Bumble is poorly....

[Welly]

You can get the block back on the mounts while you're waiting for the head. Have you got new engine mounts going in?

That's the plan yes. I do need to get another CSC for the gearbox before fitting - I made a slight whoopsie on Saturday when bleeding the clutch and blew the seal on my new one. Epic fail - for some reason I forgot there wasn't an engine in there....

Looking good!
Please let us know how the porting affected to spool up etc!

Same here - looking forward to seeing what's what following rebuild.

... and that flywheel. Keen to see how that goes.

Same again - hoping it won't chatter too much, but it is VERY light.

No problem mate. You will get it tomorrow. Exhaust port are much better now

Many thanks again Andrew. Any photos of the work gladly received.... :thumbsup:

 

[Andrew@A.L.D]

Didn't take any as i just wanted to get it done fast and back to you sorry

 

[superkarl]

if its anything like the work i've seen by you andrew, its pure art.

 

[Welly]

if its anything like the work i've seen by you andrew, its pure art.

I dont doubt it... it was for the loyal viewers lol

 

[Prawn]

I dont doubt it... it was for the loyal viewers lol

We are not loyal

Once you are through with being interesting we shall toss you aside and move onto the next interesting build thread

 

[superkarl]

We are not loyal

Once you are through with being interesting we shall toss you aside and move onto the next interesting build thread

until he comes back again, which is inevitable, wanting to break 600hp barrier, then we will view his build with anticipation.
its a vicious cycle.

 

[s3dave]

Good luck with the rebuild welly, are you doing the "smash its back doors in" running in method....

 

[Dani_B19]

Where did you buy the flywheel from welly? Also are you going to be running another standard clutch?

 

[Welly]

I dont doubt it... it was for the loyal viewers lol

We are not loyal

Once you are through with being interesting we shall toss you aside and move onto the next interesting build thread

Fair enough you fickle sods.... Lol

 

[Welly]

Good luck with the rebuild welly, are you doing the "smash its back doors in" running in method....

Thats the plan this time dude. The gently gently approach doesnt seem to be for the win.

 

[Welly]

Where did you buy the flywheel from welly? Also are you going to be running another standard clutch?

Gone with the scahs standard varient of the clutch this time although the one that came out was actually still in good nick to be fair.

The flywheel came from Gripforce clutches in the States. Its made by F1. I gave about £200 quid for it on ebay plus customs tax.

 

[Welly]

OK then, I have now amassed all parts required for rebuild.

The head has made its return and may be looking a bit sexier than when it went...

Just a thankyou the Andrew@ALD for the excellent work he's done with it, looking forward to seeing how this engine performs as it is now quite different to the one I removed.

I have managed to get a LUK CSC for the gearbox for £28 which was a bargain. It's not what you know... lol. I must try to not explode this one.

Obviously the bottom end is now complete at home waiting to be fitted to the car. I was hoping to do this this week, however some personal problems have hampered my progress a touch.

Planning on making a start on reassembly tonight, hoping that the weather cheers up a bit but I'm not that hopeful to be fair.

A few photos of the head work:

 

[Andrew@A.L.D]

Remember welly use APC next time :thumbsup:lol

Happy its all safe and well, would of been done sooner but UK mails were A-holes when it came to dropping it off to me

Ports are much bigger and better flowing, It would of been rude not to clean up the valves when they were out.

 

[<tuffty/>]

Nice work as usual Andrew... might have to look into doing mine when I next take the engine apart LOL...

<tuffty/>

 

[MUSH]

Exhaust ports look just like mine that JP done. Andrew my man you know your stuff.

 

[Andrew@A.L.D]

I have managed to get a JP head that was damaged some time ago and have taken measurements of it, I have also managed to get acsess to a superflow flowbench to see if my work is close to it, Well I found out that mine is a tad better in flow.

My engine now runs a copy of a JP spec head. I will be looking into bigger valves depending on cost next year.

Thanks to all for the comments on my work and good luck to Welly.

 

[Prawn]

When you say JP, are you talking about JP of JNL Racing?

 

[Andrew@A.L.D]

Didn't JP joint JNL Racing ?

From what i believe the head i have is a JNL one but JP did the work. I do have a copy of the invoice when i got it.

 

[Prawn]

I thought JP was the man behind JNL Racing.....

it was certainly JP that lightened my flywheel and balanced it, agreed by PM over forums, and I paid JNL racing for the work.

 

[MUSH]

Yeah, my engine is JNL built and JP did all the work. The head itself is a work of art.

come on then Welly get it all together!

 

[BENJAMIN]

Jp is jnl racing. Friend of mine and top guy.

 

[Welly]

I am. Will be hitting it hard later on today once I drop my nipper off. Block is back in and hanging on its mounts so stage 1 is completed...

 

[Welly]

OK, big update here from the weekend.

The upshot - it works.

Started Friday night as I said before with getting the block back in and hanging on it's mounts. Even with the front end off, not an easy job as the ****** engine into the box is tighter than a gnat's chuff.

Got that in a happy with the new belt on ready to fit and decided to pack it in for the night as was 10PM and getting dark. Also my Mum now runs a Bed and Breakfast and there were people staying so couldn't stay hammering in the garage until stupid o clock like last time annoyingly.

Back on it on Saturday afternoon once my nipper had gone back to her Mums. Went down to the local Motorworld (lush) to get some cheapo oil. Managed to get some 10w 40 Mineral and 10w 40 Semi Synthetic from there as well as a few other bits and bobs.

Then on to the local hardware joint to get 6 x M6 bolts to replace the rocker cover studs. This was for 2 reasons. Firstly, the on closest to the turbo is a problem as it's too tall and you can't wind a nut onto it when the turbo is there. Secondly, UK mail must have dropped the head in transit (****ers) and bent some of them.

Then made my way up to the car and made a start.

Started like this on Saturday:

Then this:

Then the head went on complete with turbo:

Anyway, so the head is on and timed up by this point so I was interested to see how my planned aircon delete was going to work.

Fitted the bottom pulley, and then the tensioner. Belt fits like a glove basically, really pleased with how well.

Interested to see what happens with this to be fair, the air con compressor isn't the lightest and there is now a ton of pipework missing from the engine bay. Sadly I couldn't remove the air con rad from the front end as there are bits of pipe everywhere and my grinder has gone pop. Decided to just leave it - not that fussed really so stuff it.

Left the car like this on Saturday night when rain and lack of light stopped play. So close to being finished it was annoying...

Sunday morning got up and got to the car early. Filled with fluids and it was fluid tight which was a massive bonus...

Fitted the remaining engine bits and bobs of which there weren't many, mainly charge pipework and various other little bits and bobs.

So, the time comes to spin it over to build some pressure before start up. Disconnect the injectors and go to turn the key - Click and nothing more.

Battery has been on charge so I know it wasn't that. After much faffing about turns out I hadn't reconnected the main earth to the gearbox. Fail. Got that sorted.

Engine spins over fine, nothing out of the ordinary. Reconnected the injectors ready for start up - engine turns over and over and over, but won't fire. :-/

Out comes VAG COM to find that the Crank Speed Sensor in this new block is dead. What a PITA, they aren't fun when the engine is on the stand let alone in the car. The one in the new block was NOT keen on coming out at all, but got it out eventually. Swapped out for a working unit.

Cleared codes and tuned her over and fires up first turn which was good.

Usual slight blow from the exhaust system following rebuild but that soon shut up. Engine really does sound sweet as a nut so really pleased with that - much better than the tat tat tat that I had before.

Took it out for it's 20 mile run in drive, lots of acceleration and overrun coast down - then came back and dropped the 10w 40 mineral out. Refilled with 10w 40 Semi. I disconnected the actuator completely from the wastegate penny valve so that there was no boost at all for the initial run. I plan to remove the actuator after 150 miles and replace the spring with a yellow to give some boost but not too much.

Need to change over my insurance today and then she'll be back as my main car.

So - observations....

This flywheel is noisy. Very noisy. It really chatters, both on idle and overrun. Not unexpected to be fair, I was aware that this would be the case, and now that it's fitted I just hope that the benefits show themselves. Clutch feels very nice on it to be fair, so time will tell whether it was a worthwhile investment or not.

Haven't got a clue on performance at all at this point - what I do know is that a non turbo 1.8 20v must be DOG slow.

Need to check for faults and check that all my Unisettings settings are still there and in place, and then I shall begin to run her in.

Will keep you posted....

Finished product:

 

[Sam_]

Top work. Can't believe how quick you turned it around! You must have an awesome tool collection. I miss mine back in the UK

 

[Westy]

Cracking work Welly

How many miles a day will you be covering in her?

 

[Welly]

Top work. Can't believe how quick you turned it around! You must have an awesome tool collection. I miss mine back in the UK

I'd love to have an epic tool collection - but I haven't. Pretty much it's my Halfords Professional tool kit and a few other bits and bobs - mainly stuff I've collected over the years.

You don't need that many tools for this sort of work.

Cracking work Welly

How many miles a day will you be covering in her?

Well, work and back is about 20 ish, and I will be going out pottering about as well trying to put the extra miles on her. Itching to feel some boost!

 

[s3dave]

Excellent Welly, no wonder you can work in the dark, i bet you could almost do it blindfolded now...

 

[Westy]

Can't believe how quick you turned it around!

Well, it wasn't that quick really, but not bad for 1 person

Turned mine round in 3 days but had a team of 4

 

[Welly]

Well, it wasn't that quick really, but not bad for 1 person

Indeed, plus I spent an age waiting for parts to arrive!!

I wanted to do it in the week nights but I was outright banned by my missus.

 

[Westy]

Indeed, plus I spent an age waiting for parts to arrive!!

I wanted to do it in the week nights but I was outright banned by my missus.

I wouldn't even attempt it by myself! It took 3 of us to mate the gearbox back to the block, and 3 of us to get the entire engine (including head) back onto its mounts. So hats off to you sir

 

[aragorn]

Halfords Professional toolkits for the Win!

I've got one too and its great, however the newer ones seem to have taken a real drop in quality which is a shame.

 

[Sam_]

Yeah the 150 piece is pretty awesome. The equivalent here is mad money and probably no lifetime warranty like back there...

 

[aragorn]

aye, thats what i have. The new "advanced" version is pretty pony though. They're removed a lot of the half inch drive sockets, and instead of the row of 3/8" hex/torx/screwdriver bits, theres now a little box of 1/4" drive bits with an adaptor.

The "deep" sockets also dont have the hex bit going all the way thru them any more, its just the same depth as the normal ones.

I find the row of 1/2" drive six sided deep sockets to be REALLY useful, and they've removed all of those from the new set

Old version:

New version:

 

[superkarl]

sweet welly.
so what will the yellow actuator spring give you and how long will you run that before letting it loose?

 

[Welly]

sweet welly.
so what will the yellow actuator spring give you and how long will you run that before letting it loose?

Forge rate the yellow spring between 9 - 15 PSI, which is a pretty big window to be fair. I've refitted the actuator now with the Yellow spring and she does make some boost however haven't really pushed it to see how much. Don't want to until a few hundred are under the belt and I will start winding it up from then.

 

[Welly]

A few observations so far from the new engine...

Basically, it couldn't be more different from the last - really happy with it.

Flywheel is chattery like I said, however it is also incredibly different to the DMF. For example, engine shut down is now instant, where as before it would take half a second for the engine to actually shut down due to the inertia of the flywheel on the crank.

The engine also revs up incredibly quick when no gear is engaged, making clutch control much more difficult as just touch the throttle and you're at 1500 RPM before you know what's happened.

Engine speed drop during gear change is also incredibly quick, revs drop like a stone now which is different.

I was expecting her to not pull up hills as well, however this is not the case. I went up a hill this morning in 4th which before rebuild would have certainly been a 3rd gear job. This is interesting as it is not at all what I expected. She happily sailed up the hill in 4th at lowish RPM which before (when the turbo is off chat) would have not happened.

Not sure if the above is related to the flywheel, or the other engine mods that took place whilst the engine was out.

Other than that, nothing to report so far - 60 miles down so far and haven't been giving it a lot of boost at all.... Drives really lovely though and the engine sounds really spot on.

 

[Westy]

Welly, I found that my car is now a lot more drivable off boost. As a result it is actually quite a bit more economical as I don't have to get the blower spinning like a mad man to get moving. In my case though I believe it was partly to do with the SMF but mainly down to the smoother airflow/power delivery. My map as a whole is a lot smoother.

 

[Welly]

Welly, I found that my car is now a lot more drivable off boost. As a result it is actually quite a bit more economical as I don't have to get the blower spinning like a mad man to get moving. In my case though I believe it was partly to do with the SMF but mainly down to the smoother airflow/power delivery. My map as a whole is a lot smoother.

I would completely agree with that, it's much more 'peppy' off boost which is nice.

 

[Rosso TT]

Really nice build welly. I would like to know how's the pull between gear changes when you'll get the engine at full song, in other words if you feel some sort of "stall" on gearing up.When i use to modify 2 stroke engines i remember putting an additional mass on the crank to help with gear up pick up.

 

[Welly]

Agreed mate, I'm interested to see how it behaves as well in between gear change at full chat.

As they say, there is only one way to find out.... Sadly, that will have to wait for a little while although it won't take me too long to clock up some miles in the girl.