don't hold your breath but iu think i've started the build up on the new wedge engine !

eek!

i trawled up to raceshack in tewkesbury to see conor and matty and kevo and get the job kicked off..

i've been slowly assembling parts and bits for well over a year, maybe getting on for two! and there are boxes and boxes of things, spare engine cases, spare heads, dump valves, various other bits of misc turbo gear, clocks, gauges, tinware, gasket kits, shiny billet racing internals, rods, camgear, cam, bearings etc etc etc...

so after the boxes and shrink wrap got all opened up it was time to lay it all out on the bench in the clean room and see if its all there, all teh right size all ok etc etc...

and then onto dissassembling the crank/flywheel/pressureplate aseembly. these have all been dynamically balanced as a set so all the bolts and bolt holes got engraved with a number so it all goes back together in teh same place... i resisted the urge to engrave hibiscus on the inside of the flywheel....

this build is designated #9090 in the raceshack buildbook and so it gets a complete buildsheet detailng every component, weight, material and measurement with signautes for several stages of checking on every component... (everything gets engraved with a serial number and designation too - which is very cool in a kinda techy anal overkill kinda way. but then as they say,

you can never have too much overkill...

so onto the pistons and barrels...
i've sourced some new cofap 2.1l DJ motor high compression barrels and pistons and had been trying to source some US style MV low compression ones. (the US market got a lower HP version of the 2.1 injection wasserboxer motor. the only real difference was the dish in the piston crown was lower, lowering the compression from 10.5:1 to 8.6:1 (if i remember correctly). if i can find a set of low compression pistons i can get the turbo system to run MUCH more boost without danger of detonation... (ie 20lb rather than 8lb at a guess) but pulling the box out i see they're brazilian (duh!) and think... hang on !?

so we CC the pistons to see what the dish in the top actually is....

and it's 46 cc !
with the head at 15cc and with a target of a 1mm deck height the compression ratio comes out at a gorgeous 8.7:1 HUZZAH!
wind it in ! :D

so the pistons were all weighed and numbered, as were the lovely new type 1 H beam rods that i got machined for the 24mm wrist pins. each one has been honed to fit so they all got numbered wnd weighed too...

then onto cleaning and polishing the valves and checking the heads over....
i'd done some mild porting and polishing on the heads(last summer if i remember correctly !). not much taken off but cleaning and smoothing out all the casting marks and smoothing some of the angles, especially around the exhaust ports. the head has a very sharp 90dgree bend straight after the exhaust valve and there's loads of metal in there that can be removed.
i have a spare set of 2.1 heads in a box so if i get the new workshop i'm looking at i'll stick them on a bench and go wild as a test...

all the while the ultrasonic cleaner had been heating up and degassing the water and cleaning solution in it and it was ready to have the case soak overnight to get it microscopically clean.. first back into the parts washer..

and then into the ultrasonic cleaner for a few hours

i've got a short shopping list to obtain before the test assebly and closing the case next week so all being well i can get them and will be a happy blogger this time next week.
i need to get a set of new head springs. we put them in the spring tester and they're all within an acceptable range and the pressure is not too bad but given the amount of boost that Conor at raceshack has in mind to try and run better spring pressure will help a lot. so new springs.
also new cut to length push rods. i'm using type one SCAT lobe a lube solid lifters with the WBX lifter bores bushed (with bushings courtesy of rocky jennings in washington USA) these are topped off with SCAT 1.25:1 ratio rockers to get a bit more lift. so all the geometry is different so new pushrods....

there are one or two other bits but basically all systems go !
roll on next week....

ah...
there was just one more thing.

the decision to discard the t03 turbos i was using on the last motor is definately a done deal... matty sized up an appropriate new Ball Bearing Turbo (the size of a small washingmachine and big enough to suck a small dog into)...
unfortunately the turbo is going to cost just over four times what i actually paid for the whole bus originally. i don't know whether it makes it a cheap bus or an expensive turbo...
it is the single most expensive component so far but seeing as it should double the power it's not all bad !

(looking back this is my first blog in a long while but it's now been going on over four years... how mad is that ? I like siutting here writing away nattering rubbish to mysel. it's kinda therapeutic. i'm glad i don't look on it as publishing or any garbage like that... i'm glad that i deliberately don't go back and check spelling and punctuation etc . i just like it. i like reflecting on whats going on.
i just wish i hade more space in my head to relax and chop out the time just to sit and think...
maybe i'll sort that out soon

d ")