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Author Subject: Daveyboy's Rallye Race car
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #601
phillipm wrote:
You look like you've just found an old stash you'd forgetten about in the shelves LOL


Not been getting much sleep lately LOL

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 29th Nov 2009 at 14:11
matt h 306

Regular

Location: Wiltshire

Registered: 22 Sep 2003

Posts: 350

Status: Offline

Post #602
Good work.

Another red rallye killed its bottom end a combe yesterday.
Posted 29th Nov 2009 at 15:44
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #603
matt h 306 wrote:
Good work.

Another red rallye killed its bottom end a combe yesterday.


Hate that track, it's cost me thousands! Angry LOL

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 29th Nov 2009 at 15:48
rallyeash

Seasoned Pro

Location: Devizes

Registered: 11 Dec 2006

Posts: 4,424

Status: Offline

Post #604
good work, whens the next track day?

p.s did you get my pm?

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 1st Dec 2009 at 00:13
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #605
rallyeash wrote:
good work, whens the next track day?

p.s did you get my pm?


I did mate, sorry for not getting back to you yet, were you wanting just the welding done with you supplying the tubes already mitred, or did you want me to do the whole thing?

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 3rd Dec 2009 at 01:58
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #606
Bit more progress last night, installed the crank and checked the runout, less than 0.25 of a thou at it's worst point, and dead on all the way round for the other main journals (pretty damn good in plain english!)LOL





Then some plastiguage was used to check the running clearance on all the main bearings with the caps installed and torqued down, we also checked the thrusts too. All well within tolerance so no worries there...









________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 3rd Dec 2009 at 03:57
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,839

Status: Offline

Post #607
nice, someone doing it properly Big grin

________________________________________

need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

Posted 3rd Dec 2009 at 04:07
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #608
welshpug! wrote:
nice, someone doing it properly Big grin


Cheers, but it's really just for peace of mind. With the quality of modern engine parts it's probably all good enough to throw it all back together and work just fine, but it's costing me so much to do, that I can't afford for it to fail as a result of something silly like a tight bearing or a dodgy valve etc. So I'm bieng anal and checking as much as I can, saying that I still managed to f*ck up by installing the bearing caps the wrong way round at one point, that stopped the crank from running freely I can tell you! Still, this is the first engine build for me so I'm learning as I go. Smile

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 3rd Dec 2009 at 04:26
jcphat

Seasoned Pro

Location: In the day room, Nurse!

Registered: 22 Feb 2008

Posts: 1,061

Status: Offline

Post #609
You really are doing perfectionist work and it is good to watch. Keep up the posts.

________________________________________

New Forum same high quality intellectual debate!
Team Zimmer™
Posted 3rd Dec 2009 at 04:35
dan gti-6

Regular

Location: Winchester

Registered: 26 Jan 2008

Posts: 112

Status: Offline

Post #610
daveyboy wrote:
welshpug! wrote:
nice, someone doing it properly Big grin


Cheers, but it's really just for peace of mind. With the quality of modern engine parts it's probably all good enough to throw it all back together and work just fine, but it's costing me so much to do, that I can't afford for it to fail as a result of something silly like a tight bearing or a dodgy valve etc. So I'm bieng anal and checking as much as I can, saying that I still managed to f*ck up by installing the bearing caps the wrong way round at one point, that stopped the crank from running freely I can tell you! Still, this is the first engine build for me so I'm learning as I go. Smile


LOL
I was going to post, when you brought me the block you had caps 2-5 on the wrong way round, thought you would have noticed being that number 1 only goes on one wayWhistle

Had you worried for a bit i betSmile
Posted 8th Dec 2009 at 00:07
rich_w

Seasoned Pro

Location: Havant, Hampshire

Registered: 29 Jul 2004

Posts: 5,412

Status: Offline

Post #611
dan gti-6 wrote:
daveyboy wrote:
welshpug! wrote:
nice, someone doing it properly Big grin


Cheers, but it's really just for peace of mind. With the quality of modern engine parts it's probably all good enough to throw it all back together and work just fine, but it's costing me so much to do, that I can't afford for it to fail as a result of something silly like a tight bearing or a dodgy valve etc. So I'm bieng anal and checking as much as I can, saying that I still managed to f*ck up by installing the bearing caps the wrong way round at one point, that stopped the crank from running freely I can tell you! Still, this is the first engine build for me so I'm learning as I go. Smile


LOL
I was going to post, when you brought me the block you had caps 2-5 on the wrong way round, thought you would have noticed being that number 1 only goes on one wayWhistle

Had you worried for a bit i betSmile



Laugh

True, although the writing on #1 bearing cap is orientated differently to all the others, so you can't use that to set out others Razz

Dan - I'll be up either Friday or Monday, got another head for you.

Best try and remember a cheque for the last lot for your boss too Laugh

________________________________________

Contact Details:

rich@lynxpowerengineering.co.uk
07732 822546

Posted 8th Dec 2009 at 00:26
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #612
To be honest, It only became apparent when torquing up the main bearing caps that something was'nt right. Once the bolts started to be done up the crank started to bind, and I assumed it was something like a problem with the shells or thrusts. After a little flapping from me, Chris suggested that we try the main caps the other way round and that soon sorted out the 'problem'.

I will hopefully get the bottom end wrapped up this weekend, work permitting.

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 9th Dec 2009 at 00:02
chrisd306

Seasoned Pro

Location: Perth Scotland

Registered: 26 Nov 2005

Posts: 10,061

Status: Offline

Post #613
last time i seen a dial gauge was college i think!!

coming on well!! im needing a new head for mine i think as thoguth was a tapy lifter but probly a bent valve FFS!! will run it till it dies i tink, then will get new head another gasket from rich an head bolts this time aswell!! Dont know why cars are so cheap an easy to run its great.....

________________________________________

In my garage just now

2003 BMW M3 & 2009 L200 Raging Bull
& Audi Q5 S Line
AX stock rod & Saxo Stock rod
Sold the bike an charged rallye an bought a caravan, midlife crisis or what!
Posted 9th Dec 2009 at 01:45
rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,990

Status: Offline

Post #614
chrisd306 wrote:
last time i seen a dial gauge was college i think!!

coming on well!! im needing a new head for mine i think as thoguth was a tapy lifter but probly a bent valve FFS!! will run it till it dies i tink, then will get new head another gasket from rich an head bolts this time aswell!! Dont know why cars are so cheap an easy to run its great.....


Jesus dude, it just never goes right for you does it Sad

________________________________________

Just Drive It
Posted 9th Dec 2009 at 03:43
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #615
rallyestyle wrote:
chrisd306 wrote:
last time i seen a dial gauge was college i think!!

coming on well!! im needing a new head for mine i think as thoguth was a tapy lifter but probly a bent valve FFS!! will run it till it dies i tink, then will get new head another gasket from rich an head bolts this time aswell!! Dont know why cars are so cheap an easy to run its great.....


Jesus dude, it just never goes right for you does it Sad


I think it's having a red Rallye that's bad luck in general, mine seems to be cursed too...Dry LOL

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Dec 2009 at 04:36
chrisd306

Seasoned Pro

Location: Perth Scotland

Registered: 26 Nov 2005

Posts: 10,061

Status: Offline

Post #616
what like is your diff mate, will they do another 1 at same price as you got??

________________________________________

In my garage just now

2003 BMW M3 & 2009 L200 Raging Bull
& Audi Q5 S Line
AX stock rod & Saxo Stock rod
Sold the bike an charged rallye an bought a caravan, midlife crisis or what!
Posted 9th Dec 2009 at 14:53
rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,990

Status: Offline

Post #617
daveyboy wrote:
rallyestyle wrote:
chrisd306 wrote:
last time i seen a dial gauge was college i think!!

coming on well!! im needing a new head for mine i think as thoguth was a tapy lifter but probly a bent valve FFS!! will run it till it dies i tink, then will get new head another gasket from rich an head bolts this time aswell!! Dont know why cars are so cheap an easy to run its great.....


Jesus dude, it just never goes right for you does it Sad


I think it's having a red Rallye that's bad lubk in general, mine seems to be cursed too...Dry LOL


Well i must buck the trend as mine is supreme Smile You guys will get them sorted im sure of it, that engine is gonna be better than new when finished Thumbs up

________________________________________

Just Drive It
Posted 9th Dec 2009 at 18:09
lotek

Seasoned Pro

Location: Berkshire

Registered: 04 Dec 2007

Posts: 6,107

Status: Offline

Post #618
you should be fixing her not doing this LOL
Posted 10th Dec 2009 at 02:39
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #619
chrisd306 wrote:
what like is your diff mate, will they do another 1 at same price as you got??


You would have to chat to matey at Demon Tweeks, probably be more expensive now as their prices seem to go up by about 5% year on year. I found it to be really good, however on an entirely track focused car it's not the one to have. You would want the plate type that fully locks really for best results, however as mine will do a fair ammount of road work it's a trade off I'm prepared to suffer.

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Dec 2009 at 04:41
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #620
Tonight, I checked the big-end bearing clearances on all four rods, all were ok. However, two rods have side clearance issues, both are a fair bit under minimum (8 thou.) so I'll try swapping them with the two rods that have enough clearance, if that does'nt help, some material will have to be removed from the thrust faces of the rods (I really dont want to have to do that though as that will mean the rods will need to be balanced again if I start taking metal off them) oh what fun!









________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Dec 2009 at 23:23
rallyeash

Seasoned Pro

Location: Devizes

Registered: 11 Dec 2006

Posts: 4,424

Status: Offline

Post #621
hope with a swap around they will be all good. fair play though mate certainly doing it properlySmile

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 10th Dec 2009 at 15:20
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #622
rallyeash wrote:
hope with a swap around they will be all good. fair play though mate certainly doing it properlySmile


Thanks, me too. Hopefully I'm just bieng paranoid, but the side clearance is half what it should be, so it really would'nt be a fantastic idea to bolt it up and hope for the best. I'll take them all off and put a mike on them and see if any are thinner than the rest. My guess is that they will all be pretty close and it will be the thrust faces on the crank that are tight, it will be less work and less costly though to take metal off the rods to get the space I need.

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Dec 2009 at 23:22
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #623
Well, I ordered up my camshafts yesterday:

Inlet NRD 127: 296 degree, 480 thou of lift @ 104 degrees, 183 thou at TDC

Exhaust NRD 954: 143 thou @ TDC

They were made by Piper as development cams for an engine builder who was developing engines for National Hotrod racing. That's why the numbers don't match cams normally made by Piper. These made 230 hp on a high comp engine running twin 45m carbs.

Once I get these and check fit them, I'll be sending the head away for overhaul, new guides, re-cut seats, new valves, solid lifters and shimming etc. Upon consulting Brett Simms (An ex. Longman engine builder) I'm going to be sticking with the standard valve sizes (Other people on here have also said its not worth the bother upping the size) as they managed to get nearly 280 bhp on the standard sizes. I am going to get new valves though for peace of mind.

I still have no idea what sort of HP to expect from the finished engine, both the guys I have been dealing with for cams and headwork seem confident of 240+,which is nice Smile

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 2nd Mar 2010 at 03:04
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #624
Placed my order with Piper today for my solid lifters and uprated valve springs,

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 24th Feb 2010 at 21:20
chris with a pug

Seasoned Pro

Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

Status: Offline

Post #625
daveyboy wrote:
Placed my order with Piper today for my solid lifters and uprated valve springs,
Posted 24th Feb 2010 at 22:01

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