savage bulldogs

a few pics of my project so far

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Coming along nicely - I see you have a tube of copper slip there, after using that for years with brakes and high temps making it run everywhere and stain badly I switched to the mechanic friendly Molyslip Ferroslip product

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Don't worry jay I have lube for every occasion 🤔😂😂

Copper slip for exhaust and general bolts .

Red grease for brakes (doesn't harm rubber seals ).

White grease (anti fling) .

And some strawberry flavoured stuff for my nuts 😉😂

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I'm "lucky " enough to be back at work because I'm currently converting a ww2 bombing planning office into private dwellings,  which means I'm on my own and in the middle of a airfield (miles from anything or any one ) .

Unfortunately that's slowed progress on the scooby atm though 🙄  .

I got the pump back from pat Seager and the full set of hi temp exhaust headstuds turned up too , so here's a pic showing why I didn't use the "kit bolt" unfortunately first time around.

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The bolt on the toothed idler has no makers /identification marks,  no shoulders (like the oe one above) and just didn't look good quality but I trust the suppliers choice and looks ain't everything lol .

So water pump ,idler pulleys, hydraulic tensioner fitted (again 🤐 ) cams dialed in and kevlar belt fitted .Screenshot_20200419-211631_Gallery.thumb.jpg.ce0910ed8e99160a958a16448b41d6d3.jpg

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Kept the tape over the inlet ports and fitted the thermal spacers (bolts would be to long otherwise) and old inlet so it was ready to lift . Timing belt covers and crank pulley torqued down, too .

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I struggled to get the engine through the shed door on my own "built up" ,so fitted the headers, up pipe ,turbo, clutch and flywheel  (with new spigot bearing) outside. 

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Engines currently just sat in the bay 😊but hey at least it's finally in it's proppa place 😉

When it comes to running in , I guess I'll have to use it to get to work 😇 and yes I've already asked the owner If i can "use" his disused runway 😊

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So old inlet removed and head intake ports taped up , to make it eaiser to fit downpipe, starter ect at the back of the bay Screenshot_20200422-193737_Gallery.thumb.jpg.7bf3761f7cc24fbe9376ddadcc552401.jpg

I had kept the turbo intake covered but removed it for the pics , as I've kept everything spotless during the build and don't want anything getting into the intake tract 😉

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Rinsed the inlet , intake pipework, fmic pipework and core through with petrol .Then fitted complete inlet manifold with fuel rails ect still attached ,along with alternator and started to re run fmic pipework. Screenshot_20200422-193821_Gallery.thumb.jpg.7281a99e008a8e090aee73b3d6da5e06.jpg

P.s pump ,coolant pipework, vacuum lines, fmic and intake pipework ect fitted. Filled up the coolant and primed the oil system by turning the engine over with the starter motor and spark plugs out .Screenshot_20200422-193846_Gallery.thumb.jpg.df60f21164b41c30f89976345d3858e7.jpg

Plugs and coilpacks in coolant topped up and ready for first start up 🤔🤞

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Turned the key to first stage a few times to prime the fuel system and check for fuel leaks .

Cranked it over and ......  

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😊😊🥳

Keeping a eye on coolant levels and checking for any fluid leaks for the first 5 mins , oil pressure and temps look good .

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I heat cycle my engines stationary for a few days and then drop the oil and refresh before driving anywhere. 

So seeing as it's only got 10 w 40 mineral oil in atm , it sounds quite quiet for a 2.1 forged bottom end on cold start 😎

Once up to temp on the first heat cycle , I noticed a slight coolant weap from near the thermostat. Tbh I forgot to buy a new thermostat 🙄 so due to lockdown postage being slower than usual I cleaned and refitted the thermostat and seal (or lack of seal lol)

 

So as a whole I'm very happy with the build so far and have a new hi flow stat and seal on it's way 😊

 

 

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Fitted the new thermostat and swapped out a couple of those crappy coolant spring clips for proppa jubilee ones .Ran it up to temperature a few times now and the heat cycles are complete now ,without any leaks this time 🤐🙄😊.

So slapped the front end back on this morning 😊Screenshot_20200429-140017_Gallery.thumb.jpg.adb6355af94c07e3ea629e1f8f6214aa.jpg

Just gotta drop the mineral oil out ,fit a new filter and refill with some millers running in oil . Then she's ready to tax and take to Tesco on it's essential maiden voyage 🤞

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Looking awsome as always bud 👍, mine's is looking a bit sorry for itself just now, i've nearly got it all ready for paint just all the wee fiddly bits to rub down 

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Cheers stu , tbh it doesn't look any different to when I removed it but it sounds a lot quieter and hopefully first drive will go ok tomorrow 🤞

 

I'm sure in a few months you'll be happy with boost n burble back in your life 😉

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Well seeing as it's her 26th birthday this month and it's finally in one piece...Screenshot_20200501-131511_Gallery.thumb.jpg.51c649c88865817ef3c407e04977470f.jpg

I took her for a few pints of amber nectar (vpower) to celebrate her birthday 😊

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Happy to say the 20 mile essential round trip went well ,apart from gaining a screechy power steering pump and afr very slightly lean at cruise (14.9) .

Once I start to use more throttle ,later during the running in process and if it gets leaner . I'll try upping the fuel pressure very slightly to compensate for the extra cc ,as it's now a 2.13 cc instead of a 1998 cc . Obviously once run in it will be remapped ,as the little increase in capacity, cams and turbo upgrades will need to be tweeked in 😉

As for the p.s pump,  I have replaced it once before, with another 2nd hand pump but the early v1/V2 pumps are known for leaking.  So guessing I'll be looking into doing a "newage p.s pump conversion " soon 🙄

Well I need something scooby to do again now 🤔😂

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Not much of a update but I've backed off the actuator arm pre tension and that seems to have brought the afr in closer to where I'd like it 😎

I'd also changed the angle of the turbo intake pipework but since found out the adjustment had caused the pipe to rub on the bonnet 🙄

So I had a search through the box of joiners and ally pipework I have to hand and have added a 90° silicone elbow and a slightly shorter angled piece of pipe . This has repositioned the filter in a better place to get cold air too 😎

So couple of pics of new intake pipework route .

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And a couple of the car basking in the sun ,after a good coat of wax  .Screenshot_20200508-115434_Gallery.thumb.jpg.c5676daca57e2747f7e34908574080cd.jpg

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only done 75miles so far but so far so good 🤞😊

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Been back at work this week and the a4 daily had a flat battery and was blocking the scooby in 🙄

 

Tbh it turns that was a good thing ,as midweek I noticed a couple of patches under the scooby 🤔  I'd bought some cheap exhaust wrap to go over the old stuff on the headers ,so got it up in the air to sort that and investigate. 

Soon spotted 2 minor coolant weaps 🙁

I had been using fuchs coolant with water and noticed everything looked a bit fury in the coolant system on teardown.  I found a nearly new core in the scooby scraps shed for a automatic , so thought I'd fit that so the coolant system was fresh . Ihaven't a clue where it cam from (never owned a auto anything) but guess I know it will be going......

 

in the bin 🙁🙄😂

Its Leaking bottom right corner between plastic end cap and core .

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The oil cooler modine hoses and spring clips are the original 26 year old ones , so they've done well but the combination of the hoses going hard and the spring clips going weak ,have lead to it not sealing properly 🙄

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So new modine hoses ,clips and crossover pipe ,along with a new (possibly ally) radiator needed .

Before run in can resume 😊

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Decided to go with a ally rad ,rcm/samco oil modine pipe kit and a new genuine sti header tank cap .

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So hopefully the weather's dry over the weekend I can start to run in again and use it for the commute to work next week 🤞

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Dodging in and out of the rain showers today but I managed to fit everything eventually 😎

I drained the coolant system (again) removed the leaky rad to give me a bit more space ,to get to the oil cooler pipes at the front of the engine. 

The new samco hoses where a really tight fit onto the water pump ,new crossover pipe ,oil cooler and block take off . So that coupled with the new cheap exhaust wrap ....made this one of my least favourite scooby jobs for a long while 😏

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I fitted two of the new pipes to the crossover pipe and then filled a swear jar fitting the rest but with the pipes being such a tight fit and the new spring clips being so strong .. . I'm sure it won't be leaking again anytime soon 😊

The ally rad Alyn @asperformance supplied has a slightly bigger core and 50mm thicker end caps but it fitted fine 😎

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Only issue I did have was my cheapy rad cooling panel needed to have a couple of bits cut out either end , to fit round the bigger end caps . Then a few notches cut out of it for the rad shroud and expansion bottle hardlines to bolt through. 

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So everything back together ,coolant refilled ,blead and run up to temp with the new sti header tank cap . Test drive went fine and "bang the leaks are gone " 😊

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Looking forward to the Tuesday commute going back to work now , to start clocking up these running in miles at last 😉

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First 250 miles done and I'm enjoying the commute to work 😎

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Although it does keep distracting me whilst I'm working on the scaffolding 😊

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still seem to have a coolant pressure issue though ,as its started weaping elsewhere now 🙄  . Only thing I can put it down to is the high flow stat I fitted 🤔

After looking at pictures of the "high flow stat " and comparing it to a standard stat , It actually looks like it might actually restrict flow . 

So I've bought a oe stat to replace it , hopefully that will resolve the either restriction or increase in flow 🤞

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You”ll need to start bringing your car cover so you can get on with your work 😂🤣😂

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Took out the aftermarket "high flow stat " and took a couple of pics to compare it a oe stat shape and bore size .

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Surprisingly the one on the right is supposed to increase "flow" and the one on the left is oe . The oe one has more movement on the diaphragm and a bigger bore plunger,  so to me it looks like the aftermarket one is more restrictive and would probably only increase pressure 🙄

This is to try and explain why I always use a stationary heat cycle process when running engines in , although a lot of "professional engine builders " dont .

So I always use a magnetic sump plug to catch any small metal particles floating in the oil and after a few stationary cycles with mineral oil....

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You can see the sump plug has a small amount of metal attached to it , from the honing burs and bearing coatings at first start up (normal) .

This is after 250 miles at 55% and 0.6 bar max , hardly any metal particles on the plug Screenshot_20200530-205018_Gallery.thumb.jpg.3c520b2f0c3333421799a699a85f56ae.jpg

So the first start metal particles are not running around the oilways during the running in period 😉

I've only done 30 miles on the new oe stat and fresh running in millers but so far ... no issues 🤞

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480 total running in miles done and 160 miles since changing to the oe stat ....

Still no leaks or coolant loss 🥳

Started feeding the low boost target in further up the rev range but I've only kept a low 0.65 target whilst running in. 

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So I'm now using most of the throttle and rev range ,as the engine has loosened up nicely. 

I have a afr gauge and can monitor knock but the afr is a little rich , increased displacement (now a 2.13) and more aggressive cams will mean the map definitely needs tweaking before adjusting the boost anymore. 

 

The ally rad I got from Asperformance seems to have reduced the max coolant temperature by 5°, doing the same journey in the same conditions but I still haven't been stuck stationary in traffic yet (so can't comment on all round performance yet ) 

So I'm booked in at clive attowes next friday 😊

 

 

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