Mmmm Shiny: new engine (56k warning)

[Rupewrecht]

okay laddies, here's pics of my new engine - will be completed shortly...


http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_block.jpg
http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_pistons.jpg
http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_crank.jpg
http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_crankshaft.jpg
http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_head.jpg
http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_inlet.jpg

New parts needed to fix the ****ty engine i was sold...

oh yeh, it's a BPT..well, it was

4x Forged Pistons
1x GTX crankshaft
1x set of HLAs
1x new crank

i think that's all...

anyway, car goes back to installers friday, and engine will be there before that...so, sooooooooooooon... 8)

[ABC]

Oooooooo, that's Puurdy. :shock:

[BigBoyLemonade]

Damn straight!! that looks cleaner than new!

[Toyboy]

Looking shweeeeet Rupe :wink:

[KittyKatSmack]

Purty and Shiny :shock:

Kitty is mesmerized :shock:

Kitty is drawn closer :shock:

OUCH!

*Kitty bumped her nose on the monitor*

::blink blink::

Where am I?

[Fuzzy dice]

Looks good d!!

can see those $50 & $100 bills that are moulded into looking like pistons from here!! :p :p

can't wait to see it on the road!! :) :) :)

[EZZY]

New parts needed to fix the ****ty engine i was sold...



the engine/package was in a good nick when you picked up, your mechanic took alot longer than required to PERFORM the task. who knows how long they had the thing on the dyno with the wolf (or haltech) ecu and how well they did the wiring. dont go around and commenting things like that (i dont care how much has been done.....).
if i remembered correctly, you have told us many times that your mechanic had problems with the electricals/wiring and even tuning, and i have read from other forums that you or your friends had been racing other cars... think about it dan, if the engine/package was ****ty, would i have offered you (at least twice) to get my mechanic to fit it up here in sydney???

[sik astina]

Looking good dan. when its back on the road u gotta take a short movie and upload it on the net for us to see :D


-Mick

[Rupewrecht]

the engine/package was in a good nick when you picked up, your mechanic took alot longer than required to PERFORM the task. who knows how long they had the thing on the dyno with the wolf (or haltech) ecu and how well they did the wiring. dont go around and commenting things like that (i dont care how much has been done.....).
if i remembered correctly, you have told us many times that your mechanic had problems with the electricals/wiring and even tuning, and i have read from other forums that you or your friends had been racing other cars... think about it dan, if the engine/package was ****ty, would i have offered you (at least twice) to get my mechanic to fit it up here in sydney???

well, it was my own fault i never had a compression test done.

but no, i have said that:
• they took a long time to wire it, not that they had problems, apart from laser and astina plugs being different on the throttle body.
• i told you we were having trouble with it blowing a lot of oil smoke right from the start. Both with the turbo - which needed a $1300 rebuild as it was farcked - and the engine, which was using over 4L of oil in lthe first 1000kms i did with it - from the moment they had it running.
• there was never a problem with tuning or the running of the car, apart from the oil smoke which was because of the leaking valve stem guides.
• that engine was so tired it wasnt funny! worn guides, scratched bores, piston slap, extremely worn HLAs, a cracked crankshaft. do i need to go on?
• i'm still waiting for you to reimburse me half the cost of the turbo rebuild as you said you would.
• this is the first time i have badmouthed you AT ALL, even after your repeated ignoring of my emails. I haven't bitched about it here because i have not wanted to badmouth you amongst peers.


i stand by my previous comment.

[Toyboy]

:o i have no comment,its best i stay outta this 1 :twisted:

[Fuzzy dice]

• i told you we were having trouble with it blowing a lot of oil smoke right from the start
hahha....l remember the first day you picked it up, and l followed you hone in the VW, and the astina was blowing 4 times the amount of smoke the vw was!!! :D :D :twisted: :D :D

[MrShadow]

....l remember the first day you picked it up, and l followed you hone in the VW, and the astina was blowing 4 times the amount of smoke the vw was

bwahahhahaha :lol: :lol: :lol: :lol: :lol:

ROFLMAO

Looking sweet Dan. Damn, where's my Lotto win???

[TURBO MAZDA]

Rupewrecht what are the spec's of the motor now, what compression?? what bore ??

[Rupewrecht]

pistons are 40thou oversized, and CR is 8.27:1

i'll post up the full specs of the engine when i get the jobsheet etc :)

[BigMal]

Mate looks great. Cant wait to find out how well it goes afterwards
as you really have put a lot of effort in there.

Regards

Mal

[Sandyman]

wince. looks great. i trust you will have fun?

[Rupewrecht]

http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_head.jpg

http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_longblock.jpg

getting there. it's all a bit delayed, as at some point in time, all the valve caps in one cylinder have been changed. why? buggered if i know. but had to end up buying a BG astina head just to get some of the caps and collars (the things that hold the valves on) as couldn'ty find any anywhere, and Mazda only had 6 caps and no collars...and it was a 3 week wait from japan for some. and stuff that! i'm running out of time as it is!

[Rupewrecht]

http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_cams.jpg

getting there...waiting on a new water pump

pic shows the cam timing in process

oh, and i pick it up friday...that's tomorrow :D

[BigMal]

What no shiny adjustable cam gears. :(

That 4 plus in Melbourne does them cheap. Maybe something
for later :)

Mal

[Rupewrecht]

I thought about them, but apparently there's just enough adjustability with the standard ones...just.

but they're on the list to add when i do more headwork later down the track....one day! :)

[MrShadow]

but they're on the list to add when i do more headwork later down the track....one day!

What, you mean there's MORE you can do to that engine?!?!?! :shock: :shock: :shock:

:wink: :lol:

[Dogo]

i do more headwork later down the track....one day!

not more !!!

it'll be another 10 months or so b4 u get the car back. :P

i reckon u should get a bumper bar so when u drive this thing straight into a tree u wont damage the shiny bits :D heheh

... or maybe some grind plates so u wont have to worry when u land on a gutter again :P

[pr1mo]

i was thinking more like spend that 10 months turning the car into something inspector gadget would drive. hook the turbo upto some helicopter blades, a boxing glove @ the front of the car and all sorts of other crazy stuff :P

only dan could do it me thinks

[Rupewrecht]

and you wonder why i think you're an assclown :P :P

Looks like i do need the vernier gears after all *grumble*

it's just a matter of finding some...got any more deatils on this '4 plus' place in melb, Mal? i havent searched the web/whitepages for them yet...

oh, and yes there's plenty more i could do on the head...but i'm not made of money (otherwise i'd be offerring a kidney in the for sale section) :wink:

[MrShadow]

The way things are going rupe, you may be offering a kidney, lung, liver and prostate in the "For Sale" section. Dibs on the kidney... :wink:

[Rupewrecht]

damn! four plus don't exist anymore...

and you can't afford the kidney, shads :p

[Dogo]

i think pr1mo has already claimed the prostate ....

:lol:

[Cosmo Dude]

www.kidney.org.au

[Rupewrecht]

EW DAVE EW!!!! :shock:

LOL @ rod - "The material contained at this site does not constitute medical advice. It is intended for information purposes only" Aww!

well, after making a few calls interstate, i've got my hands on some HKS cam gears! LOL but they're disgusting colors :shock:

[BigMal]

mmm Purple !!
They do look great thou even better than AEM ones.

Would have cost a packet thou. Are they MX5 ones ??

Mal

[Rupewrecht]

yeah, they're blue and purple :roll: yuck!

and yep, they're the MX5 ones - $285 each, from BD4s. $40 cheaper than from Jaustech!

[Trav]

ahh, purple - at least it will match your shirts :)

[Rupewrecht]

haha as soon as i saw that you're replied, i knew what your response was going to be :P

oh, and it's actually pink, not purple on the gears

http://bd4s.com.au/images/HKS%20More/adj%20cam%20gears%20s.jpg

[Trav]

it's just funny that we pick on your purple shirts, and you end up with purple gears. Well I thought it was _very_ coincidental :P

[Rupewrecht]

i can see i'm gonna hafta wear it to the upcoming cruise :wink: :P

[Cosmo Dude]

Good news is Rup, if you put the standard valve cover back on you won't ba able to see 'em :D

Rod

[Trav]

but rod, then he won't be able to pop the bonnet and say "look, it matches my shirt" :P

[Rupewrecht]

ROFLMAO! @ Tarv

but nah, i like the look of them exposed. i'm going to get them powdercoated anyway, so that the HKS and standard one match.

[Cosmo Dude]

What does it cost to have a shirt powder coated? :D :twisted:

[Toyboy]

LOFL @ yous guys :D

[MrShadow]

:lol: :lol: :lol:

BWAHAHAHAH :lol: :lol: ROFLMAO

[BigMal]

You are getting the stock one annodised to match the HKS and not
powder coating the HKS are you ??

Exposed cam pulleys look great mmm cant wait for thew pictures.

Regards

Mal

[Rupewrecht]

nah, getting both powdercoated to a color...possibly silver or a gunmetal grey. i don't care if it's HKS, i cant stand the colors LOL

[Bear]

nah, getting both powdercoated to a color...possibly silver or a gunmetal grey. i don't care if it's HKS, i cant stand the colors LOL

honestly I can't blame you ... if you do get them powder coated, leave them exposed and post us a shot ... it should look hot

[BigMal]

If you are going to do that to a HKS why not look at getting some
adjustables made. I heard you say the guy from 4plus is closed but
he was having them made local. You supply originals that he would use
for the ring gear and then he would have them modified with an adjustable
centre with a keyway. Was less than $200 for a pair not $300 for one.
Some carefull searching and you may be able to find another source. You
said that you could get enough adjustment with the stock cam gears so
its not like you have to have it asap !!

Regards

Mal

[Rupewrecht]

You
said that you could get enough adjustment with the stock cam gears so
its not like you have to have it asap !!

ah, but i do need them straight away - as there wasnt enough adjustment after all! :oops:

[BigMal]

What the +5deg advance hole on the cam gear is not enough ??
Adjustable cam gears allow finer adjustment than the +5 0 -5 degrees
on the stock unit. I thought you were only really trying to fine tune
the rev range the cams work in but thats just a final tweaking not
a necessity. Or am I off on what you are trying to achieve here.

Regards

Mal

[Rupewrecht]

from what i was told, the adjustable one was needed to get better clearance between the exhaust valves and the piston. or something like that!

aanyway, it's arrived, and is perfect. and i get the engine tomorrow :D

but the cam grears can be painted at a later date. atm i've got 2 mismatched ones :roll:

[Rupewrecht]

and now the engine is shrinkwrapped, and is sitting at Rank, along with the car that has been there for a week.

i'll post a pic monday..errr tuesday

[Cosmo Dude]

and now the engine is shrinkwrapped, and is sitting at Rank, along with the car that has been there for a week.

i'll post a pic monday..errr tuesday

Saw your car there. I may need to drop in and see if I can do a three card shuffle. I get your engine, you get mine and no one is the wiser :D

[BigBoyLemonade]

hmmm that would be a bad mix up

but quite possible

[TURBO MAZDA]

Correct me if I’ am wrong but adjusting the cam gears for more torque, your going to have some fun controlling it with the extra torque and boost coming on at the same time.

[Rupewrecht]

and now the engine is shrinkwrapped, and is sitting at Rank, along with the car that has been there for a week.

i'll post a pic monday..errr tuesday

Saw your car there. I may need to drop in and see if I can do a three card shuffle. I get your engine, you get mine and no one is the wiser :D

well, as long as you pay for it - as i haven't got the bill yet :lol: :lol:

Turbo - no idea - i'll find out!

[BigMal]

I am guessing that what they want to do is move the rev range
that the cams work best in the match the rev range that the turbo
works in. The larger turbo works from around 3500-7500 yet as
the old turbo would come on boost almost straight away am guessing
the cams are designed for 1000-5000 rev range. By adjusting the
position of the cams by use of the adjustable gears can move the rev
range the cams work best at closer to where the turbo does.
Guessing they want to advance the opening of the valves to get the
most air into the chambers.

Let me know if thats what they are doing

Regards

Mal

[Rupewrecht]

http://hrdwrbob.net/mca/uploads/rupewrecht/astina_engine_shrinkwrapped.jpg

sitting at Rank waiting to go in..

and dont ask me, Mal :lol:
but i do know that only the exhaust cam was changed (reground) as i wasnt springing another $1500 for new cams...

[BigBoyLemonade]

Are they just BP cam gears from a MX5?

[Rupewrecht]

yep, for the BP-ZE (MX-5) engine apparently

[BigBoyLemonade]

hmmm $281.00 each... so so tempting but I wanna buy an electronic boost controller first though

[TURBO MAZDA]

Is that trade price or standard price ??

[Rupewrecht]

that's standard price afaik

okay, got the bill etc & report of what's been done to my engine:

New Parts:
Pistons +030 Forged
Rings +030 Moly
Mains Bearings
Conrod Bearings
Thrust Washers oversized
Hydraulic lifters
Conrod Bolts
Timing tensioners
Timing Belt
Exhaust valves
Full gasket Set
Stainless Bolts
2nd Crankshaft x 1 - BP 4.2 KG lighter
Conrod x 1
Clutch Plate - Button
Spigot Bushing
Water Pump
Cam Seal
Speedie sleeve
Carby Clean
Paint

Labour:
Hot tank - Clean Engine Parts
Crack test parts
Bone-Hone Block
Surface block
Line hone mains
Grind - linish 1st Crankshaft
profile Camshafts
resize conrods/align
Shot peen conrods
Surface/lighten flywheel
Balance engine assembly
Pressure test cylinder head
Port cylinder head
Match port inlet manifold
Fit valve guides
Recondition cylinder head

Dummy Assembly
Machine piston crowns
fit speedie sleeve
cc Cylinder head
final clean block/engine parts
assemble long motor

Compression ratio: 8.27:1
Capacity: 1883-85cc

Bore: 83.49
Stroke: 85
piston -.010 below deck height

i'll add the cam specs when i get them

and no, you don't want to know what it cost me :roll:

[MrShadow]

and no, you don't want to know what it cost me

I would be guessing high 4-figures(>$7,500) to mid 5-figures (<$20,000). I have a feeling you don't even want to know dan...

You know, if you want to raise some cash, you caould always sell some wheels... :roll: :roll: :wink:

[Rupewrecht]

ROFL $20k? you were pretty close with your first figure tho :shock: :oops:

and no, Adam's first in line for the wheels :P unless you want to fight for them :lol: :roll:

[MrShadow]

ROFL $20k? you were pretty close with your first figure tho

I was just covering all bases.

and no, Adam's first in line for the wheels unless you want to fight for them

Yeah, he, ahhh, asked me to, ahhh, pick them up for him. Yeah. :roll: :wink:

goddamnit

[mrpayner]

and no, Adam's first in line for the wheels unless you want to fight for them

Yeah, he, ahhh, asked me to, ahhh, pick them up for him. Yeah. :roll: :wink:

goddamnit

Hahahaha!! I seriously thought Dan had forgotten about this! As i thought about it the other night when you were PMing me Shads... But I will step down for the honour of accepting those wheels! I have changed my mind so many times but [for now] I think i have a choice.....

Thanks anyways though Dan, I seriously thought you had forgotten about it.. that's ok though, it wouldn't have mattered if you sell them to Gazza!

:lol: :lol:

Adam

[Rupewrecht]

well, it's not like i *am* going to sell them anyway :P

[Dogo]

$$ - thats just for the engine re-build, right ?? :wink:

not to mention the original price of the setup, installing it, taking it apart to see what was wrong, and then putting it back in after the re-build.

and the bug !!! dont forget the $$ for the bug. and the guages, and the ecu, and the fibreglass for the dash etc etc and the *cough* spice jar *cough*

..and the 130km towing price :lol:

ahhh but its going to be such a beauty 'when' its done :) an impressive setup for sure. do u think its worthy of being feature car ? how about a June 'WRECHT Work In Progress' featue car until its ready?!
no doubt u allready have a tonne of photos !

[TURBO MAZDA]

Welcome to my world ?? I have rebuild my motor completly twice.

Good thing my dad is a mechanic !!! :D :D

[Cosmo Dude]

I saw the new engine today, compleate with box.
I am in envy 8)

[Rupewrecht]

yeah i was down there yesterday too - apparently they were going to put it back in later that day...

am *hoping* to have it back for the cruise. even though i'll be up the back...even slower than mike :lol: :P

[kyra]

ouch... when Dave puts it into perspective like that, it makes an accountant like me absolutely cringe!
This motor sounds like it is a monster, hopefully Dan holds keeps the boost low, except for 'special' occasions... hehe.

:lol: at the car making it to the cruise though.

[MrShadow]

:lol: at the car making it to the cruise though.
That should have been appended with: "under it's own power" :wink:

[Rupewrecht]

heheh piss orrrrrrf :wink: :lol:

but seriously, it should be there. it'll give me a good chance to run it in.

[mrpayner]

I'm sure everyone's got their fingers, toes, legs, arms and whatever else :shock: crossed that you've got your car back for the cruise... I'm particularly keen to see it again [going that is! :wink: ]

I noticed that you changed it from 2L back to 1.9lt in the sig.. how many horsies are you going to be punching through those front wheels?

Adam

[Dogo]

best wait for a dyno run for that i suppose !!

any idea what it used to be when the new engine first went in ?

[Rupewrecht]

I noticed that you changed it from 2L back to 1.9lt in the sig.. how many horsies are you going to be punching through those front wheels?

yeah, the size of the oversized pistons was slightly smaller than i first thought. And no idea! but it'll take a while to run it in, which means no boosting it/revving it high for a while

best wait for a dyno run for that i suppose !!

any idea what it used to be when the new engine first went in ?

yeah pretty much

i'd guess it had about 150-160kw at the flywheel @ 7psi, guessing from what cars i was beating (but the driver is always a factor). And compared to a standard setup, i've got the bigger turbo/exhaust/ecu etc. But it's just a guess :?

[Rupewrecht]

posting this because i can, and it's vaguely relevant :wink: :D

http://hrdwrbob.net/mca/uploads/rupewrecht/astina_hoist_rank.jpg

now THATS 4x4 ground clearance! :lol: :lol: :lol:

[Fuzzy dice]

just think, as of tomorrow your engine can sit next to mine there!!

l will still laugh if mine is done before yours!! :P :P

i'd guess it had about 150-160kw at the flywheel @ 7psi, guessing from what cars i was beating (but the driver is always a factor). And compared to a standard setup, i've got the bigger turbo/exhaust/ecu etc. But it's just a guess
l hope you have at least 200KW @ the front wheels after the amount spent, would be nothing worse than having a pulsar with a bolt in engine with more power!! :P hehehehe

[Cosmo Dude]

Dan,
Is that Brad I see under your car?

Fuzzy,
I've seen you buzzing about the area, didn't see you at Rank tho.

Rod

'96 Passion Rose 1.8 Astina
'81 White Cosmo Limited 13B Turbo
'78 Satin Spruce 2.0 Escort GHIA

[Rupewrecht]

haha no, at that time brad was attaching the plenum! i've got a picture of his bald spot :lol: :lol:

and fuzz, i wouldn't lower myself to compete with pulsars :P Come back when you have a car with class :P :twisted:

[Rupewrecht]

rather than start a new post, instead a thread from the dead.

engine is in, aircon has been reattached. new piping being down now - here's the new 3" dump pipe that'll be HPC coated (along with the new manifold) this week...

http://hrdwrbob.net/mca/uploads/rupewrecht/astina_3inchdump_01.jpg
http://hrdwrbob.net/mca/uploads/rupewrecht/astina_3inchdump_02.jpg

[Fuzzy dice]

gotta luv that flex pipe!! hmmmm!!!

and l was surprised about the weight of that...l thought it would of been heavier!! (oh sorry bout the huge dent dan! :P :P haha j/k)

[SehnKhan]

So how is this engine coming along if you don't mind my asking?

[Rupewrecht]

welll, the 'engine' is done, and has been for a while. it's just the ancillaries now - reinstallling the aircon, which means new manifold, new intercooler piping, new exhaust...

atm the exhaust + manifold are being heat treated, they'll be back late this weeks and after thatb is installation, and finishing off cooler piping, then rewiring and tuning...

still a few weeks away, but how long have i been saying that :roll:

[dfvadr]

dan why so many pieses welded together why didn't you bend 1 peice

[BigMal]

Not many shops have mandrel bend machines as they are expensive.
Easier and cheaper for most places to buy sections in various curves
and cut and weld together. If the guy is a good welder and the
penetration of the weld is right the inside will remain flat so will be
as good as one section but if too much voltage a lip/ridge will form on
the inside will occur and affect flow.

Regards

Mal

[Rupewrecht]

haha what Mal said :)

[Trav]

what about a vice and a BFH ??? ;) :twisted: :lol:

[Rupewrecht]

BFH?

Brute Force?

[JynX]

Big Fn Hammer im goin for

[Rupewrecht]

finally got a pic of the new manifold...all HPC coated, as well as the turbo housing.

and the nice braided oil feed line

also the exhausts been coated as it's runs closeish to the sump.

http://hrdwrbob.net/mca/uploads/rupewrecht/astina_turbo_manifold.jpg
http://hrdwrbob.net/mca/uploads/rupewrecht/astina_turbo_oilfeed.jpg
http://hrdwrbob.net/mca/uploads/rupewrecht/astina_3inchdump_hpc.jpg

[BigMal]

Dan,
The exhaust section looks fantastic.
How come the turbo manifold needed to be pushed so far to the passenger side.
The entrance into the turbo looks a bit congested with one piece coming in from
the side.

Ta

Mal

[Rupewrecht]

basically it's all to clear the airconditioning compressor - i wanted my aircon back! :lol:

and thats another reson for the heat treating too - so i dont 'melt' the compressor, as it's reasonably close

[BigBoyLemonade]

yeah I saw that and was very jealous! I was thinking about ripping the a/c off to get another 10kw with a dump pipe

[TURBO MAZDA]

who needs aircon !!!!!!!

Just open all the windows and the roof, same.

[dfvadr]

not the same when there is a hot breeze , thumbs up too air con

[Rupewrecht]

the first weekend i got the car back in summer last year was about 30 degrees - i nearly roasted with all the hot air coming off the engine bay...

[wiredone]

mmmm... can i touch it... mmmm

way to make me jealous...lol nice and clean...

cant wait for my powder coating...

[sik astina]

lookin good dan :D when do ya get the car back :?: its almost been a year yeh?

[Dogo]

over a year now :P :shock:

hehe

it'll almost be a year from when he got the car back the first time !! ... well almost

[Rupewrecht]

lol no, it'll be about 10 months from then :P ..|..