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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Head now back after a quick clean and face. Not warped and not cracked so I think a failed gasket. I am putting it all back together next weekend and spending this one lapping valves which really needed doing. Loving the challenge of this at the moment. Not loving the bills!
Post #417074 18th Apr 2015 3:33pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Ok I got carried away and am fully stripping the engine to do the bottom end bearings whilst im there. I want to paint the block and generally tidy up a few bits and pieces as its going to be a keeper Smile Will take lots of photos.
Post #417380 19th Apr 2015 7:14pm
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Anderzander



Member Since: 08 Feb 2011
Location: Lancashire
Posts: 999

United Kingdom 
Take lots of pictures for us please !
Post #417383 19th Apr 2015 7:20pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
bad photo from my phone of where i am at.


Click image to enlarge
[/img]
Post #417392 19th Apr 2015 7:48pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Totally stripped now, photos up soon. There was a piece of card in the oil pan blocking the pick up from an oil filter box. Really glad I have had it apart now. Just trying to decide whether to drop it at the machine shop or clean and hone it at home??? Bearings, pistons and journals look good but will obviously require measurement to be sure.
Post #418960 25th Apr 2015 4:42pm
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Fatboy Slim



Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

Wales 
I'd have the bores honed in a machine shop personally. They'll achieve a far better finish on a machine than by hand , not worth the aggro of ripping it to shreds again because the rings won't bed and its using 5L of oil a week.....
Post #418963 25th Apr 2015 5:00pm
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munch90



Member Since: 26 Oct 2013
Location: guildford
Posts: 3558

England 
few things to think about
might be worth getting bores measured propely at machine shop
if your gonna home hone then guessing your going to use one of the 3-4 stone spring loaded "honer" , there not really a honer they a graze buster and will follow any oval wear in the bore , a proper honer like a delapena will make bore round again , but you might find you have take to much out to get rid of the oval wear (thrust side of bore will wear more )

the old rings will have worn to the bore if you fit new rings to worn bore there is a good chance of bit lower compression and oil burning

my advise would be get it measured by proper bore micrometer at machine shop and let them decide best course of action , also get the ring grooves checker in the pistons at same time , worn grooves can act like a oil pump moving oil up the piston to top as the piston goes up and down
if bores are good and will take a hone and ring grooves good then that could be the way to go

I would personally only ever rebore and new pistons BUT of course its much more expensive

sorry if telling you what you already know
Post #418971 25th Apr 2015 5:31pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Hi, Thanks for the advice. I am going to take the block to the machine shop and get them to check my measurements on the bore, hone and clean. I hope I do not need to go down the new block route! Hoping to have it back together next weekend.
Post #419204 26th Apr 2015 3:59pm
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munch90



Member Since: 26 Oct 2013
Location: guildford
Posts: 3558

England 
Think you can get +20 pistons , so shouldnt need new block

or lined back to std


Last edited by munch90 on 26th Apr 2015 4:33pm. Edited 1 time in total
Post #419216 26th Apr 2015 4:32pm
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Fatboy Slim



Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

Wales 
I'd seriously doubt you'll need a new block. Worst case senario fit sleeve liners to any bad cylinders. Turners sell them from memory
Post #419217 26th Apr 2015 4:33pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Progress:

Click image to enlarge


Notice the random piece of oil filter packaging blocking the oil pick up. It could only have got in there when new or when a lower end service was happening.


Click image to enlarge



Crank bolt tool


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mucky sump


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Bagging and labelling everything should pay off later down the line.


Click image to enlarge



Click image to enlarge


Block and pistons are in the wifes car now ready to go to the machine shop tomorrow for cleaning, measuring and honing.
Post #419297 26th Apr 2015 8:53pm
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Anderzander



Member Since: 08 Feb 2011
Location: Lancashire
Posts: 999

United Kingdom 
Brilliant ! And brilliant pics - thank you !
Post #419303 26th Apr 2015 9:20pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Block ready to go; all measured up at the machine shop and the bores are fine and have been deglazed ready for the new rings. Steam cleaner hired to clean up the engine bay which I will also touch up and dinitrol whilst access is good. Looking forward to starting the rebuild tomorrow evening. Three days should see a lot of progress.
Post #420224 30th Apr 2015 4:54pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Update:

The block after stripping to bare metal, painting with POR15 and POR black engine enamel x2 coats.


Click image to enlarge


I then made sure the deck was prepped by sanding for a couple of hours with 400 - 600 grit with a flat block. After this was a degrease, pressure wash, oil gallery clean with specialised brushed, air blast, more washing, then more washing, air gun to dry and into a clean and organised workshop for building up.


Click image to enlarge


I forgot to mention the sheer amount of measuring needed; micrometer and bore gauges to check bores (all in spec), micrometer on the main and big end journals (good) and then dry fitted the mains with plastigauge to check the oil clearances (again all fine)


Click image to enlarge


Giving these bits a good clean but no need to get them shiny as they are going to get muddy soon Wink


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Stripped down each piston as they were cleaned by the machine shop which left them seriously dry, lubed and reassembled with new circlips


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Next I refitted the oil squirt jets with a spot of loctite and torqued to spec (not pictured) then I fitted the crank shaft using new bearings and thrust washers. Mains need new bolts as they are stretch fit. Torqued to a nm setting then an angle. Here I tried to use a cheapo angle metre but it was awful so I hit ebay. Got really lucky on a beta digital metre which was listed as an 'angel meter' so attracted no bids Wink Crank endfloat checked with the DTI


Click image to enlarge


Next up pistons going in with new rings having checked the ring gaps and alignment against specs, again you need new bearing shells and bolts on these.


Click image to enlarge


Last one Smile


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Now things got annoying !

The last bolt on the big end rounded so I got on the blower to Turner who were great in sending me out a replacement. This was all good until I pulled the oil pump apart


Click image to enlarge


All measured up fine and got a good cleaning, popped it back together and every bolt torqued up fine until the last one which nipped and promptly stripped Sad Purchased some identical 20mm torx headed stainless bolts in M5 and a high quality tap to try and rectify this.

So now all the measuring is done it should be fairly quick to reassemble fully this weekend.

Have also spoken to Alive tuning to find out about a VNT turbo and intercooler, not having got any luck contacting IRB.
Post #425586 22nd May 2015 4:39pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Fully built up on the stand now, new clutch master and slave cylinders fitted, new release bearing. Nipping to the car parts place tomorrow for a alignment tool and then its going in Smile
Post #426704 27th May 2015 7:40pm
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