My WCR 09 Thread, Time to get started |
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My WCR 09 Thread, Time to get started |
DNHunt |
Sep 27 2008, 01:15 PM
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#1
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
I promised my daughter a trip through the redwoods and down the California coast. My list of projects isn't long, three things really. Install new struts and bleed brakes, rebuild my engine and tune said engine. The problem is I haven't gotten the last 2 things right in the last few tries. I'm allowing plenty of time go around. This build will succeed!
Poor car on jack stands So, here I go Dave |
DNHunt |
Sep 27 2008, 02:18 PM
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#2
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
I'm going to try and document my engine build paying attention to everything I can. This will be a 2382, 98 X 78.6.
I started a while ago with case selection. Supposedly 1.7l cases are better EA I guess but I have 2 GA cases. One I sent to get machined and the other I had done locally. Choosing between the 2 I looked at the case split between the main bearings. movement of the case halves will cause a dull gray look and loss of machining marks. This case shows it was moving. I would have preferred it look more like this but, those are hard to find around the center main. It is brighter silver colored and you can see machine marks still. As a quick test you can use a not too worn old bearing to see if the the journal are enlarged. If it slips in and out easily align bore for sure. If it is tight keep checking. Bolt it together and see if you can catch the parting line with a finger nail. If you can you should probably align bore. Finally, if all of that looks pretty good you can measure the bores with a bore gauge or have your machinist do it. This case had an oval shaped bore and had been moving so it got align bored and decked. I'm still hoping the other case is better. |
DNHunt |
Sep 27 2008, 02:32 PM
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#3
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
Ah, galley plugs. Removing the pressed in factory one helps assure no leaks and gives you access to clean the passages better.
Here's what I use a 5/16 drill to pop through the stock plug. Often they come out on this drill. If not I use a #4 extractor and wiggle and work it backwards. I prep the hole with a 37/64 drill in a drill press and tap with a 3/8 NPT tap. There are 3 in the back of the case, and 2 in the passenger side front. Here it is on the drill press. And here is the tap. Beware of the passenger side back closest to the parting line. THe passage to the rear cam bearing is pretty close to the surface and if the plug sets too deeply into the case oil can be resricted to that bearing (IMG:style_emoticons/default/icon8.gif) |
DNHunt |
Sep 27 2008, 02:50 PM
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#4
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
My pistons and cylinders arrived so it was time to find out what they were like. The first thing I did was measure stuff. I measured the area that fits into the case register so I could anticipate the diameter of the shims I will need. I measured them at room temp and at 400 degrees. These are Nickies and the aluminum will expand more than the steel shims.
I also measured the height to see if they were the same and they are. Next I checked piston to cylinder clearance. This should be set at the machinist but, I wanted to verify it. First I used the cylinder bore gauge. I would expect with iron cylinders that piston to cylinder clearance would change with heat and the room temp reading I had would be way to tight at operating temps. On the opposite side I would expect ring gaps done at room temp would be fine at operating temps. Then I measured the diameter of the piston 1/2 " from the bottom of the skirt. Nice and tight. I slipped the piston into the cylinder and it slides through slowly on it's own. The under side shows it's nice and tight. |
DNHunt |
Sep 27 2008, 02:56 PM
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#5
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
Gapping rings was next.
Since the cylinders are aluminum and the rings are iron I checked the gap at 400 degrees, 65 degrees and 25 degrees. At running temps the gaps are very near what the ring suppliers suggest. I don't think I'll start it at 20 degrees. That's all for now. The pistons are off so everything can get balanced. Dave |
Todd Enlund |
Sep 27 2008, 11:52 PM
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#6
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Resident Photoshop Guru Group: Members Posts: 3,251 Joined: 24-August 07 From: Laurelhurst (Portland), Oregon Member No.: 8,032 Region Association: Pacific Northwest |
(IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/beer3.gif)
I'll be watching this thread for sure. Go get 'em, Dave! I'm hopeful that my car will make '09... but it's not likely. |
messix |
Sep 28 2008, 12:00 AM
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#7
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AKA "CLUTCH KILLER"! Group: Members Posts: 6,995 Joined: 14-April 05 From: between shit kickers and pinky lifters/ puget sound wa.north of Seattle south of Canada Member No.: 3,931 Region Association: Pacific Northwest |
good to see you working on it. (IMG:style_emoticons/default/smilie_pokal.gif)
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dw914er |
Sep 28 2008, 12:13 AM
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#8
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Planning Cities Group: Members Posts: 2,364 Joined: 1-March 08 From: Yucaipa, CA Member No.: 8,763 Region Association: Southern California |
rock on!!!!!! Hopefully I'll get to see the final result at WCR!!!
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DNHunt |
Sep 28 2008, 08:29 AM
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#9
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
QUOTE good to see you working on it. smilie_pokal.gif Can't give up. QUOTE rock on!!!!!! Hopefully I'll get to see the final result at WCR!!! Gonna whip this thing (IMG:style_emoticons/default/dead horse.gif) . Dave |
jim_hoyland |
Sep 28 2008, 10:27 PM
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#10
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Get that VIN ? Group: Members Posts: 9,303 Joined: 1-May 03 From: Sunset Beach, CA Member No.: 643 Region Association: Southern California |
QUOTE good to see you working on it. smilie_pokal.gif Can't give up. QUOTE rock on!!!!!! Hopefully I'll get to see the final result at WCR!!! Gonna whip this thing (IMG:style_emoticons/default/dead horse.gif) . Dave Looks good Dave ! Was the WCR 2008 ride too confortable ? Attached image(s) |
Root_Werks |
Sep 29 2008, 10:18 AM
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#11
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Village Idiot Group: Members Posts: 8,321 Joined: 25-May 04 From: About 5NM from Canada Member No.: 2,105 Region Association: Pacific Northwest |
Keep us posted Dave. I'll be doin' the 4cyl thing for quite a while myself. This should be a very interesting thread for me. (IMG:style_emoticons/default/smile.gif)
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Tom |
Oct 2 2008, 06:29 PM
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#12
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Advanced Member Group: Members Posts: 2,139 Joined: 21-August 05 From: Port Orchard, WA 98367 Member No.: 4,626 Region Association: None |
Great pics, Dave. You'll get it this time. Let us know if you need any tool handers or real help.
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