Steves Megane conversion build - She's finally running (VIDEO inside)
- Thread starter Stephenvenning
- Start date
Stephenvenning
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Stephenvenning
Gold Member
Stephenvenning
Gold Member
UPDATE:
Quite of bit of progress this week. First I managed to disassemble the input shaft, was quite simple once the nut was removed. The bearing was pressed off and then the components were laid out in order meticulously like i did on the input shaft. I then cleaned the gears with engine degreaser and then packed them away ready to be sent out for treatment.
I also cleaned up the other half of the casing by first shot blasting the outside and then thoroughly cleaning the inside with hot soapy water and degreaser. Removed the bearing race where the diff sits, the other bearing race will need a bead of weld running on the inside of it, once this is done, the weld pulls the bearing race inwards and it should just fall out
I had the Friday off so took the opportunity to take the turbo CHRa down the turbo dynamics for rebuilding and balancing, when i get it back Ill be ready to machine the housings to suit.
Thanks
Quite of bit of progress this week. First I managed to disassemble the input shaft, was quite simple once the nut was removed. The bearing was pressed off and then the components were laid out in order meticulously like i did on the input shaft. I then cleaned the gears with engine degreaser and then packed them away ready to be sent out for treatment.
I also cleaned up the other half of the casing by first shot blasting the outside and then thoroughly cleaning the inside with hot soapy water and degreaser. Removed the bearing race where the diff sits, the other bearing race will need a bead of weld running on the inside of it, once this is done, the weld pulls the bearing race inwards and it should just fall out
I had the Friday off so took the opportunity to take the turbo CHRa down the turbo dynamics for rebuilding and balancing, when i get it back Ill be ready to machine the housings to suit.
Thanks
Stephenvenning
Gold Member
Stephenvenning
Gold Member
TURBO TIME!
Right got some exciting news hopefully on the turbo side of my build. sent my CHRA off to Turbo Dynamics to get it balanced. It came back today and looks great, they have vapour blasted the core and rebuilt with new bearings and balanced. This therefore enables me to finally start machine the housings to suit. Should get the compressor cover done this weekend. I also made up a fixture to be able to mount the hot side of the turbo in the lathe, it needs some counterweighting to reduce vibration as it is off centre turning.
Gearbox parts are being sent off next weekend for shot peening and superfinishing. Also getting a quiafe atb diff ordered this weekend which should be here by next week.
There was one bearing race that wouldnt budge inside the casing and there was no way of pulling it out. To get it out I welded a bead of weld on the inside of the race. Once it cools the weld pulls in out the bearing race, effectively shrinking it. It just fell out after. I gave both casings a good wash again and dried them with an airline. They will be painted once Ive installed new bearing races.
Finnally Ive sent off all the bolts for the engine and gearbox for zinc plating, they will be nice and shiny when they come back
Anyway thanks for reading as always, will update on the turbo on Sunday.
Right got some exciting news hopefully on the turbo side of my build. sent my CHRA off to Turbo Dynamics to get it balanced. It came back today and looks great, they have vapour blasted the core and rebuilt with new bearings and balanced. This therefore enables me to finally start machine the housings to suit. Should get the compressor cover done this weekend. I also made up a fixture to be able to mount the hot side of the turbo in the lathe, it needs some counterweighting to reduce vibration as it is off centre turning.
Gearbox parts are being sent off next weekend for shot peening and superfinishing. Also getting a quiafe atb diff ordered this weekend which should be here by next week.
There was one bearing race that wouldnt budge inside the casing and there was no way of pulling it out. To get it out I welded a bead of weld on the inside of the race. Once it cools the weld pulls in out the bearing race, effectively shrinking it. It just fell out after. I gave both casings a good wash again and dried them with an airline. They will be painted once Ive installed new bearing races.
Finnally Ive sent off all the bolts for the engine and gearbox for zinc plating, they will be nice and shiny when they come back
Anyway thanks for reading as always, will update on the turbo on Sunday.
Stephenvenning
Gold Member
Stephenvenning
Gold Member
As promised there are updates with the turbo. Managed to set it and clock the turbo housing in the lathe to within 0.01mm. Ive bored it out to size of 47.3mm diameter (Leaving me 0.3mm for sanding and blending) Surface finish was very good and I took a 0.2mm final cut to achieve this. Ill contour to radius tomorrow and then blend with emery cloth.
Also managed to paint the gearbox housings the same gunmetal colour the rocker cover is painted in.
A short video link:
http://vid1373.photobucket.com/albu...6-3765-4E09-8139-DE3542D5538B_zpsoeww95wa.mp4
Thanks,
Also managed to paint the gearbox housings the same gunmetal colour the rocker cover is painted in.
A short video link:
http://vid1373.photobucket.com/albu...6-3765-4E09-8139-DE3542D5538B_zpsoeww95wa.mp4
Thanks,
Stephenvenning
Gold Member
Right finally managed to radius the compressor cover to match the billet 20t wheel. First cut the radius and then contoured and blended it with sand paper. I used engineers fluid to check whether the wheel was contacting anywhere. All in all a success so far.
Stephenvenning
Gold Member
Stephenvenning
Gold Member
All gearbox parts have been ordered now, all new synchros, new bearings and seals. Gears go out for treatment end of the week. Everything is coming together now. Cars coming off the road end of next month for its transplant
Stephenvenning
Gold Member
UPDATE:
I havent updated this in a while due to being very busy with the engine and getting ready for the conversion.
First on my list was to get the turbo finished and get the hot side machined for the larger HL turbine wheel. The was done the same as the compressor was machined. The radius was measured and was 7mm, a tool was then made up. The housing was fixed into a 4 jaw lathe chuck with the fixture Ive made. It was then "clocked" to ensure the centre of the hole was lined up with the centre of rotation of the lathe within 0.01mm. The hole was then opened up to 46.9mm allowing 1.2mm total clearance. The inducer hole was then machined to 52.4mm. Now using the radius tool I slowly cut the contour, much harder this time than on the compressor housing due to the turbine housing being made out of much harder cast iron. Once the desired contour was achieved it was blended with sand paper like before.
The turbo is now pretty much done, just need to weld the inlet pipe on, spray it black and assemble it.
I had a big parts order also this week, Ive ordered an 60mm core intercooler, quaife ATB LSD, forge boost pipes, scorpion 3 inch downpipe, milltek centre section, engine service parts, ARP head stud kit, helix stage 3 clutch and cover and a billet lightened flywheel. Ill also be ordering all the fuel system next week.
One thing that has been playing on my mind is the hassle of sending my block out for machining and getting all the clearances right then assebling it to correct spec. I could do it but I dont really have the time considering the car is coming off the road at the end of the month. Therefore Ive sent the block off for assembly at engine dynamics. The specs will be as following:
Kings racing bearings
ZRP h beam rods
wossner pistons
ARP cap bolts
New oil pump
New oil squirters
Blueprinted and balanced crank.
Should hopefully get it back in 2-3 weeks. Then I can assemble the whole engine
Finally Ive now installed all the bearings and seals into the gearbox casings, just need to gearbox internals to arrive back from shot peening and I can finish the gearbox.
Pictures as always:
Thanks guys
I havent updated this in a while due to being very busy with the engine and getting ready for the conversion.
First on my list was to get the turbo finished and get the hot side machined for the larger HL turbine wheel. The was done the same as the compressor was machined. The radius was measured and was 7mm, a tool was then made up. The housing was fixed into a 4 jaw lathe chuck with the fixture Ive made. It was then "clocked" to ensure the centre of the hole was lined up with the centre of rotation of the lathe within 0.01mm. The hole was then opened up to 46.9mm allowing 1.2mm total clearance. The inducer hole was then machined to 52.4mm. Now using the radius tool I slowly cut the contour, much harder this time than on the compressor housing due to the turbine housing being made out of much harder cast iron. Once the desired contour was achieved it was blended with sand paper like before.
The turbo is now pretty much done, just need to weld the inlet pipe on, spray it black and assemble it.
I had a big parts order also this week, Ive ordered an 60mm core intercooler, quaife ATB LSD, forge boost pipes, scorpion 3 inch downpipe, milltek centre section, engine service parts, ARP head stud kit, helix stage 3 clutch and cover and a billet lightened flywheel. Ill also be ordering all the fuel system next week.
One thing that has been playing on my mind is the hassle of sending my block out for machining and getting all the clearances right then assebling it to correct spec. I could do it but I dont really have the time considering the car is coming off the road at the end of the month. Therefore Ive sent the block off for assembly at engine dynamics. The specs will be as following:
Kings racing bearings
ZRP h beam rods
wossner pistons
ARP cap bolts
New oil pump
New oil squirters
Blueprinted and balanced crank.
Should hopefully get it back in 2-3 weeks. Then I can assemble the whole engine
Finally Ive now installed all the bearings and seals into the gearbox casings, just need to gearbox internals to arrive back from shot peening and I can finish the gearbox.
Pictures as always:
Thanks guys
Raptor6767
Gold Member
