Club 80-90 Forums

A long time coming, I know, but I wanted Andy to give me the nod before posting all of the pics he sent me of the rebuild.

For those that didn’t know of my recent switch to a DJ, I had some low compression issues on my old 1.9DG, and talked myself into the daddy version 

For anyone that did know, it’s been in and running a couple of weeks now, and I’m chuffed to bits with it.

Here are some pictures for those of you that like a bit of rebuild porn










































More to follow!

Plenty more, and I’ve skipped a few. Will post some extras in a few hrs

Nice clean work environment makes such a big difference to the final result. I would have ported the AMC heads cos they can be a bit clunky behind the valve seats, doesn't take long and improves the cylinder filling efficiency a little. Do the JP flywheels fit a bit better on the crankshaft these days? The early ones would go on if you threw them across the workshop blindfold!

Very nice. I'm partial to a bit of engineering porn.
 

silverbullet wrote: ↑11 Aug 2026, 17:45 Nice clean work environment makes such a big difference to the final result. I would have ported the AMC heads cos they can be a bit clunky behind the valve seats, doesn't take long and improves the cylinder filling efficiency a little. Do the JP flywheels fit a bit better on the crankshaft these days? The early ones would go on if you threw them across the workshop blindfold!

TBH, I’m not sure. All I know is, it turned up with some pictures, some Whisky, and drives 100 times better despite me driving it very gently at the moment. Just glides along now.

Best thing I did on the van in a looong time.

It's too nice to be hidden out of view, isn't it?

R0B wrote: ↑11 Aug 2026, 19:21 It's too nice to be hidden out of view, isn't it?

It is. I am now one of those people that says “come and have a look at this” 

Lovely stuff. I find the most satisfying bit is weighing the conrods and pistons to produce a well balanced engine. During my last rebuild with new conrods and used pistons it was about 4 grammes difference.

What's the MV pistons doing in the photo shoot?

Just realised. Bought for the jugs and gudgeon pins.
Love the way the conrods are marked up too. The cast marks for correct way highlighted too. Will take that on board.

Smiffo wrote: ↑11 Aug 2026, 18:30
TBH, I’m not sure. All I know is, it turned up with some pictures, some Whisky, and drives 100 times better despite me driving it very gently at the moment. Just glides along now.

Best thing I did on the van in a looong time.

Don't drive it like its made of eggshells, use the revs (4k is fine) and the most important thing is to get it on & off load to bed the rings in, pootling around will glaze the bores and then it will use oil forevermore.
Short bursts of fairly hard acceleration and then lift off, rinse and repeat. Go out and find some steep hills to drive up.

silverbullet wrote:

Smiffo wrote: ↑11 Aug 2026, 18:30
TBH, I’m not sure. All I know is, it turned up with some pictures, some Whisky, and drives 100 times better despite me driving it very gently at the moment. Just glides along now.

Best thing I did on the van in a looong time.

Don't drive it like its made of eggshells, use the revs (4k is fine) and the most important thing is to get it on & off load to bed the rings in, pootling around will glaze the bores and then it will use oil forevermore.
Short bursts of fairly hard acceleration and then lift off, rinse and repeat. Go out and find some steep hills to drive up.

Awesome


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Show off  .

When I built mine mrs booked a holiday with some friends so I ended up going on a 300 mile journey about a week after fitting it :roll:
Motorway driving first real drive out so I was speeding up and slowing down a lot went like a stabbed rat, still does lots of fun.