Post 563462 by EddyP on 2013-01-17 23:56:18
Thought you guys might be interested to see what i've been up to with a T5 lump. I originally built the car with a Honda V6 in it, but decided I wanted more power, improved reliability and something a bit different, which is why I decided on T5 lump. First off, out with the Honda: [ATTACH=CONFIG]19958[/ATTACH] [ATTACH=CONFIG]19959[/ATTACH] [ATTACH=CONFIG]19960[/ATTACH] [ATTACH=CONFIG]19961[/ATTACH] [ATTACH=CONFIG]19962[/ATTACH] Next job was to prove the fit on a spare chassis and fab up a couple of mounts, bit easier on a chassis without a body on: [ATTACH=CONFIG]19963[/ATTACH] Its a bit tight: [ATTACH=CONFIG]19964[/ATTACH] It fits: [ATTACH=CONFIG]19965[/ATTACH]
Plasma cutters are great:
Add a bit of triangulation in to suit the new nose mount:
850 engine, with 19T and other mods ready to be detailed:
Cleaned and painted:
Before:
After:
Painted
Some bits polished, before:
After
Idle Valve
Detailed
Original 4 stud hub
Welded up the original holes, faced the hubs off, and redrilled them for Audi 5 stud PCD so that I could fit better brakes and nicer wheels
I needed to fit the Focus ST selector , i've modified the brackets on the gearbox so that the cables work from the opposite direction, this meant the selector itself needed to go backwards too, then custom cable were made up
An airsaw is an essential tool
Catch can and charge cooler header tank
Charge cooler radiator, mounted in the side air intake
Oil cooler, mounted in the air intake on the other side
Walbro pump fitted
At the same time I changed the rear De dion suspension from a panhard rod to a Watts linkage, this helps with the travel of the De dion, so that there's less risk of popping a driveshaft out, which could be a risk as my driveshafts are going to be pretty short
Weld a pivot on, in the centre of the De dion
Turn a boss, and weld it into the chassis tube
Paint the chassis now that all the mods are complete:
Suspension back on
Now for the driveshafts, Volvo inner needed, and an Audi outer as i'm using Audi hubs, so I started off with a Focus ST shaft, and chopped it up
Then did the same with an Audi shaft
Luckily, the Focus shaft is sold, and the Audi shaft is tubular, so with a bit of turning of the Focus shaft
Now for welding them up, I V notched the ends of the tubes to add in some surface area for welding, then a kind mate Tig welded them up
Done
Bit of wiring next, wanted it to look smart, but didn't want to spend a fortune on Raychem boots, so found these in a breakers yard, Audi/VW use them a lot:
Now time to make the exhaust, 3" all the way, start off with a load of bits from Jetex
All TIG'd up:
Mods to the turbo oil/water pipes as it's now in a different place due to my EGT spacer
Next job was to mount the Audi hubs, machined up some adapter plates in order to bolt them to the de dion axle, was important to get the depth of these right as it sets the disc location within the calliper too
Audi RS4 brake discs, alloy bell cast into the steel disc, nice and big but lightweight!
Handbrake cable mount modified
Next, I wanted to use a braided fuel line, but the volvo connection is a weird thread, so modified it to be standard, starting with a connector I faced one end off:
Then drilled it to suit the diameter of the Volvo fuel fitting, and brazed it together
Made a pipe for the idle valve and to get the throttle body to clear my gear change cable mount
Chargecooler
Charge cooler pump
Charge cooler header tank
Ready for the ECU
Always hard to keep this many wires tidy
[IMG][/IMG]
Now in October 12 I took the car back to Emerald to be remapped, to finally wind the boost up, and see what real figures could be achieved.
The day didn't go too well, the first power run was on the same map as last time and the power had dropped off, to 292bhp, wasn't sure why, but we carried on mapping, and with the boost turned up a bit she did 333bhp @ 1.6bar.
I wasn't too happy with this, and so when I got back decided to do a full health check, and did a compression test to start with, which is when I found that No.4 was considerably down, 65/70 psi down!
So I did some test and pressurised the cylinder with the airline to see if it leaked into the crank case or not, and it did, so knew it was engine out time:
So it was time for a full rebuild, after much deliberation i've decided to go with:
Oversize AE pistons, current H beam rods, new crank (later, lighter version), new mains etc..
Things then took a turn for the worse, I took the block down to a very well known machine shop locally, supplied them with one of the new pistons, gave them the clearance, and asked for a rebore. The next week I get a call to say they've made a mistake and as a result one bore has been over bored and they're going to fit a liner. I wasn't too happy with this, so went down to see them and in the end they agreed to pay for a new block if I got one.
So I sourced a new block, got it machined and started to clean it up, after much wire brushing it looks like
Unfortunately when cleaning it I found out there was a snapped head bolt in one of the holes:
This delayed things quite a bit, luckily we'd got some left handed drills at work, so I made a guide bush up, and then started to drill it nice and square:
It came out really easy! so so relieved!!
Next I masked the block up for painting:
I've also got a very expensive set of bags and boxes on my table ready for some real work tomorrow
Next I dropped a load of bits off to be shot blasted as I want to repaint them all and make them look like new:
Then I went to see a man in a shed to balance the engine components, people like really are golden, barn on a farm, loads of kit and some beautiful bits being engineered there, the man himself, immense skill and all the bits to do everything, he even let me stay with him during the process and explained how it all worked, 3 hours there and the bargain price of £80!!
First off the pistons, rings, clip and pins are weighed:
Some material was taken out of the back of the piston skirt until each set of components had an equal mass:
Then the rods are weighed using the special fixture:
Again a bit of material was taken off the relevant end of the rod until they're all equal, this was done by just linishing the small end.
Once the little ends all weigh the same, the rods were weighed normally, and material was taken off the big end until they had an equal mass again.
Once all of this is done, through some calculations the weight on the journal of the crank can be found, this is then replicated with some bob weights, which are clamped to the journals of the crank, and the crank goes onto this machine:
Stupidly I didn't take any pics of the crank all bob weighted up, basically the machine tells you which end is out of balance and at what angle, you then add or remove mass to make it true, then repeat the process again with the flywheel, again with the clutch pressure plate, and again with the crank pulley.
Each item has a bit of mass taken out of it until it all balances up. Then the most important step is to mark it all up, so when you take it apart you know where to put everything back again.
Then spent even more money with TMS Volvo:
New shells in, with some assembly lube on them:
Later, 3.7kg lighter crank, brand new too!
Lower deck going on, and torquing up:
Assembly of the rods and pistons:
Bit of tape to stop the rods scratching the bores on their way down:
Squeeze my ring
More assembly lube on the big end:
Repeat 4 times and you get:
New head gasket:
Head on
Also decided to repaint the inlet manifold, first off I blasted it clean, then primered it:
Then painted it and baked it:
Having to do some interior bits on the car now, it's due to be at a show on the first weekend in May and it's not even trimmed yet, so picked up my seats today, they're Recaro sport lines, had them retrimmed in leather and alcantara:
Finished dressing the engine
Put it back in
Connected everything back up, got the suspension back on etc...
Fitted a new headlight switch into the dash:
Rubbed it down ready for trimming:
Head liner got trimmed
Lots more trimming
After a bit of cranking with no plugs in to get the oil pressure up, the engine started pretty much straight away, although had a pretty big fuel leak, note to self, remember to do up the bolts holding the injector rail on, petrol damages paint on freshly painted engine bits too :(
Amazingly it sailed through the MOT, just had to add a cable tie to a brake flexi as it was a bit close to the wheel.
Then when I got back from the MOT it was time to wash it, clean it, fit some more interior parts and make it semi presentable for the show tomorrow.
Needless to say, i'm now shattered.
To give you an idea of how much has been done in the last few days, the car looked like this on Thursday morning:
