Ben's Garage & Girls (not work safe)

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Re: Ben's Garage & Girls (not work safe)

by Chavtastic » Fri Dec 19, 2014 6:20 pm

Not much to show from today other than I confirmed the 9-3 radiator will not fit in the standard Calibra position. You do need to use a Saab rad, because the flow layout is different to a Vauxhall one. But in a Calibra bay, the rad fouls on the fan cowling.

So, I drilled out the 28 spot welds that hold it in place!
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Out it came
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Saab rad now fits in place, the plastic pegs on the bottom fit into the Calibra rubbers, but the upper mounts don't line up with the OEM fittings.

All fitted in place, I just need to sort out the upper mounts. Cable ties most likely!
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Sorry for the s**t picture, but you can just about see here I've got the wiper motor, scuttle panel and wipers re-fitted. I didn't get pictures, but when removing the heater system you leave a large hole in the bottom of the scuttle panel that is right behind the dash... so this had to be plated over with some aluminium sheet pop riveted into place.

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In other news I've finished stripping down the B205 engine (spare I was using for ancillaries) and that will soon be out of the way.

Some more arrivals came too
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- Securon harnesses (3 point, snap-on connector, e-marked / FIA approved)
- ATE super blue racing brake fluid
- 3/16" copper pipe, brake unions, p-clips, bending tool, cutting tool
- Bonnet pins for fibreglass bonnet
- Oil temperature gauge. I've also ordered a M14x1.5 to 1/8 NPT adapter, so the sender can screw straight into the back of the block

Next jobs
- Finishing off the engine build
- Fitting the brake system
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Re: Ben's Garage & Girls (not work safe)

by Chavtastic » Sun Dec 21, 2014 11:56 pm

So I've been getting stuck in, working long days on this!

Here's the timing cover removed. The thinner chain runs the balancer shafts. Removing the chain and blocking the oil feed to the tensioner frees up a couple of horsepower and makes the engine more responsive. They have also been known to fail, so it's a no brainer really. Timing cover was then cleaned and painted
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I was pretty happy everything else on the engine would now fit, so stripped it down one last time for a clean and some paint

Engine mounts got a quick blast of silver, and some silicone added to the voids, to reduce the flex and stiffen them up
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If I'm still unhappy with the mounts I'll look into aftermarket ones... but this can't hurt for a few quid!

Engine was then degreased with a toothbrush and given brush-on paint for the block and spray on for the head
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And built up with ancillaries again. The turbo is now fully plumbed in, after finding a 9-3 oil return is a direct fit whereas a 9000 one isn't (bolt spacing).
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Engine is now basically complete bar a refurbished cam cover, an aux belt tensioner (in the post) and some minor wiring:

These two wires need to be sorted for the T7 APC (boost controller)
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And I have to match the wiring up for my 3-bar map sensor
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Then it's time to get it off the stand, fit the crank oil seal, flywheel, clutch and gearbox (can't wait!!!)

Back in the engine bay I've finished tidying away the bay loom, I've fitted the hydraulic clutch pipe and plumbed the clutch pedal into the brake reservoir. It's all coming together I think. Fingers crossed!
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Re: Ben's Garage & Girls (not work safe)

by Chavtastic » Mon Dec 29, 2014 7:33 pm

Oil seals are done on the enigne and it's off the stand

Flywheel is on with threadlocked bolts
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Viggen clutch, checked on the input shaft before fitting
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Driveshaft oil seals fitted
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Slave cylinder pipe
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Engine and box are now mated :mrgreen:

Started making up the brake lines from scratch
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I've now got brake lines for the fronts finished (just waiting P-clips) and the rear line is now fed through into the car, just waiting on the floor being painted.

Finished taking off the sound deadening
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Continued de-greasing and scrubbing all the residue off
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It's now ready for paint to be finished on the interior, which will mean dash etc can all be put back in!

Back to the recaro seat...
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Looks like it will fit the Vauxhall runner quite easily with some brackets :)
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All coming along nicely!
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Re: Ben's Garage & Girls (not work safe)

by Stupink » Tue Dec 30, 2014 11:49 am

Veeery minor input, but input none the less, i found zero sucess with filling mounts with anything up until I tried liquid polyurethane, you can buy it in whatever hardness you want, just tape over one side well, pour it in(i'd heat the mount first and make sure the 2parts of the mix are warm before mixing) and let it set. works really well, on my mr2 i actually removed all the oem rubber, then poured it into the void and created my own mount, if you find it a bit harsh, you can then drill a few holes around it.
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Re: Ben's Garage & Girls (not work safe)

by Stupink » Tue Dec 30, 2014 12:22 pm

without double checking i believe it was just a 60a, theres plenty thickness so it doesnt need to be overly hard.. even as it is the cars quite a lot of vibration from the engine etc.. i dont mind, but it would definitely benifit really from a few holes if it got driven a lot as a normal car. as a track car its great.. but i think just filling the gaps would be about right as-is..
Not saying i did a tidy job haha https://dl.dropboxusercontent.com/u/38079758/enginemounts.jpg
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Re: Ben's Garage & Girls (not work safe)

by Chavtastic » Wed Dec 31, 2014 1:33 pm

Very nice Stu! I'll maybe try that on a spare set
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