engine rebuild project after a12 issue
Turbo Mini Forums

after my incident on the a12 and droping a valve out of the head which some of you though was an april fools but sadly not the rebuild has begun.

list of damaged parts are:
block needing a rebor off atleast +60
1 conrod very stiff on pin
1 totally screwed piston unless anyone feels a seethrough piston has a use othere than for an ashtra with a dranage hole

1 knackered cam shalft ( the lobes are very warn)
1 bent pushrod
1 missing valve(well imbeddid in piston)
1 bent valve
1 port damaged on the head.

So the [arts collection has started and im going bigger and better seeing as its all got to be done again.

engine Spec is to be:

Im going to have a cr of 8.25:1

Fresh 1293 block + 20
Avonbar 18cc pistons +20
Sc H beam billet conrods
Forge pushrods
Cemetic head gasket
Piper phase 2 billet cam kit
Piper alloy duplex kit
Centre main strap
Arp bolts throughout
Acl bearings through out


For the head I am suing the med fis head I had but having it reworked with:
31mm stainless stelite coated exhaust valves (as advised by paul ivy and gs valves)
36mm stainless inlet valves
colsibro bronze valve guides
piper springs from the cam kit
1.5 roller rockers
Arp bolts throughout.

as for gearbox I have
s/c transfer gears
s/c gearbox full rebuild with all new bearings shims shafts etc
Quafie ATB Difff with FD of 2.9

turbo wise i have keans hybred monster of a t2 good for and has been run at 21psi +
which will fit on my Mirrage manifold.

im going to be putting a double thickness series 1 intercooler down in front grill. it fits like a glove between the support bar and inner wing as if it was made for it. it is going to have to stick out the grill lo but should still look nice and have plenty of air.

I have a mj setup for the timing ready to go in. just need to decide on a map to use to run it in with I was thinking of using a standard metro turbo one but anyone got any advice on that front?

im planing on running 21 psi max on this but possibly more later if spec allows depending on how it tunes up.

Edited by turbominij on 30th Aug, 2011.

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

Well dropped all the bits down to my engine builder tonight so just a matter of waiting now still got a list of things to do to get ready for the new engine.

Including
Make new extra wiring loom
Finish dash
Install atb
Re painting various bit
Fit intercooler
intercooler piping for new intercooler
Make new actuator bracket
( the previous one is thrown together one that will do for the time and has done for 3 years. So it's time for a new nice one.

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

1 knackered cam shalft ( the lobes are very warn)


the above causeed you problem too tighter valve clearence caused all the tears iam afraid, compounding cam ware at a dramatic rated and cause the valve in the collet groves and collets to part company, "the cam wears the give away here"

Edited by BENROSS on 4th May, 2011.

The valve clearances were always set to med's value they gave me. Which was 0.015" every time I was under the bonnet doing work. Minimum of 6 months/or every oil change as as I was changing oil every 2-3k they were checked alot.

In the stripsown the valve stem was is still in with collet inplace and intacket. it broke off right at the base where the valve head meets the stem

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

Whats the theory behind this Steve?

well it’s finally all coming together nicely

after a few issues.

problem one …….syncros in the gearbox!!! is all i will say……
but finally it’s all done and nice
final spec is
totally rebuild everything using a minispares sccr gear kit, sc drop gears new bearings throughout new sincro parts and a atb diff 2.9 final drive




had the engine built using parts listed above
couple of picks of the parts

forged pushrods

conrods

timing gear

piston


finaly all together



problem two……. after fitting engine to gearbox realise there was a gap between the two of about 5mm.
This was down to the arp main studs being a lot bigger than the stock ones

So back down the engine builder who machined the ends of the main caps down to give us some clearance. And this will not have weakened the caps at all as the strength is in the centre and the lip around the bearing. My engine builder has needed to do this before on engines so it’s nothing new.


Got it back within two days as well so no time lost really and very happy.
Got the engine together and it fits perfect as you can see in this pic it gives plenty of clearance and is only minimal metal removed from the cap.




Turbo and everything fitted to the engine about to be dropped in


.........and finally got most things fitted and arranged the intercooler piping



refitting all the dash and cables at the moment so should be ready to start this weekend its been so long i really cant wait to drive it again...

Edited by turbominij on 24th Aug, 2011.

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

It looks nice, what's that intercooler?

Audi s4 b5 - 470bhp & 486ft lbs

On 30th Apr, 2012 Brett said:
yeah stick the bit in and give it a wobble

it is a forge motorsport rs turbo series 1 intercooler (ebay bargin) fits like a glove down the front of the engine with out a dizzie loads of room spare

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

Looking good.

Will you be ready in time to join us at North Weald RWYB on Sept 4th?

In the 13's at last!.. Just

looking good bud

Nice rods! And I do like that intercooler.

Hay oneeye won't be at northweld as going to t german touring cars at brans however the day before 3rd is the 8ball meet if ur up for it I'm aiming to get the mini there.

The intercooler was a total steal from eBay paid 1/3 of the price il get some more photos up fits in there lovely.

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

oooh, 8 ball meet sounds good to me, I was wondering the otherday when the next one would be.

Up for that too!

I'll get Wintersurfer on the case too.

In the 13's at last!.. Just

Might have got that wrong guys looked on there site and no mention of it sure some one mentioned it to me wonder how many people we could get there anyways at this short notice?

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

id be up 4 the 8ball on the 3rd

update on the intercooler Ended up being able to fit it behind the grill so it still looks like a normal engined mini :) even better. should prove interesting on the road against nice mr scooby who thinks peh mini o fff where that go...

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

Forged SC rods. Are you sure? If so, at last!

I appear to have misinterpreted previous posts

Edited by minimole23 on 30th Aug, 2011.

Yep they are forged cracking set of rods and at a good price to gave me a little discount as well for being a tm member.


More importantly got it started Saturday started up better than ever the mj makes a he'll of a difference! Run the cam is for e 20 min I was told at over 2k revs turned it off tinkered putting bits and back together then took it for a test drive running very rich so gotta tweak that but everything worked spot on. Gotta re bleed clutch and brakes but after that should be fine.
Going to run the engine in for a few hundred miles then get it tuned. I can't wait!!!


One more tm back on the road!!!

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power

i stand corrected i asked sc direct and got..

No they are not forged they are machined from a solid 4340 (EN24T) billet.

"Tuning should be a compromise between what is possible and what is necessary"

10)Thou shalt always quest for more power