blacksofstichill Posted May 20, 2013 Share Posted May 20, 2013 Time to add another of my projects on here, this one is for a Customer from Bournemouth and originally started as job to rebuild an engine, however I now have the complete car here to carry out the project from start to finish so I thought some of you might find it interesting. The story starts back in 2009 when Olly (my customer) saw an engine for sale on ebay, it was an I4 out of an RS2000 that had be turbo'd and built to handle 300+ bhp according to the listing. It didn't sell the first week, the second time it was up it did sell for £600 odd but he missed the auction. he spoke to the seller a few days later who had not been contacted by the original buyer so he agreed to sell it to him instead.It was in a bit of a state as it had been stood for a few years on a pallet, under a tarp, it then lived down the side of of his house for 3 years. Here are some pics of it as it was before it came up to me - http://i579.photobucket.com/albums/ss237/doctorevil72/DSC00981_zpsadce0ad2.jpg http://i579.photobucket.com/albums/ss237/doctorevil72/DSC00982_zpsde4c0849.jpg http://i579.photobucket.com/albums/ss237/doctorevil72/DSC00979_zps57e8216e.jpg http://i579.photobucket.com/albums/ss237/doctorevil72/DSC00984_zpsbcc69822.jpg http://i579.photobucket.com/albums/ss237/doctorevil72/rs2000/IMG_2941_zpseacc83e8.jpghttp://i579.photobucket.com/albums/ss237/doctorevil72/rs2000/IMG_2940_zps53473eb3.jpg On the pallet ready to go: http://i579.photobucket.com/albums/ss237/doctorevil72/rs2000/IMG_2942_zps4cbc7047.jpg And after arriving safely here - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0001.jpg clutch and flywheel removed, it has a 4 paddle clutch plate as you can see - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0002.jpg Engine stand bracket bolted on and engine uprighted on the pallet - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0003.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0004.jpg My Old Man ready to leap into action with the Forklift - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0005.jpg Just ouside my workshop door - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0006.jpg Lifted up onto the engine stand at the door and removed from the pallet - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0007.jpg Into the workshop now for a good look round it - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0008.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0009.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0010.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0011.jpg Escort RS Turbo Manifold has been mated to the RS2000 Flange, it makes a couple of studs very tight for space but looks to have done the job - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0012.jpg Oil Return fed back into the block - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0013.jpg Oil feed pipe T-pieced into the block at the oil pressure switch - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0014.jpg Non-standard Fuel Rail and Injectors - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0015.jpg More pics, etc to be added soon, cheers! Link to comment Share on other sites More sharing options...
JC Posted May 20, 2013 Share Posted May 20, 2013 Nice write up so far, I look forward to more :-) Link to comment Share on other sites More sharing options...
scottybo Posted May 20, 2013 Share Posted May 20, 2013 i think i might know your customer, i bought a bunch of parts off him a little while back Link to comment Share on other sites More sharing options...
sidrick Posted May 20, 2013 Share Posted May 20, 2013 Can't wait to see this build Link to comment Share on other sites More sharing options...
danny42 Posted May 20, 2013 Share Posted May 20, 2013 Definitely going to be following this one *sits down to get comfy* Link to comment Share on other sites More sharing options...
blacksofstichill Posted May 20, 2013 Author Share Posted May 20, 2013 Nice write up so far, I look forward to more :-) Thanks, I hope you'll find it interesting. I'll be concentrating on the engine to start with before moving onto the car itself so there's plenty of work ahead. i think i might know your customer, i bought a bunch of parts off him a little while back Quite possibly, he's had a few RS2000s over the years, did you meet him when you bought the stuff? Can't wait to see this build Great stuff, cheers! Definitely going to be following this one *sits down to get comfy* Thanks, you'd best get comfy, there's plenty to see on this one as it progresses. Starting to strip it down, engine mount off, water pump off, alternator and power steering pump and bracket all off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0016.jpg Exhaust Manifold off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0017.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0018.jpg Inlet Manifold off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0019.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0020.jpg Thermostat Housing removed - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0021.jpg Cam Cover off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0022.jpg Upper Timing Cover removed - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0023.jpg Cams removed and it's ready for the head to come off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0024.jpg Cylinder Head removed - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0025.jpg Exhaust Ports - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0026.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0027.jpg Inlet Ports - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0028.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0029.jpg Valve Spring Caps are visibly different from standard so I decided to remove 1 valve just to check them out - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0030.jpg Valve Spring compressed and collets removed - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0031.jpg Valve Springs are not standard and the Spring Caps are lightweight and non-magnetic, I'll guess at them being made from Titanium but I could be wrong, either way they're definitely uprated items - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0032.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0033.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0034.jpg The Head itself has some corrosion and carbon build up but it will hopefully all clean up fine - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0035.jpg Link to comment Share on other sites More sharing options...
scottybo Posted May 21, 2013 Share Posted May 21, 2013 yeah he lived in boscombe. at the time he had a silver mk5 rs and a blask mk6 4x4. i bought my skirts and spats off him. the black 4x4 he had originally belonged to my friends mum christina weaver (chair of the hampshire rs owners club) Link to comment Share on other sites More sharing options...
ganges Posted May 21, 2013 Share Posted May 21, 2013 here we go again......yet another great start, to another great thread 1 Link to comment Share on other sites More sharing options...
blacksofstichill Posted May 21, 2013 Author Share Posted May 21, 2013 yeah he lived in boscombe. at the time he had a silver mk5 rs and a blask mk6 4x4. i bought my skirts and spats off him. the black 4x4 he had originally belonged to my friends mum christina weaver (chair of the hampshire rs owners club) That's the guy, I didn't know where he bought the black 4x4 from but I know he sold it to Dean Weaver (I presume that's your mate unless he has a brother?) when he was finished with it. Olly's a really good guy, put himself to a lot of time and and effort so I could do this job for him. here we go again......yet another great start, to another great thread Thanks, hope you enjoy following this one too. With the head off you can see the pistons aren't standard - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0036.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0037.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0038.jpg So, eager to see exactly what else was in there I cracked on with the strip-down, crank pulley off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0039.jpg Lower Timing Cover off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0040.jpg The Bolt for the Pump Sprocket had seen a bit of action - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0041.jpg Pump Sprocket off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0042.jpg Can you spot the conrod in the background? - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0043.jpg Crank Sprocket off, chains out - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0044.jpg Oil Pump out which incidentally looks mint - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0045.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0046.jpg Oil Filter off, crank sensor out - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0047.jpg Adaptor for Oil feed to turbo at the oil pressure switch - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0048.jpg and removed - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0049.jpg Crank vent pipe removed - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0050.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0051.jpg Engine Flipped over - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0052.jpg Sump off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0053.jpg You can get a better look at the rods now, they're Forged items and going by the bolt heads they are from Cunningham Rods in the US - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0054.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0055.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0056.jpg Baffle Plate off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0057.jpg Pickup pipe off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0058.jpg Rods numbered before removal - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0059.jpg Link to comment Share on other sites More sharing options...
scottybo Posted May 21, 2013 Share Posted May 21, 2013 haha small worl eh? i bought my current escort from dean. i used to go to school with his brother mark. and his mums the head of the rs owners club hampshire. thats black escort was a rusty bag of shite lol do u know dean or his family? Link to comment Share on other sites More sharing options...
danny42 Posted May 21, 2013 Share Posted May 21, 2013 Impressive progress, not bad for a days work lol, wish i could get that much done! Someones spent a pretty penny on that motor. Link to comment Share on other sites More sharing options...
blacksofstichill Posted May 22, 2013 Author Share Posted May 22, 2013 haha small worl eh? i bought my current escort from dean. i used to go to school with his brother mark. and his mums the head of the rs owners club hampshire. thats black escort was a rusty bag of shite lol do u know dean or his family? Definitely a small world! I don't know Dean but I know of him from when he was on the RS2000-16V forum a while ago and knew his mum had to do with the local RSOC. I'm not sure how many times that Black RS has changed hands since Olly had it but it was on gumtree for a shocking £3500 or thereabouts just recently and still didn't look all that great! Impressive progress, not bad for a days work lol, wish i could get that much done! Someones spent a pretty penny on that motor. Thanks, much appreciated. The story was that the car this engine came from had a colossal amount of money spent on it, not just on this engine but it was also converted from 2wd to 4x4, had a different bodykit, etc. It's certainly got some nice bits on the engine front! Big End Shells are mint - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0060.jpg As is the crankshaft - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0061.jpg Pistons and rods out, The Pistons are Forged Arias Pistons and are in mint condition too - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0062.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0063.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0064.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0065.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0066.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0067.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0068.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0069.jpg Back to the Engine Block now - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0070.jpg Main Bearing Caps off - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0071.jpg Bearing shells are mint as are the main journals - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0072.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0073.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0074.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0075.jpg Crankshaft out - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0076.jpg Block flipped back over again - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0077.jpg Having a good look at the bores you can see some scoring, this is more than just superficial marking and the scores are too deep for this block to be re-used again without reboring it - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0078.jpg http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0079.jpg The bore on this block is not standard, it had been bored out to 86.5mm and we want to re-use the good forged pistons and rods so it means we can't re-use this block at all for this build. So, the plan of action is to use another 2.0 block which I'll rebore to 86.5mm and that will mean we're starting with good fresh bores and mint forged pistons and rods. It should certainly be a good basis for a nice strong powerful engine. Cheers! Link to comment Share on other sites More sharing options...
sidrick Posted May 22, 2013 Share Posted May 22, 2013 Keep it coming! Link to comment Share on other sites More sharing options...
HIGHTOWER Posted May 22, 2013 Share Posted May 22, 2013 Ohhhh, I've been looking forward to this post! Link to comment Share on other sites More sharing options...
Naylor2006 Posted May 28, 2013 Share Posted May 28, 2013 Oh no, I kept scrolling and it stopped Link to comment Share on other sites More sharing options...
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