NorthloopCup likes a challenge, right?

[JamesBryan]

No ECU Master EMU Black?

 

[NorthloopCup]

NIce to see someone still using some old school Graphogen and not that awful Torco s**t people seem to use these days.

Yeah Graphogen ftw mate!

You use graphogen in place of assembly lube? Do you find it does a better job?

Yeah I do mate. It’s primarily for use when the engine is going to sit for a period of time, but it offers plenty of protection for that initial start up of the engine.

 

[NorthloopCup]

No ECU Master EMU Black?

Toms department mate. But I think he’s got the Maxx before he became a dealer for them.

 

[JamesBryan]

Toms department mate. But I think he’s got the Maxx before he became a dealer for them.

Ahh that would make sense.

 

[NorthloopCup]

As promised! Get yourselves a brew, sit down and strap in.

So remember the custom cams? Yeah me too. They were made with all the vvt drillings and threads for the bolt. If you don’t know this, the thread for the dephaser pulley bolt is bigger than the exhaust cam stud. So we had a custom made bolt/stud to overcome this minor issue.

Made from some very strong material, so no chance of a failure. Thank f**k that’s the last of the dramas out of the way..........wrong!!!!

Next up we have a full on baguette eating, onion stinking t**t of a design. Only an idiot could’ve come up with this.

Good luck getting that f**king bolt in past the oil pick up pipe!! Seriously? I mean f**king come on! As you can see in the pic, there is a bolt in there and I did get it tightened up. I had to modify the pipe to allow access, and put the bolt in before the pipe was fitted. Official line - yeah we just left that bolt out mate 👍🏻
Well f**k off I don’t do half arsed.

Next up is the front crank oil seal. Remember lads, this is a complete kit that you bolt on and away you go. Yeah ok dickhead. So you need a different crank seal as the standard seal is way to small. You also need a bigger OD spacer that sits on the end of the crank for the seal to run on. This spacer does away with the oil pump chain drive sprocket as you don’t need it for dry sump.

Oh yeah let’s not forget that the oil pump didn’t have an OPRV fitted either, so I could piss more pressure than that would ever deliver! The least said about that little adventure though, the better. It’s now back here with me and has to be removed and refitted for the crank locking pin. Lol!

Moving swiftly on to another hilarious picture.

Plan on fitting a pipe to that do ya pal? Well you’ll have to have something custom made if you do. Small fry in the grand scheme of things though.

And for the final instalment of ‘f**k off’ we have this:

Can you see what’s wrong here? This was just a couple of weeks ago when we thought there would be no more dramas to stop progress..........oh how wrong I was.

So the cams as previously stated are a custom grind to suit the engine spec. They’ve been done from billets. And they made them with the full vvt drillings and also the additional length for the dephaser. The exhaust cam had a different thread in to the stud for the pulley as well, so custom stud made and fitted.
The cams were sent away for the inlet to be machined to suit the correct length and allow me to fit the belt, and before they went away, I modified the inlet cam so as it wouldn’t seize up in the cylinder head from no oil feed.

So the cams are now back with me and this brings the whole build up to date. I know I like a challenge, but this has been so f**king frustrating at times. There’s definitely been a lack of motivation caused by the issues too. Nothing worse than gearing up to get stuck in, only to be brought to a halt within 20 minutes of starting.

Next job is to start dialling the cams in finally and getting this engine making tracks in the right direction. And that’s out of my garage, into the car and onto the rollers!

We are entering another lockdown, so that’s when I made loads of progress the first time around. This one will be slightly different for me, but progress will be made.

More. To. Come. 😎

 

[frayz]

Looks like a usual XOM prototype i used to build. Nothing fits, everything fouls and tooling access impossible. You simply wouldnt believe how badly even the big OEMs can do at times.

"Oh well it fitted on CAD mate"

Yeah nice one dickhead! #facepalm!

 

[Tom Johnson]

Bout time you pulled ya finger out mate

 

[Louis]

Looks like a usual XOM prototype i used to build. Nothing fits, everything fouls and tooling access impossible. You simply wouldnt believe how badly even the big OEMs can do at times.

"Oh well it fitted on CAD mate"

Yeah nice one dickhead! #facepalm!

You can literally check on CAD if any bolts will crash too 😂

 

[Tom Johnson]

No ECU Master EMU Black?

As Mark said, I already had the Maxxecu Race on the shelf and for what I want to do sensor/injector wise it out classes the ecumaster black tbh

 

[frayz]

You can literally check on CAD if any bolts will crash too 😂

Exactly!!
Honestly dude its painful.

 

[NorthloopCup]

Bout time you pulled ya finger out mate

View attachment 1504075

😂😂

 

[NorthloopCup]

I have to ask after seeing it a few times now, why do you want to block off the oil squirters? I would have thought the cooling would have been beneficial

We blank them off because they only offer an opportunity for the oil pressure to be piss poor when they get stuck open (which they do). It also reduces the amount of oil being thrown around in the bores - always a good thing.
The cooling side of things can be done from adding a bit extra fuel in.

 

[Usr117063]

What pros are there of running 2 sets of injectors other than better driveability at partial throttle?

 

[NorthloopCup]

Forgot about these!

Nice bit of soda blasting that I got done for Tom

Inlet cam machined

Exhaust cam dowelled

 

[Tom Johnson]

What pros are there of running 2 sets of injectors other than better driveability at partial throttle?

POWER!!

 

[NorthloopCup]

What pros are there of running 2 sets of injectors other than better driveability at partial throttle?

Fuel atomisation is improved as you don’t have 4 large injectors throwing fuel in. Better atomisation, better burn, more powahhhhhhh.

 

[NorthloopCup]

Update time!

Cams finally fitted and timed up. After all the dramas over the last few months, it was nice to get in the garage and get involved. With no details on cam spec, I had to go with a recommendation from a guy I know, so it’ll be interesting to see how it performs!

Now it’s time to strip it again, fit the brand new head gasket and torque the head down. Then it’s time to wave bye bye!

 

[Radugns]

Do you find to buy those cambelt metal idlers from Gates? I only have used ones

 

[Krarl]

Do you find to buy those cambelt metal idlers from Gates? I only have used ones

I'm sure there are a few companies that make verniered cam pulleys

 

[Radugns]

I'm sure there are a few companies that make verniered cam pulleys

I mean the cambelt kit idler pulleys, not cam pulleys.
Oem kit provide only plastic cambelt idlers.

 

[NorthloopCup]

Do you find to buy those cambelt metal idlers from Gates? I only have used ones

It’s a gates belt kit mate that was bought years ago I would imagine mate

 

[incy-spider]

Loving this!


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[Radugns]

It’s a gates belt kit mate that was bought years ago I would imagine mate

4 years at least

 

[NorthloopCup]

4 years at least

@Tom Johnson will know the answer mate

 

[NorthloopCup]

Loving this!


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I am now the winning post is in sight lol

 

[Tom Johnson]

@Tom Johnson will know the answer mate

Probably about 5 years ago thats how long this engine has been on the go 😬

 

[Robbie Corbett]

Looks great, who designed the trumpets? Would be keen to know what simulation was done on them - I can see how their air flow potential might be higher but I can't see how you won't be detuning the inlet tract and harming lamina flow, possibly also removing some of the benefits of the external injector...

Were these printed on one of the Mark Forged printers? Or are they ABS?

Either way, great work!!

 

[Robbie Corbett]

Exactly!!
Honestly dude its painful.

We introduced a new rule at our place, design engineers have to be involved with the first prototype build. It removed all of the "this doesn't fit", "Not my job" BS. The standard of design has improved dramatically. We also model the tools onto the fasteners, rather than just the fasteners. You would be amazed how many people design things that you can't get tools on 🤦‍♂️

 

[NorthloopCup]

Looks great, who designed the trumpets? Would be keen to know what simulation was done on them - I can see how their air flow potential might be higher but I can't see how you won't be detuning the inlet tract and harming lamina flow, possibly also removing some of the benefits of the external injector...

Were these printed on one of the Mark Forged printers? Or are they ABS?

Either way, great work!!

@Tom Johnson was the man who sorted them, so he will have the answers mate

 

[frayz]

We introduced a new rule at our place, design engineers have to be involved with the first prototype build. It removed all of the "this doesn't fit", "Not my job" BS. The standard of design has improved dramatically. We also model the tools onto the fasteners, rather than just the fasteners. You would be amazed how many people design things that you can't get tools on 🤦‍♂️

Yep, I had 15 years of that. 😅

 

[NorthloopCup]

Progress is being made at a nice pace now! There’s only a couple of small jobs now to fully complete the build up of this engine.

Bring on the trumpets!

A view into the abyss

Rudimentary cam timing tool - essential for belt changes.

Another view into the abyss!

Final look inside before the head went back on

custom vvt blanking plug fitted

A view from above - soda blasted cam cover looks mega in the flesh

Modified lower cambelt cover

Note there’s no f**king sealant oozing out from the cam cover. This is one of my pet hates on f4r builds. It is in my mind, unnaceptable

Final shot showing the full length of the inlet tract. Probably one of my favourite views of this build tbh. It just looks like it means business!

So all that’s left to do is finish off the inlet manifold porting now, so that will be finalised this coming week ready for its collection at the weekend.

Despite the highs and lows of this build, I’m really pleased with where it’s now at. Challenge? - f**king hell yes.
Rewarding? f**king hell yes.

Now it’s time to crack 250bhp.

 

[Eddie555]

Nice Job that buddy.. [emoji106][emoji3060]

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[NorthloopCup]

Nice Job that buddy.. [emoji106][emoji3060]

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Cheers mate. 👍🏻

 

[Ant1]

I take it there was no drink involved whilst carrying out this build? 😂🤣

 

[haimsey]

Beautiful

 

[NorthloopCup]

I take it there was no drink involved whilst carrying out this build? 😂🤣

Lol no mate! Saved that for COD fridays 😂😂😂

 

[NorthloopCup]

Beautiful

Cheers

 

[Eddie555]

Cheers mate. [emoji1303]

I was gonna say "i know where you live"...... but i know you'd punch my lights out if i came round to try and nick the engine. [emoji23]

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[NorthloopCup]

I was gonna say "i know where you live"...... but i know you'd punch my lights out if i came round to try and nick the engine. [emoji23]

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Lol! The only person that will take this engine from out of my garage is Tom. Penalty of death for anyone else that tries 😂

 

[Flat Eric]

Looks incredible!!