project boost bus

[pottsey]

bit of progress today got the new engine on the engine stand ,stripped off all the bits i dont need
took the head off as my head is going on it ,the balance chain had thrown a few teeth and ended up with 8 bent valves on the inlet .the bores are nice and clean no marks whatsoever
back tomorro to strip the sump off and get the pistons etc out

 

[pottsey]

its now back on the gsi rims ,all ready to go to mr derrys tomorro so i can start stripping the engine out

 

[pottsey]

car is now down michaels ,made a start stripping out today

boots starting to get full lol

 

[pottsey]

also whilst the charger is off im gonna take it up to courtenays so i can get the pulley properly lined up so i can run it on a 5 rib belt ,not a chewed up 4 rib one lol,with it being 2.5 mm out ,got a new pulley cheap
also im gonna rip all the heat wrap off the manifold as im sure its blowing ,will be the perfect oppurtunity to get it sorted whilst its off ,as its a right pain to remove the manifold with the engine in place

 

[pottsey]

had some bits arrive
new rings ,big end shells and main bearings

more progress today ,engine is out made a start stripping down and found that the balance chain was the cause for the rattling ,looks like the tensioner may have seized .cam chain wasnt that tight either
cant tell on this pic but the chain is slack

took the weapon r off that will be going to get welded up as its blowing where one off the tubulars meets the plate

also noticed the brake pipes are corroded so whilst the engine is out they will be getting replaced too

 

[pottsey]

more progress today took the head of mine and this what i was greeted with ,wondered why it smoked lol

new rings in pistons out of fresh/new engine

next up taking the crank out to replace main bearings

been back over to courtenays today and picked the supercharger up ,now it has the pulley on properly so no wearing the belt out
exhaust manifold has gone in to be welded up and a new spacer/gasket made up

 

[pottsey]

bit more done today
finally got around to doing the balance shaft delete ,basically removing these removes 4kg of weight ,hence making the engine rev quicker and gaining 10 bhp
heres the offending shaft

so what you need to do then is undo the nut and remove the cog etc so your left with just the shaft

you then cut the end off so it can go back in the gearing

new idler and old shaft

you then need to get a long extension with a 30mm socket ,and place in the engine to knock the oil ways back 7.5 to close them up
extension bar put in ,and marked flush with the block .then measure 7.5 mm off that .then put back in and knock it in till the 7.5mm mark sits flush with block

as simple as that ,the cogs then go back in so it can carry the chain round
also i done the water pump ,but battery died on phone

 

[pottsey]

had a few hours on it today replaced the valve stem seals on the inlet side
also got the sump back on so its taking shape,new water pump also fitted

the exhaust valves were absolutely caked up so michael is taking them to work tomorro to clean them up on the wire wheel

 

[pottsey]

exhaust valves all seated in now ,with the new stem seals also

head gasket on ready for head

at long last its looking like an engine lol,head on with new head bolts
hope fully tomorro both chains should be back on

 

[pottsey]

had a set back at weekend ,was all set to get the chains on and i ended up breaking the bit which fits in balance shaft hole which the balance chain goes round.
anyway a quick text to jwalker and he had one which was popped in the post along with arb bushes ,this man has been a star also had rings,big end and main bearings ,and lower wishbone bushes off him:rock:
so not only do i need to fit chains ,drop subframe etc etc etc ,i have this little lot to fit .i also have the rear arb ,not pictured ,along with changing rusty doors and wing

 

[pottsey]

nothing to report on the engine side as i went to fit the chains friday and im missing the woodruff key which i need to line the cogs up on the crankshaft ,luckily cavaddict had one and is getting it in the post for me
anyway the weather has took hold of the paintwork and the rust has got quite bad ,the rust on the wing round the side repeater was shocking so i'll be putting the fresh wing on tomorro also the door

 

[pottsey]

wing and door replaced today ,still got the rear do to do at some point also looking round the car ,the passenger side door is also starting to go rusty along the bottom

 

[pottsey]

finally made some progress today ,ive fitted both chains today and its starting to look like an engine now
next week we are dropping the sub frame ,do the poly bushes and get the engine and box back on subframe and back in place

 

[pottsey]

few more bits done today ,rocker cover gasket and manifold on ,i did buy some exhaust wrap but after wrapping part of the manifold i realised i had no where near enough ,so took it all off .im not waiting for more to come .ideally i want it back in tomorro

dropped the subframe down and took the lower arms off ready to put the new bushes in tomorro
replaced the arb ones

 

[pottsey]

engine finally off the stand ,clutch and flywheel fitted

 

[pottsey]

been a good day today ,borrowed a blow lamp and heated up the wishbone to get the bushes out a few whacks and they were out ,let them cool down and cleaned them up .then fitted the new powerflex bushes ,that was the easy bit ,getting them back in and bolted was a bit of a pain

then i got the gearbox bolted on and engine fitted to the subframe

and then the all important bit ,back where it belongs woo-hoo

 

[pottsey]

27th april 2013
getting excited now ,drive shafts in suspension and brakes fixed back in place ,rads in inlet manifold ,alternater ,starter all wiring in place
all thats left to do tomorro is fit charger and belt ,injectors,ecu .do the oil and water ,downpipe
then strike it up,fingers crossed everything goes as planned

 

[pottsey]

 

[pottsey]

yep as steve has said its alive
everything went to plan ,primed the engine so the oil pressure built up did this 3-4 times which also got the fuel pressure up as i found out as one of the fuel pipes was leaking on the fuel rail ,so put a new o ring in ,turned it over a couple more times ,my heart was pounding like a good un then i turned key all the way and it fired up straight away woo-hoo
left it too run til it got up to temp and made sure the fans kicked in
no smoke ,no rattles it sounds sweet ,cant wait to get on the road in june now
will be overhauling the brakes making sure they are all free ,still got the rear trailing arm bushes and rear arb to do

 

[pottsey]

bit more done this weekend ,time to focus on the rear end got new powerflex trailing arm bushes and arb to go in
rear hub/arm off

heated the trailing arm bush up and whacked it out

new arb in ,was a bit of a struggle getting the clamp closed up with the new bush in

ive had some nearly new discs in my shed so seeing these were starting get a lip on them ,i thought i'd change them
one side came off really easy ,adjusted right down and it prised off nice

and new disc on

the other side was a right :swear: to get off ,ended up pinging the clips that hold the shoes off ,spent a little while getting them back on ,poxy things
as you can see this side had quite a ridge holding the shoe back


got a mate coming over tomorro night to do the rose bushes ,one of them has seized completely