Bring that Beat back... 1991 Honda Beat

[Rocket.]

Long overdue update!

While the engine was away I decided to try and tidy up engine bay, under the front and also give the suspension parts some much needed rust protection. I heard good things about POR15 so decided to give it a go with a lot of help from my old man.





Front end before



After



Also some suspension parts



The reason for lack of oil pressure was knackered oil pump, the reason for knackered oil pump was a mystery until the engine builder informed me that whilst ultrasonic cleaning the cam cover a load of crap was found in the bottom of his cleaner...

He asked me if I had had the cam cover blasted with a medium, I had it vapour blasted and it turns out some of the blast medium was caught up in the cavity in the cam cover which we then think ended up in the sump and killed the oil pump.

It would also explain the following picture which was taken after 100 miles after the last rebuild when I removed the sump for inspection.



Fortunately it only damaged the oil pump and the rest of the engine was fine, all bearings and bores untouched. If I ever try to deep clean engine parts again it will be soda blasting only!

Engine is now back in and running sweet with good oil pressure. Beat also has a new MOT with zero observations. I will be running engine in for a bit and keeping the revs down.

It is such a blast to drive but the suspension needs more work as still much too hard. Finally it feels like progress is being made. Painting still needs to be finished too.

Edited by Rocket. on Tuesday 21st June 07:32

[Rocket.]

BrettMRC said:

This is brilliant news OP

What are you thinking of doing with the suspension?

Currently on a GAZ coilover set up specific to the Beat but whoever 1st spec'd it must have no spine left

I have already dropped the spring rate once and had them revalved but I think the dampers need to go even softer especially at the front where the car is no wonly about 300kg across the front axle.

[Rocket.]

L100NYY said:

Saw it/you at The Warren on Sunday chap, Beat looked great

Ha thanks Loon, did wonder if you were there sorry I missed you as didn't hang around long. I loved the 914/6 parked ahead of me. What were you in?

[Rocket.]

L100NYY said:

In my defence my chums were parked just behind you in the following;
Vauxhall 30/98
Bentley Special
GTD40

Ha I had a good look at those, Vauxhall was a lovely old thing

[Rocket.]

Fear not the story isn't over yet!

So yes I had a major flounce when my 2nd engine went in and lasted max 50 miles!

I did try and see if anyone wanted to take the project of my hands, price wise it was high but I felt breaking the car for parts I would get back somewhere close to that but I really didn't want to do that.

So I threw a cover over it in the garage, left it advertised for a month or so and forgot about it.

No one came along at the price and after a stern talking to from my old man I have decided to have another go at the 2nd broken engine...

So we are now on engine removal no.5 since my ownership (actually lost count could be 6?)

On this occasion I've decided to try and rebuild it myself, never rebuilt an engine before so time to learn, how hard can it be?

I knew the noise was from the bottom end and here is what I have found so far...

Edited by Rocket. on Thursday 27th April 14:06

[Rocket.]

BrettMRC said:

Glad you're persevering with it!

How many miles in total on that engine? (Or was it an unknown when purchased?)

I actually ended up buying a written off Beat, gave someone the rest of the car if they would take out the engine and deliver it to me.

I was told the engine was good, it had receipts for last service prior to its accident back in 2016 with about 94,000km on it.

I was told by a friend 'by all means buy a 2nd hand engine but expect to have to rebuild it' as it turns out he was spot on!

[Rocket.]

samoht said:

Chumbawamba said:

I get knocked down, but I get up again
You're never gonna keep me down

Good luck with the rebuild

Ha thanks, hopefully it's not a case of

“Insanity is doing the same thing over and over and expecting different results.”

[Rocket.]

Cambs_Stuart said:

Could you fit a K-series in there?

Maybe but I've no real interest in engine swaps, more hassle than people think and I've been there done that on my old Elise (k series for Honda K20 funnily enough) and that never worked that well either mainly drive shaft angle issues.

The Beat engine E07A is a sweet little unit, but I guess it's a bit much to expect them all to be in fine fettle after 30 years being buzzed to 9k on a fairly regular basis, hopefully my luck can change on this one.

[Rocket.]

B'stard Child said:

cleanliness is next to godliness when it comes to building engines as I found out to my cost

This is very much on my mind, being such a small and relatively high revving unit I am going to be uber cautious, measure everything multiple times and ensure it's mega clean when I eventually reassemble it.

[Rocket.]

gweaver said:

Fairings bucked...

Any metal in the oil filter?
I guess it's a light and easy engine to work on, but IDK what is involved in terms of refurbishment and replacement of moving parts?

I haven't cut the oil filter open yet but sump pan showed some metal fragments and this was fresh oil and filter 50 miles ago.



bought myself a engine stand off ebay, engine is easy to work on and will be becoming apart this weekend. Then crank, block and head off to a local engineering shop for whatever work needs doing. Shell bearings, piston rings etc. can all be ordered from japan.

Edited by Rocket. on Friday 28th April 10:32

[Rocket.]

castex said:

Yay he's back with another one of those block knocking Beats. Good on you OP!

Hopefully not for much longer

Edited by Rocket. on Friday 28th April 20:35

[Rocket.]

Engine block now stripped and crank removed.

Bagged up and labeled all the parts and put away safely in a big box.



As this is my first attempt at an engine rebuild I am not entirely sure what I am looking for in terms of visible wear on pistons their rings and the bores.





Piston rings look OK I think, pistons have a little light scoring on the skirts but I not sure if this is note worthy or not

Bores look and feel OK apart from cylinder 3 which has a couple of grooves which I can feel with the tips of my fingers.



I will need to buy some half decent measuring equipment for the bores and crank journals if anyone has any recommendations please?

Next job to strip the head then give block, crank and head to a machining shop.

[Rocket.]

It's been a while...

Engine rebuild is about to commence in earnest.

I managed to source a good used crank and set of pistons from Japan all delivered for about £250, not terrible. Engine bores have been honed, head cleaned and valves lapped in.

I am also replacing:

Exhaust valves (worn)
Valve stem seals
Valve spring seats
Oil pump
All Crank and Rod bearings
Piston rings
Gaskets

Valves already back in the head, fun and games getting the cotter pins to secure in the valve stem / seats...