1603cc engine build

rjplenter

rjplenter

True Classic
Following Husseins lead consolidating his threads, I decided it was time to bring my engine build threads together.

Original engine build thread:
http://xwebforums.com/forum/index.php?threads/23345/

Serpentine belt conversion (Husseins thread):
http://xwebforums.com/forum/index.php?posts/190674/

ARP head studs:
http://xwebforums.com/forum/index.php?threads/25095/

And my exhaust thread:
http://xwebforums.com/forum/index.php?threads/23063/

Valve spring thread:
http://xwebforums.com/forum/index.php?threads/28988/

Marelli S135 distributor thread:
http://xwebforums.com/forum/index.php?threads/29160/

Flywheel dowel pin thread:
http://xwebforums.com/forum/index.php?threads/30083/

Why I love Xweb so much. Thanks to Hussein Holland (lookforjoe) and his machinist my serpentine belt conversion is now complete. :thumbsup:
Once I get my pistons sorted I can create a TDC mark on the modified crank pulley.

This conversion is obviously simpler for a non-A/C engine when you look at all the work Hussein had to do.

His efforts inspired me to try it too since so much of this engine was going to be new anyway. It was very much an exercise in "Can it be done?"

And with the help of Steve Cecchele (fiatfactory) we now have ARP head studs and 12 point nuts with ARP washers and also ARP stepped washers imbedded on the manifold side.


Add those to the ARP bolts in the Scat conrods and the ARP main bearing cap bolts and everything should be bolted together pretty well when it is all done.

Cheers,

Rob
 
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Nice Work! :)

I'm going to try an alternative belt routing - I'm getting a little squeal off the AC when engaged.

EDIT - what application is your timing marker from? That would be a better version to use if I re-route the belt as I intend. I don't see one like it on MWB.
 
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Kudos to both of you... great work!

BUT... Rob, lets clean up the alternator of yours... is looks really BAD as compared to the rest of your work! HA!
 
Hussein, this is the pointer I'm using:



It installs on this version of the 1500 front engine cover:


(photos borrowed from MWB)

Since the serpentine belt pulley is wider than standard, this pointer might be a little short.

Papa T, the alternator in these pics is my old one, but I have taken the new one off the car long enough to check pulley offset. Even my new alt. is not Yves-worthy, so I may have to dress it up before the final engine install. :wink2:

Cheers,

Rob
 
AS my "brother" says, "Chrome is my favorite color..."

Otherwise, like me... I've given up on all the labor to make aluminum look NEW and FRESH from the factory...

Duplicolor makes some aluminum spray finishes you would SWEAR are original. Only YOU would know.

Keep up the great work... I just hadta "bust yur balls" a little outta envy!
 
I finally found a piston machinist!

Dropped them off this morning, should be ready in a few days.

Immaculate workshop, guy knows what he is talking about, lot's of modified parts in his workmanship show high level of workmanship.
 
The pistons are back!

And he did a good job.



Next step is to soften the edges of the flycuts (to eliminate possible hot spots and pre-ignition) and then re-weigh the pistons to make sure I still have the balance I'm seeking.

Cheers,

Rob
 
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There's still a slim chance...

Originally I called this build my winter project. Then spring came and went, now summer...

Of course these builds always take a lot longer than you first imagine but in part this has been because I have taken time to source better bits than originally planned. With help from yourself and Steve and Bernice this build is way better than I first imagined.

So yes, now all the bits are together, but Kristy and I are currently under contract on a new home. If all goes to plan in about 3 weeks we will be moving, which means lots of packing right now (where did all those car parts come from???). By the time we are settled it will be winter again and instead of working in an unheated garage at 5,600 feet elevation I will be working in an unheated garage at 8,300 feet elevation. So depending on what type of winter we have this year it may take a little while to get this engine done and installed.

Pete finished his 1600 stroker build first, you are ostensibly done and I suspect Mr. Cecchele will be third. I don't mind being fourth, that's some pretty esteemed company to follow! :italia:

Cheers,

Rob
 
You might still beat me to it Rob... as the RPFCC is getting a 1500cc engine first up... the 1599cc engine will be next year, and then probably on the dyno before it goes in the car...

Piston flycuts look good, amazingly similar to the pistons I have for mine!! Get those pistons in the block before you move, so you can use that stretch gauge to set the rod bolt tension before you post it over.

SteveC
 
Weights are dead even

My piston machinist did a very good job, all 4 pistons are exactly the same weight at 418 grams each. That makes combined piston/rings/pin/circlip/bearing/rod weights of 1104 grams.

I think that's pretty good for 87.0mm pistons and is 304 grams (2/3 lb) reduction in reciprocating mass compared to 1500cc parts.
 
AAARRRRRGGGGGGGGGHHHHHHHHHH!!!!!!!!!!!!!

Tonight I was installing the piston rings. I started to ease the last oil ring over piston #4 and the ring broke into 3 pieces!!! :wall::wall::wall::wall::wall:

Now I need to find an oil ring for an 87.0mm piston. Does anyone have one lying around???

Rob
 
hmmm, Rob, I wonder if you.......?

rjplenter said:
......I started to ease the last oil ring over piston #4 and the ring broke into 3 pieces!!!.....
Click to expand...

.....had the WHOLE ring set sitting in a can/bowl of HOT water, before you started fitting them over the piston crown??
The hot water gives the rings just that little bit more flexibility! :nod:
An "old-fart" engine-rebuilder's trick given to me MANY years ago!

cheers, Ian - NZ
 
You know what Rob... I just happen to have a few spare...

One shipment of the Mondial high compression pistons I bought in from overseas got wet in transit, and on two sets of pistons the top (chrome) rings were ruined, but the second and oil control rings are fine... and they also just happen to be identical to the brand /type you have too (Mondial)

Australia post covered me for $50 and the postage (100 euro) for the two ring sets... which just bought two new complete ring sets

I think I can give you one (and a spare) for the couple of favours you've done for me recently.... PM me.

SteveC
 
Steve, you're a lifesaver!

PM sent.

Lawsa, I don't think I've ever heard of that trick. Possibly worth trying.

Tony, yep, last one. Bugger! it snapped like it was very brittle. And as I said, it broke into 3 bits, didn't just snap in one weak spot. I was about ready to install the pistons/rods and use Steve Cecchele's bolt stretch gauge to set the torque on the ARP rod bolts. Oh well.
 
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