the key!?
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  #50  
Old 04-05-2010, 01:52 PM
Nige
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Well done mate.
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