326 replies to this topic

[apbellamy]

Thanks

I can confirm that boost is fun and torque steer is interesting Currently running 7PSi and pulling like a train. AFR readings are pretty good, when on boost staying between 10.5 and 12.

[rachel]

Yes, you're nearly there it'd be great to see you at Normanby Hall Mini Day on June 20th seeing as it didn't happen last year and I'm sure loads of people would be interested in seeing what you've been up to with a modest little Metro van - a real wolf in sheep's clothing

If you need any info just let me know

Rach

[kalum]

hey, great project, love the van i really want one now.

have you got any other plans for it from this stage?

kalum

[apbellamy]

More boost and more power

[apbellamy]

We're back to probably the slowest metro van in the world

We traced the excessive boost to the cheepo ebay manual boost controller, but the damage was done. The engine's out and partially stripped now.

The main reason was the smoke. Low compression on all 4 pots and smoking pretty much all the time. There where also symptoms of head gasket failure. Turned out the head gasket was fine, but it's looking like the block has sunk between 2 and 3 (third time the head has been of with the same result each time, smoke damage but no burnt fire rings). The cheepo head gasket stood up quite well considering. The thrusts where also concerning us as the rev's where still dropping with a good few miles on it.

*melon* happens. We have a really good condition block (honing still visible and no lip) which will be getting preped, honed and checked for flatness. It will also be taking a trip to Fast Carl for an oil fed thrust conversion. Total seal rings are on order and should be here in a few days.

When it was first on the road, full emergency starts where destroying the engine mounts. The pancake filter was bent from hitting the bulkhead. We don't really want a red hot turbo smashing into the brake pipes. So while I was waiting for John to bring my engine crane over, I broke out the CAD:




Thin steel prototype looks to do the job quite nicely.




Not bad for a first attempt. I'm going to get some thicker steel and make another. The new one will be boxed in between the engine steady bar and the bulkhead side of the bracket. As it is, I think it would just concertina in under any more than normal load.

[GreaseMonkey]

Ah that sucks, sorry to hear it had to come out!! Is it totally cream crackered then?

[apbellamy]

It was never going to be perfect using second hand piston rings. This way it should be good and in theory not need touching again.

[apbellamy]

Explains why the rev's where dropping with the clutch pedal down. The thrust faces on the crank match, so that will be getting a grind.

[GreaseMonkey]

Doh

Crank endfloat?

Edited by GreaseMonkey, 18 April 2010 - 08:20 PM.

[alexcrosse]

5mm i expect, LOL

[apbellamy]

As we've done such a good job of ruining the engine, I thought I'd have a go at ruining the ride as well.

I've stuck on a couple of these



So that we can fit these



Put some poly bushes up here



The current displacers are all pretty knackered. It's taking 450psi to keep the ride height, where 300 psi should be enough and one is leaking a little bit. So while we're at it, we're going to fit a set of good used ones. And while we're at that, we thought we may as well lower it a bit. I've taken 6mm of the rear trumpets and 10mm of the fronts. Should drop it about 30mm.

[apbellamy]

[apbellamy]

The 'new' gear box is now sorted - 4 pin diff fitted with the 3.1:1 CWP, straight cut input gear and these removed from the selector mechanism.



Then we've cracked on and built up the engine.



Thanks to Mr Oneeyedlizzard the timing is set to 108 degrees.



All end floats are checked, so depending on how much beer we drink tonight we should have a complete engine tomorrow )

[mini_mad69]

Brilliant, do the oil fed thrusts take much work to do, is it a case of drilling them? and drilling and tapping the block for the screws?

[apbellamy]

Pretty much, yes. Didn't take me any effort at all. I just gave the block to Carl at Force Racing then picked it up a few days later