Back from the dead? Rebuilding a K blog

[Milkybar Kid]

Give me a shout if you want the crank inspected, can take it into my old work and use the flourescent mpi gear (or magnaflux as the yanks say)
Unfortunately i only have VW t1 journal guages or i could give you accurate bearing sizes.
If i dont reply on here get Nizzy to email me
lewis

[Pedro]

Just read this, really interesting thread, Hows the rebuild going now guys..?

Cheers,
Pete

[Mikie711]

Come on Steve give us an update.................the suspense is killing me

[Shug]

He's awaiting parts AFAIK

[steve_weegie]

Will post a bit more this evening chaps

[BiggestNizzy]

He's awaiting parts AFAIK

would that be the titanium con rods, titanium alumnide pistons & titanium valves (sodium filled exhaust)

[Shug]

And he'd still blow the f**k out of it...

[steve_weegie]

And he'd still blow the f**k out of it...

Oi, people in glass houses 'n' all that.....

[woody]

Did you get the items I left stuffed in the topiary of your front garden? Your neighbour didn't look too pleased at the time....

[Shug]

Neither would you if someone was stuffing a suspicious cylinder shape in a polly bag in your hedge...

Edit at will

[Rich H]

Neither would you if someone was stuffing a suspicious shape in Polly in your hedge...

Edited at will

[steve_weegie]

Ok, just had word back from Stu that he has worked his magic and the block and liners are ready for collection

I'll pick them up on Monday and start the rebuilding next week

Oh, and i've already booked the car in with ali so i'd better work quick

[BiggestNizzy]

[steve_weegie]

Ok, D Day is looming large & the car goes in for the engine swap on monday. Pretty much everything i need to get is now in my hands and i've started the build process.

The block has been to Stu and machined for the correct liner stand proud, as well as having the liners honed. As i'm fitting new rings, the honing process will ensure they bed in correctly.

So, tonights task is to ensure the new piston rings have the correct gap when they are fitted into the liners.



The piston ring has been inserted into its liner and pushed down with the piston to ensure its flat. The gap measured with a feeler guage, ring removed and filed in a vice until it was correct, taking material from both sides of the ring and ensuring that the two faces are flush when joined together. I've gapped the top compression ring at 0.3mm the 2nd compression ring at 0.44mm and the oil control at 0.3mm. Needless to say this is a PITA job



The rings are pretty stiff, and to avoid buckling them, they are installed with a piston ring expander doo dah...



Finished the first one!! 3 more to do now....

[steve_weegie]

Ok, made some serious progress so far tonight.



The block and bearing ladder have been cleaned up, ready for the installation of the main bearings....



New thrust bearings installed to bring the crank end play back into tolerance



The crank has been treated with a low friction coating....



And all excess buffed off



Main bearings installed into block and the crankshaft seated in.... Lots of oil applied to everything



Bearing ladder covered in sealant, and torqued up progressivly to 5nm, 15nm then 30nm with a rotation of the crank after each torque to check for sticky spots. Fortunatly there weren't any and everything is going to plan so far