Moonie

My Escort turbo decided to drop an exhaust valve head wich resulted in this...



So after it sitting at work with no engine in for 6 months I decided it was about time to do something about it. I needed a new block as mine was scored from the debris of the broken piston and was bored out to the maximum tolerance, a new head and one piston.

As luck would have it, about this time my mate (Phil79 on here) spun a big end shell in his Fiesta XR2 with a turbo engine in

So I now had the block I needed (on standard bore) and a cylinder head.

Last week I got the engine off him and stripped it down ready to take the block and head up to Impulse Developments in Rochdale to have all the machining work carried out.











1 - Reface cylinder head
2 - Helicoil as necessary exhaust manifold studs
3 - Rebore block to 0.5mm oversize
4 - Order 1 X 0.5mm oversize piston and fit to new rod
5 - Machine piston crown to lower compression and to match other 3
6 - Con rod balance
7 - Piston balance

I will be using my crank which is balanced and also my lightned and balanced flywheel. The top end will be built up using my piper cam and lifters etc.

I have also decided to strip the gearbox while it was out of the car. No signs of abnormal wear however, i am going to replace the synchro rings and rebuild with new gaskets and seals then a coat of paint.





Main shaft with synchro rings below. You can also see the bigger bearing sleve on the right hand end of the shaft (its a bernie box)



On with the engine rebuild...

Block cleaned and painted



Upper main bearing bearing shells fitted



Crank fitted



Pistons going in



Pistons in



Oil and water pumps fitted



Oil pick-up pipe, dipstick tube and turbo oil return pipe fitted



Thats where i got up to tonight, should hopefully get the head built up tomorrow night and bolted on. I will get the gearbox rebuilt over the weekend and fingers crossed it will be running next week.

smitsturbo

good work mate, any pics of the car its going into

Moonie

Couple of pictures of the car when i took it over to a show in Belgium last year...







How the engine used to look and will again soon...

Moonie

A couple more i found.....

We had a couple of beers on the Saturday and managed to surround my car in the empties!



And another pic from later on when i was really feeling the beer!

smitsturbo

looks a minter mate

Moonie

Well the engine is finally finished

I got the head built up on Saturday and bolted it all together tonight.

Grinding the valves in



Exhaust valve before



After a clean up on the wire wheel and ground in



All valves ground in, head up on stands to make assembly easier (spot the mistake)



Stem seals fitted and valves in



Valve assembly, stem seal and valve fitted (grease is to hold the collets in place)



Valve spring on



Spring/valve retainer and collets fitted



All valves fitted



Camshaft is in, all lifters and rockers fitted



Head gasket on



Head on and engine fully assembled





I will take the engine to work tomorrow to make some room for me to start assembling the gearbox. Once that’s done they can be bolted together, put in the car and hopefully running towards the end of the week.



And then it will be up for sale

Moonie

Engine and gearbox are now fully built and in the car, didnt get any pics of the engine going in as i didnt have my camera at work.

A couple of pictures from when i stripped the box down...







On with the rebuild...

Gearbox casing's cleaned and painted. I bolted the casings together then painted them to prevent paint getting on the gasket faces and inside the box.





Start of the build with an empty case. New input shaft, drive shaft and selector shaft seals fitted.



Selector mechanism installed



LSD installed



Input shaft, main shaft and selector forks installed



Close up of selector mechanism




Shafts and selectors etc installed ready for casing to go on



Casing on



C-clips and gasket fitted



5th gear and selector fitted



Gear box fully built up



The engine and box are now fitted, just needs to fit a couple of more hoses and order some plugs and oil and it will be running

fezzajsy

iTrader: (9)

CharlieSaff

Some very good work going on here