My First Build

[Tosh21]

So it turns out the head is pretty much perfect from factory and the time It'l take to polish it all, grind it etc really really isn't worth the gains! But gave it a good clean anyway and would be nice to rebuild it all with new gaskets and seals etc. Just going to lap the valves in and throw the head back on when I get my gasket kit and head bolts. Hopefully she doesn't explode when I hit VVTI change over so going straight to the redline when she's back together.

Cleaned up the valves, so glad I could chuck em on the lathe! made it so fast and easy



Started pulling out all the rads, ac will go too. Need to make space for the intercooler, PAS cooler and oil cooler.

Mocking up the new rad.



Still debating whether to take the slam panel out and make a new one to mount the rad and oil cooler off or just drill into it and rivet some brackets on. Also need to figure out how to mount a fan on the rad.

Think I've underestimated the amount of this all the work I want to do will take

[Tosh21]

Finally got some decent time down.

Pulled out all the rads and the a/c



Suddenly there was so much space I thought about putting a second in



Pulled the head apart and cleaned it a bit. Was going to soda blast it to make it look like new but it's completely pointless as I'm not going for the whole super clean and shiny car look. It would just take a lot of time plus it looks pretty good anyway.



Gave her a very very light skim while I was at it to clean it all up nicely and ensure it was dead flat



Rebuilt with new seals and lapped valves



After 2 and a half hours I finally got it back together only to realize I forgot to put the valve spring seats in. On the bright side, the second time I rebuilt it I managed to strip it, clean it and rebuild it in just over an hour.

Next I had to prep the cylinder deck (at this point I really wished I took the engine out and built the whole thing on the bench) did the best I could with blocking up the oil and water jackets.



Let the rebuild begin!



It has taken me a very long time but finally the head is on an torqued up.



Reassembled by VVTI gears which is petty easy really. If I've done it right....first test drive is going to be a butt clenching moment that's for sure.

Plan to have the cams and cover on tomorrow, water pipes, inlet manifold, pas pump and hopefully get it timed up!

Will then just be a case of figuring out a way to mount my new rad, smash it in and turn over for the first time in a month!

Very excited. Miss driving it so much

[Tosh21]

Didn't get anywhere near as far as I wanted today but hey ho can't rush these things.

Everything behind the head is bolted on, water pipe and some brackets.

Got the cams in place but not torqued down as I need to figure out where they go



Then it was a bit of a battle trying to get the pulleys right. The inlet was really easy but the exhaust is a bit of a pain and doesn't seem to want to go on so will have to get a second brain on it on monday.

So this is how she stands now.



Pretty happy with the progress it's really starting to take shape. Without the head I was really thinking that I went in way too deep and the car will never run again but now it's actually looking pretty good!

Want the exhaust pulley fitted on monday and the engine fully timed with a belt on ready to go. Then it's just throw the pas back on, inlet and some other random brackets. Going to just tape my rad on somewhere for now and make one ghetto ass header tank just for a test run.

So next week I will either Blow up or have one happy ass engine!

[andy t]

looking well,,,
like the job on the coilovers

[Tosh21]

FINALLY! She is rebuilt and timed, no contact in the engine. Even turned it on the starter for a while and no problems.

Happy days!

Lost a spacer on the fuel rail so quickly made a nice ali one. Tempted to make them all ali now!



She's screaming for ITB's! If only they were easier to get hold of.



Got a few little bits and bobs left but seems to be going well so far.



DYING to fire it up and test the vvti!

[Tosh21]

Finally fully rebuilt and back on the road. Who says you can't rebuild VVTI =P

My undertray got totally mashed up when I crashed so I finally got to making a temporary ali one until I get a new bumper and will make a nicer one which fits better.

[Tosh21]

Undertray lasted a whole 30 miles, awesome.

Car is back in it's usual resting point waiting for bits and my friend brought his riley in. Looks amazing!



Got some injectors from Nick, he found me some second hand and sent them over. Very helpful guy, excellent for any parts!

Looked into getting an exhaust flange water cut but it was quite difficult to measure the gasket and a bit tricky to draw up so I made it by hand instead. Manually rough machined the ports and finished with a grinder. Outside shape still needs grinding but wanted a test fit first



Came out surprisingly well actually. Been a lot of debate as to where I will put my turbo, would like to have it down low so I can cool it easier and have a short pipe for the intake with a trumpet in the bumper maybe but then the manifold will have to corckscrew around itself which will be a pain to make but look amazing. Also thinking about a side exit exhaust through the passenger wing but not sure yet.

Also got some ITB's! They will be getting put on with a nice ali plenum

[Tosh21]

Finished the fist bit of the manifold and welded the stubs on.



0.8mm Inconel, racecar spec!



If anyone if needing manifolds let me know I may be able to help you out

[xeraptor]

I would advice to put thick head gasket or gasket sandwich while you are at it.
It is knocking on 0.7bar and 14* of advance with my Apexi 1.8mm gasket.

I can image it would just blow up with stock compression.

[Tosh21]

I'm only going to run 0.5. I've seen lot of people run stock compression with no problems. Ill lower the boost if it struggles and save up for forged bits

[Irish_Al]

Serious amount of work going into this - respect

[Tosh21]

So cut the collector out and it actually came out really nice which is good.



Normally when making a manifold you would mock it all up with stuff you can move and bend easily but I don't have time so was a case of try imagine it and just make it. Took a while at first but finally ended up with this



Now I have all the primaries far enough to the point where I can bring them into eachother to fit the collector. This is where it either goes really well or horribly wrong. Fingers crossed that I'll have a full manifold this time tomorrow

[banan1984]

I cannot see any of Your pictures anymore mate

[Tosh21]

They still work for me :S

Pulled a mega late night last night to just smash through it and it's now ready to be welded! 1 bit is very close, the collector actually rests on another tube so might get some funny vibration but I think it should be fine. Space is so limited and my bends aren't really tight enough to fit in there but seems to be ok so far! once it's welded and moves about maybe it will free some space. Probably not.

Who wants to see some car porn?

[Tosh21]

Was ALOT of work and a few very very late nights but its done! Some bits are a bit of a bodge atm but all those bits will get changed later anyway. Ran it with just the manifold and collector, it sounds AMAZING. here's a vid, not sure how good the quality will be tho http://www.youtube.com/watch?v=MI7XmIA0cME
2.5 inch downpipe didn't fit cos the bend was way too long unfortunately so had to bodge it awith a 2 1/4. Leaks alot but itl get me to traxx Atleast. Pipe just goes to the bottom of the engine bay and bends back stopping right under the bulkhead. it's incredibly loud and smashing through the gears on the redline she sounds fantastic and bangs with every change. Pretty happy with the result!