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Thread: Project more door aka the sh!++3$ for autotests, drift days and road rallys

  1. #201
    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by rwd2ltrfiesta View Post
    sweet am watching cosely, where you get verniers or u ganna make sum?
    are the tappets a easy job 2pull apart?
    i am going to take the plung and buy a brand new set i think as i can't get hold of a second hand pair and can't be arsed to mess about making a set. The tappets you accutally just hit on a hard surface that won't damage the tappet and the middle bit falls out. After that you pull them apart with your fingers untill you get to the small ball bearing non return valve then you pull that out with a pointy nose pliers.

    Should be looking at 220bhp with the 45's i hope should be running around 240bhp with bigger induction but we shall see.

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  3. #202
    Pit Crew rwd2ltrfiesta's Avatar
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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    i ask coz i fink i got a couple sticking,
    got mine running now albeit a lower front oil seal issue, dosent sound to bad still saving for the nodiz system, i may get her r.r on the esc 1st get the carb jetted as close as then wait for the nodiz,

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    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by rwd2ltrfiesta View Post
    i ask coz i fink i got a couple sticking,
    got mine running now albeit a lower front oil seal issue, dosent sound to bad still saving for the nodiz system, i may get her r.r on the esc 1st get the carb jetted as close as then wait for the nodiz,
    saving for a nodiz system? Whats that? remember if your going to strip it down it is around £100 for a timing chain kit! so if they are sticky i would leave them or rev it harder (you have seen how far that has gotten me though)

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    Pit Crew rwd2ltrfiesta's Avatar
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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Nodiz is a mappable ignition that can be mapped via android app aswel, iv had mine running about15mins so far just to get it up to temp, haven't really revved it hard yet due to not having a complete exhaust on it yet, already got a new chain and a couple of the tensioner plungers in stock from when I was gunna change the heads and cams over,
    Gotta say tho the sound is addictive and reminds me of a lairy pinto

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    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by rwd2ltrfiesta View Post
    Nodiz is a mappable ignition that can be mapped via android app aswel, iv had mine running about15mins so far just to get it up to temp, haven't really revved it hard yet due to not having a complete exhaust on it yet, already got a new chain and a couple of the tensioner plungers in stock from when I was gunna change the heads and cams over,
    Gotta say tho the sound is addictive and reminds me of a lairy pinto
    Wow i'm way out of touch! Mapping via your phone/tablet now! Well you will be intrested in a problem i have found out with the oil pump on the i4's.......it is very common for the pressure release valve bolt to come loose and cause the relief valve to cut in well early and loose you oil pressure. The rs2k boys are so worried about it these days they are drilling and pinning them into the oil pump housing! I have just done mine too.

  7. #206
    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Found this on one of my spare 2.3 blocks! :-O



    And here is me stripping my pump down checking the rotor clearences and reassembling it back up after drilling tapping and pinning the troublesome bolt in

    Pulled apart cleaned and measured


    The pump face had a small amount of scoring on it so i quixkly rubbed it flat on a surface table with some wet and dry on it. And cleaned it off well.


    Housing drilled ans tapped and ready to be reassembled although the locking blot needs shortening here


    All rebuilt back up and the locking bolt inplace with some lock ticght too. No loose pressure release valves here!
    Last edited by freddy686868; 09-01-2014 at 03:02.

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    yea heard about them coming loose so lockwired mine

  9. #208
    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Well my new valve springs turnned up today and they look almost identical apart from the one less coil in them and they are thicker. They are oviously harder to compress too.




    I also cc'd the cylinder head today and woeked out the compression ratio of the standard engine verses the new oversized engine and there is a health increase in CR just from upping the bore aizes 1mm as you would expect.



    So after using grease to seal the valve to thw head and the perspex to the head i used a syringe to fill up the head with fluid and worked it out to be 53ml/cc ao on a standard wngine that brings the cr in at 10.95 the head might have been skimmed a little in the past as the original cr of these engines is 10.8.





    With the upped bore size of 90.5mm the cr comes in at 11.3/1 so a slight skim of the head will bring it up to 12/1 which is where it needs to be.
    Last edited by freddy686868; 10-01-2014 at 01:44.

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Well no more pictures for now I am still waiting for my cams and verniers to turn up. Some calculations now. If anyone sees me going wrong let me know

    Standard bore size is 89.4mm 8.94cm
    Oversize bore size is 90.5mm 9.05cm
    Stroke is 91mm or 9.1cm
    Hg bore 90.5mm or 9.05cm

    8.94x8.94xpi/4= 62.77184cc
    62.77184x bore stroke 9.1cm= 571.22382cc swept cylinder volume

    Head gasket volume is 9.05x9.05xpi/4 = 64.32607cc x 0.02cm = 1.28652cc

    Cylinder head volume is 55.5cc as I measured it so the compression ratio is

    571.22382+56.78652/56.78652 = 11.059 (standard bore)

    9.05x9.05xpi/4= 64.32607

    64.32607x stroke 9.1 = 585.36726

    Compression ratio is
    585.36726+56.78652/56.78652= 11.308 (oversize bore)

  11. #210
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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    I stumbled across a CR calculator some time ago that somebody had created in an excel document,
    i have no idea how to upload it here but if your interested send me your email address and ill send it over

  12. #211
    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by 5tox View Post
    I stumbled across a CR calculator some time ago that somebody had created in an excel document,
    i have no idea how to upload it here but if your interested send me your email address and ill send it over
    They have used it on the rs2000-16v forum to prove my calulations are BS :-s the hg cc is wrong i will pm you now. Thanks for the info!

  13. #212
    World Champion Decade Plus User alladdin's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by freddy686868 View Post
    Well no more pictures for now I am still waiting for my cams and verniers to turn up. Some calculations now. If anyone sees me going wrong let me know

    Standard bore size is 89.4mm 8.94cm
    Oversize bore size is 90.5mm 9.05cm
    Stroke is 91mm or 9.1cm
    Hg bore 90.5mm or 9.05cm

    8.94x8.94xpi/4= 62.77184cc
    62.77184x bore stroke 9.1cm= 571.22382cc swept cylinder volume

    Head gasket volume is 9.05x9.05xpi/4 = 64.32607cc x 0.02cm = 1.28652cc

    Cylinder head volume is 55.5cc as I measured it so the compression ratio is

    571.22382+56.78652/56.78652 = 11.059 (standard bore)

    9.05x9.05xpi/4= 64.32607

    64.32607x stroke 9.1 = 585.36726

    Compression ratio is
    585.36726+56.78652/56.78652= 11.308 (oversize bore)
    Hg pi r2 x thickness .

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    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by alladdin View Post
    Hg pi r2 x thickness .
    i converted the hg thickness wrong it its ment to be 0.2cm for 2mm not 0.02cm lol. the hg cc works out to be about 9.65cc Thanks for the info though.
    Last edited by freddy686868; 13-01-2014 at 11:02.

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    World Champion Decade Plus User alladdin's Avatar

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    Also consider piston position at tdc regarding bore, and any dome.
    Tho granny and sucking eggs comes to mind lol

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    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by alladdin View Post
    Also consider piston position at tdc regarding bore, and any dome.
    Tho granny and sucking eggs comes to mind lol
    yeah the pistons are flat top thank god! otherwise it would get a little more involved. I am going to assemle a piston back into the block tonight to see how far down the bore it is and to check the valve to piston clearance at tdc. Although the piper site confuses me slightly by saying 'lift at tdc with clearance' is IN 3.63mm EX 3.25mm. I want the true lift at TDC so i can work out how much clearance i'm going to have. So i need to read up a little on that after some measurements.

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    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Well I had these nice bits of metal of Kent today...............and I'm not impressed at all.

    They sent me Clio 16v pullies instead or rs2000 16v pullies. The order form says rs2000 s65 and they sent me ca65 cam pullies. Woopsy! So I will be ringing them in the morning about it.

    I was going to assemble a pistonrod and crank into a block today to check the valve clearances at tdc to make sure I can raise the prison crown or skim the head to raise the cr before I finalise the pistons in case I need valve cut outs in them.

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    they look nice, shame there the wrong sort

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by 5tox View Post
    they look nice, shame there the wrong sort
    Yeah I know! The ones i'M buying are hanging compared to these as mine will be covered in oil and hidden.

    Spoke to the Kent people today and they are sending out a courier to collect and deliver the proper ones tomorrow. So I'm looking forward to that tomorrow. My cams shouldon't be far off either as they were sent on Monday.

    With that in mind I have been looking at how I can increase the cr without affecting the valve clearance at tdc so it was time to get the DTI gauge out.

    I timed the no1 piston to tdc and put tthe head on the engine.


    I then lightly bolted the head to the block. I left the head gasket out as that will be my valve clearance 1.5mm in thickness.


    I then checked the valve drop from the valves seats until they touch the piston. Here were the results




    As you can see pipers figures are confusing so I have emailed them asking what the actual valve drop is at tdc and what is the clearance recommended as them figures arenoviously a mixture of the two. If this fails I will have to time the engine up and turn it over by hand to find out.

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    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    I'm going to take a guess here and say I can either raise the piston crown 1mm or skim the head the same amount. Either way it won't get me anywhere near 12:1 cr more like 11ish. I will have to do some more maths first.

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Well the right verniers turned up today!

    My cams turned up too! Not in the best of condition though. so I have contacted the seller and he told me they were insured so he will contact the courier tomorrow



    I used some silicone type stuff to try and work out how much room there is for a raised crown on the pistons i done this without the hg fitted and I had a mess around trying to see if I could replicate the exhaust ports so I compare the before and after of the ports



    The spark plug depth

    Cut into cross sections

    Exhaust ports




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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    well I have sent a sample piston and rod to performance unlimited and an email with the piston spec so they are on the way. They should be about 4 weeks which is cutting it tight for my april the 6th track session at castle coombe.

    Before I sent the piston off I set it up at 8 degrees after tdc and with a ground down valve tapped the valve centers in the piston so they can work out where the cut outs should be.



    and here is a quick picture of the new rods vs the old rods


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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    also the mould I took of the inlet ports before porting



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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    looking at the mounlding there is massive gains to be made around the valve guide/ exhaust seats where on the exhaust the inner radius looks a little tight to flow well but we will see what the porter thinks is the right thing to do.

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    good stuff . when it comes to flow things tend to be reversed on exhausts, the inner radius does very little, most flow is on the long turn in the port

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by Graham View Post
    good stuff . when it comes to flow things tend to be reversed on exhausts, the inner radius does very little, most flow is on the long turn in the port
    Right i see. This is why i didn't take the porting on myself. I'll just make a mould of them when they come back to see what they have done and to get the sizes/shapes of the ports . Thanks for the input though!

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Also good news on the cams as paypal have told me i can get a full refund as soon as i send them back ao i will be cable tieing the cams to a super thich peice of cardboard and putting fragile all over the box and taking loads of pictures to make sure i'm covered although they are insured up to £300 so the owner will most prob break the other and try to claim off the courier.

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Well after some problems with the cams and the piston i sent off (with the rod still attached) sitting there for a week doing nothing i emailed them to see what the progress was. Which was nothing as they can not measure the piston fully with a rod attached which i was not told about. So i mocked up another in cyl 2 and set that off minus a rod this time.

    I was then told it would be another wek untill the cad drawing was made of the new piston, then it would be 5 week production time which is cutting it close for the 8th of april to get the engine running and run in. So i have danted a little bit on the project. That was untill today when i recieved an email telling me the pistons had been drawn up in cad and only needed a deposit and my final instructions.

    The pistons look alot more simple than i thought they would but are just what i want (i think) the original compression height is the same as standard for maximum valve clearance but there is a 12cc intruder to raise the cr to around 12:1 to get more power out of the build.





    I thwn measured all the mains and big end journals to see if they were in tolerance for standard shells. Which they were bang in the middle of. So i ordered up new shells ready for when it i to get built up.





    I then gave the journals a light polih up with 800 grit wet and dry to make sure they wee totally wer/marked or any pick ups were removed.

    I then cleaned out the oil journals in the crank and cleaned the mains and big ends before oiling th crank right up n

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys


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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Good stuff mate...If only I understood what you were doing lol hats off to ya

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by evans2822 View Post
    Good stuff mate...If only I understood what you were doing lol hats off to ya
    Thanks! I don't understand what i am doing half the time but i just go with what i have read and hope. Measure twice and guess once isn't it? it should come together nicely though......i hope.

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Well after being stressed about the engine build we decided today we would go for a spin! We got the crapi out of retierment and went for a skid. So this morning i jump started and filled up the 2.8 with fuel and fired that sexy sounding v6 into life. Yet again i cam 16th out of 18 but it was really fun! The torque combined with thw longer wheel base ment that i could drift the cappa better than the mk2! I found the rev limiter a couple of times too .

    I have got some go pro videos which i will update soon aswell as the pictures



    Slide on!



    Me again!






    Round you go!







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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    I also lost a tyre off the rim on 2 runs which really ruined my times so if that hadn't of happened i might have done better.



    As you can see from this picture the rain came down heavy on the last runs so the mr had to use her car as rain hitting you in the face at 30mph isn't fun and ruins your vision!





    And finally the crappi is 'back in storage'

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys


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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by Graham View Post
    good stuff . when it comes to flow things tend to be reversed on exhausts, the inner radius does very little, most flow is on the long turn in the port
    I have had my new big end shells and i have put them in, torqued the bolts up and plastigauged them they came out within ford tolerances at 0.002"/0.0018" but i think this is a little big i was thinking it should be closer to 0.001"/0.0015". What do you think?

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    2 thou is fine

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Well i paid for the pistons today so they should be 4/5 weeks away.

    I also had my big and main end shells today so i fitted up the main ends and plastigauged them to see what the tolerances were. They came out at 0.002" 0.0018" which i think is a little on the large side but i have heard of people running up to 0.0035" in pintos and x flows alought i would rather it around 0.001"/0.0015".





    I will have to check the big ends soon but i am confused about the whole arp rod bolt torque/bolt stretch situation i have always torqued my arp's but people are now having problems with them streching and wreaking the rod cap. Any advice on this too graham?

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    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by Graham View Post
    2 thou is fine
    Mint! I have measured it again and it has came out at about 0.0018" i thought 2 thou would cause lower oil pressure thats all. I'm glad you agree it is fine. Thanks again, Graham.

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    My next project is to make one of these as i'm not happy about just torquing up the arp rod bolts i would rather use the stretch method


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    Do arp specify torque method ? If so why reinvent the wheel ?

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    Re: Project more door aka the sh!++3$ for autotests, drift days and road rallys

    Quote Originally Posted by alladdin View Post
    Do arp specify torque method ? If so why reinvent the wheel ?
    Yeah they do specify a torque which i have never had a problem with myself but i have spoken to an engine builder recently who has had problem using this method and now uses the strech method with out a problem. I would rather be sure than hoping on this engine build.

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