Bottom End Rebuild Pics

[A80Avant]

so what does this engine produce now Mark?

[Rusty]

Nice work sir!

[ctolladay]

One word... GORGEOUS!

Like all who have posted I would love to see my lump be worked upto that standard. Maybe one day?

Please post your dyno results as/when you know them; I'm very interested to see what you get.

Nice work!

[martinjs]

Well done Mark, Ive been waiting for this thread for 9 months.

I think the girdle plate is a great idea, just extra peace of mind i suppose, and knowing Mark he'll get bored with a GT35-40R soon enough and want more LOL.

How is the clearence between the sump and subframe Mark, any alterations needed?

[mcandmar]

Looks great nice work, i'm curious as to what paint you used? And that crank shaft looks superb

Did you use the Zetec stud kit for the extra length to bolt the girdle on or was there another reason for not using the i5 main kit? ....before i order mine.

Happy motoring,

Mark.

[Mark Halligan]

Thanks

Good point - I forgot to mention that the subframe needed modding to clear the sump which is 10mm lower, I did this a long time ago when I knew I would probably use the girdle. Modding the sump is another option too.

Reason for the Zetec headstuds is for the extra length needed with the girdle.

Paint is Blue smooth Hammerite

Cheers

[Fat Audi 80]

High temp hammerite right?

Beautiful engine work by the way. I like the girdle. The blue looks good and the reassembly a work of art!

Cheers,

Steve

[S4quattro]

TS rings seated real quick and seem fine so far.

Did you use any special method for the break in? Or did you use the conventional method? I also have TS rings on my engine, but mine is now throwing out a lot of oil in the breather filter and showing massive leakdown.

[caterpillar]

the clutch; what power does this piece manage ??? will you lay out the P/N and place you have bout the spec pieces....studs,piston,clutch,and so on

[Mark Halligan]

Did you use any special method for the break in? Or did you use the conventional method? I also have TS rings on my engine, but mine is now throwing out a lot of oil in the breather filter and showing massive leakdown.

I used the conventional method for break in, just loading the engine lightly for the first 100 or so miles.

I have heard a lot about this happening too, thats why I had the block honed with a torque plate. The guy at TS also told me that the honing should be done with a rigid hone and not a flex/hand hone to the correct finish. I also used their 'quick seat' powder on the bores during assembly.

There is also one other thing that may have made them seat better.......I am using lateral gas ports and these provide a pathway for the combustion pressure to get behind the top ring and improve seal. Although at the expense of possible increased bore and ring wear (I'll take that chance as its not an everyday car). Maybe these have helped?

To be honest I am experimenting with these rings (and the gas ports), and the good start I have had with them may well change.....hopefully not, we'll see.
A couple of times while planning the build I nearly changed my mind and went with conventional rings, but decided in the end to give them a try. If it all goes **** up I will let you know.

How long did it take before you had the problems of massive leakdown and blowby develop? Also what ring pack are you using - gapless top ring or second ring?

Cheers

[Mark Halligan]

the clutch; what power does this piece manage ??? will you lay out the P/N and place you have bout the spec pieces....studs,piston,clutch,and so on

Aelred can get you the clutch with a choice of friction material and power specs available here:http://www.s2forum.com/forum/showthread.php?t=15689

The ARP studs are avaiolable from any ARP dealer.

I got the JE pistons from Top End Performance just tell them what you want and they will get it made for you.

Cheers

[caterpillar]

nice work om the engine...thank for the answers... i love this pics,i have this in my pc stored

[S4quattro]

How long did it take before you had the problems of massive leakdown and blowby develop? Also what ring pack are you using - gapless top ring or second ring?

The problems with pressure in the crank startet after roughly 800 km (500 miles) but the engine threw out just a very small amount of oil under boost at first. After 900 km the engine blew out alot of oil. First i thought that i could be the little plastic valve under the IM that could be the cause of this, so i replaced the valve with a alu plug.
But it did not help.

I performed a leakdown test recently and cyl 1 was ok but cyl 2-5 was not good.
So i have to stip the engine and then i will know more what happend to it.

I am using the gapless second ring btw

[Audi_CQ]

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

Picture on the org. thread is gone so here's a copy:

[Mark Halligan]

The problems with pressure in the crank startet after roughly 800 km (500 miles) but the engine threw out just a very small amount of oil under boost at first. After 900 km the engine blew out alot of oil. First i thought that i could be the little plastic valve under the IM that could be the cause of this, so i replaced the valve with a alu plug.
But it did not help.

I performed a leakdown test recently and cyl 1 was ok but cyl 2-5 was not good.
So i have to stip the engine and then i will know more what happend to it.

I am using the gapless second ring btw

Sorry to hear that, I hope my gapless top ring set will be ok. There are also a couple of other forum members who are going to be using gapless rings in the near future so it will be interesting to see how they get on with them.

Good luck getting it sorted.