Daniel_Corsa
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Registered: 21st Apr 04
Location: Wigton, Cumbria
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Hamish has been on with the engine for the past few weeks gathering all the bits needed for it.
The horrible old red paint was stripped from the block and some more tasteful black put back on. All the oilways were cleaned out and finished off with a good pressure wash. Then it was onto putting the bottom end together:
Started off gapping the rings with a diamond wheel.
Using a piston mocked up with the second ring to make sure the one being gapped is square in the bore.
Crank, pistons, and rods in with new main and big end bearings, also new thrust washers. The oil squiters were cleaned up with parafin and bolted in with threadlock to make sure they dont come back out. ARP main studs from a Ford Zetec for the extra length to pass through the girdle. The girdle ties together all the main caps with the crankcase to stop any movement at high revs/ load.
Then in with the ARP headstuds and RS2 headgasket
He has used sportquattro headbolt washers to spread the load more as the ARP ones are tiny.
Cylinder head on
Then on with the cam cover and sump to see what its going to look like. He had all the alloy engine bits blasted back to fresh alloy.
So the spec of the engine as it stands
Standard crank with all journals measuring up spot on
New main bearings
New thrust washers
New one way oil valve to cylinder head
JE pistons with gudgeon pins moved 6mm higher, 8.5:1 compression
Pauter conrods 6mm longer than standard
New big end bearings
Block girdle
Dry sumped
Sport quattro head stud washers
ARP main studs
ARP rod bolts
ARP head studs
RS2 headgasket
Ported cylinder head by JNL racing
Machining on headface for water channels
Inconel 0.5mm oversized exhaust valves
Black nitrided stainless 0.5mm oversized inlet valves
Solid lifter cams from Cat cams
7A cam cover.
He will cover the rest of the spec when more of it is built up. It will be fully built up this month and hopefully mated to the gearbox and into the car!
April '06' Corsasport Feature Car  | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Tom
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Registered: 3rd Apr 02
Location: Wirral, Merseyside
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Any more updates? That engine sounds pretty impressive
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3CorsaMeal
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Registered: 11th Apr 02
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love this thread, its done like jr had got a decent car and actually built it 
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jr
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Registered: 20th May 02
Location: Kent
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far more skill then i'll ever have
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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So another month another update.
Hamish has been working away on the engine for the past few weeks trying to get hold of all the parts needed, and machine the ones he couldn't
Finished off the cylinder head shimming:
Buckets that sit ontop of them:
Turned down a bolt in the laithe to block up the dipstick hole:
Had to make up a gasket for the front cover plate:
Whilst using the laithe Hamish turned down the spacers between the main caps and girdle, left them 10thou higher than the crankcase to make sure its pulling the caps down. Then got it torqued down with the arp studs
And sealed it up to take the sump:
Then put the sump on, before he did he took a few pics to show the internals of it:
That left the engine ready to go into the car, so the flywheel, clutch and gearbox were bolted up:
And in!
Seems to have plenty of room at the front for a nice big intercooler! Excuse the state of the power steering pump and alternator just trying them on to see how its all going to work. You can also see the 25mm golf cambelt set up, increase of 6mm width over the standard belt. All the pulleys are wider to make up for this.
Finally picked up a couple of proper works fuel pumps. Bosch 044 motorsport 10 bar ones. Not from the works team you might be thinking of though.
Hamish has the coming week off work so will plug away at a few jobs that he has been putting off. The exhaust manifold and turbo are the next pieces to buy then he can do the boost pipes, exhaust and turbo lines.
Its good to finally have it all back in one piece, first time all the major bits have been together in 2 1/2 years!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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chugga_boom
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Registered: 31st May 09
Location: sidcup, kent
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this is the best build thread on here by a mile! just read it from the start cant wait to see it all finished 
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
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holy.........shit............epic, this is gonna be good
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c18xewoody
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Registered: 15th Feb 09
Location: lincolnshire
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just read from start to finish .......... omg wot a build
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Griffiths1991
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Registered: 28th Jul 08
Location: Cheshire
User status: Offline
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quote:
Originally posted by SteveoBC
holy.........shit............epic, this is gonna be good
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Matt L
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Registered: 17th Apr 06
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looking forward to more updates 
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Joe-Tait
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Registered: 11th Feb 08
Location: Newcastle Tyne and Wear
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Class
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chunky_nb
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Registered: 19th Jan 07
Location: Bridgend S.Wales
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really starting to take shape now, cant wait to see it run, will it be coming down here (south) to shows etc?
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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quote:
Originally posted by chunky_nb
really starting to take shape now, cant wait to see it run, will it be coming down here (south) to shows etc?
He plans to have it all done for Ultimate Dubs 2011 so will be down at Telford for that, and no doubt ED38 next year too.
I can't wait for the first time the 5 pot fires into life
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Matt L
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Registered: 17th Apr 06
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quote:
Originally posted by Daniel_Corsa
quote:
Originally posted by chunky_nb
really starting to take shape now, cant wait to see it run, will it be coming down here (south) to shows etc?
He plans to have it all done for Ultimate Dubs 2011 so will be down at Telford for that, and no doubt ED38 next year too.
I can't wait for the first time the 5 pot fires into life
let me know when its sorted and your down this way and ill sort out some pictures of it if he wants .
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chunky_nb
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Registered: 19th Jan 07
Location: Bridgend S.Wales
User status: Offline
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quote:
Originally posted by Daniel_Corsa
quote:
Originally posted by chunky_nb
really starting to take shape now, cant wait to see it run, will it be coming down here (south) to shows etc?
He plans to have it all done for Ultimate Dubs 2011 so will be down at Telford for that, and no doubt ED38 next year too.
I can't wait for the first time the 5 pot fires into life
I bet! by far one of nicest sounding engines of all time and with tunage absolutely SAVAGE!:
YUMMY
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joe holvey sxi
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Registered: 12th Mar 10
Location: Bromborough, Cheshire
User status: Offline
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O-M-G grats m8 good luck with the car realy looking good cant wate to see it 10/10 a**** joe
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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quote:
Originally posted by chunky_nb
I bet! by far one of nicest sounding engines of all time and with tunage absolutely SAVAGE!:
YUMMY
Hopefully like this: BANG POP BANG
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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chunky_nb
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Registered: 19th Jan 07
Location: Bridgend S.Wales
User status: Offline
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quote:
Originally posted by Daniel_Corsa
quote:
Originally posted by chunky_nb
I bet! by far one of nicest sounding engines of all time and with tunage absolutely SAVAGE!:
YUMMY
Hopefully like this: BANG POP BANG
ANTI LAG WIN!!!!
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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So it’s been a long while since an update.
Hamish has been slowly working away on the car between other things.
After the engine went in he got some crackle black paint to do the rocker cover and inlet manifold, the rocker cover has had the oil cap welded up:
Decided on a spot for the remote filter housing:
He thought the best plan of action next was to sort the bits down the back of the engine before they become harder to reach. So he started with the clutch slave cylinder retaining pin. This is normally a rolled piece of metal which you have to drift out. Decided that wasn't ideal so made this up:
That left the gearshift mechanism to sort out. He is using a S1 shifter so had to make up something totally different to the standard one. It’s probably been the most difficult thing to make on the whole car and has taken countless hours to get it spot on.
It’s a piece of stainless tube bent to clear the tunnel but as he found out it has to be bent back so it forms a straight line, otherwise the gearstick pulls to one side. From there it uses a spherical bearing with misalignment spacers to allow it to rock as far side to side as possible. This bolts to the alloy piece which in turn bolts to the gearbox shaft with a grub screw.
From there it goes forwards and up to the link bar to stop the main shaft moving side to side and make it push the gearbox shaft in and out. The bar is left and right hand threaded with rose joints so it can be set exactly.
It still needs painting and a little tidying up but he is so happy to have it working. The shift is superb and well worth the time and effort getting it spot on. The throw and sideways movement are adjustable by altering the height of the alloy piece and the height of the link bar. Obviously they are fixed now because they are the measurements settled on.
Next whilst browsing he came across some Porsche callipers, and thought they would do as a basic set of brakes to go under the 15's. This is because he will be using 15" drag tyres plus has the option to run 9" Ronal’s if he ever finds any.
So the fronts went on with brackets made by a lad on the audi s2 forum, ferodo ds2500 pads and 288mm discs:
Then it was onto the rears. Same pads and discs, but had to go about sorting my own brackets:
Came up with these which are now away with a mate being machined from alloy:
From a bit of research he found out the brakes fitted under 15's but apparently not the Fuchs wheels he had. Thinking that was a bit strange and it must have been down to the spokes hitting which he could sort with a spacer. However that wasn't the case and they have a large raised lip on the inside which means they go no where near! So he asked about a swap with some Ronal’s. Managed to get the swap done and he now has some wheels which fit again and in my opinion look a lot nicer!
Lastly he got my spoiler and boot lid back from the painters!
There is a hole behind the number plate 10mm smaller than it all the way around. The plate will be velcro'd on so it can be remove for additional cooling. The spoiler is also removable for drag racing and top speed stuff.
So that’s where he is currently up to. Still waiting on an exhaust manifold being made then he can sort a turbo and build the boost pipes, exhaust and turbo lines. He has ordered all the brake fittings and braided pipes to get them finished off then the chassis is just about done.
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Marc
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Registered: 11th Aug 02
Location: York
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Liking the brakes
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Efckitson
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Registered: 8th Jun 08
Location: Tamworth, Staffordshire
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Epic.
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Joe-Tait
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Registered: 11th Feb 08
Location: Newcastle Tyne and Wear
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Wkd though he would be getting some custom compomotives made up for it though
[Edited on 22-06-2010 by Joe-Tait]
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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quote:
Originally posted by Joe-Tait
Wkd though he would be getting some custom compomotives made up for it though
[Edited on 22-06-2010 by Joe-Tait]
These wheels are to get it on it's wheels and moving asap, saves laying out £1k+ wheels!
Think he is after some 9x16's comps eventually!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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16vKarlos
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Registered: 27th Oct 07
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again... another mental update
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Tom
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Registered: 3rd Apr 02
Location: Wirral, Merseyside
User status: Offline
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Not suprised he wants to just get it driveable tbh and wheels are easiest thing to swap afterwards. He's not cut any corners at all as far as I can tell, absolutely awesome build and attention to detail.
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