SXI... Huge project

[DeanK]

Hey, i've got a pretty big project planned for the next month..

I hope fully strip down my engine (1.2 16v) to the bare minimum, and build her back up replacing old and worn parts with new much stronger ones, while giving the head a major recondition to get out her max performance, as i hear up to 75% of her power comes from the head, along with a performance clutch kit.

I chose to do this because i originally planned to replace my head gasket but i've been convinced by my tutors at this small time apprenticeship that i go to, that i might aswell give it a re-haul while its in the workshop and in bits. I bought her finding out only now, that the engine has been pretty neglected, as she has an oil leak and some major crap in and around the cams.

I also hope to paint up the parts, replace the old hoses with some Samco hoses aswell as making a high charge density induction kit and a performance header.

I am still debating what colour sceme i should go for... I want a Blue, black and silver scheme, while my tutors all want a Red, black and silver scheme, what do you guys think?

Ill keep you posted with any progress.

DK

[nath2905]

hi and welcome, looks like you have nice little motor there mate

[PRICER]

yea looks good that does mate, as for engine re-build is it worth the hastle? as its only a 1.2 16v? re-build and clean out the head by all means but port and polish its not worth it, and not is a performance clutch lol you want to get yourself a project engine, either a 1.6 16v or a 2.0 16v as both these engines can be made to reach 200bhp with work as like what your talking of doing to this poor 1.2 16v. and you can purchase both these engines for cheap thesedays. but cool looks a nice project, and as for colour wise why dont you just spray the whole car silver and colour code EVERYTHING and put a black roof on it, it would look the dogs dangleys then! the vauxhall scene thesedays is all about how clean and OEM you can make them.

[DeanK]

yea looks good that does mate, as for engine re-build is it worth the hastle? as its only a 1.2 16v? re-build and clean out the head by all means but port and polish its not worth it, and not is a performance clutch lol you want to get yourself a project engine, either a 1.6 16v or a 2.0 16v as both these engines can be made to reach 200bhp with work as like what your talking of doing to this poor 1.2 16v. and you can purchase both these engines for cheap thesedays. but cool looks a nice project, and as for colour wise why dont you just spray the whole car silver and colour code EVERYTHING and put a black roof on it, it would look the dogs dangleys then! the vauxhall scene thesedays is all about how clean and OEM you can make them.

Cheers for the advice bro, the reason why im doing it is that i've done 3 other rebuilds at my workshop, one on a nissan primera and 2 on 2 different toyota corolla GTI - 16, all these being our project and with a huge success. I also apsolutly love doing these projects as the end result is just priceless.
The only reason why im not doing a bigger project like you say is i can't afford it and i can't be asked with the hastle at the moment but i will definitly without a doubt be going to those lengths and further.
As for the performance, i know its just a 1.2, bless it, but i have access to the machines and advice from a few engine builders who want to help aswell. In our eyes what we want is to just see how much power we can get out of it, may it be alot or bearly anything its not gunna cost us a dime, more of an experience.
At the end of the day once she's all put back together she's gunna basically run like new and im gunna have a gorgeous engine bay so in a way theres a result?
But i think im gunna take your advice and not waste cash on a performance clutch lol maybe when she's spitting out over 200 break yeah but its not worth it at this stage.

DK

[DeanK]

Day 1

Finally had the go ahead with the project and wasted no time getting stuck in, we removed all the wires, radiator, bonnet ect with relative ease, we were all ready to go ahead and get it lifted out with the engine crane in only 4 hours, we started to worry a bit while we were draining the oil, as the oil wasn't the usual black, it was coming out as a very thin almost waterly light brown subtance and went from that to a very light brown and was dripping out like water, felt nothing like it should have.
Now Haynes say the only way to remove the engine was to drop it from the bottom but we proved it was just as easy to take it out the top, just needs a pretty big crane and has to come out on the piss slightly for the gearbox to fully clear the sides.




Within a few miuntes she was out and on the deck where we removed the gearbox, clutch and flywheel.



Everything was looking alright but i knew things couldn't be going this well... After getting her put on a engine stand




and started to remove all the ancillaries, bagging and labelling on the way, we finally came to remove the cam cover... after un-doing about 25 bolts we opened her up and found her to look like this...







After a discussion and inspection we found that SO FAR.. it hasn't damaged any major parts, and that if was left any later she would have called it a day and packed in, as we also found she didn't have any tranny fliud, a few drips if that counts, and both her crankshaft oil seals had gone... But we have big plans for her and she's gunna be a stunner.
Will keep everyone updated with any progress

DK

[PRICER]

eurgh thats rather manky looking, good luck

[nath2905]

i hope i can get all mine out that fast

[DeanK]

i hope i can get all mine out that fast

Don't doubt it mate, its not as hard as many think, get hold of a Haynes manual and study that first, best piece of advice.
If you ever need any help with anything just give us a message mate

DK

[nath2905]

got 1
sound mate, just source new bits for new engine then i shall begin

[DeanK]

Day 5

Just a quick update with the project, we cracked on with getting the Valve train and the cylinder head off, which meant lining up the engine so its firing on number one, (very important for when you put it all back together) removed the Camshafts, all the hydraulic tappets, and rollers, we labelled all 16 rollers with a engraving gun, for example.....
1E - Number one piston Exhaust
1i - Number one piston Inlet
We did this for literally everything, meant that each 'Set' of Rollers, tappets could wear together, so there wouldn't be any mixing up of any of the parts, i know this may be a little excessive but it does matter in the long run.
Then slackened off the cylinder head bolts in the right order and took her off. The head from we can see from a quick inspection doesn't seem to be in too bad condition one thing you can see from the photos is the the water ways have been blocked of quite badly which meant there was a major lack of water flow through the head and block which could of caused "Hot spots" which could crack the head and really isn't advised. Also mean't that the additives in the oil and water to resist corrosion couldn't get around so mean't that some water jackets where then corroded.

Will be checking her Bottem end tomorow see if thats taken a beating aswell. Will keep you updated.

DK

Timing gear


One method of timing the engine (yellow dots)


Burnt valves, signs of overheating, crappy combustion, crappy A/F ratio


Pistons have alot of carbon build up, water jackets are blocked


Keeping everything in order xD

[DeanK]

Just an update with the project, decided to go wid Blue, Black and silver as my colour scheme, i picked out a Metallic Monza blue, dont look too bad, tell me what you think?
The engine was in pretty sh*t condition so had to spend alot of time cleaning and inspecting everything, weren't that much fun lol
Painted almost all the parts now, there weren't as many as i thought. The gearbox is looking pretty sexy, Started to rebuild the engine now the parts have finally come, might actually have her running real soon.
Got a cold-air enclosed induction to fit when its back and running along with some Tarox F2000 discs and Tarox "Corsa" pads so she can stop when i want her to nicely, and i managed to get hold of a gorgeous set of Racetech reclining seats, i'll put some pics up of those soon.
Also gunna make some under-body body panels so to stop sh*t ruining the paint.
Not much else really, any questions are welcome

DK

[nath2905]

wen thats all together that should look well smart

[PRICER]

fair play its coming along well keep us updated

[jordan1994jordan]

nice project,engines looking sweet,would love to see the new colour scheme.....pictures paint a million words!

[matty101]

Awsome project, nice to see something a bit different. and will be nice to see the end result.