Project run Wabbit run ... probably not 56k friendly

[Wabbitkilla]

Pistons and rods are now out, evidence of blowback and although the oil rings move freely they are very compressed and mucky.




Big ends show a little bloom but no.3 is marked, though the crank journal is fine

Compared to


Here you can see the difference in piston design between my 2003 and the later 2005.



So although the pistons and little ends are fine I'm going to swap in the new ones, hone the cylinders and put some new big end shells in all rods.

[Wabbitkilla]

Well today not much done in the way of hardware.
But I have cleaned the front side of the engine


The rest of the effort had involved some travelling and finding some great engineering shops around Manchester which resulted in some changes to plans.

First injectors were dropped in for cleaning and testing at B&J Racing. This is an interesting if cluttered place and they rebuild engines for racing plus big style gas engines. We found some parts that couldn't be refused due to a dropped valve...



Then we popped into Pirtek to discuss pipework for the add on oil cooler, sounds very do-able, will be high quality hydraulic fittings with single wire an-8 pipe.

Next we headed around to a new garage run by an old friend to remove the valve stem oil seals and pick up some new sealant for the sump and end casings.

Dropped the conrods new little ends, pistons, and pins at Contract Engineering in Stockport, Tim's a nice guy and came well recommended from Popes engineering supplies also in Stockport.

We called into RRG Denton to pick up the big ends and new hub nuts and had a look around d the GT86. They have the TRD special edition GT86 in and it looks the business!



While we were discussing cleaning the valves and what to use at Popes we learned of another company Excel Engineering near Bradbury who do a good job in valve cleaning. When we visited we found an excellent workshop where they do crank regrinds, honing, boring, all sorts of stuff. Tomorrow we will be dropping the head, rocker cover, end case, and valves. The guys do soda blasting and it brings heads and casings up like new, they're going to clean the valves too. All at a really terrific price. They did offer to skim the head and cut the valves in but I don't believe anything that radical is required as everything is in really good shape, just a bit of coke.

Lots more cleaning tomorrow and replacing the crank end oil seal behind the flywheel while we wait for the various parts to be ready for collection.

[loadswine]

Excellent progress, this is good stuff!  s:) s:)

[AndyM]

Great reading and good to see so many local businesses getting in on the action  s:) s:)

[puma2]

 s:bowdown: :bowdown: s:bowdown:  have to say what a great Wright up and with pictures just brilliant  s:) s:)  well done all involved in the hands on work.

[Wabbitkilla]

Well, Contract Engineering in Stockport have effectively scrapped my new little ends.


New ones ordered locally and we have a recommendation for another company for fitting them.
Going to collect the new bearings and visit tomorrow.


A bit P'd off at the moment and the guys who recommended Contract will be getting a visit too probably.

[Wabbitkilla]

Engine bay is clean now.



As a bonus I've swapped out both drive shafts for a pair supplied from Mr Bond, my originals had the hub stubs damaged by the garage who replaced the clutch and caused all sorts of problems. Gearbox is off, clutch out, and flywheel removed.
We found the best way to remove the flywheel bolts was by chocking the flywheel with a wooden block against a clutch mount tab and using an electric torque gun on the bolts. We're cleaning the end of the engine before fitting the new seal. It's not leaking but it's been on there a long time through crazy heat cycles, and a new one comes in the overhaul kit.

Today has had its downs, but some good highs.
News on injector testing shows they're all functioning perfectly with one down about 1cc, and that's before cleaning   s:bounce: :bounce: s:bounce:   not bad for 115K miles eh?

I'll post a summary when we're finished so you all can understand what your engines are likely to be needing at this kind of mileage. I can think of one or two friends who are maybe ignoring stuff that could come to bite them.

[nathanMR2]

Looking good. Be good to have an idea of the prox costs involved in this too Nic

[Wabbitkilla]

Injectors are back, all cleaned and testing spot on.

New little ends have been collected and delivered to a very reputable company called Quasar Engineering in Stockport. Quasar do work for companies all over the country including Ferrari and Rolls Royce. It does mean a delay beyound the planned re-install day of Saturday though. Hopefully it will be worth the wait. A strongly worded letter will be winging it's way to the other company, and many thanks to RRG Denton for supplying the parts so quickly.

Cleaning the block has carried on today and we had a very welcome visit from FGrob, good to see you mate   s:D s:D  

We have also been working out the location of the new oil cooler and the length of the pipes, it should be quite neat.

[FGrob]

Injectors are back, all cleaned and testing spot on.

New little ends have been collected and delivered to a very reputable company called Quasar Engineering in Stockport. Quasar do work for companies all over the country including Ferrari and Rolls Royce. It does mean a delay beyound the planned re-install day of Saturday though. Hopefully it will be worth the wait. A strongly worded letter will be winging it's way to the other company, and many thanks to RRG Denton for supplying the parts so quickly.

Cleaning the block has carried on today and we had a very welcome visit from FGrob, good to see you mate   s:D s:D  

We have also been working out the location of the new oil cooler and the length of the pipes, it should be quite neat.

Hi Nic.

It was a great bit of therapy to see both Ste and yourself - plenty of coffee as usual  s:D s:D  , the car is looking great and will give you another 100K once you've finished it, interesting point about the stem seals, puts a different light on the pre-cat issue and certainly one that needs also to be taken into account.

Guess what ------------  I ran the Spit tonight for the first time since Sept last year,   s:bounce: :bounce: s:bounce:    s:bounce: :bounce: s:bounce:    s:bounce: :bounce: s:bounce:  God I forgot how much the old engines stink on choke - had to change my cloths it was that bad   s:flame: :flame: s:flame:    s:flame: :flame: s:flame:  - but boy does it sound good with the twin pipes and it's certainly got some compression   s:scared: :scared: s:scared:    s:scared: :scared: s:scared:  

I'll post some pic's in my other thread now the engine bay is finished.  s:D s:D    s:D s:D  

See ya soon.  s:wink: :wink: s:wink:  

Rob.

[Wabbitkilla]

Cylinder head is back from soda blasting and valve cleaning, looking very nice.




Ready for valve lapping

[Wabbitkilla]

Intake valves lapped in


Exhaust valves lapped in


Oil cooler pipework is ordered with stainless fittings.  s:D s:D  

The casings are a bit too corroded to come up well with soda blasting so now they're this clean I'm going to paint them.

[Wabbitkilla]

Worked a little late tonight, we're in the putting things together stage now ... What a relief.
Still waiting on the little ends and conrods.

Valves and springs reinstalled in the head now.

If you're going to do this it's best to have two people working on it and a clean relaxed atmosphere, it takes some concentration to get the keepers to settle into place before relaxing the spring compressors.

[Mike_V]

Superb work Nic and Ste.

[Wabbitkilla]

Rocker cover painting is complete, accidentally custom style


Chain casing was rough but has taken the paint reasonably well


Oil cooler in the process of being fitted


I've replaced the drivers door mirror to boot, mine was scraped and cracked by idiots squeezing a vehicle past when took out the drivers wing a while back.

[Wabbitkilla]

Oil cooler in final position


Should get a bit of airflow

[Two's Company]

How does it cool the oil?

[Wabbitkilla]

How does it cool the oil?

There is a sandwich plate goes between the engine and oil filter with a thermostat in it. At 80 degrees it opens and the oil is diverted through this cooler. The air flowing into the side intake does the rest.

[Two's Company]

Do you know how hot the oil has been running without it?

[Wabbitkilla]

Going by the smell when we took the head bolts out .... too warm   s:lol: :lol: s:lol:

[Wabbitkilla]

Stuck waiting for parts today, we gave the cylinders a light hone ready for installing the new pistons



Oil cooler pipes will be ready tomorrow from Pirtek.
Hoping conrods will be ready tomorrow from Quasar.
Will be picking up some shiny stainless bolts for the rocker cover and chain casing.

Will be nice putting things back together.  s:D s:D

[E]

Looking good   s8) s8)

[Wabbitkilla]

Still waiting for the conrods to be ready, getting bored.

Heat protection added to cross-member


Heat protect for the bulkhead where the new oil cooler pipes will pass, sorry it's a bit blurry but you get the idea


Question, do I re-attach this label?

[K T M Rider]

Superb work Nic and Ste.

+1

[Wabbitkilla]

Finally the new little ends have been machined and ready, £150 but done properly this time.

Pistons are mow fitted.


Tomorrow is the day we start putting things back together  s:grin: :grin: s:grin:

Got a bunch of stainless bolts today for the rebuild.