Well I suppose its time I owned up and posted an opening bread in here.
Having bought (in conjunction with Mr Froggy my Dad) that beautiful Turbo II from "Old Power" I am sure many of you see for sale.
I have Wanted a Turbo II or ages and been looking. But this one popped up and we where in the area at the right time.
Was a lot of Car for the money.
Below pictures are taken from the original for sale thread
(http://www.mazdarotaryclub.com/forums/attachment.php?attachmentid=56182&d=1369313241)
(http://www.mazdarotaryclub.com/forums/attachment.php?attachmentid=56183&d=1369313254)
(http://www.mazdarotaryclub.com/forums/attachment.php?attachmentid=56187&d=1369313495)
It\'s been off the road for over a year but is in great condition that said we have since discovered its not exactly perfect (yet)
But the spec really sold it to me.
I will get some more pictures up once its clean again.
It\'s been for Its MOT Something that it passed (cough) we managed to cook the rear passenger brake pad and caliper on he way there as it seems to have locked on... Let her cool down and carry own to th test station.
Passed but later found out we developed a Brake fluid leak.
Will update on how the adventures gone so far and I obviously have a few questions... I am told Prof is the man with the answers.
Anyway for now jut want to say hi to a section o the forum I have probably passed over till now... (Well apart from Lenny Carlof... What a top bloke)
Welcome to the 2nd gen section
It does look stunning :D :D
And yeah , Prof knows his stuff .. although have the stuff he says goes well over my head
That\'s a tidy car you have there it\'s amazing how much the front lip changes the look if the car
Looks great. You\'ve a very nice collection of rotaries now :)
I really wanted this car when I saw it forsale on the forum. Glad its gone to a good home. Oh and its the best colour too!
Ade
Really pleased that this has stayed within the club as not only Aston gets to enjoy it but we all do by seeing this great looking car at events :Thumbsup!.
Oooooh nice one Aston! I\'m glad to see people enjoying FC Turbos, we both seem to be collecting Rotary cars :)
Thanks for the greetings guys...Grinder your reputation proceeds you... Not sure how as I am sure you have not spent a penny on marketing of said reputation.
Well It\'s been an interesting week
Took the car for its MOT and one of the rear calipers had locked on... So when we pulled up off the A12 and see smoke bellowing out the back I feared the worst.
It seemed to sort itself out though, after letting it cool then driving slowly to the test station.
It did cook the crap out the paint and the yellow stuff pads (that will be going once they are shot) now look more like Mustard Stuff
Test went well. Guy at the station said it was the best condition one he had seen on his ramp (all good)
Anyway sometime after the brake test it sprung a leak (did not know at the time) got a text from the guy to call him... So called him back once home and he said he found a pool of brake fluid on the floor...
He suggested that the cooked caliper may have damaged a seal.
So ordered some seals from Bigg Red (thanks to Lenny Carloff for the heads up) and time to get on refurbing.
Gred we currently got two FD\'s my 8 and the S5 FC
im really glad that someone bought the car to be honest
Like Ade , I would have fancied this car , I was even thinking of buying it and then selling my other 2 , it just came available at the wrong time for me
So my loss and your gain
I think you need to get it on a rolling road and then you can upset us lot even more with a print out ! LOL :D :D
Sprint track at RS10? I\'d love to see it in action Aston :)
Ade
Spot on! We need some videos too :)
A few repairs have been undergone but will fill you in on those later
Video will be done sometime soon
So heres the cooked caliper and the Mustard stuff brake pads
(https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/936213_467366970015474_1665369439_n.jpg)
i cant see pics :\'(
Hmm not sure why buddy...
Did you get the caliper fix yet and have you driven it in anger?
Morning Jim
Yes Calliper is done... But that was not the end of the story...
We found more... As it turned out not to be the calliper
Once you sort out any little bits you will have a great car .it\'s going to have a few things to sort with it being stood up for a while
How ironic... Currently sat at the side of the road, awaiting tools to bleed the clutch...
Cheers for that one Jim
oh dear , whats wrong with it then ?
Clutch pedal gave out on way home from Mazda Rotary Parts... Was picking up parts for some customers.
Dad arrived with tools... None the right size but by he time he had been to Halfroads it had righted itself
Just tried bleeding it and just getting a continuous stream of air bubbled from the slave cylinder.
Its improved the pedal feel but not sure if its going to last.
Would I be right in thinking this may be a master cylinder issue (if the problem persists)
see pics now.. nice :)
whats the specs if you dont mind me asking?
:spank
You left home without a full tool box!!!!.
Welcome to fc ownership
Don\'t get despondent you know it will be worth it
You should know me by now Jim... I will sort it out... It\'s going to be worth it
Ok, so I have repaired the brake and fuel lines, refurbished the calliper, bled the brake and clutch system...
So dad took it over to the dart ford meet last month and on the way back its started running really badly, was stalling and struggling to start.
Upon deeper investigation it appears we have a stuck seal on the front rotor.
It\'s had a couple of seafoam treatments but its not looking good enough to get her running properly again.
It\'s currently soaking in seafoam again (just the effected seal) hoping this may free it up. But there really is very little movement in it.
Fingers crossed I don\'t have to pull the engine and rebuild it.
I did speak to Tim at RXMotors who did the previous build, but he was not very helpful to be honest (not spoken to him before though so may have been the fact I was someone new calling out the blue)
On a side note... What kind of level of bearing failures de you guys see in the S5 FC\'s?
Welcome to 2nd gens !
Sounds like you\'ve inherited some of the bad habbits of these cars - you can get a fairly cheap rebuild kit for both clutch Master and slave cylinders - they are getting old now, so it\'s not suprsing we are seeing failures. It\'s an easy fix though, and worth it :-)
Bummer on the seal - hope it frees up. Is it running very rich and getting carboned up?
As for bearings - I think that\'s what\'s gone on mine, but have been too busy stripping my old shell down to take the engine apart yet...
Nice looking motor though...
Quote from: Arnie_O;859360Test went well. Guy at the station said it was the best condition one he had seen on his ramp (all good)
Yeah, because the only other one he\'s had on there is mine! lol
Yes it\'s running rich Prof very rich
It\'s only the one seal
The others are moving very well.
It drove fine up till now
I have managed to free them up on RX8\'s before
Hi Aston - only just found your thread as I missed the start whilst I was abroad ;)
Bummer that you\'ve had these problems, but I\'m sure you\'ll get her sorted soon enough. She certainly looks to be worth the trouble from her general condition.
I had to replace both the master and slave clutch cylinders on the FB soon after getting her back on the road as internal corrosion of the bores had taken them beyond refurb. Cheap parts from RockAuto in the USA and such a simple job cf the 8 :D
OK so Mr.Froggie and I spent a few hours tonight removing the GT35R turbo kit. The plan was to get a better view in to the engine through the exhaust port
All looks ok inside (using an endoscope type camers) and we got a better look at more of the seal...
Not long finished and we will take another look over the next few days
I want to get a look along the leading and trailing edges of the seal to make sure there is nothing jammed between the seal and the rotor housing.
These are the last checks before the decision is made to pull the engine and strip it.
Update time.
We pulled the engine and stripped her down yesterday. Turns out that the stuck tip was the last of our problems...
Rear rotor bearing had begun to start spinning.
Front rotor (the one that had the stuck seal) had spat a tip the broken piece has gone round and mashed the rotor and tip (stuck tip) up. There is also a gouge in the rotor housing, annoyingly right next to the exhaust port so an area I can\'t see with the camera)
I also need to check the step wear on the rear iron as it also broke a corner seal.
Will get some pictures up for those interested.
Sorry to hear your having a bad time of it , but if anyone can make it the car it was supposed to be its you
:yes
Picture time
Engine coming out
(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1334_485735551511949_822497119_n.jpg)
Stripped block
(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc1/1003477_485802998171871_68088598_n.jpg)
Strip, rear rotor coming off
(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/1000467_485736588178512_691902409_n.jpg)
Front rotor where the problems are
(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1000467_485736594845178_74544840_n.jpg)
Offending Tip
(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc1/1001528_485800624838775_799701527_n.jpg)
This is the stuck seal
(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/1001528_485800591505445_1807510914_n.jpg)
beginnings of a spun rotor bearing
(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/1001528_485800688172102_1330082969_n.jpg)
Ouch... just ouch...
Wow :2eek I wasn\'t expecting you to find that level of devastation in there!
A challenging first rebuild for you ;)
Its not as bad as it looks,
Its more getting the things clearanced properly again, making sure I dont strip too much weight from it.
So today went from bad to worse.
turns out that i needed a new front rotor housing due to the damage on the apex seal.
(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/1075798_486491608103010_2006585371_n.jpg)
So i am now on the look out for a good TII housing.
Does anybody know if the EGI housings are the same?
anyway I also got the rotors cleaned up washed off and they are now bagged along with the oil control rings.
still need to repair the damaged apex seal groove, but will do that at a later date.
(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/1075798_486491611436343_2070550667_n.jpg)
So begging time, does anybody have a serviceable housing for a TII or at a stretch a T2 block that i wan strip for the parts?
would a EGI one work ??
Might be worth dropping shaunwil a PM - he has my old engine in lots of parts !
EGI are no good.
Also note that rotor housings are fronts and rears Aston.
Ordered a new front rotor housing from Tim (at RX Motors) hopefully it will be here soon.
Housing arrived last week... top jub as it looks like Tim sorted me a gooden. turns out its going to need some porting to the exhaust port... time to learn a new trade.
most of the engines now clean and i am looking for a nice paint to paint the block before reassembly... can anyone recomend a good brand thats available in the UK... (i have heard some people say hammerite but really?
Anyway looks like i am going to need a bit more than just a water seal kit and some apex seals.
on a positive note the rest of my tools arrived from Maxdatrix monday so i am now fully tooled up.
will keep you all updated
Just found your thread Aston. Really bad luck fella, but on the upside, you\'ll have an engine you know and can use with confidence when you\'ve finished.
Look forward to catching up at RS10.
Chris
Quote from: Arnie_O;862321.............am now fully tooled up
:eek::eek: I wouldn\'t recommend getting into a fight with you then ;)
Just seen your FB pics, great to see you\'ve got stuck in straight away to mod those housings :)
Sorry should have got this updated
Got the new housing from Tim at RX Motors and its now been ported out by my own fair hands
(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/1148742_496710397081131_768067403_n.jpg)
(https://scontent-b.xx.fbcdn.net/hphotos-prn1/935886_496723730413131_115740195_n.jpg)
Port job finished
(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/998769_496754717076699_1325567199_n.jpg)
Next up was getting the irons painted
(https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1001428_497419513676886_683030065_n.jpg)
Got the housings and covers to do in Red next
A few bits to polish too.
Have got my water seal kit from Mazda Rotary Parts I just need to get the rest of the parts for the rebuild on order now.
Other shiny parts I am finding it hard to resist are
Gilmer drive kit from Australia
Banzai Racing Alternator Bracket
Banzai Racing Power FC Commander Holder
Pinapple Racing Sump
Pinapple Racing CAS cover (already ordered)
Greddy Elbow
What a greddy elbow like what I picked up
:p
Tell you what I will stick it in the van with me and you can have for what I got it for
That\'s the one... Buddy your a legend.
Well done Aston, your making good progress.
Chris
Went to order my Gilmers today from Aus... Courtesy of Rotary Extreme not happy they are not taking further orders till early 2014... This is not fun
Also started painting the front cover and housings.
Assembled my hydraulic press too. It\'s not fun trying to install bearings with a hammer
Bit of an update
Banzai racing brackets ordered,
Still trying to resist a pineapple racing sump
Also now got the horn for an Apexi N1 dual Catback (probably happen in the future)
Just finishing painting the water pump housing, water pump and OEM Sump
Will be looking to start assembly soon.
ARGGHHH, I want to see the car in all its glory!!! Must come and visit one day.
Ok bit of an update for those following progress
Rest of the rebuild kit arrived last week.
Had a few bits arrive this week.
Banzai Racing Power FC Commander Holder and adjustable alternator bracket.
(https://scontent-a.xx.fbcdn.net/hphotos-prn2/1384027_525154664236704_581011291_n.jpg)
And my favourites from Xtreme Rotaries in Australia a set of Gilmer drive pullies and power steering pulley
(https://scontent-a.xx.fbcdn.net/hphotos-ash3/1378729_525151997570304_629613982_n.jpg)
I know Steve Garbett is gonna love the pullies
further update today.
My Rotary Aviation Super seals are in UK customs awaiting clearance.
Also picked up a practically new Aeromotive A1000 Fuel Pressure Regulator and Gauge today from "Lotuscorsa"
(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc3/1382049_531079440310893_22451419_n.jpg)
Also got a set of Bosch 1680\'s for the secondary rail
Next up and i really have to say thanks to Clive for this one as he kindly donated a brand new FC3s sump to the build along with a sump gasket, I really was shocked at his generosity. So thank you Clive.
(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc3/1375750_531045073647663_1629315727_n.jpg)
Also have been given a GReddy intake elbow from Jim (lennycarloff) thanks Jim... pictures to follow. I really am amazed at the generosity of many of the members on here. its spurring me on to get this build pushed forward to completion.
Spent a few hours tonight reassembling the power steering pump ect after we stripped it to sandblast and paint. (again pictures to follow)
Lastly I had a brand new HKS circle Earth Grounding kit arrive today its a universal kit so will need to cut the cables to length however i have an FC kit fitted to my 8, along with the instructions installation should be pretty simple from memory.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1385031_531105486974955_1406106671_n.jpg)
Aston, Your pockets must be empty !! :eek:
Lots of nice trinkets there to play with.
Good luck
Chris
Cheers Chris,
Depending on the time period of the rebuild there may be more plans afoot... A cheeky little racing beat order may have to be placed along with the kit to make up some braided oil oil lines
Ok got some questions for the FC experts here (Prof)
I have read over on FC3s Pro that some versions of the stock fuel rail on a Turbo II can be modified to run an aftermarket FPR
as you can see above I have the Injectors and the FPR but can\'t seem to fine any images of the difference between the rails.
My Primary rail looks like the correct version to be able to mod however its the secondary rail that\'s confusing me a little.
Can anyone tell me if this rail is the correct version and if so how I can remove the end that seems to have a regulator attached
Or does anyone have a link to a guide with pictures?
(Or a heads up for a good quality set of aftermarket rails that will fit Bosch 1680 secondaries and 550 stock primaries)
Cheers guys
This is the primary rail as mentioned above
Primary rail has a pulsation damper in it.(Keep it)
Secondary rail which is the longer one has the regulator on the end, cut it off and weld it with a blank in it.
Use the Aeromotive on return line.
Quote from: Arnie_O;866590This is the primary rail as mentioned above
that pic is the secondary rail.
I know the pictures are mixed up lol
From what I hear the aeromotive has a pulsation damper in it anyway.
Are you suggesting I run the rails in series and not parallel Carl?
Bit of an update but this one is not engine related.
Spent a few hours today removing nasty rusty parts from the engine bay.
Mainly the ABS unit and bracket.
As toy can see the bracket is in a sorry state
(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/q71/s720x720/16273_10202464445151928_268966184_n.jpg)
The bolts and chassis members have some considerable surface rust in hem.
(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/q71/s720x720/1380798_10202464445631940_588571800_n.jpg)
Nice it was all removed I was hit with this nasty
(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc3/q81/s720x720/1375808_10202464443991899_407148402_n.jpg)
Some moderately serious rust this was the worst, so out with the rust removal wheels to clean all the crap up. And this is how it looked. After cleaning most of it up
(https://scontent-a.xx.fbcdn.net/hphotos-prn2/q71/s720x720/1379337_10202464443231880_403909728_n.jpg)
Once clean I hit it up with some Hammerite Rust treatment made sure I got plenty in the serious areas.
(https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/q71/s720x720/1013273_10202464442751868_352625096_n.jpg)
Time to let it all dry then look at how to move forward in tackling the "hole"
I am also in need of the following bits.
Fuse box (the long one on the strut tower) with no broken tabs
Fuse box mounting bracket (for the above)
Moderation - The last three posts have been removed at request of thread owner.
Collected my new RA Super seals today along with a shed laod of stainless steal fasteners ready for assembling the engine again
Thanks to Mick Choi for "selling/loaning" me his Racing Beat sump baffle. For the build.
Clive delivered it over last night after coming back from power gains.
Also ordered the connectors and braided hose to make the oil cooler lines up too.
Just need a Koul Tool to save the pain of making them without.
Should be assembling the block soon.
Been a busy bee, sorting he rust damage. Will look at getting some pictures of the work in progress.
Looks like I am also going to have to build a fuel rail too.
Does anybody know if there are any UK companies that sell/make Nippon Denso (OEM) to Bosche EV1 conversion plugs. Have found Somone in the US but thought I would try my luck first.
Update time
Have ordered my conversion leads for the injectors from ASNU
Aeromotive fuel Rail extrusion arrived the other day too. So I will be embarking on a new adventure of building a fuel rail for the secondaries.
Have also moved on with the engine may a but well a lot.
I prepped the passenger side of the bay for paint, after treating the rust.
And gave it a coat of paint. This is how she looked after.
(https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn1/529533_10202638705588330_391058687_n.jpg)
Unfortunately after removing the sheets and masking tape it was more that obvious that the original paint had faded just a little, to my original plan to treat the rust on the drivers side and blow in the effected areas turned in to a bit of a "Grinder" incident.
Spent the rest of the evening till midnight stripping the rest of the engine bay of everything I could, scotchbrighting (is that even a word?) the firewall and driver side area and grinding away at the rust (thankfully nowhere near as bad this side.
(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/1012778_10202638705508328_1238672771_n.jpg)
Then hit it up with some Hammerite Rust Beater, then left her to dry overnight.
(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc3/1461200_10202638705548329_2010486952_n.jpg)
Yesturday morning saw a frantic masking up session and i painted the rest of the bay, This is how it looked last night.
(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc3/1464134_10202638706468352_1623295395_n.jpg)
Unfirtinatly there where some minor imperfections and a little blow over that upon seeing it this morning i was not happy with, so it got rubbed down again this morning and repainted with all together better results.
"Project Money Pit" is not tucked up under many layers of sheets for the night while the paint goes off.... again.
Have also decided while i am at it that i will probably replace all the brake hoses in the engine bay with new ones. and am tempted to purchase a new Clutch master and slave cylinder from MRP as we had some clutch air issues before "Project Money Pit" Died on us.
Nice work there Aston :Thumbs-up
what ^^^^ he said some good work there aston liking the thread :Thumbs-up hope to see you/your dad tuesday ;) got some thing for you but won\'t post it this time :Nono!
good work big man keep it goin!
Bit of an update,
The subframe has now been painted, the gearbox bell housing has also been rubbed down and had a coat of silver to keep everything looking clean.
Next up I god to get the rest of the brackets cleaned and painted up.
Hoping the last few parts will be here this week so I can then get on with building the block.
Got a racing beat Oil Pressure Regulator and Thermal Pellet Coming.
New Engine mounts (little experimental hup hoping they fit)
New secondary fuel rail and spacers to take the Bosch 1680\'s
Also ordered new brake hard lines and clips.
Also looking to get some braided clutch lines and hardline to ABS unit hoses made up.
Bit of an update as things have been progressing the last couple of days.
We (Mr Froggy and I) built the block back up the other day using the New RA Super Seals.
(http://distilleryimage2.s3.amazonaws.com/92b3913e5b9011e3b691128442c788aa_8.jpg)
Also replaced both Stationary Gear Bearings and one of the Rotor Bearings.
(http://distilleryimage8.s3.amazonaws.com/a8ab32205ba511e393790a2aba0db6c1_8.jpg)
Been using Royal Purples Max Tuff Synthetic Assembly Lube.. built 4 enigines with this stuff now and I love how it makes install of stuff like Stationary gears in the irons so easy. Have just ordered two more bottles of the stuff.
Torqued down the block then left it to settle overnight
(http://distilleryimage5.s3.amazonaws.com/cbfb8bf85ba511e3adc2123587d614a2_8.jpg)
So Yesterday in between other things i took some time out to finish the front end assembly, then fit the Racing Beat Sump Baffle (that I kinda loaned but paid for and replaced :S off Mick Choi) got that on and the brand new Sump Thanks to Clive.
(http://distilleryimage7.s3.amazonaws.com/50a2def45c7511e399600eb5e76a152c_8.jpg)
Got a few other things sorted too along with a trip to the local fastener supplier for more Stainless hardware.
So this morning I mocked up the block with the turbo and belts in order to get an idea of what extra hoses i will require.
(http://statigr.am/viewer.php#/detail/603545705822449866_363309251)(http://distilleryimage6.s3.amazonaws.com/98b6101c5cf211e38329129895db65ff_8.jpg)
Have ordered some AN6 braided line and fittings for the water supply on the turbo and also some AN-10 fittings for the turbo oil drain line.
Had to modify the Banzai racing alternator bracket a little as it didnt want to work with the gilmers, thats all sorted now.
:mmmm Great work there Aston (and Mr Froggy!)
OK, off for some shuteye before that 5am alarm tomorrow. See you at Brands soon :Thumbs-up
Spent a couple of hours making up my new oil lines from the engine to the Oil Cooler and back, And a new AN10 braided Oil Drain line.
(https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/1486850_558949900857180_78019916_n.jpg)
after hearing Grant rave about his Koul Tools i had to get some... made life to easy... not a punctures finder in site.
I also bought some connectors in order to build myself a pressure testing kit.
So after assembling my new braided porn i went about pressure testing them for leaks... happy to report all looked good.
(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/1503820_558987887520048_718339152_n.jpg)
I now have a set of good quality "rubber" Aeroquip lines for sale... nothing wrong with them just not braided so they are now surplus to requirements.
If anyone needs a set give me a shout.
(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/1525102_559062697512567_597487975_n.jpg)
I also bought the smaller Koul Tool kit in order to build my guel lines ect.
I still have the coolant lines for the turbo to assemble too, looks like these may be AN8 and not AN6 as i originally thought.
Also collected my new clutch Master and Slave Cylinder along with a Racing Bear Thermal Pellet for the engine.
Bit of an update as we have made some progress of late.
after building the braided lines for the oil cooler it was time to build the rest that i needed for the turbo.
so 2 coolant lines where required along with 1 large oil drain.
I also had to cut a bard off the coolant neck to enable me to install a 1/4npt - AN-6 fitting. along with installing a 3/8npt - AN-6 fitting in the LIM.
The fitting in the water pump housing was the one i was most nervous about as the barb was steel in to Aluminium.
I started by cutting the barb off.
(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/1535729_10203087071357194_479463258_n.jpg)
Then slowly drilled the hole larger and larger untill it was the correct size to start tapping the thread in... that was the plan until I broke an 11mm dril bit off in the neck... pretty much flush with the outside. Anyway i got it out after much swearing, got the thread tapped and the fitting installed.
(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/1526343_10203087072077212_1725892111_n.jpg)
My KGParts Secondary fuel rail also arrived from Banzai Racing along with a nice new HKS Twinpower.
(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/t1/1012678_10203087070717178_1090182145_n.jpg%5Bimg%5DThis%20will%20get%20a%20polish%20up...%20(i%20know%20you%20wont%20see%20it%20using%20the%20polishing%20kit%20we%20got%20a%20while%20back)From%20there%20it%20was%20back%20to%20some%20of%20the%20engine%20bay%20parts...%20the%20brake%20servo%20was%20looking%20terrible%20once%20we%20removed%20it...%20I%20have%20decided%20to%20strip%20it%20apart%20and%20clean%20it%20all%20up.%20the%20Servo%20will%20get%20all%20the%20rust%20removed%20then%20primed%20with%20some%20Etch%20primer%20I%20am%20thinking%20about%20coating%20it%20with%20silver%20reflective%20tape%20as%20its%20sat%20next%20to%20a%20hot%20turbo.%5BIMG%5Dhttps://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1545225_10203087072797230_1711800457_n.jpg)
Engine also got a last mock up before it goes in the car for me to start building the fuel lines to supply the rails.
(https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/t1/1521983_10202943388965224_355567357_n.jpg)
Also got a set of new engine mounts thanks to Clive (the mans a legend)
(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/t1/1535565_10203087108118113_1508213315_n.jpg)
I know they are not round or OEM looking... they are actually uprated MX5 engine and after measuring them the bolts looked to be in the right place, the only difference was that these are about 5mm thinner than the ones i had... but the ones i had looked shot. These where available and looked to fit the bill.
plus i am told never to look a gift horse in the mouth.
(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/t1/1526399_10203087108918133_1022469346_n.jpg)
All we had to do was cut off the hook shaped barbs from the bottom side.. i then gave the bare metal a quick coat with some hammerite to protect it.
So yesturday we finally got round to dropping the engine back in the car... was was a good day.
This was a cheeky little shot captured through the exhaust port... i think i put the rear rotor in upside down?
(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/1505531_570585209693649_220029917_n.jpg)
Engine finally back in on its new mounts.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash3/994684_10203084410610677_1217950899_n.jpg)
To finally see back in the car where it belongs was a good thing... still a long way to go yet.
We also ordered a new clutch master and slave cylinder from Clive to replace the old ones... the slave looked like it has seen better days. the Master cylinder is in the car already.
Spend some time yesturday evening getting a lot of the parts back in the engine bay in a bid to understand where all the wires go again. most of the parts have been stripped and the rusty brackets sand blasted and painted in either black or FD Silverstone as it looks quite close to clean Aluminium.
:Thumbs-up:Thumbs-up fantastic looking work there Aston :god
Well done Aston (and Mr Foggy !), excellent progress and quality.
Looking forward to seeing the finished instal.
Chris
great work!
Excellent, meticulous work, looking forward to seeing this up n running in it\'s new and better revised form :Thumbs-up
Love it, looks spot on :)
You truly are making excellent progress , it is so going to be a very special car.
Looking forward to seeing this finished
Update time again.
Work is progressing slowly in between other stuff however the Radiator is now back in along with the braided oil lines i made and the oil cooler. Work is now starting to trying to properly box in the V Mount setup to divert maximum air through all the coolers. and tidy it up compared to how it looked.
I am waiting on another order of AN fittings this time some AN-6 for the fuel system and some smaller AN-3 for the brake lines.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1545655_10203117537198821_1454016816_n.jpg)
Well its update time again... spent some personal time over the last few evenings firstly boxing in The V-Mount setup as the original panals that John made where terrible and would have been doing diddly squat to aid airflow.
anyway i started with some card templates to make the sides.
(https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1511756_10203135413845726_1272412092_n.jpg)
there is a gap down the side to allow fresh air to be fed to the filter. i am hoping this will provide the air filter with a feed of outside air.
Next i built a top panel, this was quite time consuming in order to get it to fit around the intercooler reasonably well. all the edges will be sealed with adhesive backed foam and or double sided tape to minimuse rattles and maximise cooling efficiency.
(https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc3/1549272_10203135413805725_1838979013_n.jpg)
Once that was done i folded the edges to enclose the top of the radiator and tidy everything up.
Next up i moved on to the Fuel system... plans are to use the stock primaries in the standard Primary rail and mate these with a set of Bosch 1680\'s (that i bought from Mick Choi) mounted in a KGParts Secondary Rail all controlled by an Aeromotive FPR.
I started by grinding the excess brackets off the OEM primary rail and reinstalling that. then i mounted up the Aeromotive FPR on the firewall next to the wiper motor. then i started plumbing up the fuel lines.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1557719_10203135415685772_1856232568_n.jpg)
Anyway i have had to order some more line and connectors to finish this job off as you never can tell what you are going to need until you start.
next on the list... Start on the clutch line and the Heater hose along the drivers side chassis. have mocked up to look at placement of the Greddy Elbow and looks like i will need a new silicone coupler for that.
Its coming along nicely and i feel like i can finally see and end, even though its still a few weeks away all going well.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1549510_10203135414045731_654562857_n.jpg)
Its starting to look really good Aston. Well done mate keep up the good work.
Ade
Thanks for all the positive feedback guys.
Quick update.
Fuel system looks like its now finished, i just got to clean up the casting on the lower intake then i can remove the old diffusers and tap in the spacer rings for the 1680\'s
(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/1009952_10203166703267942_140789328_n.jpg)
Next up I build the new braided clutch hose and fitted. mocked up the intake system again in order to start making a bracket to support the throttle body and intake elbow side of the intake.
(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/923415_10203166703347944_2073879939_n.jpg)
Next on the list is the radiator hoses and coolant line from the heater matrix.
Good job Aston great quality.
Chris (http://www.mazdarotaryclub.com/forums/images/icons/icon14.gif)
Annoyingly I managed to brake an OMP Line tonight while reinstalling them.
Trying to work out if I should rebuild the lines with PFA Teflon hose or build my own braided lines.
Quote from: Arnie_O;872138(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/923415_10203166703347944_2073879939_n.jpg)
out of interest , the top water hose , is that a standard part that it attaches to ??
Im sure mine looks nothing like that
It looks standard however I don\'t think it is mate... Got a couple of water pump housings and they are plastic... This does look like its been modifield, however it was done my the previous owner, so I can\'t be sure.
I think the earlier fc ones were metal but the later ones were plastic. From what I remember the plastic ones can crack fairly easily. I always keep an eye one mine.
Ade
i will have to check when the bonnet is next up :)
Problem solved...
After looking at options... And speaking with Clive I headed out to local hydraulic place to get some "squeeze clamps" or whatever they are called used some of my AN3 braided Teflon hose and made up come nice new OMP lines using the old OEM banjo\'s
Well happy with the results.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn1/1622719_10203188098442808_1013930236_n.jpg)
Also got the manifold and the turbo installed again along with all the ancillary lines for that.
Seems I need a new stud for the rear of the turbo as it looks like it has been cross threaded and I sheered the stuf removing it.
Have ordered some more braided hose for the brakes, then need to look at building some hoses for the power steering wire in my HKS Twin Power and look at battery options.... Then we are pretty close.
nice ducting on the v-mount :)
Problem solved, turns out rx8 exhaust manifold studs are the correct size for the application. Stole one from a spare iron I had along with a hi temp nut.
Next up I painted the last of the brackets in black.
Extra brake hose arrived today too.
Wow why didn\'t I look in this build before!!! Very nice engine bay:):D
some lovely work done here well done Aston :Thumbsup!
Pregress is very rewarding.
Made a couple of a couple of brackets to hold some of the brake hose clamps. Have ordered (hopefully the last of the brake line clamps to mount it all up.
(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc3/t1/1779172_10203244132403622_1228592669_n.jpg)
Next up its time for the wiring... I plan to tidy up the engine loom but to start with I wanted to power up the system to pressurize the fuel rails and check for leaks. I seem to have a problem as I don\'t seem to be getting fuel to the rails.
I seem to have everything plugged back in bar the alternator.
Tried the yellow connector that promes the pump but no success. Any suggestions where to check next?
Planning to get her fired up before messing with the engine loom.
Sorted now, found I forgot to plug in the third harness plug in the cabin.
Now have fuel pressure, and leaky fuel injector seals... Have now ordered some new Petrol resistant seals. Won\'t be here till Monday... Tuesday now :(
Well we still got a few it\'s to do but it\'s now alive
(https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/t1/1176365_10203272477472231_1025482922_n.jpg)
Can\'t seem to get the fuel pressure above 22psi though.
Suspect I am going to need to check my fuel pump next.
She is also hunting almost like a bridgie but there is no bridge.
New plugs, new Magnecore R100 10mm leads.
Still got the twinpower to install too.
Video to come.
looking FAB mate, :cool
Video teaser.
She lives, this was the first start and the Gilmer belt was too tight... Loosened it off and they are a lot quieter.
Definitely a teaser - the link doesn\'t work ;)
Come on Aston sort it out, you can build a great car but can\'t get that link up
:wiggle
For those having difficulty here is a direct link... Hope this works https://www.youtube.com/watch?v=1YRQshuhImw
Link is working for me...
She is proving to be a :censored::censored::censored::censored::censored: to start... Turns out the fuel pump that was branded as a Walbro was crapped out and only providing about 20psi
Dropped in an old RX8 pump and it\'s now at 40psi...
I have ordered her an Aeromotive Stealth 340 in a 11141 configuration.
Hopefully should be here in the next few days.
Once she does start she is running nicely.
But starting is hit and miss. Currently running on 4 RX8 RE8C-L plugs as I got no RE7C-L\'s though once running ok she will be on BUR9EQP\'s
I am also going to investigate the possibility of building a hybrid starter motor... S5 front end on a 2Kw RX8 starter back end.
Also got the HKS Twin Power installed
Anyone got any suggestions would be great on what to check.
So we sorted out the bad starting, turned out to be a poor connection on my new Magnecore HT leads in the Coil packs, sorted that out and she starts on my crapped out PC680 battery now.
Spent till 2am this morning sorting a load of other stuff. now got the brake system all done and sealed, just need to bleed the air from it now. build a bracket for the Boost solenoid and fitted a new weatherproof connector to to power it up. Plumbed in all the vac lines.
Also my Seromotive Fuel Pump arrived.
(https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/t1/1554482_10203291316183187_577676371_n.jpg)
so got that fitted in the fuel pump carrier and reinstalled... now i have excellent fuel pressure.
(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/t1/1902052_10203291317703225_1926364104_n.jpg)
after most of the day on and off running i shut her down to find that there was oil leaking from the turbo "cold side" the remnants can just be seen in the picture below.
(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/t31/q77/s720x720/1795326_10203291319063259_793093567_o.jpg)
First after crapping myself and thinking i shagged a practically new turbo, i spoke to Clive and he told me to check for a restrictor in the feed line (something that was not there) so got busy making one...
(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn1/t1/q80/s720x720/1554543_10203291318383242_638048179_n.jpg)
This fits in the adapter on the block.
However after speaking to the Guys at Garrett today about my problem it appears there is already a 0.8mm restrictor pill in the turbo center housing. it looks like it could all be down to the filler neck breather that i blocked off yesturday as it was spitting fumes everyware... oil catch can here we come.
So we are closer to getting back on the road assuming my GT35 is not fudged... if it is then i am the unluckiest FC owner in the world... possibly (considering i have only had 100 miles from it so far :(
Watch this space.
Watching...........
Foiled from sorting the brakes last night by a leaky corroded brake hard line.
Another section the had corroded where one of the clips hold it to the chassis.
(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/t1/1184849_10203296400750298_1034266122_n.jpg)
I really hate repairing these things, I replaced the entire section under the car in the end.
Well last night marked a landmark in the Gen 2\'s life... She moved under her own power for the first time about 6 months last night.
It was a great feeling.
I seem to have sorted the oil leak and it seems to have been down to the blocked breather.
She is however smelling very rich and is still pouring white smoke out the exhause... Have checked and there is no sign or a water seal breach.
Could this be down to the AFR being way too rich. It seems like the old fuel pump was only delivering about 20psi however with the new Aeromotive 340 it\'s easily capable of 38psi upwards.
Braked are now also fixed, the only thing missing is some sealing around the intercooler a catch can and the wiper motor (then I can reinstall the wipers)
Thought I would drop this one in for you that have been following it.
It\'s a vid of a later start up with her sounding much healthier.
Stop posting porn or you\'ll get banned :Giggle
Seriously looking and sounding :mmmm:mmmm:mmmm
(http://i413.photobucket.com/albums/pp215/ylva51/smileys/Winkbq.gif)
ho boy just magic video well done
So here she is pretty much finished, she just needs mapping with a good base map then running in.
(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/t1/1601300_588056447946525_534412929_n.jpg)
I also managed to pick up a brand new Racing Beat Front ARB off EBay for £95.00 so that\'s on the list of things to fit soon.
She still stinks of Petrol from the exhause with some white smoke... We are not burning coolant or oil so it\'s got to be running mega rich with the new fuel system. Gone from 1000 to 1680 injectors on the secondary rail.
Simply stunning, looks awesome :Thumbs-up
Ya, she is shiny :) Looking good
Sure was worth all the effort under that hood , real real nice job.
At Last Aston, you were really challenged by lots of fiddly problems at the end.
Well done for staying focused and not getting too down.
Now you can map it and tell yourself it was all worth it after the first drive. :burnout
Chris:Thumbs-up
Well after a lot of problems and smoke, JayDee took a look at the Map but it appears there is still something wrong. So tonight we started stripping her again to pull and out the beautiful engine to strip her and inspect. It appears we have a real oil control ring issue as there is obviously heaps of oil coming from the rear exhaust port. Hopefully I have found the problem and tomorrow we will have her out and begin the steps to get her going properly.
So we pulled the motor and stripped her Saturday morning under the watchful eye of Clive (many thanks for your time sir)
(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10402099_637294099689426_5659299082006226302_n.jpg)
The oil was really quite nasty. It stank(is that a word?) of petrol and looked very graphite in colour.
Clive suspected there was definatly something amiss.
When we dismantles the motor we found several things.
(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/t1.0-9/10373829_637485493003620_7719442269411051073_n.jpg)
All the irons had been munched by the seals... I need to inspect the side seals, corner seals and oil control rings for wear still.
Clive suspected this was an injector problem that was causing over fuelling and has washed out all the oil from the rotors.
The housings look ok along with the apex seals but the irons are sadly now scrap. I doubt lapping them would make them usable again. Still I have another set of ported irons that just need cleaning and painting.
My water seal kit is here and the new oil control rings should he arriving Tuesday.
Fingers crossed everything else is ok and we can look at assembling the block again this week.
Sad news Aston. Good luck rebuilding.
Chris
So i Stripped the rotors today.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/10325596_10204099183299360_1643995268236013422_n.jpg)
Seems I am in need of some new oil seals as well as oil control rings. The faces on the oil seals have been worn flat.
I have looked and I think a set of RX8 oil seals will fit. If this works it\'s going to save a wait for these too.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash3/t1.0-9/q82/s720x720/1780766_10204099184339386_7134077822123515566_n.jpg)
Also found a nicked Oil Control ring on the front rotor.
(https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/q71/s720x720/10325161_10204099183819373_1025128258510226057_n.jpg)
Also got all the irons cleaned up and the ports tidied up polished.
New Oil Control Rings arrived today.
Checked the part numbers for the steal oil control sings (oil seals) and they are the same so joy of joys I can use some RX8 ones I have laying around.
Also brother has painted up the new irons this evening after I cleaned up the posts in the secondaries last night.
Also dropped the injectors off for flow testing to make sure they are operating and where not the cause of the petrol wash (one stuck open ect)
Hoping to pull this one off for Brooklands.
Wish me luck
Good luck pal hope to see you running it in by the weekend, got my fc booked in for mot in the morning so if all goes well see you there
Woop Woop good luck Aston.
Great news Jim
So That\'s the FC Short Block assembled... Not long finished.
All the rest to do after some sleep time lol
Well after another late night 1:30am we finally got the block in and fitted. Started her up and she ran ok.
JayDee has been over today to check over the map settings and after having a fiddle it\'s running nicely. Minimal smoke too.
Really don\'t want to jinx things but after adjusting the idle and timing it seems to be running nicely.
Going to use it today for running around and hope it will make it to Brooklands now
:Thumbs-up Great news Aston! Hope to see you at Brooklands on Sunday.
Well done that man
(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10270278_10204124716777681_2726706605774487309_n.jpg)
First outing today. Would like to say thank you to everyone that\'s helped get it where it is so far. You have all been a great help and in many cases a source of inspiration and a shoulder to cry on when it\'s gone wrong.
Yipppeeeee great stuff now enjoy the weekend, well done to you and your dad + jay-dee.:Thumbsup!