'00 track car

[AJRFulton]

A spare head has been dropped off at a motorsport engineer for reconditioning and port polishing. They will reseat and lap the valves in as well - so saves a fair bit of work on reassembly.

Also dropped off one of my cranks, along with the flywheel, crank sprocket/pulley, and clutch plate for crank grinding and balancing.

After the crank is back - I'm sending the parts of the bottom end off to future motorsport to get a bottom end (sleeved block with CSS) built.

I did pick up a 30L ultrasonic cleaner from a vendor called Vevor - bought a few things off them, they are Czech based but importing Chinese stuff (but appears decent quality Chinese stuff from the 3 items I've bought.... btw.... I'd highly recommend the 12v fridge/freezer cool box they sell - it's cheap and actually works! - Plasma cutter is functional as well, and absolutely adequate at its price point).

However the Ultrasonic bath is a wonderful bit of kit! Everything is looking like new. Here are the valves, journals, rockers, springs and retainers from an old 2ZZ I might put back together as a spare. Why I didn't do a before, who knows, but they were brown.

[AJRFulton]

On another note, it's only October, but this rebuild and next season is already in disarray.

Currently working away from home (in Suffolk) until Xmas - My work has offered me a contract in South Africa to run a project for the majority of 2022. Cannot say I want to go, but with wanting to build a house in the next 2-3 years - the money on offer - particularly in the post IR35 world - was hard to say no to.

Head out in January, will be home June/July, before heading back out in August.

[Roj]

A year of 'pain' for long term gain - with the rollercoaster of North Sea life never seeming to stabilise, I'd go where the money is

[AJRFulton]

A year of 'pain' for long term gain - with the rollercoaster of North Sea life never seeming to stabilise, I'd go where the money is

I don't generally work offshore, although I did a stint in Aberdeen this year doing desk based work that involved a fair bit of offshore work (I'm a nuclear/environmental engineer - I was involved in projects dealing with/removing problematic wastes, and cleaning out systems contaminated with hazardous substances). I left that role as I couldn't afford to be based full time in Aberdeen.

Tbh from talking to people I was amazed how poor the wages were in salaried roles for oil and gas - particularly onshore based, but offshore often type roles.

Don't get me wrong, pay is pretty good in day rate contract type roles. Of course there are still some job titles that pay mega bucks.

[Roj]

A year of 'pain' for long term gain - with the rollercoaster of North Sea life never seeming to stabilise, I'd go where the money is

I don't generally work offshore, although I did a stint in Aberdeen this year doing desk based work that involved a fair bit of offshore work (I'm a nuclear/environmental engineer - I was involved in projects dealing with/removing problematic wastes, and cleaning out systems contaminated with hazardous substances). I left that role as I couldn't afford to be based full time in Aberdeen.

Tbh from talking to people I was amazed how poor the wages were in salaried roles for oil and gas - particularly onshore based, but offshore often type roles.

Don't get me wrong, pay is pretty good in day rate contract type roles. Of course there are still some job titles that pay mega bucks.

Yeah, salaried roles are not well paid compared to the day-raters, at least until you get up to management level. Even then a contractor will outstrip a managing director in some smaller firms. Mental.

[AJRFulton]

An enforced isolation after my back to back tested positive has given me 5 days at home. Longest time at home I've had since July, so actually got a bit organised.

Been working away from home and mental shift patterns (13hr days, 11 on 3 off).... So lack of time is a big problem.

Arrived home to find a big package

You cannot view this attachment.

And..... A substantial tidy up ensued.

Built up the box, added some lighting and tidied the garage

You cannot view this attachment.

You cannot view this attachment.

You cannot view this attachment.


Oddly satisfying cutting the foam inserts to put tools in

You cannot view this attachment.

Also received another cordless windy gun to add to the collection. (Also have a Ryobi 1/2" one to go with the 2x 3/8"). Liking the little Milwaukee so far, nice low torque - perfect for 10 and 12mm stuff - the Mac and Ryobi are just a bit too powerful for smaller stuff.

You cannot view this attachment.

I definitely possess too many 2ZZ bits

You cannot view this attachment.
You cannot view this attachment.

But also got round to refreshing my rear brakes. Will do the front ones tomorrow.

You cannot view this attachment.

I forget I have came a very long way in a short period of time. I knew nobody that was into cars other than me when I started this venture, so with doing my first track day in 2019, to starting racing in 2019... And not even owning a proper ratchet set when I started out. Been a naive and steep learning curve doing it mostly by myself.

I'm fortunate my parents own a small holding (been in the family since the 1800s), so an old stable is now my workshop.

Sadly only got a few more days at home before the end of the year, then being sent to Africa for a job and not home again until Spring. A lack of time is the biggest hinderence.

[AJRFulton]

You cannot view this attachment.

Something slightly depressing breaking apart the engine..... And it is this clean.

[Iain]

The organsiation of them tools 😍

[AJRFulton]

Reconned head delivered.

Fully reseated, skimmed, decoked, valves lapped, ported (very mildly), and polished.

Discovered a (new) bent valve as well. Would never have noticed this by naked eye.

[Roj]

An enforced isolation after my back to back tested positive has given me 5 days at home. Longest time at home I've had since July, so actually got a bit organised.

Been working away from home and mental shift patterns (13hr days, 11 on 3 off).... So lack of time is a big problem.

Arrived home to find a big package

You cannot view this attachment.

And..... A substantial tidy up ensued.

Built up the box, added some lighting and tidied the garage

You cannot view this attachment.

You cannot view this attachment.

You cannot view this attachment.


Oddly satisfying cutting the foam inserts to put tools in

You cannot view this attachment.

Also received another cordless windy gun to add to the collection. (Also have a Ryobi 1/2" one to go with the 2x 3/8"). Liking the little Milwaukee so far, nice low torque - perfect for 10 and 12mm stuff - the Mac and Ryobi are just a bit too powerful for smaller stuff.

You cannot view this attachment.

I definitely possess too many 2ZZ bits

You cannot view this attachment.
You cannot view this attachment.

But also got round to refreshing my rear brakes. Will do the front ones tomorrow.

You cannot view this attachment.

I forget I have came a very long way in a short period of time. I knew nobody that was into cars other than me when I started this venture, so with doing my first track day in 2019, to starting racing in 2019... And not even owning a proper ratchet set when I started out. Been a naive and steep learning curve doing it mostly by myself.

I'm fortunate my parents own a small holding (been in the family since the 1800s), so an old stable is now my workshop.

Sadly only got a few more days at home before the end of the year, then being sent to Africa for a job and not home again until Spring. A lack of time is the biggest hinderence.

Your workshop looks great, good effort doing the foam inserts - I spent hours of my life cutting them out and making shadow boards as an apprentice when we got a load of new tool kits in, something I'd happily avoid doing again. I'm wondering if it's worth buying one of the cheap faux-German(Chinesium) chests that come pre-packed with tools and cutouts and just replace the tools with my own.

[AJRFulton]

An enforced isolation after my back to back tested positive has given me 5 days at home. Longest time at home I've had since July, so actually got a bit organised.

Been working away from home and mental shift patterns (13hr days, 11 on 3 off).... So lack of time is a big problem.

Arrived home to find a big package

You cannot view this attachment.

And..... A substantial tidy up ensued.

Built up the box, added some lighting and tidied the garage

You cannot view this attachment.

You cannot view this attachment.

You cannot view this attachment.


Oddly satisfying cutting the foam inserts to put tools in

You cannot view this attachment.

Also received another cordless windy gun to add to the collection. (Also have a Ryobi 1/2" one to go with the 2x 3/8"). Liking the little Milwaukee so far, nice low torque - perfect for 10 and 12mm stuff - the Mac and Ryobi are just a bit too powerful for smaller stuff.

You cannot view this attachment.

I definitely possess too many 2ZZ bits

You cannot view this attachment.
You cannot view this attachment.

But also got round to refreshing my rear brakes. Will do the front ones tomorrow.

You cannot view this attachment.

I forget I have came a very long way in a short period of time. I knew nobody that was into cars other than me when I started this venture, so with doing my first track day in 2019, to starting racing in 2019... And not even owning a proper ratchet set when I started out. Been a naive and steep learning curve doing it mostly by myself.

I'm fortunate my parents own a small holding (been in the family since the 1800s), so an old stable is now my workshop.

Sadly only got a few more days at home before the end of the year, then being sent to Africa for a job and not home again until Spring. A lack of time is the biggest hinderence.

Your workshop looks great, good effort doing the foam inserts - I spent hours of my life cutting them out and making shadow boards as an apprentice when we got a load of new tool kits in, something I'd happily avoid doing again. I'm wondering if it's worth buying one of the cheap faux-German(Chinesium) chests that come pre-packed with tools and cutouts and just replace the tools with my own.

Tbh, I used foam by a company called Big Dug - they do a lot of industrial shelving and storage. It was pretty easy to do. The whole socket tray took just over an hour. Spanners and sockets far less.

Thing I've learned from doing a couple of camper conversions and cutting the carpet for lining them, buy a hobby scalpel and lots and lots of blades (which cost penny's each, I think I got 50 for £4). Exact same with foam cutting, you maybe only get a metre or so of cutting before the best of the blades gone, just ping it off and put the next one on.

That's a USPro Toolbox, it's heavy duty quality, and has soft close doors, but whilst it feels well put together.... it's not a Snap On - but the equivelant from a top brand would be costing 5x more, and to me all you get advantage is a slightly nicer feeling runner and closing mechanism, as I don't see that one falling apart - it's just more basic runners.

[AJRFulton]

So, I've had a long time off of all things MR2.

I was supposed to be in South Africa on a job, but Omicron came along and the 5 month project got cut down to 8wks and the outlying work postponed to 2024, which was a bit of a financial blow. However I now have time again having taken a job in Ayrshire, so have a few hours most nights.

Anyway where are we at.

Reground and balanced my crank/flywheel and posted it off to Future with a few other bits.

Awaiting my short block returning from Future motorsports.

Had my head reconditioned, reseated and port polished.

Gearbox was dropped off at a specialist today for a overhaul - 2-3 synchro has went on it, but may as well get it given a good check.

Got a loom and fresh linkage from J-Spec. With so many engine changes and a welded subframe it's hard to get the engine out without snagging something.

Rebuilt the KSport 6 pots and got carbotech pads all around.

Going to start rebuilding the head tonight. The OEM stem seals have proven difficult to put on - to the point I'm not sure they are the correct part however I damaged a couple trying - another set arrived today.

[J88TEO]

the WORKSHOP!!!!...am green with envy!

[AJRFulton]

Hopefully a solution to all my 2zz woes

[AJRFulton]

And all the way from the USA

[Gaz2405]

And all the way from the USA

MWR built block? Tell me more......😁

[AJRFulton]

MWR built block? Tell me more......😁

Yeah MWR. Nothing exciting build wise. Carillo H beams and Mahle pistons. Built for racing and will be tuned to 175-176 bhp (power to weight class reasons - but tuner does his jiggery pokery with fueling at the top end to kill peak power and aid cooling)

Opted out the sleeved route at the last minute.

[AJRFulton]

Most of the fiddly bits over.

Leak down test gave strong results.

Need to sort valve clearances, but managed to lose my reference shims (i.e. the shims I could still see a number on). 5 out of 8 are fine, but it's always the inlet side!

[Alex Knight]

Wondering why you decided against the sleeved route?

[AJRFulton]

Wondering why you decided against the sleeved route?

Put simply - costs. I lost my South African contract (before it even started) when Omicron came about - the UK contracting sector has been hard going these last 2yrs with IR35 and Covid, so back in a full time job with a bit less disposable income - so had to rethink as the budget for the season has diminished. However the flip side is I am at home permanently, so actually have time to do work.

That short block came on offer and it was working out about £1000 cheaper than the future motorsport route - and I still have parts to build another engine. I'm not going for power, so do I need sleeves? Due to class restrictions the car will only tuned to 179bhp or so (although that detuning and jiggery pokery with the fueling/timing at the top end helps with cooling for 30 minute competition sessions).

New OEM block, professionally built by a specialist who has all the tools to built it right. With the head work - this should be as good an engine as possible.

[JB21]

Just seems a total waste to de-tune a 2zz. Set of cams and tune in a 1zz would see similar results and a fraction of the cost of what you've spent.

[1979scotte]

Just seems a total waste to de-tune a 2zz. Set of cams and tune in a 1zz would see similar results and a fraction of the cost of what you've spent.

I doubt a set of cams will get 180 out of a 1zz.

[AJRFulton]

Just seems a total waste to de-tune a 2zz. Set of cams and tune in a 1zz would see similar results and a fraction of the cost of what you've spent.

The power band would look very different between the engines. The 1zz might be able to peak there.

My power curve is usually flattish at the top end, keeping me within my 170bhp/t limit but I stay at that 160-180bhp a good bit of the rev range. That engine will behave like a 200bhp engine at 5.5krpm but kill power at the very top. How long am I at >175bhp +7600rpm a lap - maybe 3-4 seconds? It actually makes little difference to lap time or VMax running between the detuned map, and full power (which will be 195-200bhp). The gains are all lower down torque.

Plus the advantage of effectively using petrol to cool the cylinder, keeps temps 6-7*c lower on 20-30 minute sessions.

I agree it's a lot of effort, but everyone else is doing it, so by not doing it you're leaving a lot of time at the door.

It gives me options too in terms of series. I won't always run in a series where my class is 170bhp/t.

[AJRFulton]

Was a little unsure of the connector on the leak down tester I have, the results seemed a little too good for a cold engine that wasn't run in <5%. The coupler was gubbed and wasn't letting air past - good old eBay cheap Chinese quality bits.

Changed the coupler for the one from a compression tester and now have real concern.

Getting 80-85% leakage across all cylinders, and can physically hear air passing by the pistons making farty noises with the assembly lube lining them. I can feel the air coming out of the dip stick hole.

Even just putting a spark plug in and gently cranking the engine by hand - I can hear significant amounts of air pass the cylinders and can turn the engine with little resistance from the compressed air. Even just holding it with a guage in place - no cylinder is holding compression - and I don't mean not holding compression like a pin prick in a bike tube, I mean not holding compression like a pencil sized hole in a bike tube.


When I built my last engine, and built the short block myself - cold engine with forged pistons was giving about 20% leakage, and could only hear a faint hiss and hand cranking gave significant resistance. Nothing was escaping fast.

I appreciate the engine isn't run in but I wouldn't be expecting it that bad.

The plus side is..... It's identical across all cylinders.

Not being particularly experienced, I've no idea if this is normal - so any advice.

Hope not, as the return shipping costs and (wasted) head gasket will be the best part of £500.

[JB21]

General rule of thumb is more than 20% is a bad seal, 80-85% engine is toast. With the spark plugs removed I'd get an impact gun set to low torque on the crank bolt and give the crank a good few turns in 5-10s intervals, and retest. If the same results contact MKR and request they pay the return shipping.