Club 80-90 Forums

300CE wrote:look forward to seeing it in the bus

Well it it's in but just the bare engine in today

This started off as a spare DG rebuild for my Tin top which has a perfectly good DG engine, then I changed direction and turned it into a DJ, then when I stumbled across a DJ pop top with a broken engine It just seemed right to put it in there.

P1060802 by Paul_Barr, on Flickr

It's taken me a while to clean up and paint all the engine bay, change gearbox oil, remove and regrease gear linkage, rebuild the injection system as well as cleaning up and painting all this lot

P1060805 by Paul_Barr, on Flickr

P1060806 by Paul_Barr, on Flickr

Engine out of the shed and moved to the van on a trolley

P1060811 by Paul_Barr, on Flickr

Doesn't take much lift to slide it under

P1060814 by Paul_Barr, on Flickr

P1060815 by Paul_Barr, on Flickr

This is my strap winch which lifts it nicely by a piece of chain and bolts through lifting eyes

P1060816 by Paul_Barr, on Flickr

P1060817 by Paul_Barr, on Flickr

Once the engine is the right height it can be pushed back on to the gearbox

P1060818 by Paul_Barr, on Flickr

best to cable tie up the clutch lever or it is more effort to push the gearbox on
raise or lower gearbox or engine until parallel and a good shove it goes on

P1060821 by Paul_Barr, on Flickr

fit lower nuts to studs, I use stainless nyloc nuts

P1060822 by Paul_Barr, on Flickr

I fit the support bar bolts through engine mounts before doing up the M8's to the cradle so I know they will align later, then remove to fit cradle to engine.

P1060823 by Paul_Barr, on Flickr

lots of copper grease on cradle bolts, they tend to corrode into the cradle otherwise and then snap off, torque it all up

P1060825 by Paul_Barr, on Flickr

fit engine bar n torque up

P1060828 by Paul_Barr, on Flickr

winch engine up until engine bar hits the chassis and aligns with holes

P1060831 by Paul_Barr, on Flickr

lots of copper grease to stop corrosion and fit/ torque bolts with spreader plates and lock nuts

P1060833 by Paul_Barr, on Flickr

fit two top bolts engine to gearbox

P1060835 by Paul_Barr, on Flickr

ran out of light and it was getting too cold tonight

P1060834 by Paul_Barr, on Flickr

Page 13 on Friday 13th
good job I'm not superstitious

Smashing looking van Paul, looks in fantastic nick, did you get it locally? Will compliment the new engine well

Nice to see the engine going in, total opposite of my afternoon!


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300CE wrote:did you get it locally?

Came from overseas, cost me 200 quid for the ferry + recovery truck fee.

This is a cracking thread Itchy...

Nice looking Holdsworth too - welcome to the fold
Are you going to keep it?

Smiffo wrote: Are you going to keep it?

Of course, both I hope

After a hard 9 hours spannering today it's in and purring ( how people make a living doing this beats me)

Took a while to start it, fuel needed to be pumped through and the ignition timing was way out, either I got the dizzy cog one tooth out or the previous engine was out.

Ran it for half an hour until hot, oil pressure was good, early days but looking good

P1060846 by Paul_Barr, on Flickr

Good Work here!

Hello Paul,

Well done..

It's nice when they start up with no leaks..

How far was the timing out..just idle curiosity..

With luck the motor will be run in for good Summer hols..

Cordialement,

Timing was way, way out, over 45 degrees.

Pissed oil out of both rocker covers, changed covers.
Coolant leaked from thermostat, had to replace o ring even though it was new with thermostat.

other than that it was plain sailing

Just drove it for the first time, only a couple of feet forward and backwards but shows clutch and gearbox and linkage are working.
Not taxed or insured yet so can't take it out.
Did an oil change with fresh oil and filter, yesterdays half hour was with used oil and filter from the tin top, changed it last week.
Ran it for another half hour at about 1500 revs.
I have added a large dose of lead replacement to petrol.

Great news Paul, glad she's starting ok, once the timings all sorted I'm sure she'll be fine. I'll keep my fingers crossed that all is well for her maiden voyage.

With regards to insurance, give Lancaster Insurance a buzz. I'm fully comp with a limited mileage of 3000 for £139.53. That's also with 2 non-fault accidents (scoot) & 1 fault accident (the wife's motor).

Looks like I spoke too soon about oil pressure.
It's much lower than my DG, it's only just 2 bar hot 2000 rpm and I'd bet thats not even 80 deg oil temp on a day like today.
Hot idle is 0.8 bar.

Disapointing.

I wonder if thats due to crank being reground under size on big ends, it was about 0.02 under
or is it's down to standard crank bearings being used and not blue colour code, the main bearing journals were spot on blue but they are NLA

I measured tye difference between new main bearings and DG crank and it was about 0.1mm which I was surprised at, all the WBX I have stripped have had quite a lot of play in main bearings
Why are main bearing clearances so much more than big ends?
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