blacksofstichill Posted January 23, 2013 Share Posted January 23, 2013 Hi all, I've just signed up here although I've been on many times before checking out the projects, etc and some of you may already know me as a member on RS2000-16v.com. I've recently carried out an engine build for someone on that forum and after speaking to a good friend of mine he convinced me to put a thread up on here about it. Apologies in advance to anyone who's already seen the build on the RS2000-16V forum! The owner of the car David was busy getting his RS2000 4x4 bodywork into tip-top condition and wanted to have a Turbo engine in place once it was done. With this in mind he bought a spare 2.0 RS engine and a 2.3 Galaxy Engine and our plan is to combine the two engines to make a 2.2 Low Compression Engine which will be suitable for Turbocharging using standard components. So, the work began when this arrived at my Workshop Door, the 2.3 Engine - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0001.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0002.jpg Getting straight into it I got the Clutch off - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0003.jpg Flywheel off - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0004.jpg Engine Stand Bracket bolted on - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0005.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0006.jpg Onto the Engine Stand and into the Workshop - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0007.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0008.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0009.jpg Cam Cover off - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0010.jpg Timing Covers off - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0011.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0012.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0013.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0014.jpg Cams out - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0015.jpg Cylinder Head off - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0016.jpg Chains out - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0017.jpg Engine flipped over - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0018.jpg Sump off - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0019.jpg Pistons and conrods out - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0020.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0021.jpg Main Bearing Caps off - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0022.jpg Crankshaft is in good order but sadly won't be needed for this build - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0023.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0024.jpg Crankshaft Out - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0025.jpg Bores are in good order - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0026.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0027.jpg Pistons and rods, etc set aside to be cleaned up later - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0028.jpg I'll add the updates in stages as I'll mostly be copying and pasting from an existing thread on the other forum, it's very pic heavy as you can see but hopefully this'll be okay to get started with. Cheers! Gary Link to comment Share on other sites More sharing options...
bongo Posted January 23, 2013 Share Posted January 23, 2013 i'll read this a second time gary lol Link to comment Share on other sites More sharing options...
JC Posted January 23, 2013 Share Posted January 23, 2013 Nice read, keep it up Link to comment Share on other sites More sharing options...
blacksofstichill Posted January 23, 2013 Author Share Posted January 23, 2013 i'll read this a second time gary lol Cheers Marc!! Nice read, keep it up Thanks, much appreciated, hopefull you'll not get too bored once I go into detail with this! Block is now bare and ready for some reworking - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0029.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0030.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0031.jpg This Oil Feed needs to be blanked off which used to feed the balancer shafts - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0032.jpg Drilled out - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0033.jpg Tapped - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0034.jpg Bolt loctited in, job done - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0035.jpg Digging into my spares I found a half moon casting so I could see where the mismatch piece needed to be made for the block - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0036.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0037.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0038.jpg Onto the milling machine to machine up the surface of the block where the piece will fit in - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0039.jpg Before http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0040.jpg After http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0041.jpg I got a suitable bit of steel to make the mismatch piece out of - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0042.jpg Did a bit of measuring to get the angle correct - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0043.jpg Milling up the piece of steel - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0044.jpg A quick check to see if the angle is correct - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0045.jpg Some more milling - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0046.jpg Doesn't look to bad at all, will double check clearance from the chain when it's all together but it looks to be okay when I mocked it up with the crank and pump in place - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0047.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0048.jpg Drilled and tapped the engine block - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0049.jpg 6.1mm Hole drilled in the mismatch piece - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0050.jpg To make the stud for fitting the mismatch piece I used an M7 x 1.0 bolt - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0051.jpg Turned down part of it to 6mm - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0052.jpg Threaded that part to M6 x 1.0 http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0053.jpg Cut the bolt head off to leave me with a stepped diameter stud - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0054.jpg The M6 thread is a nice snug fit in the block and the M7 thread being slightly larger holds the block in place and allows an M7 nut for the timing cover bolt. http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0055.jpg Fitted into place - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0056.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0057.jpg Cheers! Link to comment Share on other sites More sharing options...
sidrick Posted January 24, 2013 Share Posted January 24, 2013 Great work. Count me in. Link to comment Share on other sites More sharing options...
blacksofstichill Posted January 24, 2013 Author Share Posted January 24, 2013 Cheers! Just noticed you're from Aberdeen, that's the area where the owner of this Engine is from, it's being mapped at Wallace Performance next month if all goes to plan. Timing cover laid into place to see how it looks - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0058.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0059.jpg With that out of the way it was time to Hone the Bores in the Block http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0060.jpg Honing Bar in place - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0061.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0062.jpg It didn't take a lot of work to get them to come up mint as they were already in good order - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0063.jpg The engine block is in good cosmetic order, so much so that you can hardly tell I've cleaned this side of it, Before - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0064.jpg After - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0065.jpg Cleaned up the other side of the block which was mostly just dusty, from this - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0066.jpg to this - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0067.jpg Block now set aside, cleaned up, honed and ready for painting - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0068.jpg I'll keep adding updates as soon as I can, cheers! Link to comment Share on other sites More sharing options...
Stu Posted January 24, 2013 Share Posted January 24, 2013 What pistons do you intend to run in this engine? Link to comment Share on other sites More sharing options...
blacksofstichill Posted January 24, 2013 Author Share Posted January 24, 2013 We're using the standard 2.3 Pistons for this, although it will be turbo'd we're not planning on huge amounts of boost with 200bhp being the target figure we want to achieve. There's already a 2.3 Low Boost Turbo RS2000 using skimmed standard Pistons which has proven to be reliable and runs around 200bhp at the moment, if we were aiming any higher though it would definitely have to be forged pistons and rods. Now I'm ready to make a start on the pistons and rods, here they are as removed from the engine - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0069.jpg Rings off - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0070.jpg On the left I have a 2.0 RS Conrod, on the right I have a 2.3 Conrod, if you look closely you'll see that there's a small hole drilled in the 2.0 rod and the 2.3 rod is blank in the same area. These holes are for oil spray to cool the underside of the piston and since I'm using the 2.3 rods I'm going to drill them in the same way as the 2.0 ones. http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0071.jpg Using a 2.0 Piston, rod and bearing shell I set up a little jig on the milling machine so I could accurately drill the same hole in the 2.3 Rods - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0072.jpg Checking the alignment of the drill with the bearing shell - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0073.jpg Centre Drilled - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0074.jpg Drilled right through with a smaller drill - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0075.jpg Drilled partially through with a larger drill to the same depth as it is on the 2.0 rods - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0076.jpg Job Done - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0077.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0078.jpg The pistons needed a good clean up, the ring grooves were carboned up - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0079.jpg A Piece of old Piston ring makes a great scraper for cleaning out the ring grooves - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0080.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0081.jpg Grooves cleaned out - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0082.jpg All pistons, rods and main bearing caps cleaned and degreased - http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0083.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0084.jpg http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0085.jpg Link to comment Share on other sites More sharing options...
ganges Posted January 24, 2013 Share Posted January 24, 2013 really good thread this, i am no engineer, but can well appriciate the work going into this, keep up the great work Link to comment Share on other sites More sharing options...
Stu Posted January 24, 2013 Share Posted January 24, 2013 What will the final compression ratio be with this package? Link to comment Share on other sites More sharing options...
blacksofstichill Posted January 24, 2013 Author Share Posted January 24, 2013 really good thread this, i am no engineer, but can well appriciate the work going into this, keep up the great work Thanks, much appreciated. Luckily I have a lot of kit in my own workshop so I've been able to do all of the work myself rather than passing it on to anyone else. What will the final compression ratio be with this package? It works out to be 8.72:1, that's without any skimming of pistons, decompression plates or anything like that. Link to comment Share on other sites More sharing options...
Stu Posted January 24, 2013 Share Posted January 24, 2013 Ah right, I didn't catch what head you were using? I was under the impression using the 2.0 head on the 2.3 bottom end gave you a raised static CR. 8.7:1 should be fine for 200bhp with the right choice of cams (most likely the OE n/a ones to give it a bit of overlap). I really like the i4 engine. It's much better than the zetec in some ways, shame it's a bit of a lard-arse. Link to comment Share on other sites More sharing options...
blacksofstichill Posted January 24, 2013 Author Share Posted January 24, 2013 Sorry, I didn't really explain this properly in the beginning, you're right in saying that the 2.0 head on the 2.3 bottom end raises the compression, that's quite a common conversion to give RS2000s a 2.3 engine as you'll no doubt already know. Some people leave the compression higher and some people have the pistons skimmed to reduce the compression slightly. This Build is the 2.3 Block, pistons and rods mated to the 2.0 head and using the standard RS cams. However, instead of using the 2.3 Crank as would be done on the 2.3 conversion we used the 2.0 crank to reduce the stroke and bring the compression ratio down which is why it comes out as a 2.2 (2169cc to be exact). I love the I4 engine and the way it pulls even as standard but you're right, it's a very hefty engine! Link to comment Share on other sites More sharing options...
Stu Posted January 24, 2013 Share Posted January 24, 2013 Ah right, thanks for clarifying. What kind of deck protrusion do you end up with? I'm guessing about -1.5mm or so? Link to comment Share on other sites More sharing options...
blacksofstichill Posted January 24, 2013 Author Share Posted January 24, 2013 No problem at all, cheers! It ends up -2.5mm doing it this way. Link to comment Share on other sites More sharing options...
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