My Winter Project

[pdtaylor18]

Thats some good work Dave, the props are all the same but I always undo the 4 nuts from the diff, 14mm and are easy to get onto, saves a lot of bother.  I forgot about JAE, I think I might need to revisit my plans for this coming few weeks.  Hopefully I will see you there in the Rex.

[Prof]

What are you planning to do with the old block? im looking for one to do up and use as a spare

That\'s exactly what I want to do with my old one - just in case this happens again !!  That way I\'d have a spare engine to drop straight in (all be it with a 3-4 day turn around time :rolleyes: )

[Prof]

Well cracked on a bit more today - but old father time prevented me finishing today.
 
Still got to fit rad, tighen belts, make intercooler fit under bonnet, fit battery, fit 2 stroke can and feed line, and fill with fluids.
 
Then got to map the 800cc injectors on the emanage - just a quick entry in a table for the secondaries - and it will be time to crank it :yes
 
Some more pics of the progress - although there are more to take as I ran out of light for the last few things done.

[BenLewisMav]

Looks good (lots of silicon!), fast progress too..
Forgot to mention, it might be an idea to change the plugs, or at least clean them up, as they are probably pretty fouled with all that premix sitting on them for this length of time. (they are pretty much brand new, so should be ok with a clean??)

Also don\'t forget to take a bit of timing out the whole range from 0 Psi-onwards [overriding the stock ecu] because, a) bit of safety margin never hurt anyone b) a big street port won\'t want as much advance anyway. Sorry if i\'m \'teaching my grandmother to suck eggs\'..
I am curious to see what power you make from the T4 .70 trim!

[Prof]

Well I sorted out my intercooler to bonnet clearance issue - cutting a rubber grommet and some minor adjustments made that another tick

Drilled my catch tank for the oil feed to the oil metering pump for my 2 stroke and then started to fit the radiator - got it all done and started filling fluids before connecting the batter - and just as I\'d topped up the coolant system my new radiator arrived - bugger - such timing

Connected up the battery and then prayed - then turned the key - it actually caught within a few cranks - followed by clouds of blue smoke - Ben who I got the engine off did say it would smoke like a gooden when I started it - as he\'d put some premix in the rotor housins to protect it whilst it sat.

Smoke coming off all sorts of areas - as gaskets bedded in and so forth, steam off the radiator - worrying - but it did get drizzled on this morning. Engine seems happy - but cooland buzzer going off - I may have not grounded the radiator properly - need to sort that out as the buzzer is driving me nuts.

Still to do:

do quick update on the emanage to tell it is has the larger secondary injectors. Adjust electric fan to come on at lower temp - it\'s set a little to high. Fill petrol tank and put premix in it this time, as the 2 stroke from the tank is going to take a while to work it\'s way down the pipes - and at the moment there are air bubbles in the metering lines - although they are moving towards the engine which is good as it means the pump is working

More pics later - having a quick rest now

[TiddlesRX7]

Wow you\'ve been a busy boy haven\'t you. Well done on the quick turn around. I don\'t think I could do it that quick.

[Prof]

Wow you\'ve been a busy boy haven\'t you. Well done on the quick turn around. I don\'t think I could do it that quick.

I had help - Aceman and Mitch - Aceman on stripping the old engine out, and Mitch helped a lot with getting the engine and gearbox etc. back in the car.  But there were a lot of untried ideas in this build - which all though I\'d worked them out on paper - it\'s a different matter when it comes to reality
 
Still, happy with the look of it - will be better when the ally rad is on, but have to wait till after the weekend to fit that.

[mpk490p]

Well done Dave, quick turn around (it what a club is all about helping each other out when needed :Giggle) hopefully there will be nothing more than a few little probs and the motor will be stronger than ever:driving

my 51IDA should be here next week but im already dreaming of a nice BP during the coolder months, this is real inspiration for it and mine would be 10 times easier than what you have achived!

Mark

[Aceman]

I had help - Aceman and Mitch - Aceman on stripping the old engine out, and Mitch helped a lot with getting the engine and gearbox etc. back in the car.  But there were a lot of untried ideas in this build - which all though I\'d worked them out on paper - it\'s a different matter when it comes to reality
 
Still, happy with the look of it - will be better when the ally rad is on, but have to wait till after the weekend to fit that.

Fingers crossed it gets you safely to Mersea Island now for JAE!!

Thankfully it\'s not a drag strip event so you don\'t have to get envious sat on the sidelines..

Although, sitting on the sidelines can\'t be much worse than permanently viewing the rear end of my car over and over again...  


Only kidding!! You should be making some good power in all seriousness with your new setup. Can find out in Nov at the Rolling Road!

[pdtaylor18]

Be nice Dave if you can list what has stayed and what has gone and for what reasons.  It would be an excellent thread for those that either want to go the emanage route or even for when you simply want to get rid as much as possible any crap that really has little purpose if you decide to get rid of emissions, airpump etc. I will list mine on my car later in its progress as although similar will not go down the emanage route.

[BenLewisMav]

Glad to hear its up and running again!
Didn\'t sound like you had 1/10th of fiddling I had to do, I guess thats the advantage of the stock ecu being there. Did you get any videos?

I bet there was a lot of smoke lol! When I first got the engine started it filled the workshop in about 10 seconds, it looked like something from loch ness, when I opened the door it was rolling out along the floor like a B-Movie

[Prof]

Ok, probably almost the last update - although I will post pics of the rad when I get it on, and also the turbo oil return line - as they are part of this engine swap  story.
 
So I got the car running well enough to drive to JAE - or so I thought - electric fan keeps blowing fuses - so water temps are getting silly in traffic - had the heating full on in the car to aid with cooling  Have jumpered the fuse for now (bad), but will investigate some sort of thermal cut out device, as it\'s only the very high start current that\'s causing the issue.
 
Also, my bit of rubber hose for the oil return line split on one end - so I had a little oil seapage - managed to get someone to bring some blue silicon hose with them, and I jerry rigged the return line - seems to be holding up - but it\'s not permanant - will change it for a braided oil return once I\'ve got one made up.
 
Final problem - air intake sensor was grounded on one side by the bracket - the plug that fits on this has 2 wires - one is grounded one isn\'t - lucky old me connected it so that both sides of the sensor were grounded and the ecu assumed the intake temps were really high so consequently retarded the engine and over fuelled it slighly - contributed to over heating issue and total lack of any power in the engine.
 
Pics - some close up\'s of the bits I did leave on - PRC - purge control valve, close up of my oil return bodge, and the 2 stroke can with it\'s breather pipe (will also revisit that idea - if I over fill the tank and go over bumps it dribbles out of the end).
 
On the way back from JAE engine temps were at a more respectable 80-95, and electric fan really seems to be working well now.

[Prof]

Glad to hear its up and running again!
Didn\'t sound like you had 1/10th of fiddling I had to do, I guess thats the advantage of the stock ecu being there. Did you get any videos?
 
I bet there was a lot of smoke lol! When I first got the engine started it filled the workshop in about 10 seconds, it looked like something from loch ness, when I opened the door it was rolling out along the floor like a B-Movie

Was going to do a vid of the startup - but it in my rush to get it going - I forgot.  I did have to run and close the front door - as the blue cloud from the exhausts was quickly making it\'s way into my house :Laugh :Hammer

[pdtaylor18]

Superb dave, top job and in a relatively short time as well. Hopefully all should be spot on for the JAE Finale.  You may even see a glimpse of my orang car by then as well.
Is the oil going through the OMP adapter yet? you could give it some pressure to aid it along? I am now double thinking on my hoses I made as Furb had issues with his ging to soft so I will pre-mix for a while until I am happy with the hoses and oil supply. Nice pics by the way and looks so much different.......almost like a new engine !!!  lol

[L18M]

nice job.. looks good also.. fancy sorting out my engine bay also..? lol