Decided, for once, to try and properly document this rebuild Meant to do one for Marks sapphire, but sorta forgot to take pictures along the way:P

Anyway, this is my old RS turbo, now owned by Gibbo (AKA the drain) The car has kinda fallen into disrepair over the last while as Gibbo was very busy with exams etc. We decided at the weekend enough was enough, the car needed sorted!

We knew it needed a new battery tray and the rear chassis legs patched. This meant we had to remove the interior (unless he wanted it to go on fire!) So we cracked on with it tonight

Seats and carpet out-









Dash out-



The rot










Not too bad really!! Floor seems super solid which is good and with the interior out the battery tray is easily enough done.

We are also going to take the engine out and give it a quick rebuild. I think he will be changing the standard head for a Burton stage three item. Should hopefully be making a start on that tomorrow. Then the car will be up in the air to get the fuel tank, exhaust and any other parts off to allow it to be patched.

The car was resprayed a couple of years back, but has managed to pick up a few dints, so a few bits will be getting painted again.

A vid of bits spread all over the place

http://uk.youtube.com/watch?v=YYgjQ5aVlHU

 

Don't hang about do ya!
She looks like she's in fairly good nick bar that bit of rot. Got any pics from the outside?
Good luck with the project

 

I'll get a few exterior pics tomorrow night. Car has only 60K on it, so i expected it to be half decent underneath!

Can't hang about with these things, gotta get stuck right in lol.

 

 

good luck mate

 

:


Brian

 

good work

 

good luck mate

 

crack on chap

 

nice one Paul doesnt look to bad seen them a hell of alot worse mate

 

Ok some pics of tonights progress!
How the bay looked when we started-



Then Mark and David got busy:P I stayed out of the way for fear of loosing a limb:P
Manifolds/hoses off


Then pushed the car onto the ramp so the shafts/exhaust etc could be removed. Found a few bits of rot on the front panel that need attention, but nothing major.




An RS turbo in kit form:P



Handy exhaust store lol

Engine out


Apart from the rear legs the car looks spot on underneath

Engine bay looks like it'll clean up pretty well too



Got the car booked in with Alan Roddy up in Ballymoney to get the welding sorted and we are looking into a painter to sort out the other flaws.
Still have to strip the rear end down, should be done within the next week

 

Yeah its not too bad! Few wee bits to sort out, but nothing major

Hopefully we'll have him at some shows this year!

 

good work looks a tidy shell

 

[QUOTE=Paul_RS;3889635][COLOR=#22229c][COLOR=black]Decided, for once, to try and properly document this rebuild Meant to do one for Marks sapphire, but sorta forgot to take pictures along the way:P

QUOTE]


I have one of marks lol

 

Great work there ,i like that workshop

 

[quote=daviddunlop83;3892162]
i was popular that day

 

good luck mate, i hope you have her back on the road soon

 

Nice one pavlov

 

Ok tonight, Mark stripped the engine and we got the fuel tank, fuel lines and the last of the brakes lines off the car.
Firstly we removed the gearbox from the block, then stripped the clutch assemby off.
Still has the AP clutch i put in 5 years ago

Un bolted all the ancil brackets etc and split the block from the head. Then whipped the sump off.


Next the piston/crank/rods/oil pump/water pump were removed from the block.






Then the valves were removed from the worked head as we didn't know if they were turbo valves or not. The turbo ones are apparantly sodium filled?


Next the fuel tank, pump and lines were dropped out.





Over the weekend comes the messy job, going to roll the car outside, get it up on high stands and powerhose the bay, and under the car to remove as much crap as possible.

Lastly just a few pics of Marks sapphire. We put this together a few months back. I'll try and get a few photos together and knock up a thread for it

 

Good progress Pavlovalovalova mr lova lova lova!!!

Love the saff too

 

Couple more updates.
Firstly car was given a good powerhose to remove the built up crap from round the engine bay.











With that finished, the car was taken to Alan Roddy in ballymoney to get the welding done.
The engine was collected from Ivor Greenwood after being acid dipped to clean it. Reassembly was started tonight.

Block on a stand







Mark honing the bores



Mark and David putting the crank in and screwing the main caps down.





Rods and pistons in.



High pressure oil pump on



Sump on





Block painted









Alt bracket painted



While this was happening Andrew was grinding the valves in



Head is nearly finshed, just lifters and rockers to do, then its time to bolt the fecker back together!

 

Fantastic work

 

good work so far lads car looks in good nick to start with so half the battle eh lol!!! im looking forward to seeing the finished article

 

It should be a really nice car when it is finished. We should be getting it back from the welders next week and then its off to painters for a new front panel and engine bay and other wee bits fixed up

 

good work. love the workshop.

 

looking good mate.

 

nice job your doing lads if you need out for it just giz a ring iv got loads of turbo bits lying about

 

 

nice work

 

cheers mate

 

Nice work all

 

Great work so far. For a minute i thought this was Dans old NMS car

 

gonna be a great RS turbo!

 

nice one mate looks well tidy

 

Another update
Alan finished all the welding, so it was time to go and pick the car up! Mark got everything rigged up and we set off...



Arrived in Ballymoney just before 8 and as usual had a good chat with Alan and Steven. There's always something interesting to have a nosey at in their workshop Steven thinks there are a few little tricks he can do to the RS turbo head to improve low load respose, so we'll be taking the head up to him. This will probably happen next week whem we take Mark's sapphire up to get a base map put on his DTA.
Anyway got the car back and i took a few (crap) pictures of it.






Welding as usual is top notch and as the car is going to be used, it was decided to waxoil below it. The rear suspension is being changed for a new powdercoated set, so ignore the arms in the pics as they will be getting binned.
Car is hopefully being taken to a painter to get a quote for doing the bay and a few other parts next week.
The RS turbo take a back seat for a bit as we need to get Marks sapph ready. I've a bit of wiring to do and we need to roughly set the adjustable TCAs and compression stuts, before it goes to get mapped.

 

Ok update time!!

Engine is nearly finished, just waiting on a few bits and bobs. It has the timing belt on now, but i forgot to take pics lol.







His new seats - Standard centres, but leather outers.



Gibbo testing the fit



Car on the trailer just before it left for paint.



Car back from paint.















It was done by TK motors. They put a new front panel on and tidied and painted the bay. Did a good job of it too!!

 

New rad



New Pro Alloy intercooler





Interior in







Engine loom in and some parts refitted

 

any more progress mate looks awsome so far

 

The last update was what we did on saturday. Haven't done anything else since

 

Looking good matey

Love that trailer, if only i had the space and money for one.