gazza808
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Registered: 30th Jun 08
Location: Peterborough
User status: Offline
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why would the bulkhead crack because you have no powersteering?
same forces are still needed at the rack end just majority is being done mechanically instead of your arms,
sticky tyres and stiff suspension i could understand.
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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I found the sticky tyres and as you say hard suspension caused it problems once the power steering was removed, when you turned the wheel you can physically see the bulk head flexing more so on the passenger side as it has nothing else bolted to it unlike drivers side, hence why I have added a strengthening brace inside the car in the passenger foot well
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Picked myself some pistons up at the weekend have done approx 1-1.5K miles so whipped the pins and rings out and got them in the parts cleaner a before and after:
All cleaned, need to now gap the new rings I've got and get them all fitted up
Found out why my speedo shit itself turns out its snapped and melted the spindle so new one needed :cry:
Anyone got one?
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ianofbhills
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Registered: 10th Feb 01
Location: newcastle
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If you've not already sorted one I have a brand new speedo drive here you can have if you cover the postage costs.
(its for an f20 pretty sure its the same as f28 though)
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Last of the parts bought for the corsa rebuild
Had to get 15W/40 mineral oil as halfords no longer sell the 10w/40 :cry:
Got myself a under drive pulley as mine was standard size so risked frying the alternator with repeated high rpm, thanks to vxlgsi for his quick delivery
:thumb:
Also massive thanks to ianofbhills for the free speedo drive worm :thumb: Owe you a beer if I ever meet you :beer:
Once the Astra is back up and running then the engine will be finished off and put back in ready for running in 
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Well been busy lately so not had any chance to work on it really but got as far as weighing my rods and pistons only one rod was a different weight the one that I was given so I bit of material removal and it was all matched up
Also remembered I had a spare land rover oil cooler in the workshop which is a good size so am gonna use that as mine is no doubt full of swarf. Gave it a quick clean out
Then had a look at the quads which run a 12v fan, this ones melted slightly but have a new one on order
Gonna modify the brackets and cooler and fit this behind my bumper and wire the fan into my radiator fans so can have it on a switch or run off the ecu, I think the fan will be great out on track to help keep the oil temps down as these little fans are pretty dam powerful
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Nic Barnes
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Registered: 5th Apr 04
Location: nowhere near ginger people
User status: Offline
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nice idea
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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quote:
Originally posted by Nic Barnes
nice idea
Cheers I'm full of them 
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Jed D
Member
Registered: 15th Mar 11
Location: Durham
User status: Offline
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good shit mate 
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Novaneil
Member
Registered: 26th Oct 06
Location: Leamington Spa
User status: Offline
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Fantastic build mate! Really enjoyed reading through it. One question, where did you buy that slimline battery box from as I can't see it in the rally designs website.
Cheers,
Neil
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Pridzz
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Registered: 18th Nov 08
Location: Exmouth - Devon
User status: Offline
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A friend used computer fans
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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quote:
Originally posted by Novaneil
Fantastic build mate! Really enjoyed reading through it. One question, where did you buy that slimline battery box from as I can't see it in the rally designs website.
Cheers,
Neil
Cheers glad you enjoyed reading it, haven't touched it for a while just been too busy 
I bought it off a lad off here can't remember his name though, its a rally designs battery so they must sell the battery box to go with it I'd of thought
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Cheers Jed
And yeah have seen computer fans used before with great effect
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Ben-B
Member
Registered: 28th Jul 08
Location: the lovely Nottingham
User status: Offline
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quote:
Originally posted by Pridzz
A friend used computer fans
Is it just me, or are they the wrong way round?
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Made a bit of time for myself tonight so thought I'd get the rings gapped and pistons and rods assembled
Also bought a helix 4 paddle clutch a while back got it sat next to my old technic clutch and it really is a case of spot the difference tbh
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Just to clear up clutch differences, paddle part is identical bar the sticker but the cover plate is different
Helix:
Technic clutch:
Note the extra strengthening fingers on the edge of the pressure fingers on the helix
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Had a few more hours on the engine today so got the bottom end together and torqued up, spins nice and freely by hand so happy with that
Gasket on and sump sealed up and studs back in
Clutch and flywheel cleaned up
All fitted and torqued up and ancillaries fitted
So with the bottom end complete made a start on the top end, stripped inlet and exhaust off and started the strip down, could only go so far as the spring compressor at work is far to big for my engine :cry:
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Bottom pulley bolt torque up and gearbox fitted
Made a start on stripping bent valves out of head, exhaust valves are definitely bent and inlets are possibly but hard to tell as all my drills have a slight wobble on  msl:
Took 4 valves out of my spare head and cleaned them up
Started lapping but something didn't seam quite right, turns out old valves have had new angle cut in them and stems wasted so gonna have to get the new ones done to match which is bloody annoying as was hoping to have it in and running this weekend :cry:
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Jed D
Member
Registered: 15th Mar 11
Location: Durham
User status: Offline
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good shit mate. what was up with the old paddle clutch?
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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quote:
Originally posted by Jed D
good shit mate. what was up with the old paddle clutch?
I think it just started to slip at held 7250rpm so paddle part was fine but cover plate wasn't quite man enough, but tbh it has done well at 385bhp
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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On closer inspection of the head I wasn't happy with some of the valve seats and thought it would benifit from a skim, so dropped the head down to a recommended local company who are going to properly 3 angle seat the valves, put all new valve stem seals in as some fell apart when removing them, skim it and totally re fresh the head and pressure test it for me at a very good price
So instead of putting the engine in this weekend I've decided I will finally get round to fitting the cage after only 2 years of owning it msl:
So whipped the sunroof cassette out, didn't realise how much weight was in it! At a guess I'd say 20kg so half the cage weight so only really adding about 20kg's to the car :clap:
Took the seats and dash trims out and trial fitted the cage
So tomorrows job is to make the platforms and weld the back half in and bolt front half in, then make a start on adding extra bars to it
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Can't beat a good bit of head
Newly refreshed, blasted, valves seats 3 angle, newly cut valves, pressure tested and skimmed for a bargain price big thanks to Nick Gwinnett (Darkhorse) for sorting me out a deal at JTR engines in Poole which I highly recommend did a top quality service and in rapid time too :thumb:
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Decided to check and clean out all of the lifters, glad I did as one had smashed its retaining ring to bits and jammed shut, must of been the valve that took the worst hit
Had a spare ecotec lifter so re filled them all and tested them, then built the head back up
Heads all torqued up and inlet on just need to find time to fit the exhaust manifold and turbo and that it ready to drop in again
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v144 sport
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Registered: 24th Mar 11
Location: Melksham, Wiltshire
User status: Offline
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I seen this car get mapped back in 2010 just before pvs was mental on the dyno just kept spinning the wheels.
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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quote:
Originally posted by v144 sport
I seen this car get mapped back in 2010 just before pvs was mental on the dyno just kept spinning the wheels.
Ah you alright mate were you one of the Clio boys? Yeah even when 4 people were sat on front end and 2 lumps in the car it still span
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