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  • Bottom End Rebuild Pics

    I wanted to post these in the Gallery but its still not up so I'll stick a few pics of my bottom end rebuild here.

    Here is the block after machining and cleaning
    Attached Files
    Mark - Modded

  • #2
    before machining and cleaning I opened up the oil feed to each of the mains, as I couldn't help thinking that the 'match' with the bearing shell is not good. Probably makes no difference
    Attached Files
    Mark - Modded

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    • #3
      Hi Mark,
      Does this mean your beast should be back on the road soon now (provided you sort out your g/b that is)?
      If so cool - I hope to have mine back some time this month too.
      Cheers
      Chris
      Audi 90 quattro (Typ 85)
      20v turbo conversion

      sigpic

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      • #4
        Block was bored and honed with a torque plate. The Total seal gapless rings specify a 280grit finish, so this was done.

        All galleries were well cleaned and flushed through using small engine cleaning brushes. The small main oil gallery plug at the rear of the block was removed and renewed after cleaning.
        Attached Files
        Mark - Modded

        Comment


        • #5
          Hi Chris

          almost run in now, Repo EM and GT35/40R wont be going on for a little while yet though. Gearbox doesn't help
          Mark - Modded

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          • #6
            Block painted
            Attached Files
            Mark - Modded

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            • #7
              ....
              Attached Files
              Mark - Modded

              Comment


              • #8
                I am using a main bearing girdle, and many thanks to Audi_CQ (Roger) for generously providing me with the details for it manufacture.
                Attached Files
                Mark - Modded

                Comment


                • #9
                  Crank was lightened by BDB about a kilo lighter
                  Attached Files
                  Mark - Modded

                  Comment


                  • #10
                    Mains caps and girdle are now secured by ARP studs (headstud kit from a Zetec engine). The stud directly beneath the one way valve in the bock (mains #3, left side) was shortened to clear it. Roger did all the work and found out the hard way HERE
                    Attached Files
                    Mark - Modded

                    Comment


                    • #11
                      The Girdle needs very accurate spacers between it and the mains caps.
                      Attached Files
                      Mark - Modded

                      Comment


                      • #12
                        Finally got the spacers how I wanted them, they can just be seen in this pic.
                        Attached Files
                        Mark - Modded

                        Comment


                        • #13
                          Pistons are JE's 82mm, 8.0:1, valve pockets 1.5mm deeper. Also with a few extra machining options including lateral gas ports. I would have liked to had them made them with bigger 22mm wrist pins for more strength and had rods made to fit them. But I already have a set of Arrows to use and I'm not made of money LOL.

                          Rings are Total Seal gapless top ring set. I've read alot about these being a real biatch to get seated on run in. But these seem to have seated fairly quickly and well. For this ring set TS advise honing to 280 grit (no flex hone) with a torque plate, I did that so maybe that helped.
                          Attached Files
                          Mark - Modded

                          Comment


                          • #14
                            Assembly
                            Attached Files
                            Mark - Modded

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                            • #15
                              ...
                              Attached Files
                              Mark - Modded

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