Update time,

Got the crank in, rings on, pistons in. Every thing is torqued up. Tomorrow morning i will fit the crank seals, and properly fit the pump... then sump on







Then it was time to do a final plasigauge on the big ends, got a spot on measurement of 0.045mm on ALL big ends, very happy with the machine shop!





Nice bit of lube



Quick measure of end float, .105mm which is spot on.



All torqued up Time for a celebration coffee



Then it was time to finally look at the new gearbox, ib5 from a mk5 escort van. Front starter, rst driveshafts fit, rst clutch fits. Just need to sort out few issues with the release bearing.





Removed 5th gear ready for fitting my lsd tomorrow.





Started to get dark, so went back to the engine lol, what is it they say about only doing one thing at a time?












And thats where i've left it for this evening, more to come tomorrow. Big thanks to Mike Kerbey for lending a much needed helping hand, which made a change

Cheers for reading

Rob,

 

looking good mate

 

Good progress mate. How did you get on with the engine builder?
I'm taking my bottom end to them on Monday.

 

Who ht howard and co? I built the engine, they machined the crank, bored the bloke to +.5mm and honed it, then put it in there cleaning tank. They also got a cps hole machined for me.

Really nice guys and their work was absolutely spot on. I gave him the clearances i wanted and he managed to get VERY close to them. And im anay about measuring things!

My big ends, were completely round (sound funny but often they are not), and all incredibly close in size, good enough to give me a spot on clearance of .045mm on ALL big ends.

Highly recommended,

Cheers for the comments, more to come today (hopefully!)

 

Cheers Tony, how you getting on with that zetec?

 

Yes, sorry Rob. I should have said machine shop instead of builder, you obviously did the build doh.

Yes, I'm having HT Howard do similar with mine plus possibly a line bore and deck face. I'm going to have them build the bottom end on mine so they can balance it all up for me.

 

Good stuff mate, they were spot on and come highly recommended

 

Nice to see progress!

What is the reason for a 5th gear change? Is the standard gear ratio too low?
I am not familiar with the UK gearboxes.

Cheers

 

Ahh, no. 5th gear will go back on. Im fitting an LSD and you need to remove 5th gear to split the casing. I 'think' 5th gear was a Ford after thought, the bc gearbox was originally a 4speed. And yes is feels nice to make some progress!

Rob,

 

im lost with this gearbox? what exactly have you done with it?

 

Good work, good continuation for the reassembly

 

Should be a solid engine this! lots of care being taken on the build. Get some pics up of todays progress Robin.

 

Im fitting my rst lsd in it mate, need to split the casing to do this, and to split the casing i need to remove 5th gear. I'll post some pics up when its done but should mean a stronger, new gearbox

Rob,

 

Cheers for the comments lads, kerbey, cheers for you help mate im at the inlaws at the moment so i'll post pics in a bit.

 

loving the progress of this mate.Keep it up!

 

We need an update!

 

Haha, you will have one this evening mate, been a little side tracked. The lsd i bought was no good so i had a painful day stripping two boxes to get a good lsd. Just putting the box back together now and finishing head prep.

Rob,

 

As Rob said the BC gearbox was originally a 4 speeder, which a 5th gear was added to afterwards. As a result, you need to remove 5th gear to remove the end casing to get inside;

.

 

Thats ok then

 

Im sick of the sight of ib5/bc gearboxes lol, i've come in to calm down or else i'll smoke, quitting smoking and working on cars never really ends well

Any how, i chipped the corner of one of the teeth on the crown wheel, not badly and i think it will be okay, BUT IT REALLY PISSED ME OFF lol,

Muz, that looks noisy! where is it from originally?

Hows the sale going puss?

 

Its not Rob its in bits

 

Puss nooooooo did any one make an offer on the whole car? you going to sell me your turbo now then?

Right time for that update!

Finished putting the last few bits on the block, to get them out the way, before the engine goes on the engine stand for the head to be installed and the cam timed up.


Take one tub of anal lube, and one big rubber thing........


My ponsy bolts









My new CPS holder, bargain from fords!



Tarted up cover, its got to come off again buy it looks all right..



I was going to paint the pulley, but just gave it a quick scrub and was happily impressed by the as new(ish) paint




Rob,

 

About time nice work

Not on the whole car
Pm sent re turbo

 

PM replied to

Next came the gearbox, and fitting my new lsd. This basically meant stripping the box and replacing the diff bearings (IB5 bearings are larger than BC) and resembling it.

Started off well,



Case split,



Gear cassette out, next the open diff came out, but thats boring



On to the LSD prep, cleaning and a change of bearings.





Predictably the bearing case had to be ground off



Some one had obviously been here before me, and wasn't very light handed lol





The above i could live with, but unfortunately disaster struck, my very low mileage superb nearly new diff, turned out to be none of the above lol both thrust bearings are tattered, the spring ring has caught and snapped and chewed chunks out of the case and its full of swarf,



Nice,







The spacer groove in the centre of the diff should be beautifully flat and as machined....





Right, time to strip my old bc box and see what that diffs like, i was really hoping i wouldn't have to!



Deep joys

Rob,

 

Ill skip a few boring bits!

2nd time round,





AND



Its utterly immaculate i was over the moon when i saw the thrust washers etc,

I guess it being an original 64,000 mile car helped!



Rob,

 

Got the head all built.

Every one was out, so in the sink it went,





Seals fitted







More lube lol















All the valves in,



The original cam, proper ford jobbie, im going to keep this for the first 500 miles or so, just can't face running in a new cam on my engines first ever start 2000 rpm for 15mins, un-mapped and tight, no thanks.





All the followers etc are in their own labelled bags so they can all go back on the right lobe,



All done all the rockers are torqued up and 'loc tited'






About time it went in the car me thinks!

Rob,

 

Hi mate, what are the rockers torqued up to? mine are to do tomorrow!

 

Hi there, think its 27-30NM

Rob,

Here you go

http://www.xr2.org/information/torqu...netorque.shtml

Rob,

 

It will be bloody noisey Its a Quaife Strtaight cut gear set and was originally out of the Red S2 'SOY'

 

cheers mate!!

 

Just a quick update!

I'll do a better one later. But THE ENGINES IN .





Needless to say, im pretty happy The front suspension is all on too.

Rob,

 

i actually love how your using your kitchen sink as your cleaning booth and your conservatory as an engine building room!! LMFAO

fair play mate!

 

Nice work getting there

 

Thats looking good!!

 

well done Rob looking good

 

stunning <3

 

Brilliant work rob

 

Well done rob hopefully you will have it all done for central day so we can see it.

Keep up the good work mate

 

+1 hope to see it at central day

 

+2 hope to see it there two, good work tho mate