Mac#1 Motorsport Worx Build
Discussion
Red16 said:
Thanks very much for following the cars progress.
Do you have a build thread on your car? I'd be interested to see it if you do.
best one here, Do you have a build thread on your car? I'd be interested to see it if you do.
http://www.zsoc.com/showthread.php?t=129613&hi...
98 pages though sorry
TheAlastair34 said:
Great stuff, i'll have a read through that tomorrow morning with a cuppa 
This afternoon I removed the turbine housing from my old turbo and gave it a clean up, here it is alongside the new GT3071R assembly
The up pipe from the old turbo compressor housing was cut off and cleaned up ready for welding to the new compressor housing.
Here's the new GT3071R, the old GT3076R and the up pipe
I didn't take anymore photos today, but in a nutshell the turbo has been refitted, along with the exhaust, coolant hoses and oil hoses after priming the turbo with oil.
The up pipe from the old turbo compressor housing was cut off and cleaned up ready for welding to the new compressor housing.
Here's the new GT3071R, the old GT3076R and the up pipe
I didn't take anymore photos today, but in a nutshell the turbo has been refitted, along with the exhaust, coolant hoses and oil hoses after priming the turbo with oil.
Yes he has indeed, and teh car still lives 
)
He's a friend of mine, current status of the car is that it has a knocking big end bearing.
I don't think he'd mind me saying this, but in the 5 years since the build, the running gear side of things has been a nightmare. Leaking exhaust manifold, then worn piston rings, now big ends.
He's on with a house extension now, but I believe he will give the car another going over this year!
) He's a friend of mine, current status of the car is that it has a knocking big end bearing.
I don't think he'd mind me saying this, but in the 5 years since the build, the running gear side of things has been a nightmare. Leaking exhaust manifold, then worn piston rings, now big ends.
He's on with a house extension now, but I believe he will give the car another going over this year!
Here's a little update on why the car has taken so long to get sorted.
With the house extension plans for the rear ground floor and front garage extension approved building work commenced.
The external shell built up at the rear of the house
This wall needed to come out and a supporting beam installed
Wall removed
Fish tank stand built and installed
Fish tank built on site
Kitchen arrived in millions of boxes and filled the front garage extension
Old kitchen removed and the room plastered
The finished fish tank wall
And the full kitchen
Garage was in a right state and certainly needed a good clear out!
Clearing stuff out made the garage look so much better and actually helped me relax a bit, it was awful seeing the place in such a state!
With the house extension plans for the rear ground floor and front garage extension approved building work commenced.
The external shell built up at the rear of the house
This wall needed to come out and a supporting beam installed
Wall removed
Fish tank stand built and installed
Fish tank built on site
Kitchen arrived in millions of boxes and filled the front garage extension
Old kitchen removed and the room plastered
The finished fish tank wall
And the full kitchen
Garage was in a right state and certainly needed a good clear out!
Clearing stuff out made the garage look so much better and actually helped me relax a bit, it was awful seeing the place in such a state!
Right then... I finally found time to get around to looking into the issue with the cars engine, it was running on three cylinders.
Compression testing the engine returned the following results
Cyl 1 = 140bar
Cyl 2 = 140bar
Cyl 3 = 140bar
Cyl 4 = 0bar
Which was certainly worrying!
The car wasn't smoking (aside from the unburnt fuel), pressurising the cooling system etc, externally everything appeared ok, so the engine needed to come apart.
Engine out
Manifolds off, couldn't tell anything looking down the inlet or exhaust ports
Even with the head off there wasn't much evidence to see, looking at the combustion chambers on the head the valves/seats all looked to be in good condition and not bent/damaged, but the pistons crowns had slight marks in the valve cutouts, indicating there had been piston to valve contact.
Removing the cam followers revealed an issue on cylinder number 4, one inlet valve and one exhaust valve had collets out of position, presumably caused when the piston to valve contact happened.
All of the valves were removed, inspected and found to be straight (surprisingly), they were then lapped in, cleaned up and the head reassembled. WD40 poured into the ports and left, no leaks observed so it was cleaned up ready to be installed.
The head was then installed using a 0.027" Cometic MLS head gasket, same thickness as standard Kawasaki gasket.
The cams were installed, timing set and valve clearances checked, all within spec so no need for further adjustments.
Engine back in the car, ready for the final pieces of work to be done prior to getting the engine started up.
Compression testing the engine returned the following results
Cyl 1 = 140bar
Cyl 2 = 140bar
Cyl 3 = 140bar
Cyl 4 = 0bar
Which was certainly worrying!
The car wasn't smoking (aside from the unburnt fuel), pressurising the cooling system etc, externally everything appeared ok, so the engine needed to come apart.
Engine out
Manifolds off, couldn't tell anything looking down the inlet or exhaust ports
Even with the head off there wasn't much evidence to see, looking at the combustion chambers on the head the valves/seats all looked to be in good condition and not bent/damaged, but the pistons crowns had slight marks in the valve cutouts, indicating there had been piston to valve contact.
Removing the cam followers revealed an issue on cylinder number 4, one inlet valve and one exhaust valve had collets out of position, presumably caused when the piston to valve contact happened.
All of the valves were removed, inspected and found to be straight (surprisingly), they were then lapped in, cleaned up and the head reassembled. WD40 poured into the ports and left, no leaks observed so it was cleaned up ready to be installed.
The head was then installed using a 0.027" Cometic MLS head gasket, same thickness as standard Kawasaki gasket.
The cams were installed, timing set and valve clearances checked, all within spec so no need for further adjustments.
Engine back in the car, ready for the final pieces of work to be done prior to getting the engine started up.
Yazza54 said:
Is that new gasket thicker than what you were running before then?
Unfortunately I can't say, I can't find any evidence of which gasket I bought and fitted last time, I know it was a Cometic MLS one but they do 3 different thicknesses, I tried measuring the old one but didn't get a definite reading, a thinner gasket last time could possibly account for the piston to valve contact.Red16 said:
Yazza54 said:
Is that new gasket thicker than what you were running before then?
Unfortunately I can't say, I can't find any evidence of which gasket I bought and fitted last time, I know it was a Cometic MLS one but they do 3 different thicknesses, I tried measuring the old one but didn't get a definite reading, a thinner gasket last time could possibly account for the piston to valve contact.Yazza54 said:
Red16 said:
Yazza54 said:
Is that new gasket thicker than what you were running before then?
Unfortunately I can't say, I can't find any evidence of which gasket I bought and fitted last time, I know it was a Cometic MLS one but they do 3 different thicknesses, I tried measuring the old one but didn't get a definite reading, a thinner gasket last time could possibly account for the piston to valve contact.Gassing Station | Kit Cars | Top of Page | What's New | My Stuff