Guy 27's s**tbox rally zafira

guy 27

Senior Member
Might as well do a thread for this years s**tbox. Last years adventure was a lot of fun. This years will be even more fun.

Plan is to do a full loop around the outside of australia. The rally itself starts on the otherside of the country (about 5000km drive)

Had the car for a few years now. salvaged a fair few parts off it, stored lots of other parts in it.

purchased with a snapped timing chain. never really did anything to it. paint is terrible as previous owner did some touch ups with a spray can and is now cracking and peeling.
main use of the car has been a nest for rats which made a nice home in the engine bay.

Her she is after fitting another hub to the drivers side so I can move it around
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The spotless engine bay
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engine gearbox and subframe out
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donor car for engine and gearbox
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a few hours later with an angle grider to cut subframe and slam panel.
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Donor engine suffered major oil starvation to the head :(
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At this point i decided it would be easier to rebuild the original motor the car had in it.

took the head off
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Engine has been honed this afternoon.
need to order parts in for it tomorrow so it can be rebuilt.
also need to strip a 3rd engine i got here to salvage some parts off it (piston, oil pump, balance shaft)

More updates and photos to come.
 

guy 27

Senior Member
If you wish to donate the link is below. Every dollar helps.
I've got some z22se stickers here that will be on the car. Time to prove to the aussies how good the z22se motors are.
Zafiras in australia have a pretty bad reputation for killing timing chains.

link for donations
https://s**tboxrally2014.everydayhero.com/au/brotek
 

guy 27

Senior Member
sent head away today.
all valves bent.
all guides cracked
a few damaged lifters.
should get it back in a few days all fresh.

ordered everything else to rebuild which should arrive next week.

cleaned up sump today. heres the mess that i found

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guy 27

Senior Member
parts arrived early. means I can start building engine this weekend.
found the vectra b I have here has the same size tyres for the zaf so saves me some money there.

just over 2 weeks till I start the drive. Will be doing close to a week in melbourne relaxing before the brutal drive across the country to the start of the rally.
Will be crossing the nullabour which has australias longest straight sealed road. 146km dead straight with nothing to look at.
 

guy 27

Senior Member
68mph (110kmh) is speedlimit on the road. not worth going faster with how bad cops are and the kangaroos are even worse.

don't get me wrong. its probably the best stretch to do a max speed run ;)
 

Matt

Administrator
68mph (110kmh) is speedlimit on the road. not worth going faster with how bad cops are and the kangaroos are even worse.

don't get me wrong. its probably the best stretch to do a max speed run ;)
Cruise Control set, windows down, tunes up......can think of a lot worse to do for 1.5 hours
 

guy 27

Senior Member
Parts arrived so I can get on with the build.

Using a $50 engine I picked up a few months back. well the bottom of it as head is stuffed and sump is broken.

checked main bearing on #4 which looked like new so torqued it back up. cleaned the block up.

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prepared top of the block for head. cleaned up 99.9% of the carbon off the pistons.
Then I still had some time left before it got dark. so new waterpump went in, new oil filter and balance chain kit.

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Was getting dark and cold so I put the sump on and left it for the night

tomorrow head will go on, then timing chain kit, manifolds and should have it on the subframe and in the car by the afternoon.

Also threw in a full set of sensors, relays and fuses into the car. they don't take up much room at all because of how few electronics are on the engine. never know what may go wrong.
 

guy 27

Senior Member
Hi just sent you a small donation to help on your way, its not alot but every little helps. good luck

Thank you very much :D


running a bit behind my schedule but getting there non the less. had a couple of bolts sheered off in the block which needed sorting out and took longer than expected.

engine and gearbox are together.

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I'm using an astra gearbox with the lower final drive so we won't go chew through as much petrol hopefully.
 

guy 27

Senior Member
Getting close to running now.

just need to put in radiator, condenser, fans, exhaust, top up fluids, change front brakes and all the wheels and shes pretty much good to go.

aiming to have it running tomorrow. :D

ai708.photobucket.com_albums_ww85_skyguy27_2014_05_06183212_zpsd7c20950.jpg
 

Dave Gilbert

Senior Member
i would love to do something like that, what a great adventure, i couldnt afford the passport never mind getting a car over there n fuel etc etc

nice work
 

guy 27

Senior Member
I'm doing this trip for under 5k thats including car. doing it on the very cheap. most people doing this kind of trip will easily spend double that not including a car but they will be gone for a longer period of time.
 
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