InsaneSwede's Astra MKI

[Rs1]

Not the results i was hoping for from this build but i guess since its very much so a rare conversion teething problems will be a plenty.

Patrick where are you wire ringing? Just around the cylinder?

[InsaneSwede]

surprised your not on solids with this spec tbh, at least its fixable! i can reccomend these guys if you're having problem with gasket sealing
www.ferriday.co.uk

Thanks for the tip,, i´ll check that link tomorrow. i´m at work right now.
and as about not running solids.. no use when not revving over 8k rpm.

Rgds

[InsaneSwede]

Not the results i was hoping for from this build but i guess since its very much so a rare conversion teething problems will be a plenty.

Patrick where are you wire ringing? Just around the cylinder?

Expect any results between heaven and hell,,,, when i´m using a car.. i´m USING it *lol*

yup,, exactly, I´ll make a groove to contain a wire that are about 0.2mm above deck, just to get really really high pressure on gasket.
Ï´haven´t seen any problems yet.. but it´s hard to explain..

The car REALLY kicks ass already at 0.9bar,, it´s INSANE

And remember i´m running 10.5-1 in compression.
I´m just taking an extra insurance against problems later on.

At 2bars.. what timing are you other guys running on your LET´s?
about 15 degree advance above 4k rpm?

Rgds

[lee303]

Thanks for the tip,, i´ll check that link tomorrow. i´m at work right now.
and as about not running solids.. no use when not revving over 8k rpm.

Rgds

i just menat for reliability, but can see your point

[InsaneSwede]

There boys and girls..
the pianowiring is done
Made my tool by myself,, feels gooood when it´s a freebie

this is some pics of it:
Milling in progress

finished groove:

This how i checed for depth:

And a ring mounted:


all in all this costed me 0.45 €

Now the fun begins again to put everything together.
Rgds

edit:
Ofcourse the shavings has been cleened off and i´ll make an oilchange when engine is together again.

[lee303]

top work that mate

[Jack]

What's the point of that groove?

[alistairolsen]

you put a wire ring in it to squeeze the headgasket behind the firing rings and support them afaik

[InsaneSwede]

Yes, exactly.

But my configuration is a little more hardcore
i´m using the ring to make some bruteforce on my cometic gasket.

Normally you got the rings about 0.35-0.4mm above the deck.
as i´m using steelgasket i have put the rings 0.15mm above the deck.

The rings won´t 'dig in' into the gasket as when using coppergasket or std gasket.
therefor the less amount over the deck.

Rgds

[InsaneSwede]

Thoughf for myself..
what the heck,, let´s fix that porous head when having it off.

there were before this mod an pipe insert = JUNK!!!
Now i did it the correct way.

first i drilled some holes
then i threaded them all the way down so the needed oilpassages would work.



then i screwed down an 'plug' with loctite for hydraulic sealing.




then i screwed down an std plug to seal.


this is were i reroute the oil: (will change to banjocouplings)


this would make a bulletproof mod for KS heads.

Rgds
Patrick

[Rs1]

Ive seen that mod a few times now, will work a treat.
Which head was it that the cast is....too soft? I know the KS crack but wasn't one of the 2 KS's prone to.....de-torqing(wtf) after a period of time???

[InsaneSwede]

yes it´s the later head that are quite soft.
but,, the funny thing is,, there are more thickness in material on the inlet side to grind in

I don´t know about the 'detorqing', i haven´t actually got any experiance of this at all when punishing my own head.

[Stefan]

I like your o-ring tool. Any more pics of it out of the bore showing construction? What cutter did you use in it - looks like a parting off bit?

[Stefan]

a deeper split in the port than the coscast head

Do you mean a longer divider in the port? Like current clean sheet 4v race engines?

As its for drag racing he could do a billet head. There's a few companies in the US that will do a complete CNC billet head, some with coolant passages in. Could have what you want then with regards to port design.

*edit* Here's a link on the billet head guys for j_g (and erland) http://www.ultrapromachining.net/pro...der_Heads.html

[InsaneSwede]

I like your o-ring tool. Any more pics of it out of the bore showing construction? What cutter did you use in it - looks like a parting off bit?

Hello Stefan.

The tool looks like this in complete:



I used old tools from my work as cnc operator.
the 'cutter' is a seco or sandvik (can´t remember) and are changable in different widths.
I didn´t have any 1mm cutter so i grinded one 1.3mm down to 1mm.

If i want to mill on different cylinderdiams i only duplicate the aluminium plug but with different diam. mine is now 87mm.
and are 88mm 10mm at the top. just to have an rigid 'stop' so i could measure with repeatability(word?)

Rgds

[5tox]

Every day im checking this thread and learning more each time,

The work done so far is amazing, keep up the good work ...

Im looking forward to more video's


steve

[kontraman]

Patrick,i've told you again,your job is amazing.I really love it.

You do well with the o-ring at the cylinder.
Have you any problems with the gasket?
Cometic is much more better than the Z20LET.
I think you have to use ARP head studs and you have to tight them more than 120nm.

I also had troubles with the inlet manifold,it was cracked from engine vibrations.
So we've made new steerings.

[les3002]

Amazing project mate, some real nice fabrication going on there.

especially like the celica gearbox, do you have any pics of the adapter plate fitted sounds interesting.

few questions:

how did you get that textured look on your inlet manifold after it was finished, almost looks cast, did you shot blast it or similar?

how did you learn to weld, iam looking at doing a tig course and would be interested to know how long it took you to become competant enough to do these sort of jobs?

[InsaneSwede]

Ohh.. I´ll try to answer all this new questions tomorrow. I´m at work at this point.
I just wanted to tell you guys i´m going on dyno the 1st of July..

Let´s all hoping for some kickass results =)

[chip]

Good luck mate!

[astra16V2004]

Ohh.. I´ll try to answer all this new questions tomorrow. I´m at work at this point.
I just wanted to tell you guys i´m going on dyno the 1st of July..

Let´s all hoping for some kickass results =)

my birthday so ill be drinking to itlmao good luck anyway chap!!!

[Nobbie]

Glad its all still looking good!.

Go on, keep it matt black!

[InsaneSwede]

a small ten second teaser on 0.9bar and halfthrottle,
bad sound but i rev it 7k rpm

http://www.youtube.com/watch?v=KQrOph9sxvo

[Classic]

looking forward to more videos later on,
so far, very good!

[wkd astra van]

hi mate you made a good job with the rings in the block but you could avoid it mate,i bought a custom head gasket for my hoping 600bhp let from italy and they are extremly good mate,here in malta we have drag escort mk1 with a cossie engine thats running 7.4 sec and 65psi boost with a gasket like mine if you see my thread there is a pic of the gasket mate good job there man.i m stuck with mapping my engine mate as its my first time cant make a decent fuel map,is it possibble you send me a pic of your fuel map so i can have an idea please,this is my e-mail mate and i will send you all my pics while building my engine

thanks there and good job