Bub's engine starts its transformation
Cap'n slog:
Wednesday 9th Jan 2019
Arrived at work to find, a full top end engine rebuild kit and a supercharger kit, nice!
Problem; no ignition kit. Contacted Joe Blow who basically said 'oops, I didn't spot your message adding it to the order' so now I'm waiting a few weeks for that to arrive. Ah well, I can get on with everything else
Thursday10th
Today I started the engine rebuild. With the engine on the bench I stripped off the tinware (the thin metal covers that direct the air around the cylinders), removed the fan and alternator and gave the engine a quick clean.
Next, the rocker covers unclip, the rocker rail comes off with 2 nuts and then 8 nuts later, the cylinder head was off. The cylinders came off with some persuasion with a rubber mallet and the pistons come off with a removed circlip and a tap with a long screwdriver to push the gudgeon (wrist) pin out.
As the great philosopher Haynes says "replacement is the reverse of removal". The new cylinders and pistons go back on but without removing the pistons first. Pushed out enough to access the gudgeon pin, one of the retaining circlip is put in the piston/cylinder gently pushed into place and the pin pushed home. The biggest hassle is getting the conrod and piston lined up correctly - fiddly but not difficult.
The new cylinder head is unleaded ready with big valves and is made of thicker material for better longevity. Easily and quickly fitted.
2 hours and half the engine was done in time for lunch. The afternoon saw the other 2 cylinders done, and work started on fitting the remote oil cooler.
The engine doesn't look much different but for the new graduated pulley from the Joe Blow Supercharger kit.
Remote oil cooler
Its an Empi 48 plate cooler which I will mount either on the roll cage or in the back of the car where it gets a decent amount of airflow.
One problem is I have to change the oil regulator spring and plungers and those bolts are notoriously difficult to remove. One loosened with lots of heat and luck but the front one will require serious and destructive efforts. New, hex head ones have been ordered.
Friday 11th
Fuel pump has been ordered (I thought I'd bought one already but clearly not) along with a couple of oil filters (cheap one for running in then a proper racing one) so that allows work to continue on the engine next week.
The fuel pump will live under the fuel tank at the front and will have a secret switch as a theft prevention device.
Jobs to do before initial road testing
Wednesday 9th Jan 2019
Arrived at work to find, a full top end engine rebuild kit and a supercharger kit, nice!
Problem; no ignition kit. Contacted Joe Blow who basically said 'oops, I didn't spot your message adding it to the order' so now I'm waiting a few weeks for that to arrive. Ah well, I can get on with everything else
Thursday10th
Today I started the engine rebuild. With the engine on the bench I stripped off the tinware (the thin metal covers that direct the air around the cylinders), removed the fan and alternator and gave the engine a quick clean.
Next, the rocker covers unclip, the rocker rail comes off with 2 nuts and then 8 nuts later, the cylinder head was off. The cylinders came off with some persuasion with a rubber mallet and the pistons come off with a removed circlip and a tap with a long screwdriver to push the gudgeon (wrist) pin out.
As the great philosopher Haynes says "replacement is the reverse of removal". The new cylinders and pistons go back on but without removing the pistons first. Pushed out enough to access the gudgeon pin, one of the retaining circlip is put in the piston/cylinder gently pushed into place and the pin pushed home. The biggest hassle is getting the conrod and piston lined up correctly - fiddly but not difficult.
The new cylinder head is unleaded ready with big valves and is made of thicker material for better longevity. Easily and quickly fitted.
2 hours and half the engine was done in time for lunch. The afternoon saw the other 2 cylinders done, and work started on fitting the remote oil cooler.
The engine doesn't look much different but for the new graduated pulley from the Joe Blow Supercharger kit.
Remote oil cooler
Its an Empi 48 plate cooler which I will mount either on the roll cage or in the back of the car where it gets a decent amount of airflow.
One problem is I have to change the oil regulator spring and plungers and those bolts are notoriously difficult to remove. One loosened with lots of heat and luck but the front one will require serious and destructive efforts. New, hex head ones have been ordered.
Friday 11th
Fuel pump has been ordered (I thought I'd bought one already but clearly not) along with a couple of oil filters (cheap one for running in then a proper racing one) so that allows work to continue on the engine next week.
The fuel pump will live under the fuel tank at the front and will have a secret switch as a theft prevention device.
Jobs to do before initial road testing
- Finish the engine, obviously
- Fit the fuel pump
- finishing fitting the headlight bezels
- get the seats to fit properly so they don't jump out the rails
- finish fitting the seatbelt extensions
- set up the rear coil over shockers
- Tidy up wiring for rear lights
- Buy and fit a horn
- fit new front springs, inserts (shocks) and bump stops
- make up additional wiring loom for accessory sockets - especially one for my heated fleece
- Figure out a number plate mount and reversing lights
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