Brians LET Cabriolet project

Brian Stirrup · 16-01-2007, 11:48

Hi

I thought it would be a good idea to strart a new post to let everyone know how I am getting on with my LET build, and to also ask any questions that people may be able to help with.

The story so far

I purchased my bargain LET from a breakers yard with no idea of its condition, something I would not usualy recomend.

It was mostly complete but the ECU and AFM were both missing.

This weekend me and my son (Sam) started the stripdown. While removing the flywheel I noticed it did not try and spin. Once the engine was manhandled onto the stand I tried turning the engine with a long bar on the pully but it did not move. I was hoping at this time it was just where it had been standing a while.

When we removed the crankshaft caps we spotted some metal filings under the caps and the number 4 piston bearing caps are welded to the crank.

The pistons were free and the bores look good. the cylinder head looks good, almost like it has not been on the car long, and apsrt from 2 exhaust studs broken off in the head all looks well.

The Turbo also looks good. The penny valve moves well after some WD40 and has almost no play in the shaft.

So here is the plan.

This is not a money no object project as money is very tight so where I can cut corners I will. Where I can save I will. As long as where I save can be easily rectified later.

The bits I will need for the project is as follows.

ECU (May have found one)
AFM (Have my eye on one on ebay, please dont bid on it.

)
Dizzy (See below)
Flywheel (See below)
Oil pump (Dave, Stef, was there a problem with your ones? did you resolve it?)
Top and bottom Gasket set (Possibly metal head Gasket, will get advice)
Cambelt Kit
Air filter
2WD conversion for gearbox (Hopefully fitted by Stefan

)

Here is the plan.

I have taken the crank to Rob (Engine builder for those who dont know him) and will drop the block and pistons to him later this week. I will be asking him to regrind and balance the crank (balanced with the flywheel and clutch) and check and rebuild a short block with new piston rings and a honing of the bores if nessersary.

I will not be selling the XE in the astra since firstly I need to use some of the parts and secondly it would be worth much more selling the bits seperately.

So from the XE I will use the following if they are compatible

Distributor
8.5mm Magnacore leads
Lightened flywheel
Clutch assembly
Inlet cam (Is that right, what benifit on the LET using the XE cam?)

The following bits will be for sale

Powercap (Painted red)
Underdrive pully in alliminium (Twin belt)
F20
Coscast ported and polished head with valves
Pair of schrick cams
Good Block
Crankshaft
Pistons (Will sell complete block with crank and pistons if wanted)
Sump
Chipped ECU
Loom
Red painted cam cover and belt cover
polished metal spark plug cover (Not brilliant, would be good to get flattened and have your own logo engraved into)
Inlet manifold (Very clean)
Throttle body (Very clean)
Exhaust Manifold (Sandbalsted and painted black)

All these bits will be put in the for sale section soon to help fund the build but the engine is still in use at the moment. PM me for details or to reserve anything.

I will post some pictures and updates as I start the rebuild procces.

Brian Stirrup · 16-01-2007, 11:53

Just forgot to mention, I will be reusing the Turbo to save costs, if it is all ok then I have saved a few hundred, if it is not good it is not very hard to change.

I will also be having the head acid dipped, checked over, broken studs removed and I will rebuild it with freshly cleaned hydraulic tappets. This should also be inexpensive.

Rob · 16-01-2007, 12:01

Nice to see a budget rebuild. Be careful though, one wrongly cut corner and it could all go tts up.

Brian Stirrup · 16-01-2007, 12:06

I am aware of that

Corners to be cut will be carefully and only if I am 100%. I was talking to Rob about piston rings and he pointed out that as I am using my old turbo, if I get smoke and have not changed the rings what do I blame. So new rings it will be.

I will be getting expert advice all the way on this one.

What I wont be doing is a £5K rebuild with all new and high performance bits. The plan is to build a strong standardish engine a bit like the XE in the Cabby, and aim to get a safe 260BHP on the RR day with an aftermarket intercooler and possibly a chip.

Dave GSiT · 16-01-2007, 12:23

Resolve the oil pump problem by buying a rebuild kit for your existing pump, and asking rob to build it for you. Cheap, easy and reliable.

Brian Stirrup · 16-01-2007, 12:25

sounds like a plan. Where do I get the rebuild kit from?

Dave GSiT · 16-01-2007, 12:26

Rob should be able to sort one out for you with bearings etc.

We going to have a little Turbo shoot out then Brian???

)

Brian Stirrup · 16-01-2007, 12:28

looks like it

I will take my old pump into Rob then tonight, along with the pistons and rods. (And no getting him to sneak on some of your special rods and pistons....

Dave GSiT · 16-01-2007, 12:30

Quote:

Originally Posted by Brian Stirrup

looks like it

I will take my old pump into Rob then tonight, along with the pistons and rods. (And no getting him to sneak on some of your special rods and pistons....

Lmao, no way mate, your too tight!

Brian Stirrup · 16-01-2007, 12:32

No mate, When you leave the nest and join us in the real world you will know its not being tight... If you aint got it you cant spend it.

Dave GSiT · 16-01-2007, 12:35

Fair point. But you'll be soon ripping it apart looking for more power when me and maybe Drizz and Andy come flying past you, dump valves chirping and exhausts flaming. While you get to make do with a minor burble rattling your straighteners and scissors in the boot.

Brian Stirrup · 16-01-2007, 12:37

Thats all I will be able to fit in the boot once the NOS is installed....

Brian Stirrup · 16-01-2007, 12:38

I look forward to reading the other guys progress reports.

Stefan · 16-01-2007, 12:46

I can do some porting on the head, inlet/exhaust manifolds, TB and inlet cap for cheap. Can also port the oil pump too for less parasitic loss.
2WD conversion can be done for cheap by using a side cover from an F20/F16 gearbox rather than the "kits" you get.

Dave GSiT · 16-01-2007, 12:50

Ahhhh Brian's favorite word mentioned twice in one post, AND a way to reuse a 2nd hand bit from a scrappie! He must be beside himself with excitement!

Quote:

Originally Posted by Brian

BARGAIN!

NOS??? Behave chap.

Brian Stirrup · 16-01-2007, 12:50

ok mate. sounds cool. perhaps we can discuss it on Saturday at Robs or would you rather discuss it alone. I dont know if you want Rob to know.

Dave GSiT · 16-01-2007, 12:57

Wouldnt worry Brian, Stef likes to share

Hence why I save him up all my bottom gass.

Brian Stirrup · 16-01-2007, 12:59

Quote:

Originally Posted by Dave GSiT

Wouldnt worry Brian, Stef likes to share

Hence why I save him up all my bottom gass.

Stefan · 16-01-2007, 12:59

I may not be there this saturday. But you can ask Rob if I can do the head and oil pump etc. It'll all be good practice for me

I'm sure something can be worked out.

Brian Stirrup · 16-01-2007, 13:00

Practice....... On my Coscast head...

Brian Stirrup · 16-01-2007, 13:02

Would I be able to use my ported and polished XE Head?

Stefan · 16-01-2007, 13:02

Quote:

Originally Posted by Dave GSiT

Hence why I save him up all my bottom gass.

A quote like that could kill us all!!!

Are you happy with your pipes? Haven't had a thank you yet

Brian Stirrup · 16-01-2007, 13:03

I presume you are talking to Dave.

Stefan · 16-01-2007, 13:03

Quote:

Originally Posted by Brian Stirrup

Would I be able to use my ported and polished XE Head?

Would seem logical to use what you already have chap.

Brian Stirrup · 16-01-2007, 13:03

He should have had those pipes stuck up his arse on Friday and vented to the outside of the car..