The resurrection of the racing......

[Funky]

Great work Tom!! Is that a Mini engine you've got to replace it. Which model is it?

[Chris_Blue]

you certainly look like someone on a mission- forged stuff?

[Tommy D]

Yes funky, the engine is from a R56 cooper s, they use the EP6DTS (same engine as the DS3 racing and the 207 GTI).

Chris, my aim is to go for a bit more power but be reliable. As piston failure is so common on these engines I am 100% going forged.

[BenS]

Looks good, enjoying the really clear writeup with pics at every stage

[Tommy D]

This week I have been rebuilding the cylinder head.
The valves have been lapped in and new stem seals were fitted.

IMG_0128 by Tom Mann, on Flickr

IMG_0129 by Tom Mann, on Flickr

IMG_0130 by Tom Mann, on Flickr

[Tommy D]

This week, I have also found the time to strip the replacement engine ready for the arrival of the new parts.
I noticed that the mini engine does not have an oil level sensor, in its place is a blank with a hex head.
You can see this in the middle at the back of the engine block. The blank will be removed and replaced with the oil level senor.

The bores have been measured, they are exactly 77.00mm, this is the standard bore.
I can now order the forged pistons.
I have decided not to go for aftermarket forged rods. After doing some research, I found out that the standard rods share the same part number as the RCZ R.
The RCZ R is 270hp so the standards rods will be more than capable for this build.

The workshop manual offers some interesting information about the standard rods, it states 'sectile conrods in forged steel'
This information gives me the confidence to rebuild the block using the standard rods.

IMG_0124 by Tom Mann, on Flickr

IMG_0125 by Tom Mann, on Flickr

IMG_0133 by Tom Mann, on Flickr
 

[Tommy D]

So early last week the new parts started to arrive.

Gaskets, bolts and chain kit.
IMG_0127 by Tom Mann, on Flickr

Hel turbo oil feed line.
IMG_0126 by Tom Mann, on Flickr

Wossner pistons
DPWP9248 by Tom Mann, on Flickr

GFCE9845 by Tom Mann, on Flickr

[Tommy D]

I started the task of installing the new pistons into the block.

The first job was to gap the piston rings.
IMG_0123 by Tom Mann, on Flickr


The pistons were fitted onto the rods.
IMG_0122 by Tom Mann, on Flickr

Finally the pistons were inserted into the block, new conrod bolts were fitted.
IMG_0134 by Tom Mann, on Flickr

IMG_0131 by Tom Mann, on Flickr

[Tommy D]

The oil pump was installed and I painted the block.

IMG_0132 by Tom Mann, on Flickr

[Tommy D]

New crank seals fitted.
Timing chain and guides fitting into the block.
Water pump refitted with new seals.

IMG_0135 by Tom Mann, on Flickr

[Tommy D]

Cylinder head refitted and torqued down.
I fitted the new inlet and exhaust pulleys, the timing chain was also fitted at this stage.
The bolts for the pulleys were left loose so that the timing can be set at a later stage.

IMG_0137 by Tom Mann, on Flickr

[Tommy D]

The engine was put on the hoist.
IMG_0136 by Tom Mann, on Flickr

IMG_0140 by Tom Mann, on Flickr

All of the parts around the back of the engine were refitted.
IMG_0139 by Tom Mann, on Flickr

Then the engine was put back into the car
IMG_0147 by Tom Mann, on Flickr

[Tommy D]

Next the engine was timed up, the cam pulleys and the crank were torqued up to spec.

IMG_0157 by Tom Mann, on Flickr

IMG_0158 by Tom Mann, on Flickr

IMG_0159 by Tom Mann, on Flickr

Then the cam cover was refitted with new gaskets.

IMG_0160 by Tom Mann, on Flickr

IMG_0161 by Tom Mann, on Flickr

[Tommy D]

That's the latest, this weekend I hope to get exhaust and ancillaries fitted.
I aim to fill the engine with fluids then attempt to start it (fingers crossed).

[Funky]

Tommy D - I am LOVING this progress, write up and pictures for your Racing!! The new engine looks great and you are obviously knowledgeable and meticulous. Can't wait to see the next steps and how she runs when she starts. Brilliant work so far!!