well , all the best with the project rob, think your gonna have a lot of fun
be great to see it hit the 9's
well , all the best with the project rob, think your gonna have a lot of fun
be great to see it hit the 9's
Just saw this car run on tv! it was at the fast show against a white civic, 'Rob' was driving.
Yep the HKS is on motors TV, its from last year when we ran the old d16 turbo.. We didnt attend all events and last year wasnt a great year either...
The hks will be on Motors TV for the next 4 weeks showing each round, 5 rounds in total..
http://www.japdragseries.co.uk/tv.php check here for times..
You can also follow us on Facebook and join our page..
http://www.facebook.com/?ref=home#!/...69701466405168
Thanks..
Well the sleeving got underway this week at work.. it revealed some interesting things that honda did. The orginal sleeve (the bore), honda had ridges on the outside of the bore, then the casting poured around as they do. Never really come across this, most manufactors just use stright bores then the casting..Anyway doing this would make the OE sleeve very strong and stable within its molding, plus displace heat faster to the alloy.. Also in the making would stop any movement when cooling the casting between the too metals..
Anyway first pic for can see the ridges, the rest is just part of the process of sleeving. Got all the percise maching to come yet.
some more pics... now at this stage..
are you doing your own machining?
Nice, I wish I had access to a mill, lathe. I know you can cool the sleeves by putting in liquid nitrogen but what do you heat the block with, got a big enough oven
Im not doing the sleeving myself but its all in house at my work. We have two mills, 2 lathes, head skimmer, Boring tools etc etc.. We have 4 guys that are full time on just rebuilding engines and engineering parts and this is just the side part of our workshop, Remember we just an independant Porsche Specialist.
Im more in charge now of the race cars we run/sponsor in the (porsche cup championship) and do general workshop work..
Heres one of the cars we will be racing this year that ive just finished rebuilding pretty much every part on it, just need get on the dyno and then have a few days out on the track with this one.. Im starting, in the near future, to build a Boxster S for next years championship.. So i feel that this year may be the last year for drag racing or take a year out as im slowly going to loose all my time and weekends dedicated to this..
Anyway back to the program..
The block will be heated in a hot wash we have, we can get this pretty god dam hot, you couldnt touch it anyway.. the sleeves dont need cooling that much as its cast iron and doesnt have the same expansion properties as alloy.. The MAIN issue you may have is the way the alloy will cool with the sleeves.. The alloy can push the sleeves out ever so slight that you wouldnt no it.. you then go along and get the block face finished etc get it all built up and once it gets very hot that sleeve will drop down and course the gasket to leak.. When the sleeves are fitted we will need a jig making to hold them in place and leave them with around 1 tone press on the block while it cools till cold.. this will stop them trying to lift out.. The rest of the sleeve is a peace of cake (so ive been told)...
Once you insert the sleeves don't you bolt on a deck plate to hold them in? Should have read further, gives him self a kick up the ass.
Ok so some more machining pics today. From the looks of things hondas casting accuracy is brilliant from the factory.. The first pictures is the remains of the old sleeves, the cuts come out so well you can even see the old casting number on the back of the old cyclinders..
As you know each sleeve has to be bored to fit so a double check of the sleeves is needed to make sure dartons machining is good, which they are..
Here are the finial base cuts taking place, yet needs cleaning up and more work. Also the start of the top cuts is there. It seems like we now know why a few peeps have trouble with darton sleeves dropping and not sealing. Ill try to explaing this and draw some pics to show.. We are going against there way of installing them and changing a few things...
Also the last pic is the start of some gears we make, we also have gear cutters so custom boxs might be on the cards one day, but with the available gears out there i very much dout we will bother...
Straight cut 1st 2nd and 3rd for my box please :-D?
Ok nearly finished now..
Few more pics of final base cuts...
and then its done for that part
The next step was to heat the block in the oven... then a hurry to get them in fast so no pics of the fitting stage.. The pic below shows one of our presses, we made this tower with rods and blocks as this will allways leave even pressure on each sleeve as its able to rock, therefore we wont get on sleeve sitting higher than the other.
We then left around 5 tonne on this, with our calculations the block should drop and leave the sleeves 5 tho higher over all. When the sleeves went in the top face was level and flat/flush, then as it cools you can slowly watch the block drop around the sleeves and bingo we had 5 tho liner protrusion. :headbang:
We are now at this point, the face needs skimming and i need it boring out yet, and we may use cooper rings yet so might have to do some more work for this.
You can see why this is such an expensive process of building a bullet proof honda bottom end. Great service to offer people. What are you doing with the p2w clearance rob
Well you will be pleased to know we will soon offer this service to the honda guys, dont expect much change from £700 tho to have the sleeves fitted..Originally Posted by rs250nut
P2W 3.5 thou i think.. ran this on the D16... i seem happy with that..
I took a few pics of the Interior today. Pretty much finished now here, just need sort some wiring, fit a big Rev counter and shift light, Lm, ecu...
That looks **** hot, how did you manage to make it look so good? If I did that it would be all creased and look pony. Look even better with a 12000rpm rev counter
That looks good mate, what did you use to trim the dash and door panels in?
Deans done all the interior last week, also the looms etc, the fuse box is now in car and no looms running around engine bay... Think he put some late nights in..its come ok pretty sweet.. we did this instead of flocking, saved loads of time and cash..
just cheapo acoustic carpet... the flooring is the same stuff the VW boys use in there campers..
Bit more of an update, most of the bits are here now to build the engine, im hoping to get the block skimmed and bored this next week and start building the head this weekend, prob give that a light skim aswell.. think our over all comp ratio will be 9.5:1 when finished.
The new cam pulleys by AEM
New dual valve springs, and Titanium retainers
New ACL Race bearings.
My new coffee table for the living room, but at the mo holding orange....
Nearly a month on since last update and nothing much has happened to the car. But on a better note ive sorted myself out with a new garage at my gaff..
Ive also made a start on building the head up, lapped all my valves etc...
before
and after
Also ive ordered a new Comp Clutch and some Avid engine mounts..
Got bored and started to wounder about a front mount mani, also i bought some amber corners to make it look more JDM
Ill try to get more work done over this next month...
Looks alot like the garage I use at my old ladys only alot cleaner. Front mount mani would be the $hit, I would be freaking though, stones,small animals, small people getting sucked up by that monster
Ok, time i got building this engine...
Unsure if ive covered this yet or not.. Im going to run 4 thou Piston to wall clearance so the finial bore cut has been done, it will prob slap around but not to worried about that.. Im yet to set the ring gaps.. im only at around 9-10thou at mo which i was rather shocked at with the amount of P2W ive set allready??, anyway really need them to be around 18ish with my 83mm bore size with the engines use (high power) in mind..
Going to crack on with the head tomorrow if i can and get it skimmed and built back up with the supertechs..
Really behind with this project now.. unsure if ill even have it out for RTOC pod day with the amount of bits im yet to buy...................
Get it built mate, this car will be silly fast
Well had a couple hours in the garage.. built the head up and finished my ring gapping...
The Duel valve springs and Ti retainers.. (supertechs)
The rocker shafts and rockers..
The Lma`s that keep the main high lift rocker in contact with the cam lobe when vtec isnt in use. Most peeps do away with the whole 3 stage rockers etc and just run the high cam as the low stage is never used anyway..
Fitted all the pistons to the rods..
also all the rings have now been gapped and checked..
Next step is to build the bottom end up..
Well still not started to get the motor together yet.. But on a better note all set for Brands hatch this weekend and first round of the PCC... Im kinda thinking to have the same wrap on the honda now instead of the camo...
Small update, things havnt really moved much recently but we hoping to try and get this car out for Rtoc Pod day, still a very slim chance but be nice to make it.. Funds for the project are slim this year and the engine conversion cost so far is close or over 5 grand so we have decided to take a step back from our orginal plan of making the car all out high HP etc and just get the thing running and out on the strip. So in which case we will be making cuts to save costs.
So the clutch system, no twin disc, just the old iron man CC clutch (which i think will do fine for us). We going to down size injector from 2000 - 1000cc due to the massive price difference, We only going to fit One bosch 044 pump and run this in line with the Welbo we have now. This will save money on extra fuel line and fittings needed.. Ive just ordered a new exhaust manifold T4 divided flange, 2 x 44mm V band for the gates, as for the gates im going to get a couple Kung fui chinese ones.. Im sure it will be ok..
Once the car is out and running we will no dout run into gearbox issues as the ratios are all wrong for us with the UK gearboxs being different from the USA boys. So this year would be good for just some small testing and get some data from things and then maybe raise the game in 2012..
Some Pics of where we are at below..
Last edited by Rob@Backyardracing; 04-05-2011 at 21:47.
thats too much for me i gta go sit in a dark room....
Sweet progress mate, You can see where the extra deck height comes from now between the B18/16. The 16's head near on sits flush with the top of the waterpump where as you an extra inch.
Couple more pics, havnt really had chance do much to the honda recently due to work commitments. Once this weekends out the way ill be back on..
And for you track junkys as some of you know as well as working and help run a mad busy workshop at the moment i manage two race cars that we race in the PCC and so far not doing to badly on this years outing. Currently 2nd and 3rd in the championship, back out at donny this weekend so if any you guys ever out and about at the tracks feel free come say hi..
Getting it done mate and hope to see it at the podI reckon their good for a high nine pass
rob, stop fannying about with porches and get the car built. I need at least some half-way decent competition this year
aiii, were desperatly trying to get the car finished for rtoc pod day, (its the best opertunity to map as you know).
weve ordered and paid for our manifold at last, t4 divided flange, twin 44mm v-band gates, should be here any day now, only missing few last parts then, fingers crossed we`ll make pod day, failing that will deffo make outlaw
I'll let you know how I get on with WGT's dyno rob - that might be an option for you. Or do you think you'll get traction @ tdi ?
Im unsure about TDI`s rollers once we start pushing high power. I think there ok on adams car to level 550-600?? maybe but i think they struggle.. But as there only ten mins down road and Paul is an awsome guy and just leaves us to it with his rollers.. For now we will stick with TDI...
What dyno is it rob ?
Well no honda updates sorry, but on the Porsche front got a good vid of one of our cars at donny out in quali..
I really didnt think i was going to get this car to make this event, i found some bearing damage and had to do a crank swap and full engine rebuild in a couple of days before. I had no chance for testing or dyno time and no practice, just straight in to the 25min qualifing window.. A heart in my mouth moment...!! I set the car up for a dry session then once in assembly area it started to rain.. Great!!
Still we managed to get a P4 and a P1 in quali for both the races, finishing 4th and 2nd over the weekend.. Thruxton next...
http://www.youtube.com/user/faze1motorsport
Small update, got the engine in today...
F**k me that looks awesome mate
Wow
Looks sooooper smooth and clean fella.
Awesome!
Are they the OE engine mounts or is that a Drag Modification? It certainly looks simple!
Cheers guys, still have aload more parts to fill that bay yet.. The mounts are OE replacement, there is a few options to go for, i didnt fancy the solid mounts so went went for the street/drag option, but also our honda engine has torque mounts, ill be fitting solid ones for them. (yet to order them) so not in them pics... will post as i go along..
Still waiting for the manifold yet, im told it should be finished this week...
The mounts are Avid Racing....
Scoff i cant remember, i was down there other week too.. Paul said its best for me to send the car to TDI south along with adams car for the day and use the Hub dyno.. Ill just use theirs for up to 500hp..
Forward facing? Who is making it Rob?Cheers guys, still have aload more parts to fill that bay yet.. The mounts are OE replacement, there is a few options to go for, i didnt fancy the solid mounts so went went for the street/drag option, but also our honda engine has torque mounts, ill be fitting solid ones for them. (yet to order them) so not in them pics... will post as i go along..
Still waiting for the manifold yet, im told it should be finished this week...
Nope top mount mate, its by AFI over the pond... T4 twin scroll, twin 44 V band gates... dont think a front mount turbo is needed... any more progress with yours pal?
Posting Permissions
Reply With Quote
