k1200rs 1380 engine build
Turbo Mini Forums

Well, I have finally made a start, after a bit of running around to find some cost iron rod and 3/8unc die for plugging the head bolts, 1/4 cast iron plugs and 1/8 brass plugs along the buying threading taps to match, so I can block the water and oil ways







Today finished product



But here the tap slipped, so i need to drill out the tap again

Edited by philc on 27th Jul, 2010.

moderators, please delete. thanks

if you take the " width=640 height=480" out of the img code (ie [img]) the pics should show

Yes i moved to the darkside

Instagram @jdm_brett

Today finished product




But here the tap slipped, so i need to drill out the tap again

Pedro Silva

http://miniciados.blogspot.pt/

Edit: pah! Beaten to it!

Edited by theoneeyedlizard on 27th Jul, 2010.

In the 13's at last!.. Just

block has come back from the machine shop with its first skim and a good old dip in acid

Some more progress made yesterday and a big thanks to Martin at MJA engineering in Bromsgrove for letting me use his machines and the use of his time.
So, mmm the template, :dontknow:
Used some blue die to help with the marking for the studs, made sure the head was square to the block and fixed down

And centred each stud hole with the tightest 10.5mm drill bit I could find.

Then dotted each one


In the first instance we decided not to go into the water ways with only 11mm thread, then on reflection and after a conversation with Colin I think I will have to and ensure it is water tight with loctite.
This was very time consuming as I wanted to make sure it was right first time.

Next is to drill into the waterways and tap them, and then blank off the waterways as going to go dry deck.

More progress made, drilling and tapping block for stud and blanks off the water ways




She was a bit tight on the studs but on she went :laughing7:


This was really boring and time consuming almost 5 hours :angry9:


And the finished product, though the shaft closest to the time chain needs a couple of mm taking off as it is wider in diameter than the other, this is for next week. :crybaby2:

Bit more to update, started to do a little porting, just to sharpen up the edges, just need polishing now






Had the head welded for dry decking, I didn’t think £30 was bad at all




And the end bit welded but I think the inside needs welding aswell, just for my piece of mind

Completed a bit more today, had all of the holes welded on the head, so ready for dry deck


Finished polishing the inlets and exhausts today, just to take off the rough and sharpen up some of the edges



Just wanted to ask a couple of questions about the head

Not a lot done yesterday, head had its first basic skim, to remove the weld, I did not realise how much ali heads distort, though not too much on mine, as JK says in his build guide 'note the shadows' :laughing7:



Took out the bung, drilled and tapped for the oil feed


I did not tap one of the stud threads straight so that needs sorting, 4th one in



In respect of the oil feed to the head, I am going to blank the oil feed on the block

Then I have two choices I think and this is where I need a little feed back, where would the best place to drill and tap either the black area or blue, then put in an adaptor, then a pipe to feed the head

Offset bored to match the head ?

Rusty by nature

Nice project. Is this to be turbo'd?

you cant really offset bore to line up the chambers in the head on a 1380, it really would have to be a custom head gasket, and then we also start getting to the point of bore wall thinness akin to a 74.7mm bore, THIN!!

Head studs are already drilled so you wouldn't be able to line up the head chambers left to right.

+60 or liners are required and relocating ALL the head studs if you want to try and line up the head

Edited by Sprocket on 28th Jul, 2010.

Also offsetting the bores seems like a massive amount of work considering performance people are already getting without such measures :)

Can't wait to get started on mine

So, have decided that the head bolts I have drilled and tapped where crap, so ran around yesterday to find some 16mm cast iron bar, no chance, could only get 30mm for £14, which needed to be turned down for a 14mm tap. So I have spent the morning turning that down, very boring and tapping it with a 14mm die.
Whilst in the process of getting the bar, I asked the guy at the counter if he knew where I could get the studs holes drilled and tapped using a cnc machine, well he took me down the road and introduced me to Bob, who is going to do it on a Saturday morning for me with a few beer tokens chucked in, how lucky was that.

Spent an hour or so last weekend re drilling and tapping all of the bolt holes

And tonight putting new 14mm blanking plugs in along with a few brass plugs for the waterways, new a few more brass ones then can be skimmed ready for cnc.

Looks good. How did you tidy up the extra metal on the plugs? Hacksaw or something more exotic? I've got the same to do to my block and head for dry deck.

if your dry decking the head why don't you plug the water gallery holes on the block too?

Team www.sheepspeed.com Racing

good stuff

Team www.sheepspeed.com Racing

I'm being tight. I've spent £6 on two lengths of brass bar. I will just spin them down to the right size on the lathe and turn a thread on them. I'll be doing both block and head.

seems to me this is the 'easy' bit of the 16v conversion,i'd get stuck with all the igntion side of things,
keep up the good progess!!!