Resto and story of "Bricktop"

[Red October]

My journey with F789 NLB.......aka Bricktop.

In December 2011 I started looking out for a good bodied phase 2 gt turbo, in January I found one with no rust, good body and pokey lump......

http://i1173.photobucket.com/albums/...lC60_121-1.jpg

http://i1173.photobucket.com/albums/...PQ60_121-1.jpg

http://i1173.photobucket.com/albums/...fw60_121-1.jpg

http://i1173.photobucket.com/albums/...vw60_121-1.jpg

http://i1173.photobucket.com/albums/...Gg60_121-1.jpg

http://i1173.photobucket.com/albums/...MGg60_1214.jpg

http://i1173.photobucket.com/albums/...IMG_0410-1.jpg

Bodywork was mint as it has has a full respray with all new panels, seals and rubbers, the engine didn't miss a beat at 12psi with a t25 felt good so I decided to buy at 2.5k with a set of refurbed speedlines thrown in.

Got the car home with no problems until I opened the header tank and found this:

http://i1173.photobucket.com/albums/...IMG_0407-1.jpg

A quick call to Justin from ep who lives down the road and the head gasket was swapped and few other bits were tidied up.........

http://i1173.photobucket.com/albums/...ZSlC60_121.jpg

Had a relatively problem free summer until the Wednesday before national day when the car went in to have some custom decals put on:




And because I was working I dropped the car off at a mates garage for new redstuff pads and hoses. When I picked it up on the Friday I was due to drive ND a young yts scrote was underneath and I could hear a cracking sound coming rom the bay, the car was running and had been a while. Tunrs out the lad had forgot to put any coolant in ffs. After falling out with my mate and giving him a big bag off fcuk all I drove ND carefree a little hotter than usual but still normal.

Put the car on the rollers and she made 170@12psi which was a bonus.

http://i1173.photobucket.com/albums/...5/_MG_1574.jpg

http://i1173.photobucket.com/albums/...5/_MG_2939.jpg

http://i1173.photobucket.com/albums/..._1552-Copy.jpg

Spent all day on track but the dials kept getting higher and higher each time we went out. Finally on the last set of laps I decided to turn the boost up a lot and then this happened:

http://www.youtube.com/watch?v=E3c0B2zhLMA

and
http://www.youtube.com/watch?v=VmpasxLBQPY long
http://www.youtube.com/watch?v=kwaO3fKXFko short

Got towed back to the campsite and found out underneath the charred remains of a newly powder coated engine bay id split the top rad hose and cooked the head.....
Over the next few hours we raplaced everything and got back running again and managed to get the car home through buxton and Sheffield with no problems and a little boost

Little did I know this was the start of the ultimate decline of the engine.......

Car seemed lumpy now didn't use it as much and a little smoke had developed at full boost. Nest the afrs seemed to be swinging to extremes until the car was so lean I daren't run it any longer. id had oil coming from both manifold areas and multiple fires had broken out like the one at ND.

Sent the car down to GT Motorsport in stoke on trent who managed to help blunty achieve his 230bhp and I knew mark at gt is one of only a handful of tuners who had seen 500bhp out of the Subaru small block so it made sense.

http://i1173.photobucket.com/albums/...tober5/010.jpg

Im a big believer in built not bought but when I started the engine rebuild with too many differences and variables I decided to let a ex wrc mechanic have the headache.

Mark took the lump apart:

http://i1173.photobucket.com/albums/...tober5/013.jpg

http://i1173.photobucket.com/albums/...tober5/012.jpg

http://i1173.photobucket.com/albums/...tober5/011.jpg

http://i1173.photobucket.com/albums/...tober5/016.jpg

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http://i1173.photobucket.com/albums/...15641-Copy.jpg

http://i1173.photobucket.com/albums/...tober5/021.jpg

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http://i1173.photobucket.com/albums/...tober5/020.jpg

http://i1173.photobucket.com/albums/...tober5/019.jpg

A quick call to mike at gt turbo spares and id got a full bottom end rebuild kit bearings washers tarabusi pistons liners ect

Purchased a set of piper high lift springs, 285 cam, campus pulley and belt and a mocal 13 row oil cooler and sandwich plate.

Purchased a cossie 2wd fmic and pipework, carb refurb kit and jets, MLS gasket set, new pump, pins, bolts, nuts, washers, jubilee clips, hoses
http://i1173.photobucket.com/albums/...4749525_n1.jpg

Now was time for the turbo refurb by Bernie at bernies blowers

T28 with billet comp wheel and wet bearing

http://i1173.photobucket.com/albums/...0600402_n1.jpg
http://i1173.photobucket.com/albums/...6469495_n1.jpg
http://i1173.photobucket.com/albums/...5678321_n1.jpg

Then it was time to get the head sorted:

Reading the thousands of threads I came across marky bs build thread and decided to get the head maxed.

I put larger valves in out of a metro turbo a series, with retainers and collets. The head was extensively ported and polished, throated all on a flowbench at chase engine services who supply heads for the mazda duratec series.

http://i1173.photobucket.com/albums/...3978290_n1.jpg
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http://i1173.photobucket.com/albums/...2321408_n1.jpg
http://i1173.photobucket.com/albums/...312_152325.jpg
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http://i1173.photobucket.com/albums/...301_104531.jpg
http://i1173.photobucket.com/albums/...tober5/023.jpg

vs a ported one
http://i1173.photobucket.com/albums/...tober5/003.jpg

Inlet manifold has been matched and polished also. So has the tubular manifold. All held together with MLS gaskets.
http://i1173.photobucket.com/albums/...13462_n1-1.jpg
http://i1173.photobucket.com/albums/...312_152303.jpg

Then purchased a set of the sid dawn uprated pushrods and a set of his roller rockers

http://i1173.photobucket.com/albums/...tober5/026.jpg
http://i1173.photobucket.com/albums/...312_152955.jpg
http://i1173.photobucket.com/albums/...312_153010.jpg
http://i1173.photobucket.com/albums/...312_153000.jpg

Next I decided to get the nodiz pro ignition controller and do away with the aei and renix dissy setup.

Purchases all sensors cabling from demon tweeks and scoff at efi parts along with a 36-1 trigger wheel that's welded against the campus pulley

http://i1173.photobucket.com/albums/...15633-Copy.jpg

Have already purchased a 8psi fpr, uprated pump, 3 bar map sensor wasted spark 4 pack with competition leads on iradium plugs.

Cooling wise I managed to pick up this big radiator via james on here and fitted a 16" pacet fan.

http://i1173.photobucket.com/albums/...tober5/059.jpg
http://i1173.photobucket.com/albums/...tober5/058.jpg

Car has also had full interior swap with black and red leather trim. pics to come.

Tubular exhaust manifold, turbo housing and downpipe are being ceramic coated next week next week with pics to follow.

The build is currently underway and should have some more pics and info in the coming week

[Tony Walker]

Most comprehensive singular post ever fantastic reading
I still can't beleive I was out on track all day and had no idea you'd popped it.

[wilton_warrior]

im defo following this as a how to do lol, keep it up

[Nad-5GTT]

A thoroughly good read, look forward to the updates.

[Red October]

Most comprehensive singular post ever fantastic reading
I still can't beleive I was out on track all day and had no idea you'd popped it.

Cheers Tony I tried my best to put it in order, gutted the links didn't show the pictures. Every time we went out and did another stint the temps and gauges would go up another notch, on the last few I turned it up 20+ and it was fun while it lasted. The powder coat from the fire extinguisher has made a right mess also. Its on trailer this time around thank god so if it blows I can fix it at home.

[Red October]

Cheers for the encouragement lads.

Forgot to add the head is being dismantled to enable the introduction of catcams inner springs and double retainers, to help with the valve float that occurs hopefully around 8 to 8.5krpm to compliment the roller rocker, uprated rods and 285 cam.
Get some legs out of the T28.

Watch this space

[Dave Reed]

Cool project mate..

Just one thing though.. I'm not sure I would of used the metro turbo valves being as they are a 2 piece valve and tend to break of

[Logg]

Sounds like you've had a right up and down time with your GTT. Good to see things are on the up fir you.

[Red October]

Cool project mate..

Just one thing though.. I'm not sure I would of used the metro turbo valves being as they are a 2 piece valve and tend to break of

Had the sodium filled ones dave are they the ones you mean?

[Dave Reed]

Had the sodium filled ones dave are they the ones you mean?

I'm not sure mate, I know the standard ones are.. Worth a phone call though, coz as soon as you rev that thing it'll spit the valve out

[Red October]

I'm not sure mate, I know the standard ones are.. Worth a phone call though, coz as soon as you rev that thing it'll spit the valve out

Been on the phone to mini spares and they reiterated what the head people said is that the valves are mini metro competition valves, not the 2 part ones you mentioned. My bad with the wrong description.

[Red October]

Just a update on ceramic coating. Dropped the turbo housings, tubular and bjr downpipe off at the coaters. Was going for aliminium iodizing but it too expensive so instead had race ceramic black instead. Pics to follow next week

[BluntyR5GTT]

i dont think i really need to comment on this thread as me and ash speak virtually everyday.

But i will say the dedication thats being shown is top notch and hes not afraid to try something new. The engine will be fantastic once all set up and i can 100% say mark at gt motorsport is one of the finest tuners/engine builders in the game

roll on this summer pal we will have some fun

[Trevhib]

Great project, thanks for sharing

[GT Josh]

Photo bucket fail. You big gayboy. Upload proper pictures!!!

[Goobie]

Photo bucket fail. You big gayboy. Upload proper pictures!!!

Sorry but

[andybond]

Just a update on ceramic coating. Dropped the turbo housings, tubular and bjr downpipe off at the coaters. Was going for aliminium iodizing but it too expensive so instead had race ceramic black instead. Pics to follow next week

What's the difference Ash? Is it like zircotek?

[Red October]

What's the difference Ash? Is it like zircotek?

Camcoat mate, 277 delivered including vat. zircotek want 20 working days turnaround and offer 1 45% surcharge if you want it 8-15 working days ffs.

I went for camcoat because of the turnaround time at zircotek and the attitude of the sales woman was gash, when I asked specific info all I got was copy and paste off their website which I could have done myself.

ill bob some pics on soon pal.

[Red October]

Photo bucket fail. You big gayboy. Upload proper pictures!!!

Hahaha josh you bell end!

its pissed me off tbh I might re do the thread!

[Red October]

Great project, thanks for sharing

Cheers trev

[Red October]

i dont think i really need to comment on this thread as me and ash speak virtually everyday.

But i will say the dedication thats being shown is top notch and hes not afraid to try something new. The engine will be fantastic once all set up and i can 100% say mark at gt motorsport is one of the finest tuners/engine builders in the game

roll on this summer pal we will have some fun

nice one andy hope you all had a boss weekend at noble pal.

[Red October]

Another quick update: Just purchased a brand new ice setup, 800w vibe 4chan amp, 1200w vibe sub and enclosure and vide 375w coaxial 6x9s. To compliment the new alpine/apple head unit and vibe blackdeath door speakers that are in situ.

[Tony Walker]

Quite a rare post on these boards, i do miss some thumping but i just couldnt bring myself to turn it up and further enhance peoples stereotype of my car lol

[Red October]

Quite a rare post on these boards, i do miss some thumping but i just couldnt bring myself to turn it up and further enhance peoples stereotype of my car lol

Haha Tony if you saw where I live you would say its in keeping with its surroundings hahaha. If your windows are down thumping your asking for a slap tbf.

[Tony Walker]

been there a couple of times but dont know it particuarly well. I dont think my 5 fits in very well round my way lol i think i piss them all off each morning enough as it is

[Red October]

Bit of a update...................

Fell out with my engine builder at the end of May as his divorce and extra curricular activities were too much of a burden.

Had the car back and had it transported down to sunny Tipton where Sparkie has kindly offered to build it back up.

He stripped it down completely and uncovered many problems...

1. sump full of melted stem seals.'
2. Cam journals fooked, block also worn to the point of rattle (new block required)
3. oil pump fooked
4. Carb has a crack bigger than sticky Vicky
5. 0.75 crank had took a whack and was also fooked!

Mark has took many pictures and we've replaced more or less everything for new or reconditioned so despite costing a fortune at least ive got a A1 lump. Fingers crossed it should be running of sorts in the next few weeks, albeit on a base map and a T2

Pics and update coming soon watch this space............

[GT Josh]

Nice one lad. Never run with stem seals.

[Trevhib]

Can't beat a Sparkie build

[Red October]

Car is toast as many of you are aware by now.

Engine is to be stripped and full independant professional assessment to be done on the cause.

More to follow.

[chris]

Sorry to here this mate. Are you going to start again?

[Red October]

Sorry to here this mate. Are you going to start again?

How I feel right now and having spoken to my mrs he answer would be no. Had to sacrifice annual holiday this year amongst other treats, she'll probably leave me if I build another one.

[chris]

I was really looking forward to seeing this done aswell what happened. Are the insurance guna cover it you must be devastated

[Red October]

I was really looking forward to seeing this done aswell what happened. Are the insurance guna cover it you must be devastated

Had a massive valvetrain catastrophe on idle after startup basically. Dropped many valves its shook itself to pieces. Then next week we shall find out if we are correct in our diagnosis of the susprct areas. Once we have established factual evidence I can go from theres and see what the options are, or break it.

Its completley ruined, 3.5k in the bin.

[chris]

A big investment mate but its the time and effort that goes into it. Anyway its done now keep us posted

[casper]

Thats shocking Ash.Let me know if theres owt i can do.

[bood]

Just read and looked at all your pics.

So sorry to hear things have not turned out well for you.

[Red October]

Thanks for the support guys, the amount of help and parts foc has been overwhelming.

Need to repair my heart before the engine, im absolutely gutted, truly truly gutted.

[chris]

I am only 45 mins from you so if/when you decide to have another go always willing to lend a hand

[Red October]

The following video was taken 1 week after it died catastrophically idling on its mot.

If you watch the video in HD you will see the galleries are full of needle bearings from the rollers as they disinterested at 1200rpm. Due to the disintergration collets were ripped off and valves were dropped. As said before sparkie or a independent garage will strip it under camera to ascertain the full extent of the damage. Ignore the commentary as I was shaking and hadnt actually realised the rollers had come off.

Enjoy, because after 12months of hard slog I definatley aint.

https://www.youtube.com/watch?v=Ouoc...e_gdata_player

[kentraider]

really feel for you buddy.......

[chris]

What a mess mate feel really sorry for you

[R5MJH]

really feel for ya bud id be p1ssed if it was £500 quid but the RTOC massive will help im sure, chin up

[Adey aka Ewok]

such a ****ter, gutting. hope you get it sorted soon

[Dave Reed]

Fella, that is shocking.. you've had piss poor luck so far!

Don't give up though..

I must say though I did always think that roller rockers required a roller cam design, but saying that, I've only known of v8's with roller rockers etc.

[Red October]

Its not the money ive lost its the time thats done my head in, a full year in the making is time I will never be able to recoup. Im aware this isn't an isolated case so it will be interesting to see how this all pans out with sid. He has been the perfect gentleman so far and if its conclusive that his rockers are to blame then im sure he wont just leave town and run away from this, id be an idiot to think hes just going to hand over a bag of cash based on a load of recipts and what me and sparkie reckon. But somethings gotta be done, like I said before this build disintergrating has blown my mind and disposable income for 2013.

Thanks for all the kind words and encouragement especially the offer of help coming from all angles has been great. See whats what next week and ill get some pictures up.

[R5MJH]

Fella, that is shocking.. you've had piss poor luck so far!

Don't give up though..

I must say though I did always think that roller rockers required a roller cam design, but saying that, I've only known of v8's with roller rockers etc.

i had friends in the past that raced minis with A series engines that had roller rockers fitted and these engines revved well with no probs, but they were designed to work on that engine

also they both have push rod engines so not that different

[Red October]

i had friends in the past that raced minis with A series engines that had roller rockers fitted and these engines revved well with no probs, but they were designed to work on that engine

I think these rockers work just that the rollers cant take the hammer, the fact the needle bearings escaped and they fell apart was testament to that. The other dubious thing is when the elongated pushrod needles are installed this massivley changes the angle of the ratio which may also have a bearing on what happened tuther end.

[Red October]

Ive decided to keep the car and carry on if the damage is hopefully none terminal. If it is terminal then ill carry on anyway!

Should I start another resto thread?

[andybond]

Ive decided to keep the car and carry on if the damage is hopefully none terminal. If it is terminal then ill carry on anyway!

Should I start another resto thread?

Restoration of the restoration.

[Red October]

Obviously everyone knows there has been some issues with my build due to unforeseen problems........

here's some more pics of the 1st engine restoration(before the roller rocker problems)

Decided for optimum track and heavy boosting cooling the c1j would be high on the agenda of the build........fitting of the clio 172 radiator is tough as it requires chopping the engine mount slightly. It fits butt up against the front of the engine bay and with the 16 inch pacet fan it snug to say the least but sparkie is the man!











Now being a bit of an oddball that doesn't really follow the crowd I decided to get a FMIC with the PWR as to cover all the angles, im aware of carb freeze etc but the CC will be on a switch and a piece of cardboard always solves the trick........

I spoke to forge about a bespoke FMIC that would allow me to keep the oe look without chopping up the front and it had to fit behind the grille not lower down (orthodox FMIC position) as that would where the 2x 450mm CC rads would sit. Forge were useless and I decided to get a decent one off ebay that has again different style of fin.







once that was sorted........pipework runs were decided and CC positioning was also sorted...











next the mocal oil cooler..............which is turning into the quite the stack!





Then finish the pipework, relocate the header in the scuttle and finish dressing the engine...... Also finish the CC with the mounting of the rads underneath where the FMIC would normally go (no pics sorry) and mounting of the pumps, reservoir/swirl, electrics and pipework.....









After this the car went for its MOT and you know the rest..............

Next post will be pictures of the engine removal, strip down, assessment of the damage and the plan moving forward....... all build done by Mark Branston aka Sparkie' all engineering design of the lump and dogsbody ME!!