AE86 booter project

[Farside]

Yeah, an hour is total overkill and will just damage the valves.
There are some who say anything but a proper valve seat cutter and new valves is a waste of time, but they're not buying the stuff, so can afford to be precious with their attitude.

 

[Dieselman 63]

Yeah, an hour is total overkill and will just damage the valves.
There are some who say anything but a proper valve seat cutter and new valves is a waste of time, but they're not buying the stuff, so can afford to be precious with their attitude.

Well I only overhaul so I don’t have the personal sting of the cost, but the price of the machine to cut our seats was about 20x less than the cumulative cost of parts on an engine that threw a rod!

Doing it right ends up being cheaper.

 

[Farside]

Well I only overhaul so I don’t have the personal sting of the cost, but the price of the machine to cut our seats was about 20x less than the cumulative cost of parts on an engine that threw a rod!

Doing it right ends up being cheaper.

How did lapping the valves lead to a rod being thrown?

 

[Ctreanor13]

I can't wait to see this at some of the local shows or out on the road around Monaghan

 

[Myles1970]

I can't wait to see this at some of the local shows or out on the road around Monaghan

Me too!

 

[Myles1970]

New valve seals in, valves/springs installed and cylinder head reinstalled with new head gasket....

.... now to study-up on trial fitting the cams before measuring the valve lash. They're shim-under-bucket types, so hopefully they will be within spec as I don't fancy having to wait for new shims from Japan (this engine was never available here).
Then it'll be new camshaft seals, final cam installation and setting the cam timing...

 

[Myles1970]

Putting on the bling

 

[Myles1970]

Got the screen fitted today with some help from Myles junior...




... Also some "Evenflow" stickers, worth a look at their YouTube videos for some raw Irish country lads who drive like they shouldn't

 

[Cris B]

Got the screen fitted today with some help from Myles junior...

View attachment 450016


... Also some "Evenflow" stickers, worth a look at their YouTube videos for some raw Irish country lads who drive like they shouldn't View attachment 450018

Alan! ALAN! ALLLLAAAN!

Looking good!

 

[Myles1970]

So as per above, I have ended up waiting for shims (overnight) from Japan.... been waiting over 2 months now, just need the last (of 7) which is due here in July .
Meanwhile I've wrapped the quarter window trims and got a new set of clips (€230 ouch!) as the originals wouldn't hold them. Happy enough though, what you think?




The clip for one of the corner pieces couldn't be got, so I improvised with a fastener from a ebay special box of clips, and a drill:



What didn't go so well was the carbon fibre wrap on the bonnet...



...buy cheap, buy twice as they say. That'll be coming off and I'll give it to a local guy I just found out about who supposedly has won awards for his work

 

[Myles1970]

Well the engine is in...

 

[Myles1970]

..... It took a bit of jiggling, but I got there in the end. Now there remains a bit of plumming, some work on the exhaust manifold and o2 sensor and a fair bit of wiring.

I've decided to go through the bulkhead using a deutsche bulkhead connector to keep it tidy and to simplify things for when the engine has to come back out...

 

[Keithmac]

Very nice job there, looks great!.

I like the Deutsch connectors, not cheap but a very good quality connector.

Looks like you can see theb light at the end of tunnel.

Are you going to run a PDM? (Power Distribution Module), if my fusebox plays up again I'm considering going down that route.

 

[atomant48]

Very nice job there, looks great!.

I like the Deutsch connectors, not cheap but a very good quality connector.

Looks like you can see theb light at the end of tunnel.

Are you going to run a PDM? (Power Distribution Module), if my fusebox plays up again I'm considering going down that route.

Do tell more - PDM.

 

[Haz87]

Do tell more - PDM.

What is a PDM, and why do you need one?

PDMs: What Do They Do, Why Do We Need One, and How Do We Install and Use It?

www.hpacademy.com

 

[atomant48]

Thanks for the link. Really interesting - like the sound of that a lot.

 

[Myles1970]

Are you going to run a PDM? (Power Distribution Module), if my fusebox plays up again I'm considering going down that route.

Yea no I have all the chassis wiring so I've just been running with that and everything seems tickityboo (so far) so I don't see the need for the added expense....and I enjoy the fault-finding too

 

[Keithmac]

Yea no I have all the chassis wiring so I've just been running with that and everything seems tickityboo (so far) so I don't see the need for the added expense....and I enjoy the fault-finding too

Fair do's, if it ain't broke don't fix it

 

[Myles1970]

EXHAUSTING work



the headers/four-branch of unknown origin had seen better days. It had a welded joint/sleeve that looked like it would have restricted flow, so I had to cut that off. When offered up to the car, the bend pointed upwards towards the floor, so I measured the preferred angle - 60° - and ordered same from tube-bender on ebay.





As it turns out, the 20v blacktop ecu requires a heated O2 sensor, so a bung was ordered and welded-on to where the previous O2 sensor had resided... Then, I was left with a 60cm gap and a 20°. bend between the manifold and the Kakimoto system. Everyexhaustpart on ebay provided a couple of flanges, a 60-50mm reducer and a flexi section.

And voila:



What followed was an hour of contortionism while I tried to wrap the thing with kevlar..... Supposedly reduces engine bay temperatures and speeds exhaust evacuation, I just know it hides a cheapass manifold and will pass until I learn to tig a stainless equal length header