[engine_work] 2.2 Gti6 Engine Build

[Mad Scientist 106]

Pulleys have arrived, head on its way back.

 

 

I have been looking at oil tank designs and, as long as it fits, i think this is the one:

 

 

 

 

It is very comprehensively baffled, fully strippable for cleaning, and uses a flange, rather than a steel band and o-ring, to hold the two halves together. I will be blocking all breathers, so running the engine under an internal vacuum. As a result, there will be lots of air scavenged to the tank. It has a very well designed oil/air seperator and breather to handle this. I think it will fit, but I am going to make a dummy and check tonight.

The drysump kit should be here early next week.

Edited May 2, 2012 by Mad Scientist

[petert 549]

Looks good. How much, where from? The ability to pull apart and clean is a must. Otherwise, first blow up, who knows what shrapnel is left behind.

[camgti 56]

Pete, Im keen to get something like this. You want to share the shipping?

 

Great build to BTW

 

Cam

[Mad Scientist 106]

Sent you a pm.

 

The tank is made by ah fabrications. It's basically to Roy Millington's specs.

 

If you don't know who that is by the way, google millington diamond.

 

 

[Mad Scientist 106]

Well then.......

 

Been a while since I have done much to the car for various reasons, not least as I was waiting for the bottom end back.

 

Needless to say, I now have everything sat in my garage awaiting assembly. I have some time off work to get things finished next week, mapping is booked for mid August, and I'm itching to get behind the wheel again!

 

Plenty of updates over the coming days.

 

[pip470 61]

Looking forward to it. Nice work.

[Mad Scientist 106]

Got a fair bit done today.

 

Managed to get the dry sump tank mounted nicely on rubber isolators. Its on the bulkhead behind the gearbox, so it means i've had to relocate the coolant tank, and shorten the solid coolant pipe on the back of the engine. I just need to measure up for the new coolant tank that i'm having made by AF Fabrications.

 

I also set about fitting the Gripper diff. True to form, the box needed some fettling. In fact, its still catching now, and I don't want to remove much more from the gearbox casing as its not that thick. I think i might machine the diff a touch to suit, which is how it should have been in the first place.

Finally got the fuel rail cleaned up and ready for some paint.

 

Tomorrows jobs:

Get the trimming and welding of the "tunnel" done, to give the manifold plenty of room.

Sort the inner arch protection that I need for the drysump pulley, as its very exposed.

Make a bracket for the remote oil filter.

Plus whatever I remember as I go!

 

Pictures towards the end of the week, when its all done, as I can't be arsed now!

[Mad Scientist 106]

Forgot.......

 

I also discovered that the exhaust cam oil feed (to vacuum pump) has been plugged, by Sand, as they were fitted to an XU7 head without the vac pump. This prevents the oil bleeding off when the drive from the vac pump isnt in place.

I was thinking about a bias pedal box to suit my huge Tarox brakes in the future anyway, but for now I think I need to remove it somehow and keep the servo setup.

 

Its going to be tricky to drill and tap such a small piece of alloy, to pull it out with a bolt, but I think thats the only way to do it.

 

[Dj_mini 7]

What size tank have you used on your install?

Have you got any pics?

Thanks

[Mad Scientist 106]

I had it made to my drawing by AH Fabrications. Nothing on the market would fit in the engine bay, so I had to go custom. It's not round, but is incredibly well baffled and has a separate air separator (which is round). Holds 6.5 litres to the top baffle line.

A picture paints a thousand words though, I'll take some tomorrow.

[Mad Scientist 106]

I'll update this properly soon, but just haven't got time at the moment. I'm in the final dash to get it finished. Mapping booked for next week!

 

Just spent the evening dummy building the engine and checking absolutely everything several times. Based on the last engine, I've assumed nothing. Good news is everything is spot on.

 

I'll get it built up properly tomorrow night hopefully.

 

[marksorrento205 80]

Glad all is well this time mate!

[Mad Scientist 106]

Tomorrow is d day. D for dyno.

[clen666 2]

Good luck! Great read so far mate

[Baz 421]

Good luck Pete, been lurking quietly! Looking forward to the outcome!

[Mad Scientist 106]

Cheers guys. I'm a bag of nerves.

 

Just woke up next to another man in a hotel!

 

Mark Sorrento 205 has come along to help me. We have another hours drive to get to Saltash, where Sandy is due to meet us at half eight.

 

The engine is in the car, but it will be coming out to go in the dyno room. Cams still need fitting, but I decided to let Sandy do it, as it's second nature to him! I still need to build the inlet up, as the revised angle manifold is in Sandy's boot. Colin only finished it last week.

 

Update later, hopefully with pleasant news!

 

[Mad Scientist 106]

We've made it to saltash. Just waiting for Sandy to arrive. First job: kettle on.

[kyepan 291]

We've made it to saltash. Just waiting for Sandy to arrive. First job: kettle on.

for goodness sake, don't let it boil!

 

and best of luck, fingers crossed for you.

Edited August 13, 2012 by kyepan

[welshpug 1,621]

Videos of noise please

[petert 549]

Live streaming would be better.......

[Baz 421]

Hope you took some biscuits!!

[BlueBolt 156]

And the outcome was.......???????

[Mad Scientist 106]

Not good I'm afraid. My run of luck seems to continue.

 

After 2 epic days of messing around with it, we had to abandon because the crankcase was pressurising. Being totally sealed now due to dry sump, this was causing problems all round, including pushing out a crank seal. Best guess is probably blow by from a bad ring seal, but until it comes apart we won't know. I've left the engine with Sandy to investigate.

 

Even though there are still things to overcome, I've still had a great couple of days. I'd like to say a bIg thanks to Sandy, Mark, Alvin and Colin for all the effort so far. We will get there in the end!

[kyepan 291]

Hang in there.

[TT205 42]

Bugger