FANTASTIC!!! as already said - very very well deserved! Nice one fella!

 

Daz,
absolutely blinding project! from start to finish, should be made into a film or something!
congrats on the front cover although i think it and you deserves heaps more credit than it gives!!!
gutted that it ended the way it did, but am sure its the same for everyone who has read the project, we cannot wait for ur next creation!!!

ian

 

If ever there was a deserved cover car then this is it. Sheer grit and determination to build and do it all yourself.

Congrats Daz, hope the rebuild goes well. If i can help with anything, just ask

 

Awesome stuff Daz, you deserve the recognition :thunmb:

 

I've finally managed some car time after moving house so I've managed to investigate my failure further.

I've stripped the block down today and the result was fairly dissapponting. I initially thought I'd only need one piston but they are all fubared.
Only one of the piston faces showed any signs of real damage but when I managed to get the pistons out of the bore it was soon apparent they were all useless

The sides of the crowns on all four pistons had debris embedded in them. Had they been like this and done any mileage they'd have ruined the bores.

The bores are marked but when i run my finger nails over the marks you cant feel anything. A quick deglazing hone and a new set of rings would have sorted that. So it's looking like I'll have to buy a new set of pistons Atleast I have one shiny new Cosworth piston I can use as a paper weight.

On the plus side I thought I may have had an oil pressure issue but the bearings look brand new so its not all bad.

Anyway some pictures.

This is obviously the piston from the dropped valve


This was the best of the other 3 as you can see its fecked







So I'm thinking of some 100mm hone to fit Wiseco's

 

Daz, wonder if Steve still has his wisecos

 

He does but i think they are too small. Text him last night and he seems to think they are 99.5mm. I need the 100mm ones as my current cosworth ones are 99.75.

He did say you'd know for sure what size they are can you confirm?

 

Its a long while since i measured them, think they are 99.5

 

:
Congrats on yr Mag cover Daz...and also "feel " for yr engine failure.
Dont give up

just like to mention there is a similar thread by "P1Prodrive" on his build on the P1 website that is just as interesting !!

 

For those that havent seen it here's my feature in this month's Japanese Performance magazine.

 

 

Congrats on the mag feature .

Best of luck fixing the engine as well!

best
rossi

 

Excelent Daz. End of

 

brilliant well done Jolly Green Giant

 

haha ok show off, only joking daz you have earned it

 

Right then, onwards and upwards.

The rebuild has started. I've cleaned the block today. I've also decided to paint it as it had started to show the early signs of corrosion due to exposure to road salt and not being cleaned since it failed. So the block halves got a good clean. They were then given a couple of coats of aluminium primer and left to dry. They were finally given a couple of light coats of gloss silver. This will of course protect the block and make it easier to clean.









Just waiting on parts from Mark and I can get cracking with assembling it all

 

Gotta be the cleanest engine in the world!

TX.

 

good luck with the new build daz

 

Very nice Daz, keep the updates coming asap

 

Parts arrived from Mark today.

Cosworth 99.75mm Pistons (8.2:1 cr)
Cosworth head gaskets (0.78mm)
8 Supertech one piece Niterided Stainless Steel Inlet valves (standard size)
8 Supertech one piece Inconel Exhaust Valves (Standard size)

 

That was nice and quick, i take it this is not going to take long before it's back on the road?

 

Not sure yet Si, might go for some other upgrades whilst i'm at it.

 

Daz - i love your spirit.
Built it - broke it - decided to rebuild it - then decided to upgrade even more

 

I've decided to re-use the bearings that were in it. They are mint even after 6000 miles and about 20 1/4 mile runs. Was all set to replace them but I really don't see the need to.

 

Was at API this morning... Jap. Per. was knocking around and read the feature on your great project - loved the read!

Then I come to this thread to post said sentiments... Only to see the failure!

But at least you've started the ball rolling in sorting it already - you'll soon be enjoying it again in no time

Just turn this 'negative' experience into a positive... As you say, if you were to have given the project to a specialist, it would've cost you about DOUBLE what you've spent on it (minus the self-satisfaction too!). So, taking that into account, even with this new rebuild, you're still 'ahead' in the money stakes!

Chin up, mate.


P.S. And I did LOL at poor Simon being referred to by JP as the venerable "Jolly Green Giant"!

 

Cheers Joz,

What makes this worse is that the failure was a simple mistake by an engineering company that I got to machine the valve lifters for me.

They've admitted their part in it and have made a generous contribution towards the repair costs which just about covers the parts that'll need so I'm happy with that.

Onwards and upwards as they say.

 

...BTW, although you got a blinding deal on the StopTech big brake kit , are they ACTUALLY up to the job of hauling down your beast from the silly speeds it's capable of?!?!

 

Well, that went better than expected, I'm sure. I'm impressed by their honesty/offer in this matter - fair play to their aftersales customer service! Nice one.

Don't know whether to say that's actually 'good' news or not though, as if they hadn't made the mistake, it wouldn't have failed in the first place. But, hey, we're all human.

A bit of a ying and yang result, I suppose >>> "/"

 

Aye they could have told me to **** off but they didn't.

Although I've sold them on now the Stoptechs were superb. I never got to try them on track but they seemed to cope with slowing me down at the end of the 1/4 mile OK

I need to do something with the rears and Stoptech dont do a rear kit so I really fancy some K-Sports all round as they'll do the job extremely well but also look the absolute bollocks too

 

Yep, I've got the 330mm/8-pot K's and DS2500 pads on the front of my STi 5 - and they do have a pleasing amount of power and, importantly, confidence-inspiring 'feel', as soon as you touch the middle pedal. Unsurprisingly, they're a world apart from the inadequate OEM 4-pots, where you had no bite/feel through the topmost travel of the pedal!

And yes, the K's, with their much nicer revised logo layout, and the discs/bells etc., do look the doggies through the alloys.