ClioSport.net

Register a free account today to become a member!
Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members through your own private inbox!

NorthloopCup likes a challenge, right?



NorthloopCup

ClioSport Moderator
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

ClioSport Moderator
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.
297FA001-FAFA-4318-85D8-20E6DC69CB3F.jpeg
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.
E02AEB5E-E31E-4E89-B046-8AD163207C52.jpeg
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.
F7DAF9D9-8689-4BEF-82EA-724D1D6A8C6B.jpeg
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.
C2C7A5E4-179E-4B20-8F6C-7FD646362DD2.jpeg
F6DB3716-A675-43A5-9BC3-F5D786182750.jpeg
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:
244DD3F5-BDDA-4BB2-885B-A3AA8FB7469D.jpeg
650203D5-BEBB-4A88-A264-183ACBFCAB81.jpeg


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. 😎
 

Louis

ClioSport Club Member
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 😂
 

NorthloopCup

ClioSport Moderator
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.
 

ZachB

ClioSport Club Member
  182
What pros are there of running 2 sets of injectors other than better driveability at partial throttle?
 

NorthloopCup

ClioSport Moderator
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!

A8B0B903-F2C4-47BF-A946-6CB6D6F52636.jpeg
62619B20-7AEB-4299-BDED-8FB3C7E87F93.jpeg
684C59D6-DC06-4714-8A15-3420D1B4415E.jpeg
E0164C12-FF47-4148-8149-647EFDADD034.jpeg


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!
 

Touring_Rob

ClioSport Club Member
  182, E46 M3, 1000RR
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!!
 

Touring_Rob

ClioSport Club Member
  182, E46 M3, 1000RR
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

ClioSport Moderator
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

ClioSport Club Member
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

ClioSport Moderator
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!
E8B4CC97-7C2D-468B-B925-5723E3997348.jpeg
A view into the abyss
BE4B7927-916E-4994-9DB6-FD60D7E56972.jpeg
Rudimentary cam timing tool - essential for belt changes.
56A43085-D9BF-467E-B161-E5326910AD94.jpeg
Another view into the abyss!
CCE03D0C-89EB-4BBF-9184-4899C42AFBE6.jpeg
Final look inside before the head went back on
A6080F5F-F81F-49A2-9C3F-A5E61C71A8CB.jpeg
custom vvt blanking plug fitted
47CA079E-7C87-4E8E-8B1D-1841E28F67ED.jpeg
A view from above - soda blasted cam cover looks mega in the flesh
4009EFD6-7C46-4F28-B1B3-7193DA2561C6.jpeg
Modified lower cambelt cover
65642892-083E-4BA7-8E8C-F4D9E967F753.jpeg
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
63501B26-A133-412F-B6C7-DBAB0378B6A4.jpeg
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!
CFB2FA14-BCF9-4D8E-B7C4-2C2547642FB6.jpeg


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.
 


Top