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Author Project "Monty" - 2012 = 447hp
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
22nd Apr 10 at 21:25   View User's Profile U2U Member Reply With Quote
Got more done today

First off was fitting the output shaft seals

This is the propper tool we use at work (Same as mini's)





Next up was fitting the z20let oil pump

First off remove the wrong seal and fit the correct seal





Then fitted Steve's pick up pipe



Found out that the z20let oil pump uses M8 bolts (2x M8x25mm Cap head screws) and M6 for the rest to the block (12x M6x20mm) I had to drill the 8v baffle plate and alloy sump to allow M8 cap screws to go through





Fitted dust cover and bottom pully



Then Fitted water pump and New cam belt and timed engine up including XE inlet cam, I have retarded the XE cam by 6 Deg!

More tomorrow

Dale

[Edited on 22-04-2010 by DRS]

[Edited on 22-04-2010 by DRS]
Graham88
Member
Registered: 16th Apr 07
Location: South East Kent Drives: E46 M3
User status: Offline
23rd Apr 10 at 01:56   View User's Profile U2U Member Reply With Quote
Love the whole project, gonna be epic
shaunmods
Premium Member

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Registered: 12th Mar 07
Location: Glascote, Staffordshire
User status: Offline
23rd Apr 10 at 10:32   View Garage View User's Profile U2U Member Reply With Quote
Stupidly clean! Dale I really hope for your sake PVS isn't a bog again this year
rowland
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Registered: 4th May 08
Location: Greater Manchester
User status: Offline
23rd Apr 10 at 14:46   View User's Profile U2U Member Reply With Quote
it was good to meet you the other day mate
so you changed the grey in the end then it looks much better anyway will look smart with the black n white.
excellent work on the engine keep up the top work
stu_c
Member
Registered: 11th Dec 07
Location: Westleigh, Greater Manchester
User status: Offline
23rd Apr 10 at 17:05   View User's Profile U2U Member Reply With Quote
oh my word dale it looks like its never seen the road!!!

cant wait to see this in person
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
23rd Apr 10 at 21:52   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by Graham88
Love the whole project, gonna be epic


Cheers

quote:
Originally posted by shaunmods
Stupidly clean! Dale I really hope for your sake PVS isn't a bog again this year


I hope it isn't too, I'm not going to park it in the field if it is

quote:
Originally posted by rowland
it was good to meet you the other day mate
so you changed the grey in the end then it looks much better anyway will look smart with the black n white.
excellent work on the engine keep up the top work


Yer likewise Dan, good to put another name to a face Yer I wasn't happy with it at all Yer i'm happy with it now

quote:
Originally posted by stu_c
oh my word dale it looks like its never seen the road!!!

cant wait to see this in person


Cheers Stu, Yer will be there at PV in all its glory

Done alot more today will sort pictures out and post them up tomorrow
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
25th Apr 10 at 20:40   View User's Profile U2U Member Reply With Quote
Bit a late update but here goes

Pictures of cambelt on and timed up with inlet retarded




Then Steve Milton lightened pot flywheel with LUK clutch (haven't upgraded as clutch is pretty much brand new)




Checked in a few boxes for bits in previous conversions found brand new set of genuine engine mounts (all 3) and all 4 genuine cv boot kits



Then gearbox on and time to get it in the car






Then i fitted the turbo with cossie actuator




Then Fitted oil cooler and mounts



Intercooler on




fitted the webber fuel pressure regulator



Fitted throttle body, Top hat and started and all the hoses




Then i started on the wiring and tidying the looms up






cleaned filler neck and front arch liners



Goodridge Brake hoses with the stainless option for fitments



Does anyone know if the standard reticulation valve works ok on evo5 software?

Fitted all brake pipes and headlamps!

Hopefully more in the week

Dale
jr
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Registered: 20th May 02
Location: Kent
User status: Offline
25th Apr 10 at 20:42   View User's Profile U2U Member Reply With Quote
first time ive ever seen a gearbox referb that doesnt involve spraying every single bit halfords sliver
spankyjames
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Registered: 26th Jun 06
Location: Corsham, Wiltshire
User status: Offline
25th Apr 10 at 20:44   View User's Profile U2U Member Reply With Quote
top work dale, cant wait to see it all finished
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
25th Apr 10 at 20:51   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by jr
first time ive ever seen a gearbox referb that doesnt involve spraying every single bit halfords sliver


All about breaking the colours up, i also sprayed the clutch bracket black aswell

quote:
Originally posted by spankyjames
top work dale, cant wait to see it all finished


cheers, yer i can't wait to drive it
Nic Barnes
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Registered: 5th Apr 04
Location: nowhere near ginger people
User status: Offline
25th Apr 10 at 21:00   View User's Profile U2U Member Reply With Quote
probably one of best fpr you can use. baffles me why people still use and fail with fse regs.
Dale
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Registered: 7th Oct 07
Location: Swindon
User status: Offline
25th Apr 10 at 21:18   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by Nic Barnes
probably one of best fpr you can use. baffles me why people still use and fail with fse regs.


because its new and shiny and people think because its after market it works.... ( I know i like shiny things too )
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
28th Apr 10 at 20:01   View User's Profile U2U Member Reply With Quote
Little update nothing great

Got more loom stuff ( can't remember what its called ) to tidy looms up



New fuel pipe and clips, job for the weekend (Big thanks to mike)



Bought TX crank pulley as I'm not running PAS so I don't need twin pulley




and finally a few pictures from underneath with brake pipes fitted back on with new braided hoses






Cheers Dale
Sean-B
Member
Registered: 1st May 07
Location: Wolverhampton Drives: 200SX S14a
User status: Offline
28th Apr 10 at 20:09   View User's Profile U2U Member Reply With Quote
Absolutely amazing work and at such a pace as well!

Love this build!!
Rick Draper
Member
Registered: 10th Feb 01
Location: Cheshire
User status: Offline
28th Apr 10 at 20:25   View User's Profile U2U Member Reply With Quote
Stunning Dale, stunning.
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
28th Apr 10 at 20:51   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by Sean-B
Absolutely amazing work and at such a pace as well!

Love this build!!


cheers Sean

quote:
Originally posted by Rick Draper
Stunning Dale, stunning.


cheers Rick, measured the shaft, check on MIG
Rick Draper
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Registered: 10th Feb 01
Location: Cheshire
User status: Offline
28th Apr 10 at 20:54   View User's Profile U2U Member Reply With Quote
Cheers Dale, just dropped you a PM on mig.

Thanks again.
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
29th Apr 10 at 18:48   View User's Profile U2U Member Reply With Quote
Well popped to vauxhall at lunch picked up a few bits





Still got to pick some more bits tomorrow! Will hopefully get loads more done over the weekend

Dale
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
User status: Offline
29th Apr 10 at 19:13   View User's Profile U2U Member Reply With Quote
This must be costing you a bomb mate

Will be worth it once its all done
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
30th Apr 10 at 22:28   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by wooly101uk
This must be costing you a bomb mate

Will be worth it once its all done


depends what a call a bomb there is a fair amount gone into it

Also a little update

Got the intercooler pipes bead rolled so not popping off for me




Then i fitted the new exhaust heat shields and stat and stat housing




Cheers Dale
daymoon
Premium Member

Registered: 1st Aug 08
Location: Selby, North Yorkshire
User status: Offline
30th Apr 10 at 23:14   View Garage View User's Profile U2U Member Reply With Quote
some one has an ocd...


Looks spot on though
Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
1st May 10 at 19:38   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by daymoon
some one has an ocd...


Looks spot on though


I don't believe it or not..... Just like my car to be nice and clean! everything else is a mess

Got more done today with Mike (Thanks once again)

todays job was to do the fuel pipes

So routed the return line from the FPR



Then routed the feed to fuel rail




Then ran them as close to the original route as possible



Underneath




Wanted to keep the original route and fuel filter (although it need painting)



with the fuel tank fitted



And how the car sits at the moment



Cheers


[Edited on 01-05-2010 by DRS]
AlexW
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Registered: 25th Oct 08
Location: Essex
User status: Offline
1st May 10 at 21:41   View User's Profile U2U Member Reply With Quote
Been reading this thread as and when its updated, Loving your attention to detail, exactly what i would love to do providing i had the time and money.


You should be really proud of this car once its on the road (I wont say finished as a project car like this is Never finished!)
shaunmods
Premium Member

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Registered: 12th Mar 07
Location: Glascote, Staffordshire
User status: Offline
1st May 10 at 21:50   View Garage View User's Profile U2U Member Reply With Quote
Dale are we still on for swapping cars at PVS?.......

its just perfect. No other words to describe it. Serious effort going into it!
Mark.W
Member
Registered: 3rd Jan 07
Location: County Durham
User status: Offline
2nd May 10 at 10:04   View User's Profile U2U Member Reply With Quote
Outstanding work Dale,one of the best examples of a corsa on here

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