Project Custard - Gearbox issues

[enid_b]

(blushes) Genius may be going a bit far. I'm just lazy and don't like to struggle.

As ever I offer the use of the pit, tools and my services to anyone in the club who needs it.

Very generous offer... where's Enid and his stars ?  s:) s:)

does anyone still remember them?

E

in fact well done alex,

Custard, in honour of your tenacity and determination of 'project custard', i award to thee, a coveted Golden Star !

[StuM]

Awesome - have heard of these mythical stars, but never 'seen' one awarded during my time!  

Congrats custardavenger!

 s:bowdown: :bowdown: s:bowdown:

[custardavenger]

OMG I'm so honoured. Will save the speach for later. lol

[custardavenger]

OK now I'm abale to post pics again here a few of the mod that led to me spending the day tuning and erm damaging my engine.

The original set up.







Original MAF location in intake pre Supercharger



The modification

New MAF bracket (I later found out where to buy these. DOH!)




MAF bung




MAF in new location post intercooler


BOV moved


Old MAF position plugged

[custardavenger]

Ah meant to add that all this will be replaced very soon. Am looking into building a custom Charge Cooler but there will be more on this later.

[custardavenger]

And now for the damage   s:roll: :roll: s:roll:  



Little spider I found when I took the head off. How did he get in?






I didn't bother taking pics of the con rod. It was covered in moltern aluminium but this seams to clean off ok. Will need to replace the small end bearing so will concentrate on it more once I buy the parts.

The bore seems ok but will not know for sure untill I manage to get the deposit off the wall. Any recomendations on what to do this with would be great. was gonna try a light abrasive by hand. was also told by the chemist at work to try nail varnish remover (acetone) to brake it down. Will be having a go at this this weekend as once I know whether the bore will need machining I will know what I need to order. Then it's on to the head.

[Anonymous]

Why don't you take it to an engine specialist and get it hone'd and crack tested. Shouldn't cost a great deal.

Rob.

[custardavenger]

Not sure where to take it. Any suggestions? I'm not too worried about cracks. The only problem would be if the bore is damaged enough to need a re bore. If I can I would rather keep it standard get it back in then locate a spare whick I may do a proper build on. Seeing as how easy it is to remove it. If the bore is damaged then I'll be forced to change the internals which will then move it on to what can I afford.

Just a bit of history the engine is a toyota replacement with about 30K on it so it's in great condition other than the obvious.

I will definately be looking at getting the head skimmed and would be interested in recomends for that. (Mill at work not really man enough)

[Anonymous]

Not sure where to take it. Any suggestions? I'm not too worried about cracks. The only problem would be if the bore is damaged enough to need a re bore. If I can I would rather keep it standard get it back in then locate a spare whick I may do a proper build on. Seeing as how easy it is to remove it. If the bore is damaged then I'll be forced to change the internals which will then move it on to what can I afford.

Just a bit of history the engine is a toyota replacement with about 30K on it so it's in great condition other than the obvious.

I will definately be looking at getting the head skimmed and would be interested in recomends for that. (Mill at work not really man enough)

I have an uncle who as a business in Stoke which did my spit engine when I re-built it, I suppose that's to far north for you. The only other thing is to look in the Yellow pages for engine refurbers.

Rob.

[custardavenger]

Stoke on Trent? I go through there when ever I go to Manchester. Would you like to do the enquiry for me and let me know costs?

[Anonymous]

Stoke on Trent? I go through there when ever I go to Manchester. Would you like to do the enquiry for me and let me know costs?

I'll have a word on Friday for you.

[Anonymous]

Hi Rob

Just had a chat with my cousin - Sandra, no problem with honing your bores and carrying out a check to make sure it's OK , you are talking about £35 for the whole job.

Their contact details are:

A Yates & Son
Marlborough Road
Longton
Stoke on Trent
Staffs
ST3 1EE

Tel No 01782 313260

Good luck

Rob.

PS - They have one of the new valve cutting machines which gives a finish that does not require lapping afterwards - god the hours I could have saved   s:roll: :roll: s:roll:

[markiii]

now thats a good price

[Anonymous]

I'm betting that will need more than a simple hone....

[custardavenger]

Cheers for looking into that Rob. That does sound good.

OK so I'm back in Salisbury and on the way down I stopped in at TTS to have a chat with Richard. Basicaly we were talking more about them building a charge cooler, I wanted to see if he could get hold of the cores but he doesn't think so which leaves me with the one place I've found in the US. Anyway he mentioned again that I should think about water/meth injection and it has a convincing argument. After thinking it over this maybe the way I will go short term. I'm not sure how much the engine is gonna end up costing me so I need to be clever with the little money I have.

And on to the block (gonna sort block before I even look at the head). I have had a rub at the deposited aluminium and I'm still not sure how bad things are. I plan to break down the rest of the block and bring it up with me so I can then get it looked at on that offer (Well done Rob). I really don't know where to go from there. if I can't rebuild with stock components then it seems right to build the engine properly. Then there are so many options. Richard already suggested that I should get a least a stage 1 cam to get more out of the Rotrex.

Of course now I think of it there is a third option. 2nd engine to go straight in. Was planning to get hold of a knackered engine to build and then swap in later so I could just get a runner and drop it straight in, giving me time to save and build mine, and also more cash to thet the things I want to do this winter done.

Oh well. I'll see how the block goes first.

[loadswine]

How about a 2zz in there Rob? I know where there is a 2zz swap kit as well.  s:wink: :wink: s:wink:  
Sorry for giving you wallet wrenching ideas mate, but thought "while you are at it....."
I would!  s8) s8)

[custardavenger]

Cheers Nige. Mate. lol. Nah I don't want a 2zz, would have to change way to much stuff (PFC, Rotrex etc) it's just not worth it. I'm just happy trying to perfect my SC set up. If I was starting from stratch then maybe I would.

[custardavenger]

Ok so engine now it it's component parts. Just need to get it cleaned and wrapped to take back up. I'm really glad I've taken it apart as I think i would have had problems with No.1 and 4 big end bearings.

Rob, I presume this place you've recomended does full engine reconditioning? Either way I'll bring my crank up as well in case they can check that too.

[Anonymous]

Ok so engine now it it's component parts. Just need to get it cleaned and wrapped to take back up. I'm really glad I've taken it apart as I think i would have had problems with No.1 and 4 big end bearings.

Rob, I presume this place you've recomended does full engine reconditioning? Either way I'll bring my crank up as well in case they can check that too.

Yep full service, they did my Spit or at least all the machining then I put it together.

Good luck - they will look after you.  s:wink: :wink: s:wink:  

Rob.

[custardavenger]

Sweet. I'll give them a call this week and hopefully pop over on Friday. I'll be so happy when I finally get a price on the block and can start working out how much parts are gonna set me back.

[custardavenger]

Been to drop off engine today. They were helpfull. and he's gonna try and hone out the damage, If that doesn't work then he'll do a bore. Also left them the crank to polish and the damaged con rod to replave and hone the small end bearing. Just waiting to hear back on how he gets on then I can start ordering parts.

[custardavenger]

Ok been looking into other things while waiting to hear back about the block. Been thinking paint. Was gonna put an order together for various paints from VHT. Am considering painting the block. Any coments or recomendations would be great.

I'm also trying to find out what paint Team dynamics use as I fancy trying something with my wheels.

Also been reading up on Batteries and am a bit confused now. Seams some say yes and some say no. The reasons I want to change it is because of size and weight. Gonna be measuring up to see what looks best. I have two plans. One easy one hard (I like the hard one, typical). More to come.

Made a start on the manifold today. Cut off all the brackets, gonna clean the rust and maybe blast it before paint/wrap/paint. Just waiting for locking wire to turn up.

Other than that I'm close to starting production on the throttle bodies so I'm gonna have a busy winter.

Will hopefully hear about the block tomorrow so I'll then be in a stage when I can sort out parts.

[uktotty]

I have some black VHT never used, we can give that a go??

[custardavenger]

I'll take you up on that Russ. Be good to get an idea of finish.

[custardavenger]

Update.

Ok so engine need a rebore. Been pricing up everything and its getting expensive. My original plan was to throw the engine back in as stock, get another engine and build it big bore with performance components then swap it in later. Now I've been looking at prices I need to make a desicion on whether to buy another engine now and put that straight in. Would mean I would save on all the parts that would need replacing on taking an engine apart. Gaskets bolts etc. Having now contacted partfinder it seems £750 to 900 + vat for an engine. While to put mine back in, probably £800.

Gonna see what all the offers are on engines. One place sounded really good (included full intake) and had two engines but would have to try and haggle them down.

Opinions please.