This is looking smart Geoff Are you doing it in Epsom?

With regards to QEP are they helping you with the engine rebuild or just machining the parts?

How tough would you rate the rebuild? Ever done one before?

________________________________________

Just Drive It

Not really an update but a question for those that may know!

I have an XU10 sump,oil pump, 26 tooth sprocket and the associated chain. Is there any reason not to use the pump? - only it has the oil pump baffle and will also have the 6 bar spring

Thanks guys, will be getting a few more pics over the weekend. Engine re-assembly is slightly delayed though, should have the bottom end back from decking and liner skimming next week hopefully!

Sunday things progressed much better. I got the low oil pressure switch I ordered from thinkauto calibrated. I used a bike inner tube cut into a section with the valve at one end. I used a jubilee clip to clamp and seal the tube by the valve, I fed the rest of the tube through an old bit of coolant pipe (to stop the tube expanding to the point of exploding) and clamped the other open end around the pressure switch - I used duck tape to stop any other exposed tube over-inflating. I wired the switch through a bulb and battery and then pumped the pressure up to about 30 psi using a pump with a pressure gauge. Quite conveniently there was a very slight air leak so the pressure dropped very gradually so I could see exactly were the switch closed - initially at about 20 psi. By adjusting the allen key inbetween the terminals I raised the activation pressure to about 25 psi. Here is the set-up:



I then moved onto the wiring - I wanted to incorporate it into the loom to keep it tidy and easy to follow, I drew out a wiring diagram to file away -





I spent a bit of time cleaning and painting - very pleased with the results. I gunked and wire brushed the inlet manifold and top engine mount bracket, for the exhaust manifold I used a wire wheel in a drill (would have taken ages with a wire brush) then blasted it with a pressure washer - I was really impressed with the results of this, worked far better than I expected! Anyway heres the results -





The last little thing was the bumper side mounts, I managed to buy the metal part of the mushroom that the bracket slides onto from pug but the outer rubber part is discontinued - fortunately the old ones were salvageable using plenty of WD40 and a small file to get rid of the rust. I used plenty of grease to make sure it doesn't happen again any time soon. Also on re-assembly I ran a tap through all the nuts and the bolts through dies.

Here you can see the metal part (I also got the bolt that screws into the metal part from pug)


Rescued outer rubber mushroom


That was it for the weekend so I now need to order the required parts - droplinks, track rods, oil filler pipe, fuel supply bits. Hopefully next weekend I'll have the bottom end so I'll be able to get the engine together and finally everything can go back together!

Good thread, subscribed

________________________________________

Goldie the track car.

^^ just about to ask the same thing..

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveys Project thread here
309 3dr K20 Type R

Time now for a long overdue update. The final year of uni is proving quite intense so spare time has become a rare thing!

This instalment was making a start on assembling the engine, I didn

Hmm thats interesting. I'll have to keep an eye on that if I ever have to have the head off. If the threads do strip is helicoiling possible?

I have been struggling to find an alternator belt that will fit, by taking rough measurements it looked like it needed to be a 725mm 5 rib belt but annoyingly as far as I can work out not all manufactures simply name them with the length and number of ribs. Eventually I got one called a 5PK718 made by gates, needless to say measuring it, it isn

5th of December- THE ENGINE STARTS!

Saturday I mounted the new aluminium Rad (fitted with the thermoswitch and plug, both required 32mm sockets) and filled cooling system.

I filled the engine with oil, connected the rad fan loom and fitted the battery (may need to extend the pos terminal wires as they are pretty tight). The AFM and associated ducting/filter were then fitted and plugged in.

I decided to make a temporary job of wiring in my 25psi oil pressure warning light and double checked all the loom connections were connected inside the car.

I then went through a list of final checks I wrote for myself before running the engine:

How much are you looking for for those as they would certainly help for a tidy job!

Cracking on through the jobs list I picked a few and got to work. To start with I re-routed the excess loom further past the battery so it wasn

All looking very smart buddy

With regards to the pipe insulation you have used to protect the coolant pipe do you know if it is high temp resistant as the top of the rad and the inlet manifold will no doubt get very hot at times

________________________________________

Just Drive It

You make a good point, I'd hope that it wouldn't get too bad, considering there will be airflow around the area. It's something I'll have to keep an eye on!