jimmyesh on Thu Sep 16, 2010 9:01 pm

Been relatively busy the last couple of days;

Firstly the redesigned turbo oil drain mod on the sump is done (small brass-coloured connector is the drain for the oil breather tank);

I welded a new lambda boss into the downpipe for the wideband UEGO sensor for the Stack wideband gauge/kit (that should hit my door-mat tomorrow :aviator: )

The boost leak in the inlet manifold weld has been rectified by Ziggy and his Tig skills.

I've drilled & tapped one of the inlet manifold mounting holes in the head and fitted an M8 Time-Sert for my peace of mind as the Duratec has one very short hole due to the head design. The Time-Sert allows me to stop worrying about stripping the threads out of it! 🙂

The twin Spal cooling fans are now fitted to the rad.

So glad I took this apart now! :oooh: - When I examined the timing-chain cover I found that I'd fitted a bolt that was slightly too long when locking the crank-pulley at TDC during the previous build 😳 Basically it had punched a hole right through into the timing-chain area, that'll explain my mystery oil leak then! :aaah: Luckily this has now been rectified by my mate, Ziggy and his Tig welding skills 🙂 (It's the small bolt right next to the crank-hole)

The turbo now has all its new water & oil lines connected, is fitted to the exhaust manifold and is wearing its new turbo blanket as-per my endless mission to control radiant heat in the bulkhead area.

I spent a while today setting the gaps on the rings to CP's specifications - those nitrided top-rings are a real Bic™ to file! :aaah: Even worse when you go straight to filing the second rings which are cast iron, therefore easy to work with so you run the risk of taking too much off - I took my time and got them all bang-on.

Finally, tonight I fitted the rings to the pistons than fitted the pistons to my Eagle rods.

I'm going to start rebuilding the whole engine back up tomorrow - things are looking good at the moment 🙂

jimmyesh on Fri Sep 17, 2010 6:29 pm

Pumanoob - that Duratec Turbo Puma will be a weapon. The 1.7 zetec-se is the same layout as the Duratec and also uses a similar engine mount so should be a bit more straightforward 🙂 .

Another bit of activity today on the never-ending project that is my Fezzer! 😛

I was about to leave the house and head on up to the workshop when a roll of graphite exhaust wrap landed on the door mat - I ordered it to cover my downpipe and replace the white heat wrap (that I'd proffed from work! 😳 ) - this matches my manifold now and doesn't get dirty as much.

Note the extra lambda boss for the Stack wideband UEGO sensor;

Got sidetracked into sorting some neater pipe-runs and doing some more heat-proofing;

Finally got round to fitting the pistons 😀 I took it slowly and liberally coated the pistons, rings and bores with copious amounts of oil. Luckily no rings were broken in the process or else I'd have to order more from the States and start re-gapping them! :aaah:

I torqued the ARP big end bolts up to spec with some ARP moly lube and re-checked the ARP main bolts too.

The headgasket and head were fitted and the ARP head nuts torqued to spec with yep, more moly lube! 😛

I started fitting the cams but had to leave to collect my little girl from the child minders.

Here's where I'm up to;

Hopefully I'll be putting the engine back in the car at some point next week - here's hoping work give me the time to do it! 🙂