Project Bigals........

[Broxi]

The last bits for Alans car arrived thismorning, so i decided it was time to sort it out.

Now my workshop leaks like a Sive, and we are moving into another one on the 1st Jan. 3 times the Size, and has abulit in spray booth. :party0045:

Due to this i had to find somewhere dry to put the engine together, so Sally gave permission to use the Kitchen Floor. (Roll on getting the Workshop. as my back is killing me from bending and moving around in a confined space.) as long as we did not make a mess and covered the floor.

Cheers Sally. :cool:

I do not have any pics of me Assembling the block as my camera has died, was not till later Sally thought of using the camera in her Mobile phone; hence the pic Quality, or lack of it.

2002 bugeye.

When we removed the old block we decided the Open deck would not be up to the job, and decided to use my old Closed deck unit.
We had this re-bored +.25mm, Omega Pistons, New Sti Crank, H-Section Rods with ARP bolts. ACL Race series Bearings.

RCMS 1.1mm Thick Multi layered steel head gaskets. RCMS Oil Pump.

Equal length Headers.

Exedy Hyper twin Carbon Clutch. (See Pics of all the Layers. (Do not like the sound of the running in and warmining up procedure.))



http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a4ad277.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=248') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a9b4c08.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=258') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9aa66be7.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=259') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9aae5f89.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=260') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a5aaefa.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=250')

Now the Exedy clutch, which comes complete with flywheel. the flywheel is so light i can hold it with my little finger.
If you look closely you will see their are Two carbonfibre drive plates.
http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a9345c5.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=257') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a8a098d.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=256') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a81f5cf.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=255') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a7974a5.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=254') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a71deaa.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=253') http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a698b7b.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=252')
http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9a536486.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=249')

http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9b803bac.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=263')
http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9abeb980.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=262')
http://www.southwestscoobies.org.uk/sws_imagehosting/thum_14595a9ab6da3f.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=261')

Will get a Few more pics tomorrow.

Derek

[plumbscooby]

good man derek:biggrin:

[bob]

Looking good Derek....Double check the cams....:hysterical:

[AutoMan]

Your misses must love you....lol
If I tried building an engine on er indoors's kitchen floor I would be receiving a letter from the solicitor the next day.....lol

D-I-V-O-R-C-E......:hysterical:

[leplumbiere37]

Start It On The Saturday Morning, You Will At Least Get Three Days In And The Letter On Tuesday

[Broxi]

Your misses must love you....lol
If I tried building an engine on er indoors's kitchen floor I would be receiving a letter from the solicitor the next day.....lol

D-I-V-O-R-C-E......:hysterical:


:hysterical::hysterical: She is very good to me.

Went up to my workshop today, and could have has a shower, the water coming in was That bad. :eek:

But my new one will be available early next week. :party0010:

Here is a few more pics.

Todays work was done out in My garage.

you will see alan's paint handy work, no masking up :eek:

http://www.southwestscoobies.org.uk/uploads/30122006066-thumb.jpg (http://www.southwestscoobies.org.uk/uploads/30122006066.jpg) http://www.southwestscoobies.org.uk/uploads/30122006065-thumb.jpg (http://www.southwestscoobies.org.uk/uploads/30122006065.jpg) http://www.southwestscoobies.org.uk/uploads/30122006%28001%29-thumb.jpg (http://www.southwestscoobies.org.uk/uploads/30122006%28001%29.jpg) http://www.southwestscoobies.org.uk/uploads/30122006-thumb.jpg (http://www.southwestscoobies.org.uk/uploads/30122006.jpg) http://www.southwestscoobies.org.uk/uploads/30122006068-thumb.jpg (http://www.southwestscoobies.org.uk/uploads/30122006068.jpg) http://www.southwestscoobies.org.uk/uploads/30122006069-thumb.jpg (http://www.southwestscoobies.org.uk/uploads/30122006069.jpg) http://www.southwestscoobies.org.uk/uploads/30122006070-thumb.jpg (http://www.southwestscoobies.org.uk/uploads/30122006070.jpg) http://www.southwestscoobies.org.uk/uploads/30122006071-thumb.jpg (http://www.southwestscoobies.org.uk/uploads/30122006071.jpg)

[Welsh Scoob]

Mann, when i bought my scoob with a blown engine, thats why i spent **** loads on engine having it built for me. i was considering building it my self, after seeing those pictures im so glad i didn't, i would of been pulling my hair out. its been bad enough doin my FMIC. i think i will leave it for a while before i do any thing else.:rolleyes1: :rolleyes1: :rolleyes1: :rolleyes1: :rolleyes1: :action-smiley-065: :action-smiley-065: :action-smiley-065: :action-smiley-065: :action-smiley-065:

goodluck dereck.

cheers welsh scoob

[Broxi]

More pics will follow in the week, but the engine is in, and the car is running.

started first turn of the key.

Alan does not have an impreza, he now has a superbike, well you would think so the way it revs and sounds.

the lightweight clutch means its reving very easily.

and the equal length manifolds has removed the burble, and boy does it sound good.

ECU light is on, i do not think you can check the 02 models without a proper computer, but i think it may be the crank sensor.

Derek

[mudmatt]

got the radiator sorted then derek!

[bob]

http://www.obdtools.co.uk/store/index.php

Boosted bought a code reader from here some time back £50 I think he said...

[scoobyDAZZA]

looking good
which turbo did you go for in the end ?

are you doing parallel fuel lines ?

wondering if that's the same clutch as mine , exedy twin plate , dont think mine says carbon though RRP £1250 + VAT mine was

[Broxi]

yes all sorted.

[scoobyDAZZA]

turbo ?

[Broxi]

Still get the VF35, will change this once the car has done 1000 miles.

[scoobyDAZZA]

thought it was a 34 ?

if he wants MAHOOOOOOOSIVE power and have the turbo in the standard location then have a look on owen developments site
upto 500 bhp iirc , or an MD321T from Lateral Performance, upto 450 bhp

[Broxi]

yeh think you could be right VF34.

He plans on getting this from Andy.F

AFP35H – Is a custom machined Garrett GT 35R this is also available with a ported shroud compressor cover and requires dedicated exhaust up pipe, down pipe and a remote wastegate. A complete bolt on package is available. This turbo can produce up 600bhp.

Spool up on this turbo is very much dependant on the engine build including factors such as compression ratio and camshaft timing.

He knows it means a few mods to make it fit.

Gems ECU and probably some cams.

Derek

[scoobyDAZZA]

just a few mods to make it fit
:lol:
RCM do all the twisted stuff :)

[Broxi]

well It has been a While since this was updated and a Few Things have Changed...

A TD06 20G has now been fitted... the Car is in at Engine tuner at present having a Simtek ECU fitted and mapped...

However the Exedy Hyper D-Core Twin Carbon clutch is slipping with the torque.... unless you get heat into the clutch and keep the heat their... it is no good... hence why this clutch is designed for track use.

Exedy confirmed that you need to perform 3-4 5 second slips of the clutch whenever it looses heat to prevent the clutch slipping.... not much good for the road...

Engine Tuner are now supplying a Lightweight Steel flywheel and Rally Clutch kit... to cope with the power levels...

The Exedy hyper is now up for sale.

Will update on performance in a few days...

[scoobyDAZZA]

TD05 or 06 ? thought you told me 06 ?

[Broxi]

TD05 or 06 ? thought you told me 06 ?


Yeh my Bad.... Sorry it is a TD06 20G

[beachsleeper]

Lookin good, The Kitchen Floor, is the best place to build engines. You dont have to go out for lunch. But a engine stand helps, bud. :cool:

[Broxi]

Lookin good, The Kitchen Floor, is the best place to build engines. You dont have to go out for lunch. But a engine stand helps, bud. :cool:

Got the Engine Stand after doing this.... Much Easier.... lol

Now i have a unit to do the work in... well for a few weeks at least..

[Olly P]

"Engine Tuner are now supplying a Lightweight Steel flywheel and Rally Clutch kit... to cope with the power levels..."


Whats a Rally clutch kit?:confused:

[tiny]

shame about the clutch but if its no good for road use then I guess it had to go ;)

look forward to seeing the results

[AutoMan]

It's a Group N clutch kit as used in Group N Rally cars.....

[scoobyDAZZA]

Cerametallic

[tiny]

does that mean the gearbox isn`t on its way out then?

[Alan Jeffery]

If you've been listening to the noise, you'd be forgiven for thinking it was!
I've got a twin plate in my Evo, but it's not the carbon version. Rattles like stink when you put your foot on it, but worth it for the grip and the ease of use. It feels like an ordinary clutch, but bites like a pit bull.

[Broxi]

So has the new clutch Arrived and been fitted then?

Alan say's he cannot survive any longer driving an old mans car. (Rover)....

He is bidding on a flat cap and a pipe on ebay so he looks the part lol....

[Alan Jeffery]

Yes, the clutch has arrived, no, we haven't fitted it yet, as we want to sort out an oil leak from the turbo drain as it's right in front of us.
Our courtesy cars are carefully chosen so as to match the needs of the owners! the Rover in particular does a sterling job of this, having no street cred whatsoever. Anyone abusing it would look really stupid, much in the way of getting cross with a small yappy dog on the end of your lead. any attempt to drive it badly would be met with scorn by the population, so the only way to drive it is quietly, with your head well down, in case someone sees you in it. I know of one other tuning establishment that has courtesy cars. Thiers end up on u tube being ragged around the moors!
We're on the case today mate, so tell the man his ordeal will be over soon...

[Alan Jeffery]

Oil leak fixed, clutch in and back on dyno.
Next problem! injectors maxed out early.
Checking the fuel pressure revealed no increase in pressure with boost. Dead test showed plenty from the pump. Checked boost pressure into reg. was fine, so we need a new pressure reg.
Back on tomorrow!

[briharri147]

Good luck with that Alan

[Broxi]

The car has been totally Transformed and has made 406 BHP running 97 Ron fuel at 1.65 Bar

Please see following thread for Printout....

http://www.southwestscoobies.org.uk/showthread.php?t=10475

[Broxi]

Well its been back to AJ's to tweak the map.... and boy what a difference....

Torque is up and you can sure notice it on the road.... its a Flyer....

http://www.southwestscoobies.org.uk/sws_imagehosting/thum_147d2a50320575.jpg ('http://www.southwestscoobies.org.uk/vbimghost.php?do=displayimg&imgid=1084')

[briharri147]

Very nice