My Astra Sport - GSi Turbo rebuild.

seanr28 · 09-05-2007, 21:27

About 2 years ago, I Purchased a yellow Astra Sport that had already been transformed into a Turbo, using A C20LET engine from a Calibra Turbo by previous owner.

The Car started life as a 1.8 16v Astra Sport

Time for a re-build, and and dam good tidy and clean!

Pics of the car as I got it........

***Tom Williams*** · 09-05-2007, 21:30

what needs doing to it?

seanr28 · 09-05-2007, 21:31

It soon became apparent that something was not right as every time I removed the plugs I had traces of water in cylinders 2 and 3. Although the car appeared to be running fine.

I decided to take the head off, get it checked etc.........I then replaced the standard head gasket with a cometic 1.9m one.

After re-fitting the head (that was fine) and cometic gasket I still had water in cylinder 2 and 3, so I decided that this was a problem with the block itself.

I then decided to change the block and re-build to a standard LET spec...............2 years and thousands of pounds later.......

seanr28 · 09-05-2007, 21:34

I will continue later, with loads of pics and current status.

seanr28 · 09-05-2007, 22:29

Engine removed, pics of the bay, looking rather sorry for itself

seanr28 · 09-05-2007, 22:33

Engine then spent over a year on the Kitchen side!!! LOL The girlfriend was not impressed! I only moved it upstairs at xmas as there was not enough room the cut the Turkey.

At this stage the Bottom end had been assembled with the following

JE87mm Pistons
Steel Rods with ARP's
BMW spray nozzles for under piston cooling
Z20LET Oil Pump with modded pickup pipe

Modified oil pickup pipe to suit the Z20LET oil pump

seanr28 · 09-05-2007, 22:35

Then came the Flywheel and paddle Clutch

seanr28 · 09-05-2007, 22:37

Engine was moved upstairs for a while in the spare room where I assembled a nice and shiney Chrome sump, along with the Clutch and flywheel

seanr28 · 09-05-2007, 22:38

More to follow shortley! 60 - 70% complete

elgan · 10-05-2007, 09:35

is that an all m vaux flywheel/clutch and cover plate combo?

seanr28 · 10-05-2007, 13:15

Flywheel is from Courtney and the clutch kit is M Vaux.

seanr28 · 10-05-2007, 19:09

More progress with engine bay pics, unfortunetley the card did have some rust, nothing serious though!

seanr28 · 10-05-2007, 19:10

Subframe prepared with New lower arms and bushes.

***Tom Williams*** · 10-05-2007, 19:12

sean what clutch is that? and what is it rated too? where from and how much

seanr28 · 10-05-2007, 19:18

First attemp with Spray gun using 2 pac.

Finish is stunning, but the colour match was'nt great.

Fumes were bad, wont be doing that to often

Funny enough, the colour mach looks pretty good in natural daylight...

seanr28 · 10-05-2007, 19:21

More paint work, almost ready to re-fit engine!

seanr28 · 10-05-2007, 19:22

F28 convereted to FWd with Quaife Diff installed, all clean and painted in silver

seanr28 · 10-05-2007, 19:24

Head work with new Bronze guides

wazpaz · 10-05-2007, 19:26

looks a good project

My missus would kill me if part of my engine went near the kitchen let alone sitting on the work tops.

lol

seanr28 · 10-05-2007, 19:33

was there for well over a year!! She was'nt happy but its the only pplace I had space!!! LOL

zoomshane · 10-05-2007, 19:46

Sean m8 u put all da effort in, lookin good matey. Cant wait to hear her purrin lol

***Tom Williams*** · 10-05-2007, 19:49

sean - what clutch is it? power rating? where from?

seanr28 · 10-05-2007, 19:53

its a v-max clutch with 3000lb pressue plate, it was purchased as part of the group buy on here about 9 months ago

supposed to be rated to about 400bhp..........well see though!!

should be up and runningin about a month or so, just uploading more pis now

***Tom Williams*** · 10-05-2007, 19:56

any more info on who did the group buy and where it came from?

do lmf do m-vaux stuff?

seanr28 · 10-05-2007, 19:59

Engine and gearbox in....

Cometic head gasket and Steveboy slim stud conversion with ARP Nuts