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Author Subject: Engine overhaul!
greenbelt

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Location: How's Life In London?

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Post #151
Good stuff. Keep the updates coming mate.

________________________________________

Standard Black 6
Black HBSC6 Smoke
Posted 28th Nov 2010 at 22:05
720puggti

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Location: West London

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Post #152
Here are the photos, words to follow:


^^^ Getting into the corners wore my fingers down!

^^^ Prepping takes a lot of time and masking tape...


^^^ Using etch primer this took all of 10 minutes to apply. It really did give good coverage.


^^^ Done a test piece on the cross member to see how good my skills were. Jose was at hand to tell me where I was f*cking up Smile


^^^ It was now coming together and looked very solid and proffesional; even if I do say so myself!






^^^ Starting to look more like it's old self.



^^^ Engine in and started; all ok!

________________________________________

Deepak Gohil


Posted 30th Nov 2010 at 04:00
rallyeash

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Location: Devizes

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Post #153
just read the whole thread, fair play mate, attention to detail is excellent

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230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 29th Nov 2010 at 00:57
coskev

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Location: Oswestry

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Post #154
Also just read though the lotCool

Nice work,bay looks spot on now its paintedSmile

________________________________________

Red GTB1756 powered Fabia VRS daily driver,LBSC Gti6 eater........

Mac1 ZR R1 kit car build in progress.
Posted 29th Nov 2010 at 02:40
cwspellowe

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Location: Calderbank

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Post #155
Engine needs a bit of tlc though compared to the bay! LOL

________________________________________

Bye bye Sundance Kid Sad
Posted 29th Nov 2010 at 02:47
rallyeash

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Location: Devizes

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Post #156
when you sticking that engine book up then?Hyper

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 29th Nov 2010 at 23:15
720puggti

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Location: West London

Registered: 18 Jan 2009

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Post #157
rallyeash wrote:
when you sticking that engine book up then?Hyper


errr... It's up in the FAQ section - if I recall rightly Smile

________________________________________

Deepak Gohil


Posted 30th Nov 2010 at 03:27
720puggti

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Post #158
First, welcome to the new subscribers and thank you for the nice comments. And thank you Welshpug and cwspellowe for bothering to stay with this!

Right, now I've got some time I can write this stuff up!

Where do I begin???

When I got it running after I replaced the bent valves and the tapping stopped, the bas**rd fans decided they were gonna give up the ghost and the engine overheated! By now I was out of money, time and patience so I left it to one side.

While I left it to stand I decided instead of just "tidying the bay up" I'd actually go the whole hog and spray the thing. So I started to strip it all back and as more stuff came off the more I felt like I'd bitten off more than I could chew. You see I've no experience spraying. Enter Jose - He gave me a few pointers and with some patience the end result was pretty good. Especially considering I used aerosols to do the job. The main thing really was to learn a new skill; and that I did.

Painting takes time and patience and a lot of prep. Without any compressed air or a booth I had to be ultra clean with a hoover and degreased the surface between every coat. Encountered a few problems after the initial success that was the cross member. I think the most difficult bit was getting the spray can in the right angle. It was quite tricky and led to one or two runs... Oh well, not that you're gonne see them now! That was another thing, the engine bay was good practice, cos if I cocked it up it didn't really matter.

As a process I first removed rust using a wire wheel and 40 grit paper. Next 320 grit and primer over this. At this point I could have busted out the 800 grit and then painted, but the awkward shape would probably lead me to sanding back down to the metal. So I applied the paint straight on top, didn't bother to flat it back either with 1200 grit for the same reason and laquered straight on. Overall it came up very smooth with no scratches from the areas where I used the wire wheel and 80 grit.

Anyway, I've babbled enough I believe. Any questions, comments or criticism is welcome Smile

Hope I haven't bored you!

________________________________________

Deepak Gohil


Posted 30th Nov 2010 at 03:50
720puggti

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Post #159
cwspellowe wrote:
Engine needs a bit of tlc though compared to the bay! LOL


Yeah I know, it's been stood gathering dust. But it'll look nice and clean once it's all back together. Not gonna spray anything on it though as I don't want it to look tarted up; standard will do me fine Smile

________________________________________

Deepak Gohil


Posted 30th Nov 2010 at 03:59
jose

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Post #160
a couple more weekends and this will be finished im sure Smile

________________________________________

Nile Blue GTi6

Alpine White 205 GTi 1.9 - Project

Air Con Pipes Thread.......

Machine Polishing - Paint Correction - Swirl Removal in West London - PM for details
Posted 30th Nov 2010 at 04:03
will130787

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Location: Reading

Registered: 24 Sep 2009

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Post #161
I have stuck with this project and I have to say I think your doing a sterling job Smile

Keep it up!

________________________________________

Ex Astor 6 owner Sad

Also an Ex owner of a Bianca 6 Sad

Now an ex owner of a 2005 9-3 2.0T 210bhp Aero Swedish Saloon thing!! Soon to be 250bhp.... Superman

Now driving Mk5 Golf GTTdi, mile muncher

But still live for the 306 Ninja
Posted 30th Nov 2010 at 16:27
720puggti

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Post #162
Thanks for the support Will Smile

Just thought I'd post an update...

When I discovered the fans weren't working I had a feeling it couldn't be a fuse or relay etc as everything had worked before; the system had been lying about in bits. I discovered it was actually the connections that corroded while off the car (will post photos of this too).

So I bought a new set of fans from hanpug and hooked all this up.

At the same time I bought a pattern exhaust from jonnie205, as the one that came with the car was a straight through noisy "silencer".

With both of them fitted I ran the car up and... It doesn't overheat! and it runs nice and quiet with no taps or knocks Big grin

Just got to spray the rusty slam panel now and finish building it back up....

________________________________________

Deepak Gohil


Posted 6th Dec 2010 at 01:28
walker_texasranger

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Location: Sunny Retford

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Post #163
Just read through this thread, top job Thumbs up

I wish i could do stuff like this myself, it must be very satisfying having worked that hard seeing it all up and running again.

Nice thread Smile

________________________________________

Almost standard 1999 Bianca Rallye
Hilux InvincibleX daily

306 No.13 Doh

Carp and specialist Anglers Click here
Posted 3rd Jan 2011 at 17:02
720puggti

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Post #164
Thank you for the kind words Walker^^^ It certainly is satifying seeing it all come back together and working.... although I now have a nice story for everyone...

I thought it was about time I posted something up; I'm crap at keeping this thing updated and only browse the site now rather than actually posting anything anymore.

However, the Nile beast doesn't exist anymore as i found it wrapped around a very straight lampost. Saving the details I was one '6 down and required another to put this now "infamous" engine into (trying to boast, but I'm sure it's not working as no-one really keeps an eye on this thread!).

So, I managed to beat ratboy to a '6 I found on eBay; 1999 PH3 72,0000 miles, FSH, MOT and Astor in colour with a snapped cambelt! What a find I hear you cry, especially since I saw change from 450. However, it needs a re-spray; keyed and dings all over the place :S But it doesn't look too bad when covered in dirt.

So cutting a long story short:
1. Written off Nile '6 With a re-con engine
2. Cheap Astor with snapped cambelt
3. Re-con engine now in Astor

There's still a bit to do in regards to getting it all perfect; not including the re-spray. Just need to start selling all the parts I have lying about and get a few pics up.

See you all in a month?????

________________________________________

Deepak Gohil


Posted 12th Feb 2011 at 00:49
720puggti

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Post #165
How about 6 months?

A lot's happened since getting the astor, amongst which I realised the 6 is too expensive for me on every level. So I've now a derv (Citroen ZX, runs on veg oil you know...!), and have gone on the thrift after breaking the astor that nobody seemed to want.

I thought about re-homing the engine in a 205 and going all out on it, but I don't think I'll have the time (I'm starting a new joCool. So, the engine is now up for grabs in the "For sale" section of the forum.

Thanks to everyone who stuck with this project, and I'm sorry it wasn't better (more pics would have done the trick) and I didn't keep a regular progress report.

Hey ho though, long live the ZX! (I'm gonna drive that into the ground... no projects there!)

________________________________________

Deepak Gohil


Posted 6th Sep 2011 at 20:36
ballardpaul

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Location: Croydon

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Post #166
Just read this through, very impressive! It's weird how hours fly by while reading project theads.

Shame with the outcome, wasn't expecting that.

________________________________________

Phase 2 Blaze GTi 6 (Standard) Sold
Phase 3 Supercharged China GTi 6 (249.8 BHP) Sold
Phase 3 Supercharged Diablo GTi 6 (443 BHP)Sold
Nissan 350Z (300 BHP)
Posted 6th Sep 2011 at 21:20
owain

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Location: Essex

Registered: 20 May 2009

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Post #167
Is indeed a shame, I've been enjoying this thread for an awfully long time. Could've been worse, you could've destroyed that nice new engine with that lamppost.

Now *that* would've been annoying Doh

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Membership expiring soon, get in contact on our new little forum project.
Posted 10th Sep 2011 at 15:19
720puggti

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Post #168
It is a shame, but I've got to make room for new things in my life.

I definitely learned loads doing all this and picked up a new skills in painting (although I'm not goin to offer these services to anyone as I'm still pretty p*ss poor!). Above all, I now know this engine and it's wiring very well; helping me to help others Smile As well as alll it's characteristics.

I would have definitely been gutted if I found it front first in the lampost, but lady luck was on my side.

I want to make the part about the bent valves and FAQ though, there are too many questions about tappers, and those photos and readings go a long way to help people understand how easy is to bend a valve and how difficult it is to spot.

________________________________________

Deepak Gohil


Posted 11th Sep 2011 at 22:42
720puggti

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Post #169
Hello! Is there anyone out there??

I've just looked back at this thread as I posted in another thread where I gave advice on an engine rebuild.

I've been working on aircraft for over a year now. I get involved in all sorts from working on the jets through to working on the bogs, but I don't think I have half as much fun as I did when I worked on this car.

It's all a bit of nostalgia now.

I wonder if I could make a living out of restoring more exotic engines... V8s, 10s, 12s....??

________________________________________

Deepak Gohil


Posted 13th Dec 2012 at 08:43
eliotrw

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Location: Southwark

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Post #170
Yes. Do it in your spare time!.
Thats like my ideal job except I have no skills.

(well actually i'd love to own some kind of restore and upgrade place for classics.)

Think E46 M3 engines in E30 M3's and stuff like singer do with old porsches. That would be sweet

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Ex- Phase 3 China GTi-6 T-Reg
Posted 13th Dec 2012 at 09:27

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