Project Deathtrap: Jack's 1.2 Corsa

[DaveB]

Jack, those discs look very worn; not surprised you've got loads of pad left lol

[Jack]

Originally Posted by CraigGreen

What you gonna do, hone it out or look for another block?

It's been honed and is back together.

Just needs torquing up and it's all shnizzly wizzly.

[Jack]

Mum went out, dad kidnapped me and we spent an hour ripping stuff off.



Got my headset and stem together too.

[S700TTT]

hi mate what you got planed for the 1.2 , im looking for one at the moment ? you thinking of selling it let me know ?
was it a good runner ?

let mw know

cheers scott

[Jack]

You can have it matey! It ran alright except for the tappets. They were very very loud. But it went well enough, and kept up with my cav easily.

[S700TTT]

Originally Posted by Jack

You can have it matey! It ran alright except for the tappets. They were very very loud. But it went well enough, and kept up with my cav easily.

hi mate iv sent you a pm ,

i have another 1.2 that leaked alot lol , this would be a great help ,

[Jack]

Gave them a quick coat of stonechip. Jack gives not a sh.t.

[Benn]

Stonechip? Dude.

[Tom Williams]

Stone chip? they are alloy Jack they will not rust.

[wascool2]

lol maybe he was thinking that somehow in the distant future they turned into steelies lol, its either that or he was thinking they were just steel wheels in disguise .

[Tom Williams]

I spot immediate errors - those centre caps are wrong.

[Jack]

Originally Posted by Tom Williams

Stone chip? they are alloy Jack they will not rust.

They were a bit scuffed and scratched and it was the first thing to hand.

[Jack]

Originally Posted by Tom Williams

I spot immediate errors - those centre caps are wrong.

You pedantic git.

As long as they're straight and fit over my 256mm brakes... I'm not fussed.

[turbo gav]

So whens the let going in?

[Jack]

If I didn't change it now I'd only forget.



Torqued up! Finally remembered to take my Haynes manual with torque figures. Sorry to everyone I phoned a few weeks ago.



We had to put some helicoils in the oil pump housing, as some gooback had stripped the threads. Paper towels to stop stray swarf.









Sump in the parts washer.



Tapping le thread.



Helicoiled.



I would be happy eating off that, to be honest.



Block face...



... and after a quick clean.



The new head gasket. A bit of confusion as it covers up some water ways.



But the old one was the same...





The dipstick had a dip in the parts washer too.



So did the rocker cover.



Helicoil on the thread that caused all of this trouble in the first place.



Very nice! </Borat>



My lovely new £45 (!!!) pulley as the old one was tres noisy (that's french).



Timed up the engine and spun it over to make sure it all worked beautifully, and all of the paper towels I'd jammed down the spark plug holes went flying across the workshop.



Timed up and covers back on.





The instructions you get with a Flame inlet manifold. Shame it's not that easy in real life.



Put on to make sure all the holes line up. I'm going to have to get it modified on the end, as I'm allergic to drilling threads out of re-usable, expensive parts like the throttle body. The end of the flange is nowhere near flat either, and I'm buggered if I'm just going to slather sealant on the end and hope for the best.



All tucked away for the day.

[djivesp]

good work there mr jack apparently the holes in the head gasket are smaller than the waterways to increase water pressure or some cack, so it's all good . Very nice with the 'powerbox' or whatevers they are called, it's going to be a quick little engine

[chrisscirocco]

top progress!
like a new engine

[Jack]

Originally Posted by djivesp

good work there mr jack apparently the holes in the head gasket are smaller than the waterways to increase water pressure or some cack, so it's all good . Very nice with the 'powerbox' or whatevers they are called, it's going to be a quick little engine

Should be a good giggle.

1.6 8v flywheel and clutch cover on the way!

[Benn]

Did you change the water pump?

[Jack]

Originally Posted by Benn

Did you change the water pump?

Nah. We spun the current one over and there's no play or bearing noise or anything. It'll be fiiiiiiiiine.

[Gaz86]

for the peace of mind i would have done the oil pump too

that powerbox is shocking whats it made of? i know theyre cheaper than the origional but the price you pay should include "some" skilled workmanship.
as a comparison if i made that id chatge for materials plus £20 cos thats an hours work if ever i saw it.

rip off britain eh? everyone is cashing in.

[Jack]

It wasn't expensive. The appealing thing for me was that it came with everything I needed. Hoses, pipework...etc.

The welds on it look good, it's just designed really badly. I've got a few ideas.

[Jack]

Dropped the inlet off along with a nice 15mm thick piece of ally.

The plan is to replace the flange on the end of the inlet with a really thick piece, then drill and tap it and screw some studs in.

[CraigGreen]

Nice work Jack. Good move on modding that power box too, it is quite shocking tbh.

Easy mod though & £perbhp still very cheap in the grand scheme of things.

[LongLiveTheNova]

Nice work on the engine Jack.
Is that a powerbox off CorsaSport?

Another word of warning, if the top bolt holes(that hold it to the bottom inlet) are open to the inside of the box(i.e. could cause an air leak), use some fibre/gasket washers under the metal washers to get an air tight seal.

The cheaper powerboxes may not look the best, but they get the gains. Best mod my engine has
Power/Torque increase was RR proven on mine too

BTW, i found there was a reason why you couldn't use studs/nuts, i think something on the tb gets in the way, so you can tighten the nuts. Hence why people use bolts.