Freds FE3 into the ute swap DONT POST HERE.

[fredio54]

today didnt go quite as planned...

spent the first part of the morning having a bit of humour trying to pass a wof. they have just brought in a new "if you can see smoke, it fails" measure. thats the state of emissions testing here. my mates corolla failed on this, having over 200k on the clock, and not being well looked after... it has a little white smoke after idle and a little bit while giving it a bit of [shizzle]. not too bad, not billowing... still FAIL they said. sock up the tail pipe i said. and sure enough, it filtered out the smoke, and didnt restrict it enough to stop it running well. in we went, and i got the whole thing on video. bloody funny. esp when we took the pin out and gave it a rev! shot the old white sport sock about 30 feet across the road with a pop :-)

packed up the tools next and headed for pick a part. spent till about 3pm there and then eating afterwards, picked up the following bits :

radiator hoses and clamps
plastic fans (twin 12" off a mondeo)
injector clips
surpression caps for the coils
a pulley to machine into a vband flange (yes i found one that will work mint)
an oil cooler from a audi (nice unit, but may not be able to use it because of fitment issues and time/$ restraints.

reorganised the tools, knocked the small ring gear off of the small flywheel, packed rings, flys, pulleys, turbo, verniers, cutting fluid etc up, and headed to the auckland fsae workshop to turn down the flywheel for the smaller ring gear. slow going. so far its lost 0.8kg to 9.7kg from 10.5kg. that weight is lost going from one ring gear to the other, i havent removed material from the back explicitly to lighten it yet. but i will. i'll also be removing material from the outer rim to allow fitment to my small bell housing. it might come down to about 8kg in the end, all from the outer edge. a significant inertia saving.

i'll get some pics up after i go outside and secure my tools...

fred.

[fredio54]

updated the clutch/flywheel thread here :
http://www.mx6.com/forums/showthread.php?t=156505 (turbo clutch fit in N/A tranny?)

images here :

the lathe :



The ring gear seperated and a choice of two small ones to replace it :



fitted up on the lathe :



turned down for the new ring :



0.8 kg of swarf :



there ya go, inline images :-)

fred.

[fredio54]

some pics of this week ends work :

block all cleaned prior to taking sump off :





coolant hot out pipe welded in place (yucky welds... settings wrong... dirty pipe...embarrassed...)







dirty japanese bastards









put away for the night :



the sump finished and ready :





tune in next time for more exciting pics thrust forward into your face whether you want it or not by popular request :-)

fred.

[fredio54]

monday night was spent under the engine cleaning the jap filth out, my trusty GIRL friend (got it sick?? ;-) ) helped me for four hours toothbrushing the main caps and bolts and robs braces. a lot done, but not as much as i'd hoped.

last night was similar, finished cleaning down below, fitted up the oil cooler, knocked out the rear main, tapped the block for a bolt to hold the spacer and windage tray, and just about got blown out of the car port...

this arvo i am going out to the uni shop again to finish the flywheel, if the wind isnt too bad, i'll try to get the engine in tonight. once and for all, but i wont rush things... so we will see. still quite a bit to do. but very close.

i have some pics, might post em up after work later. or at 2 am with an engine in for good.

fred.

fred.

[fredio54]

the flywheel with the ring gear shrunk on, covered in condensation, and still at about -20...



my trusty assistant :



half done with the cleaning :



possibly the only photo in existance proving that the skyline can go between stopped and running and be somewhere below 5k in the middle!! :



that was monday nights efforts...

next post tuesday...

fred.

[fredio54]

last night wasnt half of what it was supposed to be...

the rain was pouring, the wind was blowing and gusting, one of those days...

working outside in a carport on an open engine isnt all its cracked up to be i'll tell you that.

i did get the bottom end cleaning finished

i drilled and tapped the block for a bolt to hold the spacer and windage tray, though, with a cordless, and no one to keep the other axis straight, it is a wee bit crooked. nothing serious, will still do the job... its only for during assembly anyway.

i found my oil cooler, and installed the longer threaded tube and lubed the silicone washer with synth, and torqued the nut down on that.

i got my trusty assistant to whip the caliper off the back of the telstar. surprised to find that the hub and rotor appear to be one piece? am i blind? or are the mx6/626/etc like that? so i now know that i cant use that for the rear disk conversion on the ute.

i whipped the rear main out of the block, and cleaned up the carport a bit, covered over the gear, and narrowly avoided having a telstar bonnet that i had foolishly left propped up to fend off the rain cut my head off. mental note, dont leave large flat things lying around in 60mph gust winds.

the cooler tube is ported for smoother oil flow, its all in the details i tell you, i would have done more to the block and head, but it aint worth it with out stipping it...

pics :











no swarf in block!! or else!!!!! :





the carport just before bed... :

http://www.youtube.com/watch?v=25yjmwmnLO8

fred.

[fredio54]

rebels hy35 powered mx3 with 2.5l klde in it. dead stock, and farkin fast :

http://www.mx6.com/forums/showthread...20#post1742520

looks like the vid might be broken...

cant wait to give it a fang in the ute, if its even close to that, its gunna haul arse.

fred.

[fredio54]

ok, heres a vid of me machining the flywheel and pressure plate. if you listen you can easily hear where i go from pressure to fly. the fly is heaps harder.

http://www.youtube.com/watch?v=kCEXBapyRhE

note the steady hands, same ones that make for the nice welds ;-)

i'll get some pics up soon. in the mean time, nick can feel special being the only other mx6.com member to have seen the finished product.

its now 9.2kg from 10.5, and got surfaced this morning, and balanced this afternoon. i'll let you know the final weight, but it wont be less than 9.

fred

[fredio54]

btw, the stock fe3 unit weighs 10.3, though, its pressure plate is lighter than the f2t one, but overall, i'd say they would have the same mass, and the same inertia, just because of where the mass lies on the stocker

i think mine is well ahead of both of them stock inertia wise.

fred.

[fredio54]

right, flywheel machining part 2 :-)























there ya go, aint they pretty. mmmmm.

fred.

[fredio54]

because i couldnt get iso metric fine pressure plugs without ordering them, i made my own plugs from a bolt...





all sealed and ready to go.

fred.

[fredio54]

cant be [fizzle]ed with pics tonight, its 10 past 11, and the sump, flywheel clutch, rear main, braces , oil pickup, spacer, windage tray, alternator mount, are all on

mounts, cas, thermostat, plumbing wiring to go, and a mod to the tin for the box, as the sump hangs lower... it WILL be in tomorrow night at this rate!! :-) can you feel the glow from my grin from there?

good night ppl.

fred.

[fredio54]

got up late, got the cas, thermostat, heater pipe, and mounts done

still need to leak test the coolant pipe and put some paint on it, then duck down the road and buy an oil filter and some rubber hose. after that it will be lifted up and in.

cant wait.

[fredio54]

well, as it turns out, the engine is in

but

the box wont bolt up without the engine binding on it

i of course thought that my fly was at fault, and ground bumps out of the box, that didnt work (not required in the end)

then fitted robs bell up and found that it was free for about 30deg and then hit, so i gave it a bit of a thunk around, pulled it off, found the culprit, and removed that lump from mine (required anyway) still no dice

scratched head a lot

noticed guide tube hitting friction disk, pulled box again, and shortened that by about 8mm

still binds

scratched head

carcenomy is owed a beer : input shaft sits flush with bell, f2 cranks (had an f2 on it orgininally) have a much deeper recess in the end than fe3!!!!!!!!!

so i need to slice about 10mm off the nose of the input shaft and i'll be well on my way to building an exhaust manifold.

pics some time tomorrow.

fred.

[fredio54]

Could someone delete this ^ post, somebody obviously cant read (or write).

I'll say this standalone statement :

i have measured the recess in the end of the crank for the spigot bearing, and it is 8mm proud of the gearbox mating surface. the fe crank has a shape like this :

|___|

the f2 has more like this :

|    |
 \__/

so it IS the input shaft nose that is binding. there is nothing else left. i'll eat my words if this is not the case.

fred.