ZX 16v

[xanax]

Nice work !

[welshpug]

https://flic.kr/p/v8h1RN

fancied a change of wheels...

[welshpug]

minor update - MOT ran out end of October so its been off the road whilst I tinker with a few bits, namely welding the exhaust and making pattern part tat actually fit properly, its quite shocking how crap the fit is!

New bushes on the bottom of the rear dampers, lifted the ride height a little on the back, swapped the bottom engine mount for a fairly fresh standard one but filled the voids with PU adhesive.

Annnddd managed to trace down a very reasonably priced genuine bosch fuel pump on teh bay of E all the way from Latvia, the walbro replacement I fitted only lasted 3 months, wasn't amused with that.

MOT booked for later today

[welshpug]

one thing I love the SL434's for is that they are proper competition wheels for cars that used the same front end architecture (hub carriers drive flanges etc) , and thus they have quite epic brake caliper clearance radially....






that's a Renaultsport Brembo caliper from the Clio 3/Megane 2 over a 310mm rotor on an alloy bell, with NO spacers :o granted there's bugger all clearance to the top corners where the nipples are, so I will run a small spacer to add a margin, but I am very pleased with that

[zx_volcane]

amazed you got those under 15s? No doubt it stops pretty well then!

[welshpug]

they're not on my car yet, but a friend (AdamB ) has them on his car under a 15x6" MO with a 10mm spacer, I'm sure if he had the 7" wide ones they'd clear without a spacer


yes these do work very well without being particularly heavy, I've used them on Adam's ollldd car, the V6 rallye, and were quite epic with Carbon Lorraine RC6's.

[welshpug]

I sold the engine to Blandy back in December, as I had happened upon the basis of a full engine build, in the form of a Block and higher compression pistons.

The last few months have been a battle of collecting bits, deciding what direction to take it and budget constraints, and making it work with what I already have to hand!

Currently, I have a big jigsaw puzzle, almost ready to assemble, crank has already been fitted and plasticauged, along with a Conrod and piston in to check deck height and valve clearance.







checking valve clearance -






Decided to paint it a striking colour





Big thanks to Carl Robson and Sandy Brown for helping out with the conrods, also thanks Sandy for the pointers in what to measure.

Also Ed and Steve at Warners for supplying the o.e parts at very good prices.

[Danny Wideboy]

M8, that pulley goes on the side of the head, not the top, FYI.

[Lwilliams]

goood people these days don't know what their doing

[darrenjlobb]

Mmmm a Robson Engineering box, I know whats in there Excellent Rods!

[welshpug]

Yeah, they're specific to my build too!

[welshpug]

Final Parts for the bottom end I think, thrust washers, had been on backorder for about 6 weeks.



Made up a bracket to hold the dial gauge (the magnetic stand is Dan's and ion his garage, didn't have it to hand)



pushed the crank, and got my end float figure



0.13 of a mm, ideal, tolerance is 0.07 to 0.32mm.


Further progress is at a halt till I make/earn more money, as the ehad needs checking over and the seats cutting

[Eeyore]

err ma geerrdd just listened to the video of it on bodies and cant wait to get mine on now...

[welshpug]

so, an update!

took the head and valves to South Wales Pistons for them to check the face and guides and cut the seats and valves.









Piper double springs





o.e stem seals, branded SKF.



pushed into place with a socket and a dab of oil.

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fitting the springs and collets, what a faff! dab of grease helps, also not having the cam ladders gives and extra inch or so of clearance, I wrapped the head of the spring compressor in tape so the lifter bores weren't damaged.




Cleaned and refaced the tappets.






checked the clearance to the freshly re-fitted oil spray bars, looooads, could sling a 96mm crank in there easily.



fitted and torqued up the crank, fitted the windage tray oil pump and the dipstick guide.





new hockey stick seals for number one mains cap




Turned back over.




o.e steel gasket.

[cully]

Payen Head bolts



then cams in and ladders sealed with wellseal, water pump and timing belt kit on.




doing the cam timing.







then off the stand and fit a Steel lightweight flywheel with new bolts and a new dowel.




Standard clutch fitted, will see how it copes with XXX amount of torque, I don't tend to abuse my cars so probably just fine! starting to look much more like an assembly, less spare bits kicking about




Dragged the ZX around the units and washed it off, stuck it on the lift.




Forkinghell this might actually happen!



BOOSH.



TRUMPETS




a very rare Milltek exhaust was sourced, tailpipe is rather large but thankfully only externally.



however the peugeot sport Group N Decat twin tube downpipe had a sleeve fit end for a magnex catback, also pretty small here at 2".

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trying to sort your tag Welshpug

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so I bought this





measure mark chop grind weld.





fitted with o.e single piece clamps.



Filled up with fluids.

fired up and running the cams in.




argh!

fuckit I'm off to the pub!

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think ive sorted all your img tags

[welshpug]

ha! thanks

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pub!!

[Piggy]

Good effort!

You must be excited

[bashbarnard]

schweet

[C2K]

Looking good Mei

[welshpug]

I decided to buy some brakes.





Thats a saxo vts/xsara vtr Indianapolis wheel without any spacers, 205 speedline needed 3mm, no cyclones to hand.



Pro race 1's, Direct pug fit, not the grey ones that don't fecking fit that Bowen sold me, tit.

And faff with the cooling system to get cleaner colder air to the trumpets without having to use an airbox.





205 rad and Spal 9" pusher fan, couple of brackets made up from stuff I found knocking about.




A bit of plastic coated aluminium and foam board

Need some pipe adapters as the top hose is a different diameter and I'm keeping the heat exchanger, so needed to tee into the bottom of the rad, looking to source probably a 406 expansion tank and place it on the chassis leg in front of the PAS bottle

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forgot to add these few pics






thanks to Dave at Satchell engineering for welding these up for me.




got a 205 expansion tank behind the headlamp.

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this week I bought some Trumpets.




They do look mighty short but are actually 50mm, the length is to suit my total inlet tract vs cam profile and stroke etc, I let Colin do the maths.

[cully]

coming along nicely

[welshpug]

yep, I think its pretty much mapping time, cashflow dependent.

[cully]

cash flow Yup its that time of year again when you can buy yourself a bigger present

[welshpug]

this time of the year is no different to me tbh, never been a big spender for christmas, its just the daily needs to be kept going and it needed discs pads and handbrake shoes and a service last week.

I did a clutch on a Ford Fusion this morning so that's a little more cash towards it!

[welshpug]

So a few weeks ago I borrowed a trailer,  and my BMW's alternator died on the Thursday evening just as I was loading up the ZX ready for the Friday morning trek to Launceston, cue DCC's Landrover to the rescue!!

this was the view at about 6.30





9.30, That sign, a very welcome one.




Bumper off and strapped down.





Dan popped down to Truscotts and got a brand new expansion tank cap, the used one I had didn't seem to be holding much pressure, though it wasn't boiling over at all.

big thanks to Neil, he's a bloody good teamaker, as well as Pinto building machine, I'm sure he knocks out two or three a day at least of the hotrod high power beautifully finished engines!

oh and Dan picked up some bits from Sandy...





After a few issues with some tricky to find wiring faults causing an injector to not fire, Sandy cracked out his wiring kit and made me a new outer injector sub loom, cleaned the plugs and got cracking, then found an issue with the lambda dropping out, seems the heater circuit was a bit iffy and the lambda kept going full lean, gave that a clean stronger live feed and it seemed to be fine thereafter, once the few niggles were nailed down the map came together very quickly.



only managed to get a few short clips, no power figure yet but we do know we're at the limit of the GTI6 injectors at 3 bar  (running up to 85% duty IIRC), and the Clio 250cc are filling the rest as required, so its around the 240 bhp mark.

next jobs are to sort the clutch cable as it seems to have been cooked with the prolonged periods under load on the rollers, will need to find some material to protect it from the heat, buy some pads and fit my brakes.

[allye]

That makes a very naughty noise indeed.

Will you ever sort the exterior?!

[welshpug]

The bonnet is black now, It was a red one Anthony gave/sold me some time ago.

I plan to get a few cans and sort the rest maybe, unless I find a cheap painter

[Danny Wideboy]

I think, if my engine made those noises, I wouldn't be worried what it looked like.
Quite the opposite probably. :-)

[welshpug]

so, MOT ran out on this in April last year, I think?  lots of stuff happened before and just after then, new job, Girlfriend, a few different daily diesels.

ZX had sat in the corner abandoned for quite a while, though still a runner with a fresh battery, the bodywork being 2 different colours was beginning to get a bit boring, and whilst the new job is less per hour I'm doing 50% more hours a week, walk 50 yards to work, and get proper overtime, I still begrudge having to save over a months wages just to get a cheap blow over, yet IO know full well I am no sprayer :lmao

so, almost 2 years ago I helped my girlfriend sand back her 26 foot Kingfisher bilge keel junk rigger Yacht, hell of a job, spent weeks on end covered in blue and grey fine dust!

and then we Painted it, proper Hempel etch primers on the steel keels, normal yacht primer on the gelcoat followed by a lovely Gloss blue above the water line and black antifouling below, wet sanded between the last few coats of primer and each gloss coat, and I was particularly impressed with the finish from an over brushed roller job, can't find any pictures right now though :doh

so I decided to do the same to the ZX, sand it down with a makita DA borrowed off my girlfriend, flat back the fiddly bits by hand, then hit it with a roller and boat paints   annoyingly I'd forgotten what kind of roller we had used and that we had followed with a brush, so the first coat of primer went on a bit thick and almost like crinkle paint :lmao  easily rectified with a quick flat down before a few more coats though

20200428_115108 by WELSHPUG, on Flickr

20200421_151431 by WELSHPUG, on Flickr

20200415_161230 by WELSHPUG, on Flickr

20200411_212547 by WELSHPUG, on Flickr

20200404_155727 by WELSHPUG, on Flickr

20200428_151934 by WELSHPUG, on Flickr

20200428_160750 by WELSHPUG, on Flickr

20200428_160758 by WELSHPUG, on Flickr

20200428_160806 by WELSHPUG, on Flickr


20200429_192914 by WELSHPUG, on Flickr


and here's the colour I'm going for

20200416_191621 by WELSHPUG, on Flickr


BLACK! 

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erm, hmm. there's meant to be a bunch of pictures there, they worked fine on 3 other forums!