patrick the pulsar

Today I took the bottom end into work to strip & check for damage etc.
removed lower sump & upper sump, oil pump, water pump crank pulley. Timing chain & guides. Oil pickup, baffle plate, mains & journals.
The crank doesn't look in to bad condition apart from one of the flywheel bolt treads being knackered ( got a polished & balanced crank to go in) the bottom end shells mains & journals have very slight wear as do the thrust washers.
Main & journal shells will be replaced anyway.
Pistons were removed & still look pretty shiney, just slightly carboned up (nothing a bit of brake cleaner won't sort)
Now for the shocking part, whilst checking the bores it would appear there is a lot of pitting on the cylinder walls. I'm pretty surprised the damage hasn't snapped a piston ring. Unfortunately the damage isn't going to come out with a hone so now I will need to source a new block to accept my 86mm cps as I don't want to go overbore.
I personally think the damage was caused from the engine sitting for a long period of time without a squirt od wd40 down the bores.

I also pulled the end case off the gearbox removed selector forks & rods. Just need to strip input shaft & main shaft but from what I can see of the gears & synccros etc it all looks pretty good.
Will take this into work & press the gears & synchro hubs off & see what's what.

Well done for getting stuck in there    If you do need a replacement block whats that gonna cost against a set of 86.5mm cp pistons?

Nice to see you getting on mate

pulsarmoley wrote:Well done for getting stuck in there    If you do need a replacement block whats that gonna cost against a set of 86.5mm cp pistons?

Will pm bob tomorrow but his away till new year now.
86.5 cps will cost £350 plus shipping but then I need a rebore & hone probs £120
If I get a new block I only need new piston rings

The cost of the replacement will be the determining factor then. You will probably have to hone the replacement as well for piece od mind but I suppose you have a honing tool?

what about the gearbox? is it easy to verify all the stuff inside? i'm a bit afraid of rebuild mine....

fred05 wrote:what about the gearbox? is it easy to verify all the stuff inside? i'm a bit afraid of rebuild mine....

Sorry Fred I've only just seen your post. To be honest I think our gearboxes are pretty straight forward to strip etc
Get stuck in.

Haven't updated for a while. But today I got the gearbox pretty much back together (just the end case to go on)
Stripped all gears & cyncros etc. all looks in extremely good shape.
The gearbox that I'm using now is the one the car originally came with. (Hopefully be better than the old so called rebuild one......)
I'm just waiting on parts to be delivered then its time to crack on.
Bob has kindly sorted me a bottom end which I will be picking up shortly.
I can now see why people just buy a second hand forged lump. All the parts work out pretty expensive, saying that I am pretty anal & replace things that possibly don't need it

Parts so far
Timing chain & tensioner genuine
Thermostat genuine
Cyclinder head, ported & flowed, 3 angle seats, bronze guides, cc matched, shimed
Hks 264 cams
Rocker stoppers
Cosworth head gasket
New cp riston rings
Acl main bearings
Acl rod bearings
Acl thrust
Arp big end bolts
Brand new oil pump genuine
Brand new sump pan genuine
The list goes on. Hopefully be worth it

At least if you've sourced and fitted the bits its gives you peace of mind. When do you reckon you will have it back on the road?

Update time. This build has take forever.............. But I should be finishing off the engine tommorow & picking it up from work ready to put back in the car.

Clean pistons




The head

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The block.

Nice work james

Purchased new stack oil pressure & boost gauges. Expensive but look the tits......

It's been a long process with lots of problems along the way & I now have a empty wallet...... To be honest tho I love these cars & think building them is part of the fun but can see why people buy a ready build engine. I will 100% agree it's cheaper to buy one already build & stress free.
I'm up again early tomorrow to go into work to bolt the gearbox, transfer box & engine loom on & it should be back in the car by tommorow afternoon.
God I'm looking forward to having a lay in on Monday. I've been up at just gone 5 for the past week to get into work early to get it built. Good fun mind,

Great effort mate well done will be worth it when its running

Some nice work james ..... i know who to call when i want mine rebuilding    ...