S3 WOT, 2 cylinders lost compression

[Sparky]

I shall leave it to Henry to answer that as he wishes!

[skiing]

Exhaust was purchased and fitted a decade or so ago from one of the usual suspects. I think it was mainly fitted as the engine was out. It has been off once before for a head rebuild (around 8 years ago I think) - head rebuild could well be part of the issue now! - and it was never quite right after refitting. It leaked etc. and various other challenges as Sparky mentioned. I loved the noise it made though! For me I have always wanted to go back to a standard twin pipe outlet in anycase - so will prob go for another more easy to fit and remove system. Needless to say, last time it was removed and re-fitted, copper coated nuts etc were supplied by me but not used…

[Dan E]

Sparkles give me a shout if you struggle with the leads and plugs I can offer much advice!! 

[Sparky]

You're a true friend.  But isn't that the advice you borrowed from me last week?

[Dan E]

SSSSSHHHHHHHH

[Sparky]

In other news, I have been unable to continue my butchery today following an eye examination involving pupil dilation leaving me looking doe-eyed and cute, but unable to see shit in daylight.  Dremel supply replenishment was achieved today, so tomorrow I will attempt a surgical strike before resorting to Milwaukee mayhem.

Did I mention my Milwaukee?

[Chillidoggy]

I heard Sparky can fix Esprits over the phone during a summer solstice. Rumour has it it’s some kind of Voodoo magic but no one really knows. There’s a video circulating on the web of him naked in the garden, throwing down some chicken bones, going into a trance, stomping around and chanting before making a phone call which apparently fixed the problem.

Astonishing.

[pete]

Before or after the threesome

[Sparky]

13 minutes ago, Chillidoggy said:

I heard Sparky can fix Esprits over the phone during a summer solstice. Rumour has it it’s some kind of Voodoo magic but no one really knows. There’s a video circulating on the web of him naked in the garden, throwing down some chicken bones, going into a trance, stomping around and chanting before making a phone call which apparently fixed the problem.

Astonishing.

@Dan E will corroborate.

10 minutes ago, pete said:

Before or after the threesome

You win a cigar!  That may have been too subtle for some.

[Sparky]

Armed with fresh burrs, I renewed my attack on that travesty of an exhaust.  More than 4 bloody hours to remove 5 manifold nuts.  Even then I could barely clear the head past the monstrosity.  Anyhow, at last it's off.  Contact witness for all exhaust valves, with 3 seriously damaged.  Little point my investigating the head further.

Onward to the block.  All looked pretty good initially, until I was running a cloth over piston no. 2 and noticed movement.  Tested the others, and I'm able to move 3 liners with thumb and forefinger (no, I didn't make the schoolboy error).  Point of interest: the only seemingly solid liner is the cylinder that had both valves bent.  A fair step at the top of the liners.

I'm going to remove the engine, but it'll be shipped off to be rebuilt as I just don't have the space.  I'll leave all the difficult decisions to the rebuilder!

 

[pete]

PNM?

[Sparky]

Would be my preference, but Pete is up to his ears in rebuilds.  Henry's in a hurry. so looks like Max500.

[Sparky]

Been a long time coming due to commitments of involved parties, but Henry's car is now safely in storage at a secret secure location.  I removed the engine yesterday.  Top tip:  don't put a 912 in a 907 hole without lots and lots of planning.  Christ on a bike, the bodgery is monumental.

Despite having already spent hours in a bloody battle involving head and exhaust removal, it still took another 9 hours to remove and make ready for the pallet.  'Custom' wiring, plumbing and what I can only describe as shimming all needed careful documentation during removal.  Some items would only give in to butchery.  This will be a sumbitch to get back in, and the exhaust will be a laugh a minute.

A few pics that tell some of the story, but by no means all of it, as I was too preoccupied!

The day begins.  Those liners may need a little extra sealant.

Awful clearance.  Took a while to figure out the forward section of engine surround had multiple woodscrews through it in an attempt to draw it forward of alternator and thermostat exit pipe.

This is AFTER removing the surround.

Crossgate rod/cable never coming apart.

Finally, out.

Sheared tensioner/alternator mounting.

A lot of stuff to be done in the bay.  Some bad hoses, and stacks of making good on electrical connections.  It worries me when I see loads of washers on top of an engine mounting.  I can only assume it was an attempt to stop the ridiculous exhaust hitting the chassis.  Three of the pipes are still in there, intertwined with the chassis.  Extreme violence has so far failed to seperate the poorly-named slip joints.  Very few nuts/bolts/screws are to specification; I have found Philips screws in place of bolts.

Don't think we'll see that again for a while.

[tomcattom]

1 hour ago, Sparky said:

It worries me when I see loads of washers on top of an engine mounting.  I can only assume it was an attempt to stop the ridiculous exhaust hitting the chassis.

Or is the mount shot? My LH mount had settled so far that the exhaust cam sprocket had begun to cut into PS hose. I was surprised how much higher the engine visibly sat in the bay after putting brand new mounts in.

[Sparky]

No, mount is fine.   This looks to be just one of several attempts to stop interference.

[skiing]

Sorry to see such bodging on my old girl - but I am sure it will be engineered much more effectively when it goes back in... I am now awaiting what the deal is with the engine itself and starting to order some parts. All such fun! Thanks as ever to the guru Sparky for fighting his way to this point... 

[skiing]

An update! - The engine is stripped and cleaned and being inspected. First reports indicate that crank, pistons and liners should be ok (crank to be polished etc). So it will be mainly head work - new cam carrier required but I am on that. Current target completion date - some time in October hopefully.... 

[andydclements]

Can we just be clear, October 2022?

 

I'm used to seeing project creep impacting timelines.

[Sparky]

*following

[drdoom]

1 hour ago, andydclements said:

Can we just be clear, October 2022?

 

I'm used to seeing project creep impacting timelines.

🙉 🙉

[Chillidoggy]

October? Can’t help but think that’s a long time for an engine rebuild, so presumably you’re doing it yourself?

[skiing]

I am being conservative on the timing - the re-build will commence properly in August so on the basis that it is done in early September, I have said October to allow for extra time... 

[Sparky]

That's it, oi tells ya!  No more feckin cars.

[Escape]

1 hour ago, Sparky said:

That's it, oi tells ya!  No more feckin cars.

So many times have these words been uttered. But I wouldn't know what else to do!

[skiing]

It is done! I drove it home! Sparky has been a legend even if my lovely car fought him at every stage…