V6 mk3 project thread ( vid added Page 8 + page 10)

paul Woods · October 3, 2007, 06:23

hi guys,basically the jig bolts into a normal mk3 engine bay and allows me to weld the drivers side engine mount plates onto the chassis in exactly the right place without having to dummy fit the engine at all.....then when the engine is fitted i know its going to sit in exactly the same position that it does in nigels,basically saves me a good 3 or 4 days work on all future mk3 v6 swaps

loadswine · October 3, 2007, 20:35

Paul started sorting out the engine today. I've only just seen the pics myself and its looking good.

"today i was mostly hiding round the corner from the camera stripping a v6 engine down for nigels car...within a few hours it was down to the block....

And the whole thing got degreased,jet washed....sump off and resealed and some paint on the block too.....

We found a leaking crankshaft oil seal,just a weep from it but we fitted a brand new seal just to be sure.

More engine building tomorrow and maybe a bit of head porting."

loadswine · October 4, 2007, 20:25

Paul's update for today folks:

Well today i decided to make a nice heatshield for the front firewall,cant have nigels pint getting warm in the cubby boxes now can we!

Its 1mm ally but with a bluey tinge to it,possibly anodised in some way? is that even possible?

The rest of the day was spent porting heads,no fancy equipment,no data to rely on,just me.... a selection of dremel bits and a 25,000 rpm air dremel,and goggles!...brutal!

The objective? simple....take the heads out as far as i possibly dare without putting a hole in something! ....i started by putting the inlet gasket on and spraying over it with red aerosol,this gives the boundaries on the outside of the head,you can see here the port on the left is already opened right out (ive removed a serious amount of material from these let me tell you!) and the port on the right has just had its outer lip ground down at a 45* angle so you can see how much we are removing overall from the entire port......lots! I balance the ports using my "eye dyno" and "finger dyno"

To give you a little idea of just how much material you can remove here is the ported head in the foreground and the unported in the background....ok the foreground is going to look bigger but the head behind is only 6" away from it,the difference is huge.

These need finishing off,we arent going to polish them like folk used to do in our mini days,thats been proven to be worse for power,current thinking is to leave a roughish finish that helps atomize the fuel better as it gets disrupted on the head walls....i dunno you decide!

Theres another day of porting to go through before engine final assembly.

loadswine · October 8, 2007, 21:24

Work got underway again today:
"well following the finished head porting (we opened these fellas out as far as we dare!) it was time to nail it all together,here is as far as i got.....heads back on and timing belt fitted...

And cam covers and top cover painted....

The more observant among you will see thats two front covers!!! yes we are fitting another front cover to the rear so that nigel can fill the engine with oil,the front cover is wedged under the parcel shelf.Its a simple solution to the problem and will need nothing more than a spouted funnel to do oil changes

More engine building tomorrow

ps forgot to say if we simply swapped covers the top panel wouldnt work....so thats why we have two front covers and not simply swapped them.....if we were leaving the top panel off then it wouldnt be an issue "

roger · October 9, 2007, 09:33

Quote from: "Paul's update"we arent going to polish them like folk used to do in our mini days,thats been proven to be worse for power,current thinking is to leave a roughish finish that helps atomize the fuel better as it gets disrupted on the head walls....i dunno you decide!

And to think I spent a fortune in having my ports polished in yester-year s:cry: :cry: s:cry:

aaronjb · October 9, 2007, 10:40

Quote from: "roger"And to think I spent a fortune in having my ports polished in yester-year s:cry: :cry: s:cry:

s:shock: :shock: s:shock: s;)

s;)

kanujunkie · October 9, 2007, 17:16

Quote from: "loadswine"Its 1mm ally but with a bluey tinge to it,possibly anodised in some way? is that even possible?

probably not anodised, but ally quite often comes with a protective thin film of plastic on it, here at work ours is a bluey/green colour

paul Woods · October 9, 2007, 18:01

checked it for a protective film,it hasnt got one....looks like its in the alloy itself

kanujunkie · October 9, 2007, 20:27

strange, but anodiseing ally of any size isn't a great wowser to do, you may find its even a result of some kind of heat treatment, if you can find a type marking then then you'll find that the heat treatment code is the part after the type code, so thats something like this 6061-T6, 6061 is the type code and the T6 would be the heat treatment code

anyway enough irrelivent crap back to V6's

loadswine · October 9, 2007, 21:31

Nice link there Stu, and back to the V6 it is, with more gratuitous engine gleaming bits. Take it away Paul:-

"today i have been detailing engine parts,it takes ages to get everything clean and painted but its worth the effort.....starting with fitting the centre plenum section and fuel rails....

Here you can see the front cam cover fitted to the rear and the new oil cap position.....

Also there is usually a thick plastic harness section that runs along the rear cover,it would have gone right over the oil cap,not good,so i redid the harness so it goes above the oil cap....

A little forward thinking for cambelt changes,the cover was going to be next to impossible to remove in situ,so ive cut it in half so that each side has four bolts holding each half cover on....both sections will now remove when the engines fitted....

Here is the coolant filler body painted,even gave it some chrome dome head nuts holding it down...

And heres the plenum painted.....

And a brief overview of how the engine looks now....

Heres a few bits i painted but didnt have time to fit today....

So pretty good progress but still a way to go...

loadswine · October 10, 2007, 20:33

Today's action from Woodsport, commentary as usual from Paul:

well a very busy day,i started by tackling the dipstick issue,there was no way for nigel to check his oil with the stick in its stock location so i made a new dipstick assembly from scratch.

I cut the bottom off the old tube and inserted some new thinner tube inside this and welded it....

Then bent the new tube to shape and welded the top section from the old tube onto it....the top and bottom parts mean it retains its oil sealing properties.

Then i used nigels 1zz dipstick and uncrimped it from its handle,cut it to the perfect length and recrimped it.....we double checked this and its going to measure the oil exactly the same as the old stick,finally the new assmebly got painted.

Next i cleaned down the mk2 gearbox and painted it....

Then fitted the 5s-fe fidanza flywheel,and ACT 5s-fe clutch kit.... for people new to v6 swaps the 5s-fe flywheel needed modifying to fit the v6 crank.

Then gearbox and engine were bolted together....

Next the whole lot was pushed under the car ready for install....

And a few moments later it was in the bay....

It was now i hit a small snag...we had a damn good look around the engine and we think the bracings are too much of a comfort fit around the plenum.....basically i screwed up! it clears it ok but i havent allowed for engine flex under acceleration,schoolboy error!

So i chopped the braces back out with the plasma cutter and positioned them 1" further back,we now have plenty of clearance,i will know for next time!

but hey,how good does that look?

Tomorrow i need to briefly drop the engine out on the floor to reweld the braces and repaint where ive welded.

kanujunkie · October 10, 2007, 20:48

Christ Paul, if you wanted 10 out of 10 for attention to detail and quality of work then you get my vote

got any jobs going?

Draggon · October 10, 2007, 22:05

Damn Sexy looking install s:)

s:)

paul Woods · October 11, 2007, 06:48

cheers kajun,actually i may be looking for a bodywork type person soon.

kanujunkie · October 11, 2007, 08:50

only one type of bodywork i like to play with s:wink: :wink: s:wink:

Ivano · October 11, 2007, 16:24

looking very very good! s:twisted: :twisted: s:twisted: I'm soooo green! s:mrgreen: :mrgreen: s:mrgreen:
s:bowdown: :bowdown: s:bowdown: Paul,just outta curiousity why did you go with the 3VZ and not the 1MZ like Blitzo? the reason I'm asking is because I'm building a 1MZ for my Mk3 s:twisted: :twisted: s:twisted:

loadswine · October 11, 2007, 16:30

Availability, cost, wiring issues. I'm taking a guess that your not in the UK.
If you are and you've manged to source a 1MZ cheaply, then good for you mate, they aren't the easiest things to find cheaply here.
I only know of 1 mk2 with a 1MZ.
Good luck with your build. s:)

s:)

northernalex · October 11, 2007, 16:48

Paul, that looks absolutly fantastic.. very beautiful... Wish i had the pennies to buy one...!!

Am very jelous too!

Anonymous · October 11, 2007, 20:16

Best car porn I seen in ages s8)

s8)

loadswine · October 11, 2007, 21:54

Here's more!

"another eventful day at WS HQ,i started by welding the support bars back into their correct position,and with them repainted the engine could finally go back in,i added the plenum and throttle body and plumbed most of that up...

next the coilpack/amp was mounted on the passenger strut....fits like a glove too,you'd swear it was meant for it.... its important to earth the body of this unit or sparky no worky...

Next the clutch line was sorted,mk2 line mates straight to mk3 hard pipe,its the perfect length as well....

Also the front torque mount was prothane bushed and fitted...

Now i started to remove the ABS rings from the mk3 shafts and place them onto the mk2 CV joints,all went well until i inserted the CV's back into the hubs and i could clearly see the ABS ring was engaging fully into the hub! upon close inspection the mk2 outer CV spline is around 10mm shorter than the mk3 spline,so this would lead to two things happening.....

1, the ABS wont work
2, the wheel bearings would collapse within 5 miles,not good!

So back to the drawing board on the shafts.... and with a bit of playing about we discovered mk3 shafts fit into the mk2 diff,thats a stroke of luck! dont u just love toyota.....so in one hit the ABS problem and shaft problem is sorted...plus with the added bonus this v6 will have a supported output shaft set up,although that will mean i will have to make a custom mount carrier....coolio.

mk2 cv,lack of splines is a problem!

mk3 supported shaft bracket

Heres the bay as it looks now.....

kanujunkie · October 12, 2007, 00:09

Paul, wouldn't it be better to use a set of post facelift shafts as they're solid rather than the pre facelift hollow centre ones?

paul Woods · October 12, 2007, 06:23

i thought this was a post facelift car?

markiii · October 12, 2007, 08:19

it is

loadswine · October 12, 2007, 08:31

Yes, definitely facelift, its a 2003 and it had 6 speed box etc.

spit · October 12, 2007, 08:40

Haven't posted in this thread for a bit - too fascinated. Some excellent work there Paul.