black_mk1
28-01-2008, 21:36
Ok, bits are arriving thick and fast so I thought I should start my build thread :)
28/01/2008
The unsuspecting donor (note TB Decal already applied) :thumbsup:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/282.jpg
Engine unloaded from the back of my sprinter with just the help of an old armchair :)
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/283.jpg
Sadly I cracked the (I think) Idle control valve - it may superglue but looks pretty precision made so may need another :confused:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/284.jpg
And my first mod completed (it only cost 5p) :blabla:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/281.jpg
16.02.2008
Not much photo worthy activity over the last week or so, mainly cleaning up the engine and waiting for parts to turn up.
Not finished yet, but cam belt done and cleaned up:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/285.jpg
Flywheel arrived in the week - its a thing of beauty :):
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/286.jpg
So today, as the sun was out I thought I'd make a start on removing the 4AGE
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/287.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/288.jpg
About 2 1/2 hours later the engine and box were on the deck :)
I just need to jack the back up tomorrow and drag it out.
17.02.2008
Not much in the way of updates today, I managed to drag the old engine from under the car on my own - nightmare on a gravel drive :(
Anyway, engine out, have since degreased the engine bay:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/289.jpg
Dirty, oily horrible 4AGE:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/290.jpg
My pile of crap is growing in the back garden :) :
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/291.jpg
The only bonus was I found the 4AGE was fitted with a SC manifold so that will be going on ebay :)
22.02.2008
Day off work, wife and children out of the way and with a minging hangover I braved the cold to tackle one of the worst jobs:
Engine mounts off :) My ears are still ringing...
OS:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/292.jpg
NS:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/293.jpg
I also sorted the rear firewall out and decided to forget the access panel and modify the existing one.
A few cuts and bent roughly into position:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/294.jpg
I just hope that it's back far enough:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/295.jpg
Then welded up and treated to a coat of zinc primer:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/296.jpg
That's it for today:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/297.jpg
19.03.2008
Slow progress due to illness over the last couple of weeks but here are a couple of updates:
Oil Sender relocated as per JB's build, makes a tidy job and I used one of these to convert from 3/8" to 1/8" BSP.
http://secure.thorite.co.uk/vc78Xx112661/Connectors-for-tubing-and-hose/Nickel-plated-brass-BSP-fittings/Reducing-bush---taper/p-91-166-44271/
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/298.jpg
Engine and box bolted together without problems, starter motor and slave cylinder bolted on too:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/299.jpg
Bolt wise, I got 2 of the top 12mm bolts lined up and 2 10mm bolts either side of the diff at the back.
I also drilled out an existing hole in the gearbox to 12mm (marked red below) and used a 12mm bolt which threaded straight into the block no problem.
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/300.jpg
21.03.2008
A mate came over on Friday so we decided to get a couple of crap jobs out of the way :)
Engine mounts finally cut out, they just need to be drilled now:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/301.jpg
Fuel tank dropped and walbro 255 type pump installed.
I didn't get any pics of the pump installation but here's the proof we had the tank off :) :
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/302.jpg
While the tank was out of the way, I chopped off the end of the water pipe (the one pointing to the left):
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/303.jpg
Then put on a 90 degree bend on pointing to the right:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/304.jpg
Then it decided to snow and hail and while the engine cover provided some protection....
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/305.jpg
...we were beaten within a couple of minutes:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/306.jpg
The mounts should be getting welded in on the 5th and 6th April as the wife is away so I have arranged with a couple of mates a swap weekend :)
05.04.2008
Ok, the big "swap weekend" arrives and I collect the engine crane and a couple of ugly mates (I'm the good looking one on the left ;) ):
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/307.jpg
Car lifted up as high as possible:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/308.jpg
Who needs axle stands when you have a "Jones" :P :
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/309.jpg
Engine slipped under and into position:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/310.jpg
The car the lowered down so the engine could be lifted up:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/311.jpg
Engine lifted up:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/312.jpg
And inlet manifold installed:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/313.jpg
Mounts tacked into place, the drivers mounts was miles out and the holes were about 3 inches too high so they has to be adapted:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/314.jpg
It then started to snow and got dark so we headed to the pub for a couple of beers :)
06.04.2008
So, with first light (nearly), the engine was dropped and the mounts fully welded and painted:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/315.jpg
Engine was then lifted up again and suspended from the new mounts:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/316.jpg
And I do believe its in :)
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/317.jpg
We then decided to burn out the strut rods and suspension bits we removed earlier:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/318.jpg
The blow lamp was not too successful so we gave them some shit with the gas axe:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/319.jpg
Unfortunately we destroyed the threads on one of the strut rods, now informed by Mr T as "discontinued" - bah
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/320.jpg
That's about it so far, lots more to come :)
13.04.2008
During the week I have just been cleaning up and painting suspension bits so not much in the form of pictures.
Today, I started bolting the suspension back on, these bits were rust free so I treated them to a couple of coats of paint:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/321.jpg
O/S Drive Shaft went in but i'm concerned about the clearance between the hub and the ABS ring - It isn't even torqued up yet as I need to borrow a 30mm deep socket. Not sure yet if it needs a spacer of if something needs grinding :)
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/322.jpg
I also finished the rear torque mount. Not as strong as some but should hopefully do the trick:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/323.jpg
Next is front mount and the rest of the suspension back on etc.
19.04.2008
Well, not much progress this week as we have been away for a few days on holiday.
To close the above issue of driveshafts, I can confirm the ABS ring needs to be knocked off (Thanks Paff).
Today, I painted up the last few remaining suspension parts, ready for fitting tomorrow.
Note, new strut rod thanks to MartG :)
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/324.jpg
I nearly finished off the front torque mount today, it's a little different to most as I decided to keep the rubber bush as close as possible to stock position.
I figured that previous problems with the front mounts ripping out of the body are probably caused by the "usual" extended design, putting an levered load on the mounting bolts, rather than push/pull.
Time will tell I guess and it will probably make more sense when fitted:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/325.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/326.jpg
Body mount needs to be welded up:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/327.jpg
Tomorrow continued on post #6 (http://forums.twobrutal.com/showpost.php?p=141429&postcount=6)
28/01/2008
The unsuspecting donor (note TB Decal already applied) :thumbsup:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/282.jpg
Engine unloaded from the back of my sprinter with just the help of an old armchair :)
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/283.jpg
Sadly I cracked the (I think) Idle control valve - it may superglue but looks pretty precision made so may need another :confused:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/284.jpg
And my first mod completed (it only cost 5p) :blabla:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/281.jpg
16.02.2008
Not much photo worthy activity over the last week or so, mainly cleaning up the engine and waiting for parts to turn up.
Not finished yet, but cam belt done and cleaned up:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/285.jpg
Flywheel arrived in the week - its a thing of beauty :):
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/286.jpg
So today, as the sun was out I thought I'd make a start on removing the 4AGE
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/287.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/288.jpg
About 2 1/2 hours later the engine and box were on the deck :)
I just need to jack the back up tomorrow and drag it out.
17.02.2008
Not much in the way of updates today, I managed to drag the old engine from under the car on my own - nightmare on a gravel drive :(
Anyway, engine out, have since degreased the engine bay:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/289.jpg
Dirty, oily horrible 4AGE:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/290.jpg
My pile of crap is growing in the back garden :) :
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/291.jpg
The only bonus was I found the 4AGE was fitted with a SC manifold so that will be going on ebay :)
22.02.2008
Day off work, wife and children out of the way and with a minging hangover I braved the cold to tackle one of the worst jobs:
Engine mounts off :) My ears are still ringing...
OS:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/292.jpg
NS:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/293.jpg
I also sorted the rear firewall out and decided to forget the access panel and modify the existing one.
A few cuts and bent roughly into position:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/294.jpg
I just hope that it's back far enough:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/295.jpg
Then welded up and treated to a coat of zinc primer:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/296.jpg
That's it for today:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/297.jpg
19.03.2008
Slow progress due to illness over the last couple of weeks but here are a couple of updates:
Oil Sender relocated as per JB's build, makes a tidy job and I used one of these to convert from 3/8" to 1/8" BSP.
http://secure.thorite.co.uk/vc78Xx112661/Connectors-for-tubing-and-hose/Nickel-plated-brass-BSP-fittings/Reducing-bush---taper/p-91-166-44271/
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/298.jpg
Engine and box bolted together without problems, starter motor and slave cylinder bolted on too:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/299.jpg
Bolt wise, I got 2 of the top 12mm bolts lined up and 2 10mm bolts either side of the diff at the back.
I also drilled out an existing hole in the gearbox to 12mm (marked red below) and used a 12mm bolt which threaded straight into the block no problem.
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/300.jpg
21.03.2008
A mate came over on Friday so we decided to get a couple of crap jobs out of the way :)
Engine mounts finally cut out, they just need to be drilled now:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/301.jpg
Fuel tank dropped and walbro 255 type pump installed.
I didn't get any pics of the pump installation but here's the proof we had the tank off :) :
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/302.jpg
While the tank was out of the way, I chopped off the end of the water pipe (the one pointing to the left):
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/303.jpg
Then put on a 90 degree bend on pointing to the right:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/304.jpg
Then it decided to snow and hail and while the engine cover provided some protection....
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/305.jpg
...we were beaten within a couple of minutes:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/306.jpg
The mounts should be getting welded in on the 5th and 6th April as the wife is away so I have arranged with a couple of mates a swap weekend :)
05.04.2008
Ok, the big "swap weekend" arrives and I collect the engine crane and a couple of ugly mates (I'm the good looking one on the left ;) ):
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/307.jpg
Car lifted up as high as possible:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/308.jpg
Who needs axle stands when you have a "Jones" :P :
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/309.jpg
Engine slipped under and into position:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/310.jpg
The car the lowered down so the engine could be lifted up:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/311.jpg
Engine lifted up:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/312.jpg
And inlet manifold installed:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/313.jpg
Mounts tacked into place, the drivers mounts was miles out and the holes were about 3 inches too high so they has to be adapted:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/314.jpg
It then started to snow and got dark so we headed to the pub for a couple of beers :)
06.04.2008
So, with first light (nearly), the engine was dropped and the mounts fully welded and painted:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/315.jpg
Engine was then lifted up again and suspended from the new mounts:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/316.jpg
And I do believe its in :)
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/317.jpg
We then decided to burn out the strut rods and suspension bits we removed earlier:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/318.jpg
The blow lamp was not too successful so we gave them some shit with the gas axe:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/319.jpg
Unfortunately we destroyed the threads on one of the strut rods, now informed by Mr T as "discontinued" - bah
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/320.jpg
That's about it so far, lots more to come :)
13.04.2008
During the week I have just been cleaning up and painting suspension bits so not much in the form of pictures.
Today, I started bolting the suspension back on, these bits were rust free so I treated them to a couple of coats of paint:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/321.jpg
O/S Drive Shaft went in but i'm concerned about the clearance between the hub and the ABS ring - It isn't even torqued up yet as I need to borrow a 30mm deep socket. Not sure yet if it needs a spacer of if something needs grinding :)
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/322.jpg
I also finished the rear torque mount. Not as strong as some but should hopefully do the trick:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/323.jpg
Next is front mount and the rest of the suspension back on etc.
19.04.2008
Well, not much progress this week as we have been away for a few days on holiday.
To close the above issue of driveshafts, I can confirm the ABS ring needs to be knocked off (Thanks Paff).
Today, I painted up the last few remaining suspension parts, ready for fitting tomorrow.
Note, new strut rod thanks to MartG :)
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/324.jpg
I nearly finished off the front torque mount today, it's a little different to most as I decided to keep the rubber bush as close as possible to stock position.
I figured that previous problems with the front mounts ripping out of the body are probably caused by the "usual" extended design, putting an levered load on the mounting bolts, rather than push/pull.
Time will tell I guess and it will probably make more sense when fitted:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/325.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/326.jpg
Body mount needs to be welded up:
http://www.twobrutal.co.uk/forum/images/recovered/2008/01/327.jpg
Tomorrow continued on post #6 (http://forums.twobrutal.com/showpost.php?p=141429&postcount=6)