The Manifold Build, part 1.

21/06/10 0 COMMENTS

To be able to fit the turbo and the manifold I decided to keep the alternator position from the former engine, i.e. the right hand side. This creates the possibility to have both a good shape of the manifold runners and downpipe, something which is difficult to achieve with the turbo in it’s original position. The turbo is moved down/forward and the turbine housing is clocked down to get the entry pointing up, the compressor housing is rotated to get a long, flowing bend into the intercooler.
I have used the stock manifold and some plates to create a stable jig, there isn’t a whole lot of room in between the compressor housing and the engine or the wastegate actuator and the body so it’s really important that the positions are stable when the manifold jig is fabricated.

It’s a pretty large turbo, the compressor housing is quite a lot bigger compared to the stock unit. Nice.

The Engine Build

06/06/10 0 COMMENTS

Even though it’s a while since my last update things is getting done in the garage.
The short block is done. Cylinder liners, pistons, rods and of course the crankshaft is in place and the cylinder head is coming along nicely. Shimmed the valves last night and that means that the valves, valve springs and camshafts also found their way home.

Piston Ring Gapping

11/04/10 0 COMMENTS

Now that the liners finally have the correct dimensions the piston ring gap can be adjusted. It’s pretty nice to have removable liners when going to another garage to borrow a piston ring gapping machine (or whatever it’s called). Once you measured the start value of the gap and calculated the gap the piston manufacturer specified you just have to grind and measure. Grind and measure, grind and measure… After a while (I honestly don’t want to know how long this would have taken without the machine) I had eight rings with the correct gaps. Back to the garage to fit them.

I’m always nervous when fitting piston rings, you get the feeling that they are just about to snap the whole time… This time there were no problems at all and the pistons are ready to be fitted to the rods.

Block prep

07/04/10 0 COMMENTS

The block recieve new liners and then need to be the right bore and finish. After boring with a stress plate the last hundreds of millimeters are honed to the correct size. The lube is as sticky as it looks.

With the correct tools it's easy to get the job done.

The liner on the left is bored, the on the right is honed.