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Old 30-08-2007, 23:56   5 links from elsewhere to this Post. Click to view. #1
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Kreads Cav Turbo

After an injector failure i melted a piston, which ended in one slightly broken cav turbo

so ive been busy over the past few weeks sorting my car out, working out exactly what i wanted to do and how much i wanted to spend, and how to spend that budget!!

basiclly i worked out that 3k was the budget but it could have been spent in several ways, forged pistons and rods etc or have a spare block that max has which has pistons etc with 1000 going towards pistons and rods alone i decided that that 1000 could be better spent elsewhere as my target is only really 300 - 350 bhp

biggest problem with that is the standered kkk isnt much good for more than 280 - 300 brake, so ive decided to sort everything else out to have it ready for a garrett turbo at a later date!!

so here it goes

spent saturday stripping the slightly broken engine out!!



then degreased and pressure washed the engine bay so it was all sparkly!!
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Old 30-08-2007, 23:56   #2
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i then got max's spare bloke back to my house (how heavy!!)


where i spent some time cleaning and stripping it of all its parts ready to be cleaned and painted



including grinding of the old bottom pulley bolt

and here's a load of bits which i have been accumalating over the past few weeks

Uprated Oil Pump


Cambelt kit and Water Pump


Sard Adjustable fuel pressure reg and adapter


Bosch 044 Uprated Fuel Pump


4 Paddle clutch


Steel head gasket and Head stud Conversion


8v Sump gasket and inlet and exhaust gaskets plus the other drop link i hadnt replaced


Uprated conrod Bolts Magnecor leads and enlarged top hat


Plus it was my bday on wed so i got this to play with aswell!!


plus ive got an xe inlet cam and new wishbones engine mounts various other gaskets and bits and bobs

and a full set of hoses from roose motorsport (every single hose that they make for the let)
and a crazy head with big valves double valve springs solid lifters flowed ported polished etc on the way soon

Tomorrow will be spent stripping the fooked engine of all its needed parts and finishing prepping the new block ready for it all to be assembled!!
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Old 04-09-2007, 10:21   #3
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quick update

got the block outside and degreased and pressurewashed!!



then whilst i was at work on saturday my mate started putting it all back together

the block and anything that didnt come up nice and silver was sprated in heat resistant paint which came out a nice charcoal colour which i really like!





not the best of piccies but you get the idea, mates girlfriend also scrubbed the inside of the sump intil it was as clean as the outside,

Conrod bolts oil pump water pump and new tensioners and pulleys all fitted, just waiting on roose to make all my pipes so i can crack on and finish it!!!
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Old 06-09-2007, 13:54   #4
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good work mate but you should replace the cam belt rollers with the metal ones. i dont trust the st%tty plastic ones
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Old 11-09-2007, 20:03   #5
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Update

still waiting or some parts so progress is slower than i would have liked but hey ho a ew pieces have been done

i'm waiting or a crazy head to arrive but that might not happen or a while so ive brorrowed a spare head my mate had although it did need new exhaust valves so i ground the new ones in





then i cleaned it all up with carbcleaner and a bit of elbow grease and some degreaser

and cleaned the tappets out



then we decided to fit it to the head





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Old 11-09-2007, 20:15   #6
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awesome i've always liked your cav
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Old 22-01-2008, 00:47   #7
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blimey its been 4 months since i last posted,

basicly after some wait roose finally made the hoses id ordered and most of the other parts arrived, so we went about putting the car all back together.

sadly a didnt take many photos of this stage but im sure most of ou knw what its like to put an engine back in!!


quick shot of fitting the new intercooler in the dark!!


But it hasnt been the best of 4 months!! after finally getting the car running, and it was running exceedingly well, it started amazingly quick, couple of cranks to bring the fuel in then it just fired up. no struggling no coughing, bit of smoke but nothing that didnt clear within a few minutes.

sadly though on its way to the mot, baring on mind this was october before it was running and i hadnt had the car since early september, it decided to pop a core plug!!! bugger, so it went home on the back of the lorry!



so another few hours of stripping it back down and replacing the offending core plugs, did all three to be sure, and it was back to the mot station.

this time however he did mention that A it was to low to mot (Turned out the springs had given up and the car was on its bump stops, which it had started to crush!!) they were the same springs that had been on there the previous year. and B as a result of being that low id scraped the fuel lines at the back, so back again to swap all the springs over for slightly higher items and time to replace the fuel hoses, since i was under there i also replaced the fuel pump for my bosch 044.

sailed through the mot only needing a new abs sensor!! hoorah so back on the road after arounf 10weeks with out my own car.

drove well but due to a dodgy connection on the fuel pump it was sucking in air and as we all know thats not good, so again spent some time under the car sorting that out!!

finally though all was good, car was now feeling great, going like stink, holding 17psi easily but 2 days after christmas things didnt quite go to plan.

took a drive into work on a day off, in a bit of a mood so took some agression out on the car, as it was dry did a 4k launch out of a round about, at the top of first there was a stupidly loud bang and it felt as though the front of the car had fallen out!

i had no drive what so ever, so the car went home again on the back of a lorry



it was either the transfer box had had a fit or the diff had dropped a bearing, our money was on the second option, but whilst it was all gonna be out i decided to lay out and make inprovments to the 4wd wether this one was broken or not.

had a spare box anhow and the vts had started to slip in wet weather, was fine in the dry but soon as the roads became greasy it didnt like 1st or 2nd, seemed ok before the rebuild but i was only running 240bhp then, would imagine im closer to 280 - 300 now. so time for an upgrade, had heard excellent things about Mike Haywards Locked Boxs so took a quick trip down to see him and pick up some of his locking gears,

got the transfer box out and confirmed that i had killed the gearbox, so out that came to.

some piccies of cleaning and building the new transfer box





any how new transfer box is mated to new recently recon gearbox and in the car, just need to get the subframe, drive shafts and wheels back on, fill it all up with fresh oils and job done all back on the road,

update soon as thats done.

couple of mincing shots

on the rollers, it was so low it took them about 30min just to get it on there!! lol


fitting the VTS box
this is my angle grinding outfit


lovely tail!! my mates mrs boot build is trimmed in this rather fetching pink adn purple fluff!!


Few updates on some of the other mods its had done since aswell once its all back on the road!!
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Old 22-01-2008, 11:59   #8
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Just read this thread, come a long way in 5 months, LOL

At least you got to ride on the back of 2 different towing lorries, lol
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Old 22-01-2008, 12:55   #9
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Originally Posted by DaveB View Post
Just read this thread, come a long way in 5 months, LOL

At least you got to ride on the back of 2 different towing lorries, lol
yeah i a strange way the car looks really good on the back of a lorry!! first time though it was a bugger to get on due to being so low, came extremely close to sraping my intercooler, took about 20min of careful hoisting.

lots happened and a lot to happen before im entierly happy with the car, but isnt that always the case.
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Old 22-01-2008, 16:45   #10
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shame about it being on a flat bed onwards and forwards though still looks good though
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Old 22-01-2008, 17:00   #11
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nice build, that isnt an 8v sump gasket above though...
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Old 24-01-2008, 12:43   #12
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Quote:
Originally Posted by rudd86 View Post
nice build, that isnt an 8v sump gasket above though...
Doesnt have the baffle plate, but just use the standered one with this, whats it from then? the book said 8v cavalier
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silver cavalier turbo - Vauxhall Owners Network This thread Refback 26-01-2008 14:30
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silver cavalier turbo - Vauxhall Owners Network This thread Refback 24-01-2008 22:06
silver cavalier turbo - Vauxhall Owners Network This thread Refback 24-01-2008 20:12
silver cavalier turbo - Vauxhall Owners Network This thread Refback 24-01-2008 20:10

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