Ballsface and clamshackles.. just typed out a really long message on here and then accidentally pressed a keyboard shortcut and lost it all! what a spunktrumpeting jizzbanger. So I'm going to type it out for the second time!
The main thing holding the car build back is money at the moment so I'm putting in as many hours of over time at work as I can to pay for it. Hopefully selling my Corrado driver and replacing it with something crap and cheap to run to free up some Rocco funds. Not keen on doing it but needs must, I can handle driving something crap if I know this will be on the road sooner! I'm going to try not to rush this second build as much as the first time though. I was so keen to get it on the road I didn't spend as much time as I should have done on some parts, mainly thinking things through. Also I've realised it's such a waste of time and effort trying to cut corners as you just end up redoing those things later how you should have done them in the first place! Hopefully I can stick to this ethos from now on.. the novelty of doing things for the first time is wearing off slightly and I'd prefer to do a job once now, do it properly, have it work and not have to re-do it if I can avoid it!! I had limited skills when I started this but that has increased to a little bit of skill, so we'll see. I've been offered a working 1.8t engine to drop in this car, and for cheap too. I did think about it, I could have had a running car sooner! It was tempting but I'm determined to get an engine built, I've never done it before so I like the challenge. I'm not particularly anal or diligent which are qualities you need when engine building so it's a good test!
So this week I visited a local machine shop to pick up some of Herman's engine parts.. and he now has a part lightened and fully balanced rotating assembly.. result. This thing should be smooth as now.
These crankshafts are supposedly balanced before VW install them but they're not all done to precision it would seem.. The crank and pulley were added together and spun up. Then material was removed from the number 1 piston counterweights:
Either side of number one piston big end journal:
And on one of piston 3's counter weights:
Here's the balancing report.. the bottom sheet is for the crankshaft and the top sheet for the flywheel and pressure plate. No material was removed from the flywheel which is pretty cool, it means our lightening job must have been a pretty good one! Pleased with that for a first effort.
After getting my block sand blasted and painted I found out a machine hone wasn't good enough for it and the 120k block would need reboring to be built back up.. a massive arse and more £££!! You can see the wear in each cylinder..
One bore was so bad it had wear around nearly the whole circumference
The machinist was surprised I didn't have oil blowby and a smoky exhaust! With the price of a rebore and new pistons and rings I decided to look for a new block as I already have my rings and pistons waiting to go in! I managed to find an Audi A4 cabriolet block on ebay that had had turbo failure. It only had 53k miles on it and looked in good condition.
Drove down to give it a health inspection and it still had the original cross hatching! The bores looked much better so I snapped it up!
I asked the machinist 'what's the advantage of you honing it? what's wrong with me just using a honing tool on a drill?' to which he quietly replied 'well my honing tool cost £60,000'. Good salesman..