So I started the tear down of my baby today. The global plan is to get the head, clutch, flywheel, injectors, Apexi, pistons, rods, and Madness oilcooler all installed and done by Wednesday. Lots to do!

The turbo itself is waiting a couple of more weeks for some uber-cool Fireballed parts. Can't say too much, G-16 classified. Ask Brain for more info if you dare!:D

So here is today's work documented for posterity!

The parts begin to come off:


Front end off:


A hidden message to a future wrench:


Valve Cover Off:




The comment was: "those calipers are bigger than your head!


Alta crank pulley coming off:


Ready to remove timing chain. Also known as the point of no return:


Crank view: (remember kids, measure twice, release once)


Head coming off:


It's off:



Dancing interlude at lunch time. Floor Jack bee-bop, "it's this seasons new black"


Oil pan coming off:


Crank side view:


Pistons coming out:


Unless you know what is going on, you NEVER want this view:


Deglazing those cylinders:


Nice honed cylinder walls:


BEFORE:


AFTER:


Offset those rings (cameo VW appearance):


Time to go back in:


Almost there:


Nice and new forged bottom end:


From there it went back together fine. Tomorrow is clutch/flywheel day!

 

GREAT JOB and I love the pics, keep them coming. You are doing what I would love to do.
M

 

Mario-
You bet! I plan on doing aboat load more pictures, and maybe some video when the turbo actually goes in to the car.

I have to say this has been my dream and driving plan for my car for over a year. I have scrimped and saved up the money to make it happen and I can't believe it finally is. I know I'm not the only turbo conversion Fireballed is working on or has done, but I am the only customer installed kit so far.

To that end I can not thank those guys enough. Brian answered all my calls today, a SUNDAY, about ring gap, clearance issues, torque specs, and other stuff. I know he has caller ID too, so he could have easily just said "eff it, it's just a customer". But he didn't he was available and happy to help me out. What more can I ask for my money? Hubie was awesome in person and just as quiet as he is on the boards. Soft spoken but extremely knowledgable. His results speak for him. I have every confidence this car is gonna fire up the first time once it is all together.

Of course my "pit crew" here in AZ are amazing too. Without their help, there is no way I would undertake rebuilding this motor. I am a shade tree mechanic, but my buddies have true skills at this stuff. Kudos to them for being willing to take vacation time from work to help me out. True friends.

 

awsome work man. It's great to see someone doing this conversion with load of pictures to go along with it. You are one lucky man to have great friends helping you do this. I allways dreamth of one day doing some engine work on mine with forged pistons and a bigger block.

Keep those pictures coming and can't wait for the video clips.

 

I concur! Very educational for sure. You'll be feeling a lot of envy around here, but in a good kind of way. Thanks much for sharing...

 

Wow! I envy not only the idea, but the fact that you have the ability and huevos to do this yourself.

 

Great picts! Please keep us all updated.

 

speechless... Awesome that you are sharing pics. Thank you very much for doing so. Looks like fun.

 

x2

We get to live vicariously thru you .

I have a question - assuming one did not already have a MCS and one wanted to go Turbo ONLY - would it a MC be a better choice?

 

Maaaaaan.... and here *I* was, feeling like a stud just because I put my own cold air intake on yesterday...

:: slinks away in shame ::

Can't wait to see what everything looks like with the turbo on the car!

 

Great thread, thanks for posting. I also would like to follow this project until the turn of the key.

Just a few questions,
Why didn't you just pull the engine right out?

Is there a reason why you didn't bore the block(instead of just honing) for new (oversized?) pistons?

Did you have the entire reciprocating assembly balanced with the new parts?

 

1-That was the original plan. But as a few things from Fireballed are still getting finished up, it will be a few weeks until the turbo goes on. As a result I decided to do as much as I could and then make sure the car runs fine before the turbo goes on. I still don't know if we are pulling the engine for the actual turbo install. Haven't decided which way to go yet.

2-In keeping with number 1 above, it would add yet another degree of complexity as well as another source for problems if the car didn't turn over and start right up upon completion. Sure, I could get some more power, but for me, it wasn't worth the hassle of doing it. Especially having NOT done that work before!

3-No. The crank, crank bearins, rod bearings, and counter weight all are stock. I am not planning on raising my revs to Honda levels so don't feel it is needed. I also did not go with over the top retainers, springs and guides on the head. This car is my daily and won't see the north side of 7500 rpms EVER.

 

From what I understand it might actually make things easier dealing with the MAP sensors and when the engine sees boost. I am not the best to answe this one though. I know how to put stuff together, but the electronics and those things that function "behind the curtain" are not my bag.

 

I get it now, I thought the turbo was going on while it was all apart.
I wasn't thinking of just increasing the displacement, but having straight cylinders to run new pistons.
I just come from a different school of engine building, I have always had the setup balanced after new pistons.
Whether the engine will see 7500rpm or not, it's just piece of mind.

Please don't think i'm knocking your rebuild, that's not the case at all. Just concerned about the integrity of the non-balanced internals seeing 20-30(?)psi.

 

I think this is very smart and as you pointed out you have the time to do so.

The pics are great - the one with you grinning is priceless

 

Updates!

Wobble sockets, and extensions are your friends when working on a MINI:


Subframe comin' down!




Time for some PU bushings:


The usual suspects:


Steering rack bushing in place:


TIme to drop the half shafts to get the tranny out:


O Rly:


After a lot of planning and gently prodding the tanny is coming out:


Stock is for suckas!! :P


Flywheel and clutch off:


UUC goodness:



This was the only SNAFU today. UUC had sent M10x1.25 35mm bolts for putting the flywheel on. The problem is the crank is threaded 1.0. Easily fixed with some ACE grade 10 hex bolts.
On:


Clutch in place and all torqued up:



The head will be in my hands tomorrow and will be back on by the PM. Should be able to have it started on Wednesday at this rate. A SW car job actually getting done on time

 

ha ha great stuff... yer doing it right... just remember... shes a whole new girl after this.... make sure you treat her right and respect the power....

 

Yeah I will try

I think in the long run waiting a couple of weeks for the Turbo to go on after this will be a good decision. With the head work and the other stuff I am doing now, I am hoping to be north of 200whp (169 on Jason's mustang a couple of weeks ago). This will also allow me to break the clutch in and then really explore the turbo right after it goes on. Oh, BTW, where's the closest 100 octane from the Fireballed garages??

 

Jay has it on site..... cali... uhhh they can get some for ya so just ask ahead of time... I had to order it in...never found it on pump... stupid cali

 

So lame. You can get it in Prescott even and not Cali!!

Will be nice to have it on board when driving back on the 10 from LA. Eboost is your friend as they say....

 

Is it normal, or are the old stock pistons really burned looking? Do they just have a rough texture to them? The new ones look awesome, and light weight.

 

I know of a station in the valley that has it at the pump. Last I checked it was 6.50 a gallon or so.

 

Very nice! I'm going to watch this thread closley.

 

yeah but I wouldn't worry about it..... 17 lbs of boost alone makes silly power....on 91 all day.... with 101 octane... you could take off if you had wings!

 

Great stuff...... we need more of this on NAM