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My Little Weekend Project!


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#41 djtimodj

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Posted 15 September 2009 - 10:36 AM

Ok guys the three shop's im looking at having some work done at are, Abbey motorsport, TDI london, and Advanced motorsport engineering (AME).

If i go for a bottom end build i my build list could look like this;

Cosworth forged H-beam rod's
Cosworth forged piston's (95.5 or 96mm im not sure yet)
Cosworth headgasket
Cosworth headstud kit
Cosworth mainstud kit
Cosworth race bearings/OEM
Reconditioned OEM heads/valve train.
Polished crank jurnals, skimmed heads and re-bored/honed block.
Koyo/japspeed 50mm rad.
GTM oil cooler kit.
APS garrett twin turbo kit.
APS 3.5 inch downpipe's or keep my HFC's??
AAM or CJ motorsport stage 1 fuel return.
Deatschworks 600/800cc injectors.
Haltech platinum ECU.
Defi boost,oil temp & exhaus temp guages.
AEM wideband.

Its very hard to get a good accurate quote from builders because they don't know how long/ if it all goes to plan what sort of cost will be involved.

Ill get my a** in gear soon and get this thing going! lol...
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#42 3FIDDYZ

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Posted 15 September 2009 - 12:19 PM

Whos robbed the bank now Mate :dance:

Nice looking kit list but as I know as much about going FI as I do about the Walla Walla tribe of papa new guinea I am just going against brand names of the items on your list!

You not doing the cams whilst your at it?
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#43 djtimodj

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Posted 15 September 2009 - 01:09 PM

Whos robbed the bank now Mate :dance:

Nice looking kit list but as I know as much about going FI as I do about the Walla Walla tribe of papa new guinea I am just going against brand names of the items on your list!

You not doing the cams whilst your at it?


No mate the thing is i've not had time to rob the bank yet!! lol..

Im still in two minds due to the cost of building the engine where as i can have this up and running on m stock block for about 1500 more now??

I was looking at cams but people in the USA are making 800WHP on stock heads and stock cams!! I would want a high boost setting of around a bar. (14-15psi to give around 500WHP so the stock cams and heads will get me there)

Also Dan@AME would advise not to use cams due to the added wear on the valve train and more things to fail! I like the idea of only upgrading the things that NEED to be upgraded such as the internals and cooling system.
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#44 djtimodj

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Posted 15 September 2009 - 01:30 PM

Few pic's of when i was cleaning the block today.

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Broken piston rings! Most of the broken ones look just like this!

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#45 3FIDDYZ

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Posted 15 September 2009 - 01:56 PM

STROKE IT, STROKE IT!!! :dance:
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#46 Stuart_J

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Posted 15 September 2009 - 04:19 PM

No mate the thing is i've not had time to rob the bank yet!! lol..

Im still in two minds due to the cost of building the engine where as i can have this up and running on m stock block for about 1500 more now??

I was looking at cams but people in the USA are making 800WHP on stock heads and stock cams!! I would want a high boost setting of around a bar. (14-15psi to give around 500WHP so the stock cams and heads will get me there)

Also Dan@AME would advise not to use cams due to the added wear on the valve train and more things to fail! I like the idea of only upgrading the things that NEED to be upgraded such as the internals and cooling system.


Depends a lot on where you want to end up, luckily you have a spare block which you can use if you pop the stock motor but you are never going to get the full potential out of thev rest. Also how long will you keep the car. If you intend keeping it for at least a couple of years then I would def go for upgrading the internals. Mine is running 450-480 & thats a lot of fun. I dont know what suspension or brakes you are running. Mine has Tein Suspension & better brakes & can just about cope with that, much more & you will need to look at putting more rubber on the road as well, all will add to the cost.
I get the feeling from your enthusiasm if you build it stock you will always wonder why you didnt go all the way.

Of the builders you mention I have trusted Abbey with mine, mainly on recomendation & experience I had with them a few years ago with my Subaru, they seem to do a good job for a fair price & are refreshinly lacking BS. I havent had any dealings with the others so cant comment
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#47 TONY420z

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Posted 15 September 2009 - 05:48 PM

[quote name='djtimodj' date='15 Sep 2009, 11:36' post='234077']
Ok guys the three shop's im looking at having some work done at are, Abbey motorsport, TDI london, and Advanced motorsport engineering (AME).

If i go for a bottom end build i my build list could look like this;

Cosworth forged H-beam rod's
Cosworth forged piston's (95.5 or 96mm im not sure yet)
Cosworth headgasket
Cosworth headstud kit
Cosworth mainstud kit
Cosworth race bearings/OEM
Reconditioned OEM heads/valve train.
Polished crank jurnals, skimmed heads and re-bored/honed block.
Koyo/japspeed 50mm rad.
GTM oil cooler kit.
APS garrett twin turbo kit.
APS 3.5 inch downpipe's or keep my HFC's??
AAM or CJ motorsport stage 1 fuel return.
Deatschworks 600/800cc injectors.
Haltech platinum ECU.
Defi boost,oil temp & exhaus temp guages.
AEM wideband.

Its very hard to get a good accurate quote from builders because they don't know how long/ if it all goes to plan what sort of cost will be involved.

Ill get my a** in gear soon and get this thing going! lol...
[/quote

Hi if you need aam fuel return +750cc rc injectors +kayo rad i have them at home going cheep
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#48 djtimodj

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Posted 15 September 2009 - 06:57 PM

Hi if you need aam fuel return +750cc rc injectors +kayo rad i have them at home going cheep

Pm me the details mate im interested. :dance:
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#49 Zmanalex

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Posted 15 September 2009 - 07:24 PM

Tim, looking at your pictures, your failure has most definately been caused by Det. :dance:

Good luck with the build mate. B)

Alex.

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#50 djtimodj

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Posted 15 September 2009 - 08:01 PM

Tim, looking at your pictures, your failure has most definately been caused by Det. :dance:

Good luck with the build mate. B)

Alex.


Yeah Alex I would say Det looks like the cause of this faliure! No wonder the motor had crank case pressure problems!!!!!

Sam form TDI gave me a very good explantion of ring land faliure cause by det.
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#51 MartinW

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Posted 16 September 2009 - 04:20 PM

Sam from TDI gave me a very good explantion of ring land faliure cause by det.


Presumably they are the weakest link and being on the upstroke, when premature detonation happens,
therebye incurring multiple times the force they should be subject to
(when they are at the top and almost 'static')
????
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#52 djtimodj

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Posted 16 September 2009 - 07:10 PM

Presumably they are the weakest link and being on the upstroke, when premature detonation happens,
therebye incurring multiple times the force they should be subject to
(when they are at the top and almost 'static')
????



The way it was explained to me mate was when Det. occurs due to lean conditions the flame face on the piston can go from its normal operating temp (400c approx) and the underside of the piston and skirt around 100c. to around 900c. this temp differential cause's irregular expansion on the piston and makes the flame face piston to wall clearance far to small and cause's the ring lands to touch to cylinder wall. The cast piston is very brittle and as soon as the ring land catches the wall it can and will snap off!! :lol: :(

Just a little update on the build too....

Finally got my block down to DRB engineering where my mate works and got it into the parts washers.

First wash was degreaser in boiling water. 15mins cycle.
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Then the block was chemical washed in solivent at around 50c. for 15mins

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Then a finally water wash to remove the solvent.

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The block is nice now and ready for machine work :lol:
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#53 Dave G

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Posted 17 September 2009 - 11:53 AM

As a few have said before, this is a really interesting thread and makes for great lunchtime reading at work! :lol: Keep up the great reporting and pics...I'm fasinated to see how it all ends up. I hope you reach your goal within your time frame and budget...shotgun on a passenger ride at a meet (was I first?!?) :(

#54 djtimodj

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Posted 18 September 2009 - 04:10 PM

Not much of an update but ive had a quote back from TDI for the machine and labour costs :surrender: :shutup2: :band: LOL.....

And i have dropped my timing cover inspection covers off at the polisher's. Both covers polished for 10!! i had a go with sand paper/dremel/metal polish but it would have cost more than 10 in dremel bits!! lol.. they should be done by mid to end of next week.
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#55 djtimodj

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Posted 19 September 2009 - 02:02 PM

Update. Got a call today to say my covers were done! (i dropped them off yesterday at 4pm!)

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Good job for a tenner! :surrender:
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#56 bundus

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Posted 19 September 2009 - 06:31 PM

Blimey thats awesome for a tenner - in fact its awesome even at 50 each :surrender:

Where did you have that done mate? Id love to know of a good cheap polishers - Id get my whole engine bay done :shutup2:

#57 djtimodj

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Posted 20 September 2009 - 11:47 AM

Blimey thats awesome for a tenner - in fact its awesome even at 50 each :surrender:

Where did you have that done mate? Id love to know of a good cheap polishers - Id get my whole engine bay done :shutup2:


Yeah for a tenner i was very pleased!

The guy is an older gent and works from home in a workshop in his back garden!

Ive searched his name but only found his ebay shop. http://stores.shop.e...s__W0QQ_armrsZ1

He mainly restores old candle stick's ect........
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#58 Stuart_J

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Posted 29 September 2009 - 12:21 PM

Update on my Engine

Small ends were Ok but 2 of the Cosworth pistons were failing, the map will be checked as the car IMO fuels pretty heavily but its unllikely that it contributed to the problem.

So its a set of new pistons etc & not Cosworth

Edited by Stuart_J, 29 September 2009 - 12:22 PM.

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#59 mrsteve

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Posted 29 September 2009 - 01:31 PM

lookin good tim, did you make a decision on upgrading the internals and everything else then or is it still subject to budget?

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#60 djtimodj

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Posted 29 September 2009 - 11:20 PM

lookin good tim, did you make a decision on upgrading the internals and everything else then or is it still subject to budget?


Yeah i think in 90% gonna do the internals ow but ive just got to convince jess (my GF) that its the most "cost effective" route! :cry:
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