[car_overhaul] Zx 16V Project Pt2, Re-Shell And Power Upgrades....

[B1ack_Mi16 67]

Sure they will. So it's not a big issue.

But ideally you should change the pad then when it is still a little bit more material left than compared to a 28mm disc.

 

Also the 28mm disc can probably wear down to 26mm legally, so as long as you keep an eye on it I can't see it beeing a problem.

Edited November 11, 2015 by B1ack_Mi16

[welshpug 1,657]

I sold the engine to Blandy back in December, as I had happened upon the basis of a full engine build, in the form of a Block and higher compression pistons.

 

The last few months have been a battle of collecting bits, deciding what direction to take it and budget constraints, and making it work with what I already have to hand!

 

Currently, I have a big jigsaw puzzle, almost ready to assemble, crank has already been fitted and plasticauged, along with a Conrod and piston in to check deck height and valve clearance.

 

 

Flickr

 

 

checking valve clearance -

 

 

 

 

Decided to paint it a striking colour

 

 

 

Big thanks to Carl Robson and Sandy Brown for helping out with the conrods, also thanks Sandy for the pointers in what to measure.

 

Also Ed and Steve at Warners for supplying the o.e parts at very good prices.

[calvinhorse 870]

Progress! Awesome!

[blandy 29]

looking good

 

Hopefully once youve had this one done and running for a while and get bored ill have this one as well lol

 

Whats the spec you are going for?

[Tom Fenton 1,541]

I'd use a straight edge and feelers to check the piston to deck height, I've done it that way with the dti before and not got repeatable results.

[welshpug 1,657]

I know what you mean, the piston can rock in the bore if there's a bit of wear

[welshpug 1,657]

Final Parts for the bottom end I think, thrust washers, had been on backorder for about 6 weeks.

 

 

20160411_105010 by WELSHPUG, on Flickr

 

 

Made up a bracket to hold the dial gauge (the magnetic stand is Dan's and ion his garage, didn't have it to hand)

 

 

20160411_190046 by WELSHPUG, on Flickr

 

 

pushed the crank, and got my end float figure

 

 

20160411_190059 by WELSHPUG, on Flickr

 

0.13 of a mm, ideal, tolerance is 0.07 to 0.32mm.


Further progress is at a halt till I make/earn more money, as the head needs checking over and the seats cutting

[welshpug 1,657]

so, an update!

 

took the head and valves to South Wales Pistons for them to check the face and guides and cut the seats and valves.

 

20160515_182416 by WELSHPUG, on Flickr

 

20160515_182445 by WELSHPUG, on Flickr

 

 

Piper double springs

 

20160515_182431 by WELSHPUG, on Flickr

 

o.e stem seals, branded SKF.

 

20160518_185150 by WELSHPUG, on Flickr

 

pushed into place with a socket and a dab of oil.

 

20160518_185217 by WELSHPUG, on Flickr

 

 

fitting the springs and collets, what a faff! dab of grease helps, also not having the cam ladders gives and extra inch or so of clearance, I wrapped the head of the spring compressor in tape so the lifter bores weren't damaged.

 

20160518_194119 by WELSHPUG, on Flickr

 

Cleaned and refaced the tappets.

 

20160531_204018 by WELSHPUG, on Flickr

 

 

20160531_212248 by WELSHPUG, on Flickr

 

 

 

checked the clearance to the freshly re-fitted oil spray bars, looooads, could sling a 96mm crank in there easily.

 

20160522_132157 by WELSHPUG, on Flickr

 

fitted and torqued up the crank, fitted the windage tray oil pump and the dipstick guide.

 

20160526_194635 by WELSHPUG, on Flickr

 

 

new hockey stick seals for number one mains cap

 

20160526_093542 by WELSHPUG, on Flickr

 

 

 

Turned back over.

 

20160522_162433 by WELSHPUG, on Flickr

 

 

o.e steel gasket.

 

 

 

Payen Head bolts

 

20160522_163108 by WELSHPUG, on Flickr

 

then cams in and ladders sealed with wellseal, water pump and timing belt kit on.

 

20160604_231216 by WELSHPUG, on Flickr

 

 

doing the cam timing.

 

20160618_222112 by WELSHPUG, on Flickr

 

20160618_220408 by WELSHPUG, on Flickr

 

 

 

then off the stand and fit a Steel lightweight flywheel with new bolts and a new dowel.

 

20160530_192525 by WELSHPUG, on Flickr

 

 

Standard clutch fitted, will see how it copes with XXX amount of torque, I don't tend to abuse my cars so probably just fine! starting to look much more like an assembly, less spare bits kicking about

 

20160623_231258 by WELSHPUG, on Flickr

 

 

 

Dragged the ZX around the units and washed it off, stuck it on the lift.

 

20160625_172931 by WELSHPUG, on Flickr

 

 

 

Forkinghell this might actually happen!

 

20160626_004848 by WELSHPUG, on Flickr

 

 

BOOSH.

 

20160626_005920 by WELSHPUG, on Flickr

 

TRUMPETS

 

20160626_013230 by WELSHPUG, on Flickr

 

 

a very rare Milltek exhaust was sourced, tailpipe is rather large but thankfully only externally.

 

20160626_133647 by WELSHPUG, on Flickr

 

however the peugeot sport Group N Decat twin tube downpipe had a sleeve fit end for a magnex catback, also pretty small here at 2".

 

20160629_210434 by WELSHPUG, on Flickr

 

 

so I bought this

 

20160629_110454 by WELSHPUG, on Flickr

 

 

20160629_210447 by WELSHPUG, on Flickr

 

measure mark chop grind weld.

 

20160629_213817 by WELSHPUG, on Flickr

 

20160629_215406 by WELSHPUG, on Flickr

 

 

fitted with o.e single piece clamps.

 

20160629_220817 by WELSHPUG, on Flickr

 

Filled up with fluids.

 

fired up and running the cams in.

 

20160628_232045 by WELSHPUG, on Flickr

[calvinhorse 870]

Yes! Looking good Mei! Looking forward to more updates

 

Didn't fancy using that stainless fanimold then?

[welshpug 1,657]

Not quite yet, I measured the lengths and did a few calculations with the help of a few tables i found and they may work very well with a decent pair of secondary pipes.

 

next update will be mapping hopefully!

[calvinhorse 870]

The new exhaust he had was 4 into 2 all the way to the back then into a single box, crazy thing.

[Reebmit 51 4 Cars]

Looking good Mei ....

[camgti 56]

Excellent! I love seeing and engine come together, have ITBs fitted in what seema like a few minutes!

 

Thanks for taling to time to share!

[welshpug 1,657]

just realised I hadn't dropped the pics on here that I posted elsewhere, cso the start of this post is from september.

 

 

I decided to buy some brakes.


Peugeot 206 cup car Alcon 290mm brakes by WELSHPUG, on Flickr


Peugeot 206 cup car Alcon 290mm brakes by WELSHPUG, on Flickr



Peugeot 206 cup car Alcon 290mm brakes by WELSHPUG, on Flickr

Thats a saxo vts/xsara vtr Indianapolis wheel without any spacers, 205 speedline needed 3mm, no cyclones to hand.


Peugeot 206 cup car Alcon 290mm brakes by WELSHPUG, on Flickr

Pro race 1's, Direct pug fit, not the grey ones that don't fecking fit that Bowen sold me, tit.

And faff with the cooling system to get cleaner colder air to the trumpets without having to use an airbox.




20160821_161554 by WELSHPUG, on Flickr

205 rad and Spal 9" pusher fan, couple of brackets made up from stuff I found knocking about.


20160809_175628 by WELSHPUG, on Flickr

A bit of plastic coated aluminium and foam board

Need some pipe adapters as the top hose is a different diameter and I'm keeping the heat exchanger, so needed to tee into the bottom of the rad, looking to source probably a 406 expansion tank and place it on the chassis leg in front of the PAS bottle.

 

 

this was the final version of the rad bracket.

 

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Tigger Dave at satchell engineering welded these bits of pipe up for me.

 

 

 

got a 205 expansion tank tucked in behind the headlamp and its working just fine.

[welshpug 1,657]

this week I bought some Trumpets.

 

satchell engineering dcoe pattern throttle body trumpets, 45mm bore 50mm tall. by WELSHPUG, on Flickr

 

satchell engineering dcoe pattern throttle body trumpets, 45mm bore 50mm tall. by WELSHPUG, on Flickr

 

 

They do look mighty short but are actually 50mm, the length is to suit my total inlet tract vs cam profile and stroke etc, I let Colin do the maths.

 

[camgti 56]

Thanks for the update!

 

Cant wait to see hpw it goes! I bet your excited to say the least!

 

Out of interest, are the brakes expensive and hard to find?

[welshpug 1,657]

second hand yes they aren't common, they're around £1600 new, AP Racing do a very similar setup and similar cost.

[camgti 56]

Nice find then!

 

Thanks for the info.

[welshpug 1,657]

So a few weeks ago I borrowed a trailer, and my BMW's alternator died on the Thursday evening just as I was loading up the ZX ready for the Friday morning trek to Launceston, cue DCC's Landrover to the rescue!!

 

this was the view at about 6.30

 

mapping day at SRD in Launceston with Sandy Brown by WELSHPUG, on Flickr

 

9.30, That sign, a very welcome one.

 

mapping day at SRD in Launceston with Sandy Brown by WELSHPUG, on Flickr

 

Bumper off and strapped down.

 

mapping day at SRD in Launceston with Sandy Brown by WELSHPUG, on Flickr

 

 

Dan popped down to Truscotts and got a brand new expansion tank cap, the used one I had didn't seem to be holding much pressure, though it wasn't boiling over at all.

 

big thanks to Neil, he's a bloody good teamaker, as well as Pinto building machine, I'm sure he knocks out two or three a day at least of the hotrod high power beautifully finished engines!

 

oh and Dan picked up some bits from Sandy...

 

mapping day at SRD in Launceston with Sandy Brown by WELSHPUG, on Flickr

 

 

 

After a few issues with some tricky to find wiring faults causing an injector to not fire, Sandy cracked out his wiring kit and made me a new outer injector sub loom, cleaned the plugs and got cracking, then found an issue with the lambda dropping out, seems the heater circuit was a bit iffy and the lambda kept going full lean, gave that a clean stronger live feed and it seemed to be fine thereafter, once the few niggles were nailed down the map came together very quickly.

 

Sandy Brown mapping the DTA S40 ecu on my XU12 Citroen ZX 16v by WELSHPUG, on Flickr

 

only managed to get a few short video clips, no power figure yet but we do know we're at the limit of the GTI6 injectors at 3 bar (running up to 85% duty IIRC), and the Clio 250cc are filling the rest as required, so its around the 240 bhp mark.

 

next jobs are to sort the clutch cable as it seems to have been cooked with the prolonged periods under load on the rollers, will need to find some material to protect it from the heat, buy some pads and fit my brakes.

[petert 586]

Where's the dyno chart? I'm more interested in the torque curve.

Edited April 8, 2017 by petert

[welshpug 1,657]

no chart, old skool rollers, all it has is a Pair of Dials, wheel speed and power.

[welshpug 1,657]

so, MOT ran out on this in April last year, I think?    lots of stuff happened before and just after then, new job, Girlfriend, a few different daily diesels.

 

ZX had sat in the corner abandoned for quite a while, though still a runner with a fresh battery, the bodywork being 2 different colours was beginning to get a bit boring, and whilst the new job is less per hour I'm doing 50% more hours a week, walk 50 yards to work, and get proper overtime, I still begrudge having to save over a months wages just to get a cheap blow over, yet I know full well I am no sprayer

 

so, almost 2 years ago I helped my girlfriend sand back her 26 foot Kingfisher bilge keel junk rigger Yacht, hell of a job, spent weeks on end covered in blue and grey fine dust!

 

and then we Painted it, proper Hempel etch primers on the steel keels, normal yacht primer on the gelcoat followed by a lovely Gloss blue above the water line and black antifouling below, wet sanded between the last few coats of primer and each gloss coat, and I was particularly impressed with the finish from an over brushed roller job, can't find any pictures right now though

 

so I decided to do the same to the ZX, sand it down with a makita DA borrowed off my girlfriend, flat back the fiddly bits by hand, then hit it with a roller and boat paints annoyingly I'd forgotten what kind of roller we had used and that we had followed with a brush, so the first coat of primer went on a bit thick and almost like crinkle paint :lmao   easily rectified with a quick flat down before a few more coats though

20200428_115108 by WELSHPUG, on Flickr

20200421_151431 by WELSHPUG, on Flickr

20200415_161230 by WELSHPUG, on Flickr

20200411_212547 by WELSHPUG, on Flickr

20200404_155727 by WELSHPUG, on Flickr

20200428_151934 by WELSHPUG, on Flickr

20200428_160750 by WELSHPUG, on Flickr

20200428_160758 by WELSHPUG, on Flickr

20200428_160806 by WELSHPUG, on Flickr

20200429_192914 by WELSHPUG, on Flickr

and here's the colour I'm going for

20200416_191621 by WELSHPUG, on Flickr

BLACK! 

[petert 586]

Excellent. Shouldn't need to anti-foul it for another 25-30 years.

[calvinhorse 870]

New Girlfriend with a Yacht and a DA Sander! Sounds one hell of a woman! 

[welshpug 1,657]

She now also has a 5t mercedes sprinter and a 7.5t C1 driving licence, she learnt to drive in my car and passed both tests last year!