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martinhodge 03-12-2015 22:11

not a zr i know
 
well havnt been on here in a while .

anyway im rebuilding my rover coupe

well before shot blasting i decided to remove all the underseal and seam sealer from the joins of the chassis rails so that i could stich weld down the car to stiffern the chassis up a bit and to make it a bit stronger .

so spent a few hours with a scrapper and a wire brush attachment cleaning up the areas that i was gunna weld up .

quick jet wash out side

http://i193.photobucket.com/albums/z...pshu3jos6v.jpg

some of the damage and rust

http://i193.photobucket.com/albums/z...psns1j9hoj.jpg

damage to front passenger sill

http://i193.photobucket.com/albums/z...psfcx1nxzy.jpg

where the tyres used to rub . this will be cleaned up and welded up .

http://i193.photobucket.com/albums/z...pso8kvj15t.jpg

rust and damage to rear drivers sill

http://i193.photobucket.com/albums/z...pswepjoyiv.jpg

rust to the drivers rear quater .

http://i193.photobucket.com/albums/z...psxthri9rv.jpg

all the oil and crap under the car

http://i193.photobucket.com/albums/z...pss543s8zk.jpg

where some one had done a repair on the rear anti roll bar before . tempted to cut this out and re do it as it isnt straght and not the best of repairs .

http://i193.photobucket.com/albums/z...psgxtanfri.jpg

http://i193.photobucket.com/albums/z...psnxouxkcy.jpg

removing all the seam seeler on the chassis rails .

http://i193.photobucket.com/albums/z...psvbvgs12c.jpg

removing all the seem sealer from the rear end

http://i193.photobucket.com/albums/z...pstevd23j0.jpg

i am fitting a new tank and uprated feul pump so banged a hole in the old one to remove the old fuel

http://i193.photobucket.com/albums/z...psysbbos3j.jpg

http://i193.photobucket.com/albums/z...psu3pnoubr.jpg


then after all the areas are exposed a light dusting of weld through primer to stop it rusting .

http://i193.photobucket.com/albums/z...psh3xihsh7.jpg

now on wards to remove the rear panels which i have left the body shop man to do

martinhodge 03-12-2015 22:13

so built up the front suspension and brakes .

http://i193.photobucket.com/albums/z...psmdyvnrel.jpg

the engine rebuild .

one fully balanced bottom end and reworked head .

bottom end balanced and matched to the pulleys and the flywheel .

flywheel been skimmed as well .

the crank was brand new and was still out weight wise lol

http://i193.photobucket.com/albums/z...psvd0ngjop.jpg

http://i193.photobucket.com/albums/z...psncwjokje.jpg

blocking off a oil passage and tapping the oil pump so that it forces all the oil round the oil cooler not just some of it like in the oe set up .

http://i193.photobucket.com/albums/z...psgpdz1ydb.jpg

http://i193.photobucket.com/albums/z...psdnqasuod.jpg

some head work .

basically taking all the machine marks out of the chamber faces to reduce the risk of det . and recutting valves and porting and maching all the manifolds to the head .




before

http://i193.photobucket.com/albums/z...psdozkvc1m.jpg

after

http://i193.photobucket.com/albums/z...pshqmpqife.jpg



http://i193.photobucket.com/albums/z...psabub4hth.jpg

had to get all the shims for the solid tappets remade . std car has hydro tappets . but they lock at higher rpm so roversport replaced them with solid ones

but this means that these will need to be checked and changed as a serviable item .

http://i193.photobucket.com/albums/z...psedwl5ovh.jpg

checking and calculating volumes

http://i193.photobucket.com/albums/z...ps7z9pxvky.jpg



http://i193.photobucket.com/albums/z...pswcjfonzx.jpg

cleaning the sump out and welding in a baffle plate for those hard corners !



http://i193.photobucket.com/albums/z...ps5e79p7n2.jpg

http://i193.photobucket.com/albums/z...pskxbhgoav.jpg

http://i193.photobucket.com/albums/z...pszxk59znu.jpg

new je 1 mm over sized forged pistons

http://i193.photobucket.com/albums/z...psrrnnsca3.jpg

fitted with 3 layer steel head gasket and arp head bolts

http://i193.photobucket.com/albums/z...psxwsoduta.jpg

forged conrods

http://i193.photobucket.com/albums/z...ps9qtqu2hh.jpg

doing a dry build and checking all the bearings etc .

http://i193.photobucket.com/albums/z...psddh6gsf4.jpg

http://i193.photobucket.com/albums/z...psb7sfbpef.jpg

http://i193.photobucket.com/albums/z...pskt0amsc3.jpg


http://i193.photobucket.com/albums/z...psmogfufu3.jpg

martinhodge 03-12-2015 22:13

m moving house soon so having to get the engine out of the house and into my garage as im keeping the garage . and that way dont have to worry about moving it on move day .

it will end up in the new house dont you worry .

now i had forgot how heavy these things are so i had to man up and lift it out the house on the std trying not to damage the door frame on the way out lol

http://i193.photobucket.com/albums/z...pswsmvlydh.jpg

taking off the std .

http://i193.photobucket.com/albums/z...pssssmcjvc.jpg

http://i193.photobucket.com/albums/z...pstljgw0mj.jpg


std oe valeo clutch going on this is only for the run in of the new engine . to make sure a theirs no leaks etc from seals and to give me a much smoother run in time rather than a much more aggressive clutch .

http://i193.photobucket.com/albums/z...s6tafzjbr.jpeg

aligning the clutch

http://i193.photobucket.com/albums/z...psfv6aafhx.jpg

its started raining now . i will get the gear box on later and start fitting up all the mounting points and other bits and bobs so im ready to just crane the whole thing in . i will get the engine loom on as well .

http://i193.photobucket.com/albums/z...psogvmxjc8.jpg


stoped raining so gear box on engine

http://i193.photobucket.com/albums/z...psjh7cjtjj.jpg

next step is to get the lower tie bar mount bush remade in poly i seen some one d it before on a forum some where .

martinhodge 03-12-2015 22:14

right its getting quieter with work etc now due to rolling up to xmas . so gives me and bodyshop man more time ti crack on with the body work .

http://i193.photobucket.com/albums/z...pswemauoxx.jpg

boot floor needs replacing as i will be shot blasting the whole rear end etc and i dont think their will be much left once i do .

this is due to years of coupe leaky boot syndrome .

http://i193.photobucket.com/albums/z...psv0zsng26.jpg

rear shelf out .

http://i193.photobucket.com/albums/z...psjaiv3y4a.jpg

rest of interior and carpet out

http://i193.photobucket.com/albums/z...ps9nkx8qem.jpg

http://i193.photobucket.com/albums/z...pssipqyp99.jpg

doors etc stripped and off

http://i193.photobucket.com/albums/z...psnrqohtzw.jpg

http://i193.photobucket.com/albums/z...ps3vjwp0bu.jpg

bushes pressed into the arms

http://i193.photobucket.com/albums/z...pskc7zougm.jpg


passenger side rear quater removed mostly . will be removing it higher up on the rear piller as per hs a bit later on when ready to mount new one up

http://i193.photobucket.com/albums/z...pspz6kaxmn.jpg

http://i193.photobucket.com/albums/z...psbr6mz3iw.jpg

damage an rust to inner sill and this is the good side!!

http://i193.photobucket.com/albums/z...psq6mnqbys.jpg


http://i193.photobucket.com/albums/z...psbd6fdfz4.jpg

http://i193.photobucket.com/albums/z...savyabfml.jpeg

will need to get the inner sill repaired or find a new part for it

martinhodge 03-12-2015 22:14

ue to mine being broken i managed to find a superflex bush that fits

http://i193.photobucket.com/albums/z...psphhrdoas.jpg

had to burn the old bush out .

new bush fitted

http://i193.photobucket.com/albums/z...psv3pufcdj.jpg

http://i193.photobucket.com/albums/z...psgn0iqawe.jpg

http://i193.photobucket.com/albums/z...psynompjos.jpg

its a very tight fit and ur need a vice to get it in or use a long nut and bolt and some washers etc like i did but the fit looks good .

martinhodge 06-12-2015 20:12

well both sides off car now pics to follow next week when i manage to get down their

anyway a huge thanks to to mr and mrs taylor . add and stacey to every one else for giving me a couple of old t25s .

http://i193.photobucket.com/albums/z...psux7za5l3.jpg



i only need the core and the exhuast housing .

i will get the exhuast housing machined out to take a 0.64 wheel and i will get a much bigger t3 compressor housing machined out to take a much bigger gt28rs billet comp wheel .

and then get it rebuilt with 360 thrust bearings etc . cr turbos will be doing the work .

this will just be a stop gap turbo whilst i run the new engine in before fitting the gtx turbo .

one housing is scrap

http://i193.photobucket.com/albums/z...psmcufaf7n.jpg

and one housing is gd but a broken stud .

http://i193.photobucket.com/albums/z...psxjp0bp9d.jpg

so a quick easy out job should sort that out .

between the two i should have all the bits needed for a complete unit .

basically turning a t25 from this into this

http://i193.photobucket.com/albums/z...psveeiulkj.jpg

martinhodge 29-12-2015 19:04

right shot blasted off the areas that where rusty .

and the areas that im planning on reinforcing and stick welding . chassis rails etc


http://i193.photobucket.com/albums/z...psoernlhiz.jpg

http://i193.photobucket.com/albums/z...pshcg8gjzi.jpg

http://i193.photobucket.com/albums/z...psxvg9bqrm.jpg

http://i193.photobucket.com/albums/z...ps1sexpkzo.jpg

shot blasted rear sills

http://i193.photobucket.com/albums/z...psa57uiquw.jpg

http://i193.photobucket.com/albums/z...psx6wrfd1r.jpg

http://i193.photobucket.com/albums/z...pss1gdmeau.jpg

http://i193.photobucket.com/albums/z...psufuflkka.jpg

http://i193.photobucket.com/albums/z...psx37zdhqc.jpg

tank removed

so coudl shot blast this area so can bang a few stichs in here as well

http://i193.photobucket.com/albums/z...psjdlcjkti.jpg

fuel lines removed so can stich weld that side as well

http://i193.photobucket.com/albums/z...psxz3m2ukx.jpg


had to get inside the boot as it was rusting their as well due to the rear screen leaking

http://i193.photobucket.com/albums/z...psf3uxztom.jpg

http://i193.photobucket.com/albums/z...psfjhcnz8t.jpg

boot floor plan blasted

http://i193.photobucket.com/albums/z...psjbsmw4cr.jpg


now all the areas have been cleaned up and sorted out time to start welding 8)

JOHNDQ 02-01-2016 16:02

Looking good :)

martinhodge 25-01-2016 16:48

wheels refurbed in a sparkly . grey kinda colour . cant really see the sparkle in the photo. wrapped in new toyo r888s

http://i193.photobucket.com/albums/z...pssnf1sbyn.jpg

and springs shot blasted and coated in red . again photo changed the colour for some reason

http://i193.photobucket.com/albums/z...pssi6bobrz.jpg

martinhodge 26-02-2016 14:42

suspension rebuilt had the cups reannodised as well

https://scontent.xx.fbcdn.net/hphoto...fb&oe=57593B9A


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