Had already bought the paint before your comment Alex haha. I enjoy cleaning so will give me a challenge ;-)

Nothing done on the engine today whilst I'm awaiting parts, got the remainder of my parts ordered that I require for the rebuild so I set about cleaning the engine bay up ready to accept the new lump once complete.

This is how the engine bay started off

And the finished product

Whilst it's so easy to access vacuum out your PAS fluid and fill with fresh

It's not meant to be changed in any service schedule tbh,but neither is gearbox oil

Whilst it's so easy to access vacuum out your PAS fluid and fill with fresh

It's not meant to be changed in any service schedule tbh,but neither is gearbox oil

Funny you should mention that I noticed it was on min and looked a bit horrible. Does it take a certain spec fluid or does any old power steering fluid do?

Funny you should mention that I noticed it was on min and looked a bit horrible. Does it take a certain spec fluid or does any old power steering fluid do?

Yeah it's special stuff,motor factors will sell it,Febi make some which I used.

1 ltr is plenty

Excellent build, top work!

Update time. Work has been fairly slow as I have been making sure everything is 100% spot on.

Cracked on getting the block honed up to the finished size.

Then skimmed the top flat. Only removed 5thou to get it to clean up

For the statement regarding the cylinder walls looking thin, still plenty of meat left in them.

Left the block overnight to go in and steam clean it off and get it painted.

Came into work this to find this....

Set about masking the block up ready for paint.

After painting the block I came back a few hours later to be greeted with this....

And the finished article after removing the masking tape.

Going to make a start on rebuilding the engine tomorrow, get the pistons fitted to the rods and have them dropped in along with the crankshaft.

Edited 1 March, 201610 yr by Southy

Now that's bright lol! Not too my taste but it's unique..

Love seeing this depth of skill :-)

How long do you estimate it will take until it's back up and running?

Now that's bright lol! Not too my taste but it's unique..

Love seeing this depth of skill :-)

How long do you estimate it will take until it's back up and running?

Thanks very much, I want to get it to match my colour scheme. Once everything is refitted to the block, very little of it will actually be seen.

I'm hoping to star dropping the engine back in next weekend. So probs another 3 weeks yet till she is back on the road and running once again

Looks awesome mate. I know where to come if I want my engine painted

Looks mental mate.. lovin' it.

The missus wants an engine to rebuild, it's either a 1.8T out of a vRS (when we finally get one) or a Vx Z22SE.. 

More work carried out for the engine build over the last couple of days.

The pistons have been fit to the conrods, not before weighing them all to make sure they are equal in weight.

The block has now been mounted onto an engine stand and the undercrown cooling jets have now been refitted and the new piston and conrods have been dropped into the block.

The main caps for the block was treated to a wire brushing.

My shells for the big ends and mains turned up, aswell as my order from TPS containing my thrust washers.

So I set about fitting the crank into the block and this is where it was left (caps have been fitted also just never took a pic)

Today I went into work to use one of the machines to set about modding one of the flywheels which I produced the other year to allow me to fit it once the car goes back together.

First of all the flywheel was fitted in the machine and checked to make sure it was running true.

3.5mm was then removed from the clutch plate surface of the flywheel to gain sufficent clearance to allow the pressure plate clearance to unclamp the clutch plate once the clutch was depressed.

Then the built up unit sat next to an original DMF setup. I will be re-balancing the clutch assembley next week to double check its okay still.

Real top notch skills! :-)

You're a wizard!

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Thanks very much guys. Hoping to start making some major progress this week now I have all my replacement parts.

Managed to get the ARP lube on all the bottom end and get it all torqued up this morning.

Whilst I was torquing the bottom end down I had threw some parts in the wash off tank at work, mainly the sump, sump baffle and the oil pump. The oil pump came up like new again seen as it was black.

I decided to strip the oil pump down and check it for any signs of wear. Considering the car has done 100k now there is no signs of anywhere on the pump gears so everything was cleaned up and put back together with Graphogen to help protect it upon inital fireup.

Then the tensioner and drive chain for the oil pump was refitted.

The housing for the timing belt end wasn't as clean as I liked so I left that off for the time being so I set about fitting the crankshaft flywheel end seal. The one that came supplied from Darkside came with a plastic tool that allows easy fitting to the crank end.

And finally a cheeky ahot of the top end.

Once again I will be heading in early to clean a few more parts up and get them refitted. I plan on trying to get the cylinder head fitted tomorrow all being well.

Edited 7 March, 201610 yr by Southy

Looking well now everything is so clean [emoji108]

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Thanks very much Phil, its taking more time now however as I'm tarting about cleaning and painting parts etc but will be worth it in the end.

Sand blasted my water pipe at work as it was looking a bit of a mess, will be painting this back in black.

Cleaned up the crank front seal housing and fitted the new seal and then set about fitting it along with the cleaned up sump.

I have had to buy a new timing belt backing plate as the one on my engine has broke.

Set about vleaning the head up also to make it look pretty for when it goes back together.

I'm going to order my injectors the start of next week but I'm also looking into ordering a camshaft. Currently awaiting to find out a price and specs on the Piper camshaft thats available.

This really is something else. Keep up the great work mate

Thanks very much Charlie, its getting there. Not had much time to do a great deal lately in it due to work. Ordering my injectors come Monday, I've ruled out a cam for now due to the costs involved. Would of been nice whilst it was in bits but it's another £600 I can't stretch the budget to.

Got the coolant pipe painted up.

Fitted the coolant pipe along with a few cable holders and brackets and the replacement cam cover plastic.

Then set about pulling the injectors outta the head. Will be giving the head a final clean off come Monday and then a re-oil up before setting about refitting it.

Most likely won't be able to fully torque the head down due to how tight the headbolts will need to be so will leave the final 90° turn till its bolted back in the engine bay.

Edited 12 March, 201610 yr by Southy

Thread porn

Massive fan of the work going into this car, and the thread makes such interesting reading compaired to others just bolting parts on (mine included )

Would love to see this in the flesh when all is said and done.

I snapped the plastic backing too. Reason being that you must remove the cam pulley first.

So you'll struggle to get the new one on with the pulley still on!

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Thread porn

Massive fan of the work going into this car, and the thread makes such interesting reading compaired to others just bolting parts on (mine included )

Would love to see this in the flesh when all is said and done.

 

Thanks very much pal, I do enjoy a good project thread to read instead of just clean car pics (guilty of those myself at times), makes it much more interesting. I will more than likely be out and about with the car this year at several shows so you will most likely see it, be a shame not to show it off a little after all this work carried out

 

I snapped the plastic backing too. Reason being that you must remove the cam pulley first.

So you'll struggle to get the new one on with the pulley still on!

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You can just about get it to go behind it but its a little tricky and needs to be in the correct position. I will however be fitting the head back on without the pulley to make life easier.

Great work, what injectors have you gone for? There is a NPS cam for sale in the classified for 300 from a very famous seller! Might be worth a punt?

Great work on this Adam it is truly a work of art. Shame to get it dirty lol.