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#1
16-02-2010, 02:28 PM
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2.15 Stroker P1 Project
Thought i might start up a project thread on here so people have a vague idea who i am when i finally make it to some meets once this is finished!
You guys made me very welcome and I have some interesting shot of the build process so thought it might be nice to share. Car started smoking one morning on cold start so it got taken to Chris Palmer Auto's in Bristol for Spencer to take a look at. They found masses of petrol in the sump. 600 hydro carbons to be precise! Told this would normally be below 100. The cause it still unknown until my engine is stripped down but look like piston 4 has an issue – Compression Test Results: Pistons 1-3 = 155-160psi, but number 4 down to 135psi. Leak Down Test Results: 1-3 = 10-15% but number 4 = 22%. Spark plugs: 1-3 were black where it had been running lean and number 4 had a fine glaze of oil over it. There was a small amount of tiny swarf particles found in the sump. Bores and top of pistons and valves etc look of with the camera (although he can’t seen them too well with the camera) but it’s feared the side of the piston might be where the issue lies, and the small bits of swarf could have blocked but the oil pump cause the loss in pressure. So anywho I had to make a decision and after about a month of research bugging the hell out of other specialists, mappers, and Techy gurus I opted to go for a 2.1 Stroker Kit, capable of 550bhp. I only wanted to rebuild once and didn’t want to be restricted by the build spec, this is what we decided on: Actual build outsourced to Advance Automotives, build by Nick Johnson. Closed Deck Block with under piston oil squirters Striped, cleaned, honed and bored Rear thrust converted 14mm head stud converted Machined block faces and modified oil ways 2150cc Stroker kit New 2.5 STi nitride crank cross drilled Manley steel H section rods and ARP2000 bolts Mahle 2618 race material lower deck stroker pistons, rings and pins ACL full RACE bearing set Full gasket/seal set 0.6mm 3 layer Cometic head gaskets ARP 14x12mm head bolt set Skim and clean cylinder heads 12mm RCM modified high flow oil pump New cam belt, rollers, and tensioner New modine oil cooler New sump pan and pick-up New water pump Fuel lab 3 port adjustable FPR with braided lines and pressure gauge Reversed fuel rails Cossie sump baffle plate RCM light-weight pulleys nickel plated Cool running thermostat. Then for uber-blingness I am getting parts painted or powder coated in 74F / Red / Black and replacing bolts with shiny stainless options: Painted block Rocker covers Header tank PS pump reservoir Timing belt cover Pulley cover Fan shroud Rad brackets Fuse box cover Ancillary brackets holding alternator / air-con / PS pump etc I already have: Engine External: HKS 3” Hi-Power Strait through Centre pipe HKS 3” Hi-Power back box H&S 3” Decat downpipe GT spec Gen II Tubular unequal length headers, Harvey Smith Custom up-pipe, Headers DEI Titanium heat-wrapped Up-pipe DEI Titanium heat-wrapped Downpipe DEI Titanium heat-wrapped RCM Hi Flow Induction, Lateral Performance MD321T Turbo, Power Enterprise 550cc flow matched injectors, Bob Rawle Remap, Walbro 255 Fuel Pump, NGK PFR7B spark plugs gapped to 0.6, 3 port boost control solenoid, Ported throttle body, Insulating manifold spacers, Header tank spacers, GT spec Gen II FMIC, J Performance High capacity Aluminium Radiator, Exedy Single Plate Organic Clutch, Fidanza 4.4kg Lightweight Flywheel, Prodrive Slam Panel, Full Samco setup. Heavy Duty Battery, Hot coolant throttle body mod. HKS SSQV DV, SETRAB 26 row Oil Cooler with custom made stainless braided lines Group N Engine mounts PowerFlex Polyurethane Exhaust Hangers Handling: Prodrive Alcon 330mm Brake Upgrade, 330mm Godspeed Rotors 316mm rear Brembo 2pot conversion, Whiteline 22mm adjustable ARB, Whiteline rear Droplinks, Whiteline front sway bar bushes Whiteline steering rack bushes Whiteline front anti-lift kit, PowerFlex Wishbone Bushes Prodrive geometry Stage 1 fast road setup, Anodised blue split bells, F+R Braided Hoses, Ferodo DS2500 Pads, Goodyear Eagle F1 tyres 
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#2
16-02-2010, 02:30 PM
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Here’s the build so far…
Sourced myself a Closed Deck Block pair with under piston oil squirters –   Worried by this at first, but once taken to 92.5mm it wouldn’t be an issue as it would machine out.  Block cases @ Advanced after inspection  UV crack testing  Pressure testing  Measuring bearing parent bores  14mm head-stud conversion  Rear thrust conversion  Bore alignment template before rebore  Bore to 92.5mm    Cleaning the cases      Crankshaft assembly          And that’s where were at at the moment! My engine and heads are all coming out the car next week so should have some more pictures then! Cheers! Spooky
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#3
16-02-2010, 02:42 PM
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I'm liking this thread matey.
 Can't wait to see the progression of this one 
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#5
16-02-2010, 03:52 PM
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Crikey.....13 posts then this....you know how to make an entrance!
Good luck with it!
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#7
16-02-2010, 04:16 PM
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Quote:
__________________
Eat, Sleep, Race , Repeat
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#9
16-02-2010, 04:21 PM
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Quote:
Actually, ignor the later, i just saw your post on my 22b thread! How does it sound!?
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#10
16-02-2010, 04:23 PM
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I can guarantee it sounds the dogs, been for a blast in CJ's and it sounds fookin great!
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#14
16-02-2010, 05:28 PM
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Quote:
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#17
17-02-2010, 09:56 AM
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Out of interest. Who is doing your mapping?
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#18
17-02-2010, 10:05 AM
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Quote:
Next choice would have been Paul Blamire or Pat Herborne.
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#19
17-02-2010, 11:28 AM
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I used Bob for my mapping before the engine change. He is spot on. Used to enjoy the drive home from Swindon
I am now using Simon JGM, the legend in the making. Got a sesh with him on Friday at Surrey RR, along with a few others from here.
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#20
17-02-2010, 11:48 AM
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Quote:
So what have you changed since you last map Mr.Wozel sir ? Can I come and spectate?
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#21
17-02-2010, 12:20 PM
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RCM Induction Kit fitted yesterday, new simtek map being fitted by JGM on Friday at SRR.
CJ, Nick (Blue Bugeye), Simon and I will be there from about 10.30am I expect. Plus others I expect. More than welcome to come and watch if you want to.
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#22
17-02-2010, 01:23 PM
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looking very good, whos doing your maching work?
__________________
all over it jaffa style!!!
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#23
17-02-2010, 01:55 PM
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Thanks Tone. All the machining and building is being done by Nick Johnson @ Advanced Automotives. He is closely affiliated with RCM and does some work for them when they are too busy...
The engine removal, head removal, redress and refit plus all my toys are being done by Spencer Chard @ Chris Palmer Autos...
__________________
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#24
17-02-2010, 02:43 PM
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So............ a cheap rebuild then
 Yet another cracking project to watch on here.
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#26
17-02-2010, 03:25 PM
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Quote:
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#27
17-02-2010, 03:31 PM
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Cool, the more the merrier.
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#28
17-02-2010, 03:34 PM
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Lets stop Hijacking this thread and move our session conversation to a suitable home. I'll get something in General going.
 Sorry Spooky, you can get your thread back on track now 
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#29
17-02-2010, 03:38 PM
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Quote:
Cheers Worzel 
__________________
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#30
18-02-2010, 12:24 PM
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Love it, doing a rebuild myself but i dont think i have the sort of money you have....
 Looking forward to the end result, keep up the posts flowing.....
__________________
1.6 Terzo........ Non turbo.............http://www.surreyscoobies.co.uk/foru..._vehicle&id=87
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#31
23-02-2010, 11:06 AM
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Latest update, bottom end is now complete
Just waiting for Spencer to whip out my old engine and get the cylinder heads off and over to Nick for long build to be completed.                Also got this pic sent to my phone late last night… Rocker covers, PS tank, Header tank, various front end bolt on block brackets all tarted up! Just need to paint my timing belt cover, and a few other things and I’m done. 
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#32
23-02-2010, 11:39 AM
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excuse me
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#36
25-02-2010, 11:33 AM
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Just a wee update.
Ordered an RCM billet timing belt guide HKS LTD Edition Rad Cap (1.1) HKS Oil Filler Cap Tuesday night I took a road trip to pick up my powder coated bits. Got some nice new shiny bolts for them today! Not sure how the Allen key style will go down on the rocker covers, but no biggie to change them back over. PS Pump Reservoir and Header Tank    Rocker Covers    And just another shot of the Aircon / alternator / PS brackets / Slam panel brackets   Also got a few bits sand blasted for me to spray myself in 74F blue, will post picks when they are done. Will be picking up the MD321T Saturday morning and most likely adding a few more things to the list while I’m at the garage. Really really looking forward to Saturday! I get to see my car again, I haven’t seen it since 01/10/09 
__________________
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#37
25-02-2010, 01:22 PM
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Mate, that is a lovely pile of BLING!
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#39
27-02-2010, 06:13 PM
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Took an early morning road trip with my mate dan to Bristol this morning to see the crazy west country folke and drop off my blinged up goodies!
took a stop off on my way to collect my new tubby too. Wasn't a great start me on the phone to Matt both saying were in Costa coffee before realising we were at different services, but a burger king and 10 miles later i picked up this baby, Lateral MD321T    Got to CPA and after a cuppa when to have a butch at my baby, she looked so lonely tucked away in the back, cold, with the lights off   Fitted a new headunit while i was there and done some shiny nut and bolt replacements under the bonnet   Before leaving tucking her back in for the weekend...  Estimated time of completion is about 3 weeks, so long as i don't ad anything else to the list. Although i did add a few more things to the list already today, DOH!
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#40
15-03-2010, 03:43 PM
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Small update, not much interesting to post until the engine comes out tomorrow and gets stripped. Hopefully this will happen to make sure i'm ready for the 26th!
Lateral Performance Custom 76mm Hybrid Inlet pipe with breathers blocked off. Lateral Performance MD321 series fitting kit. 
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#41
15-03-2010, 04:07 PM
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Quote:
Very Very nice mate...
__________________
1.6 Terzo........ Non turbo.............http://www.surreyscoobies.co.uk/foru..._vehicle&id=87
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#43
15-03-2010, 04:24 PM
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This really is going to be another stunner
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#46
15-03-2010, 04:42 PM
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Ridding Your System of Impulse Buys!
I wish we all had a pound for every time we had said that.
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#48
15-03-2010, 05:58 PM
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Nice to see someone doing it right Spook. That will be a lovely pice of kit when finished mate, good on yer......... and it's a P1
Only 700 left world wide now and I know of 3 that have gone from a nice road car to a stripped track car. Are you coming to the 10th Anniversary at Prodrive ? I have not checked the list by 80 P1's have confirmed and I have booked the Holiday Inn at Banbury (Nr Prodrive) on Sat 8th of May. P1's all meeting up in lay by then all 80 are driving in convoy to Prodrive to meet up with other clubs. Holiday Inn - Banbury (Reception 01295 234567)
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#49
15-03-2010, 06:03 PM
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Cheers Fudge! I can't wait to drive it again, it feels like i have butterflies in my stomach 24/7 for the last month or so, the wait is agonising! Maybe i'll pop down to Tonbridge one night and meet up in an effort to clock up some running in miles?
I think that will be a plan Clive, what time are you heading up there on Saturday roughly? could get a convoy together and tie it in with a bit of grub and a few beers? Will speak to me mates who are along for the ride and sort out sleeping arrangements!
__________________
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#50
16-03-2010, 01:51 PM
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Yeah that would be good Spook.
Regarding Sat 8th I can arrange the time around you and your convoy. I reckon if we get to Banbury for early evening, then have a meal and a few gallons at the hotel Feel free to use some milage driving to Tonbridge. I can take you for a spin to give you an idea of what 560 is like in a P1.
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