Do you have a pix to post of the 308 block sprinkler? Not of the injury with the stud. Sounds much cooler than the traditional coffee table. Your rebuild is looking great. I'm very alarmed by that synchrometer littering pieces. I have a few of those, and will check the manufacturer. I thought they were Webber, but again will check. Great thread!
My synchrometer has the marking "STE" "Made in West Germany", and has no brass counter weight. Also, there is a cage type plastic screen built in as if to possibly catch parts that could fall off? I never even considered this failure mode to begin with. Very scary. It's the same one sold by Superformance in the UK. They have pretty good stuff.
Sorry 2Dinos, Didn't think to get a pic of the 308 sprinkler. With any luck I'll never need to use the block to water the lawn again. The EMPI tool is made in Taiwan under licence from EMPI in the US. I've bought another after the first one failed (this was before I realised that it killed the motor) and will use it but will install guaze. Cheers George
Progress has slowed a little but it should only be a matter of weeks before the engine is back in. Heads are fitted with some 2nd hand cam shafts that were in excellent condition. One of the exhaust shafts was fitted with an air pump drive which I removed. I had to have my Black Stallion dizzy converted back to spline drive from dog drive to match the new camshafts. Shims have all been set. Gear reduction starter is fitted. Cams are being degreed now and should be finished by the end of the weekend. Fingers crossed for an installation next weekend. Image Unavailable, Please Login Image Unavailable, Please Login
Looks excellent, so which started did you go for ? I like the idea of modern technology on our older engines. Lee '77 GT4
Lee, It's a Gustafson starter I believe. I'll fire it up later tonight to do a cold compression check before the engine goes back in.
Well finally the engine is back in the GT4!!! I started at about 5pm and finished with front and rear exhaust mainfolds fitted at 7.30pm. When I removed the engine I had already removed the rear head before I did the lift. This made the removal easy. The installation wasn't so smooth. I used the same method of lifting the engine by the front head only but this didn't work as well especially now that both heads were on. I had to remove the front RHS engine mount in order to get the front headers on. I also had to us a ratched strap to rotate the engine forward once it was 1/2 way in. I also had to jack up the rear of the engine to get the rear headers in place. After a lot of swearing she's finally installed. The rest should be easy. Hope to have it running by then end of the weekend. Image Unavailable, Please Login Image Unavailable, Please Login
Finally it's running again!!!! http://www.youtube.com/watch?v=jR2wKM0K9YY Worked all Sunday afternoon and finally started it about 5.30pm. The new started spins it over alot faster than the old bosch. I still have to hook up the drive shafts and fit the inner guards before it's ready for it's first outing in 3 months. So in total this is what was done: New (or very close to) borgo pistons/rings New water pump New starter New cam belts New alternator/aircon drive belts Rebuilt alternator Modified BSM dizzy Used good condition cams Sump baffle upgrade New main bearings New big end bearings New small end bearings Honed liners New stainless steel exhaust valves New inlet valve (#2 cyl) New exhaust valve guide (#2) Rebuilt heads Cleaned block All new seals and gaskets and heaps of other items I can't remember now. I'd like to say it's be fun but most of the time I was freaking out that I may have done something wrong. I'm glad it's over now. I haven't figured out the final $$$ yet but I suspect it's around the $7K AU mark. Thanks to all for the support. See U on the road. Go the 308!!!
Good on you George and if it's any consolation it cost me over double that and took 1 year to do.How was the clutch?
Hi Maurice, The clutch was good, about .5mm wear in the driven plate, the pressure plate, TO bearing were good. The flywheel had a surface machine as matter or course. I did have some trouble with the clutch a while back but that was just an adjustment that was way off. Cheers George
Well I took the Gt4 for it's first run in 3 months yesterday. Just to get fuel, a 30min trip. Drove fine and sounded even better, didn't take it over 3500rpm but that was enough to have some fun. Couple of minor adjustment needed. The engine was mounted on 5 washers on each front mount and I have replaced these with 20mm brass spacers. Now the gear linkage needs adjustment as reverse is very hard to find and 3rd is against the gate and 2nd is nowhere near the gate. All forward gears were fine. The clutch cable needed an adjustment. The ignition timing was about 5 deg advanced so it was very hard to start the car again at the garage. Thank god for the new Gustafson starter or we would have been stranded on the first run. Ignition timing adjusted the car now starts first turn of the key. I'll do the gear linkage adjustment today after some Fchat research. The engine now makes this sweet resonate noise on overrun as it running down through 2500rpm. I had to do this several times as it sounded soooo cool. Very very happy with the results. Special thanks to Gleggy and Marc on this unplanned project. Cheers George
George, I am soo happy for you! Not for the reasons it happened, but for the result! Sounds like you did very well. I can't wait to hear a full-on 7,000RPM run story!!! If you can pull off a video, post one! Not enough can be said for how these little go-karts sound under full throttle. I know I LOVE the way mine sounds. Congrats again from a fellow GT4 owner. JIM
Great news! Like Jim, sorry you were forced into this rebuild, but now you can look forward to many happy years of motoring!
Thanks Karen, Jim, Js, All is good now with the gear linkage adjusted. Reverse is easy to select as is all the forward gears. I have a grand total of 30Klms on the new engine and hope to put another 300-400Klms on this weekend. One item that did not work however is the 2nd gear when cold fix. I drilled a relief hole in the rear engine cover but 2nd is still hard to select until warm. No big deal, I can live with this. It's almost a way of preventing you from drivetrain abuse until everything is warmed up.
That's normal Brook. I just made a comment regarding this in another thread in the 308 section. BTW, congrats on you getting your car back on the road so quick. Wish I could say the same.
Maurice, I'd only just put in Redline 75W90 just before I cooked the engine. I saved the tranny oil and reused it. I know a lot of people use the NS Redline but Redline themselves don't recommend it. From what I've seen the NS product has the viscosity of ATM fluid. I know the NS oil fixes some GB problems but I'd be concerned about it's long term use. Cheers George
