Jamie’s car build.....again!

[jamie_1992 66 1 Cars]

Some might remember my original build when I brought the car around 6 years ago now but for any that don’t il give a quick run down.

 

i got the car as a standard 1.9 Gti non runner and immediately removed the engine and fitted a gti6 engine retaining the 205 gearbox, run the car as a road car for a year or so, then took off the road for a total strip down and most of the interior didn’t make it back in the car, I then used it as a weekend toy for a while until I decided I needed a little more from it and set about the current works.

 

anyway here’s some build pics so far and il try to add a bit more as I go 

 

[jamie_1992 66 1 Cars]

Edited August 29, 2018 by jamie_1992

[jamie_1992 66 1 Cars]

 

 

 

 

 

 

 

[jamie_1992 66 1 Cars]

[jamie_1992 66 1 Cars]

Now the car sits in the workshop awaiting various upgrades 

[jamie_1992 66 1 Cars]

So one of the things that’s been annoying me for a while is the wiring on the car and that most of it is redundant and just generally messy, so first job was to rip the lot out and start from scratch, I managed to get hold of an interior wiring loom and fuse box built by Alex Crosse and set about getting it wired in, it still needs work as he ran a different dash to me but it’s saved a lot of time from building looms ect

[jamie_1992 66 1 Cars]

Then spent a silly amount of money on some gauges 

[jamie_1992 66 1 Cars]

Next on the list is the engine and I wanted to get the new engine management in and running before the engine rebuild.

 

So a phone call to a nice helpful chap called sandy and I had a new DTA s40 ecu and custom build loom sent, I then ordered some jenvey 45mm throttle bodies with all the various bits to go with. 

I also set about fitting a swirl pot and Bosch 044 pump from torques along with some new hose and fittings 

 

 

 

 

 

 

 

[Biggles 65]

36 minutes ago, jamie_1992 said:

Ooo, I quite like that.

 

[jamie_1992 66 1 Cars]

Once all the new bits were on and working it was time to rip it all out again for the engine build 

Engine out and on the stand ready for a strip down 

 

 

 

[jamie_1992 66 1 Cars]

Strip down brought up some issues, one being a fair bit of corrosion to the head I took it to the machine shop and he said it was too far gone to fix, luckily I had a spare head although all the valves were bent so I had the good valves removed and fitted to the good head, they were recut and lapped in along with new oil seals 

whilst I was having machine work done I had the block rebored by 0.5” 

 

 

 

 

 

 

 

[jamie_1992 66 1 Cars]

New parts for the engine build 

 

rought spec is high comp pistons with steel rods

newman ph4 cams with catcams pulleys 

catcams springs and retainers 

 

 

 

[jamie_1992 66 1 Cars]

Engine starting to go back together 

 

 

 

 

 

 

 

 

 

[Grantpipe 0]

Looks good. Hopefully will have similar build underway shortly.

 

[jamie_1992 66 1 Cars]

So today I timed up the engine, I decided to go for the lift at tdc method.

 

first step is finding tdc using a dial gauge, then fit a timing disc to the crank 

 

 

 

after this you turn the crank 90 degrees so the pistons are out the way of the valves and then set the dial gauge up on the folower inlet side on number 1, then turn the cam clockwise until you reach the desired lift (2.75mm) then repeat for the exhaust but turn anti-clockwise.

 

 

 

Then bring the crack back round to tdc and fit cambelt 

 

 

got a few little bits left to put on the engine then can look at refitting it 

[johniban 59 1 Cars]

Great right up! looks similar to my car just much cooler! same colour, itbs ect.

 

Whats the reason for jenvey 45s? would you have not been better with 48s with high comp pistons?

[jamie_1992 66 1 Cars]

1 hour ago, johniban said:

Great right up! looks similar to my car just much cooler! same colour, itbs ect.

 

Whats the reason for jenvey 45s? would you have not been better with 48s with high comp pistons?

Yer in hindsight I should have got 48 but I hadn’t planned to such an extensive engine build at the time of ordering 

if a set come up for sale I might look at changing them 

[johniban 59 1 Cars]

A lad on facebook was selling 48s, hes also on here, josh gault 

[welshpug 1,657]

wont need 48's on a 2.0 unless youre reeeeally spinning it over up the revs, for which youll need much more than a ph4 cam.

 

make sure you confim radial clearance on the valves as well as the vertical clearance, and check the size of the crown, have read a few instances of wildly inaccurate compression ratio figures and valve cutout centres a little off.

[jamie_1992 66 1 Cars]

Here’s the calculation for the compression ratio 

[welshpug 1,657]

nice work!

[jamie_1992 66 1 Cars]

Got a bit of time in the workshop today, engine is just about done now 

 

also got some new suspension bits (some will know what’s special about it) and gave a quick lick of paint as they’ve been stood for a bit 

 

[Batfink 201]

Well that looks a lot better

[johniban 59 1 Cars]

Nice bit of kit that, wish i had the money to buy one for mine :) 

[blandy 29]

Nice build and cracking write up ref the cam timing etc what figures you hoping for? I’ve just done very similar build but must admit I ran scared when timing and took the engine to a specialist as only ever played with diesels.