Since this is my first engine I’m building things are going slow because I’m taking more time, double checking, researching, asking questions, etc. It also goes slow because its done in my spare time after work and Brightside responsibilities are accounted for. We got it on the machine and Rob worked his magic on the CNC and the boring of all 4 cylinders went without issue. Also in the same setup we were able to deck the head. Now we can say the cylinders are perpendicular to the cylinder bores within 0.0005. Meets my standards!
Once Rob had that completed we moved onto one of the improvements that him and i devised would help with location of the main caps. We would dowel all the main cap bolts and clearance the block locaters so all the dowels can do there job without interference.
The advantage of this was to positively locate the main caps in position every time without any binding occurring while torquing down the caps. Hardened downs were purchased from mcmaster-carr and we were set! This day was very productive and everything went smoothly. Some search for tools around the city but otherwise i’m very happy with the outcome so far. More machining to go, i’ll write part 3 shortly.
Going to step back and start from the beginning……on this one. I’ll be quick!
In the winter of 2009 I finally decided that it was time to retire my beater VW Golf and get the car I had been wanting for so long….. The Golf had treated me well, got me through university traveling 120km each way multiple times a week and with next to no maintenance but sadly it had seen better days and was absolutely NO fun to drive.
I’ll probably take the time to write a separate post on the golf when i have the time. The car deserves its story to be told! Still kind of miss the thing 3yrs later. Watch out for an upcoming post about it. i’ll have to do some digging for pics but to be honest i don’t think i really took many of it while i owned it.
BUT it was replaced with the car i had been wanting for a LONG time and after 4mths of negotiating with BMW and 8weeks of waiting for the car to arrive after being ordered with the EXACT options and colour combinations that I wanted. Figured I would not compromised and go for exactly what I wanted as how often am I really going to be purchasing a new car?
And here she is, the day I brought her home.
I finally had the opportunity to dust off the 4g63 engine block in the corner of the shop sitting in the rubbermaid container waiting for the day it would be cleaned up, bored 0.020 over and have the stroker 100mm crank installed to build a stroker 2.3L with a couple more goodies for the talon. That day came sooner than later with the offer for free machining (got to love the battering services!).
The block I start off with had unknown history and was a block that was given to me from a friend who got it from another guy kind of deal. So first step was to ensure we were starting with a good core before spending all the time machining and prepping the block. The block was magnafluxed for cracks and fractures and when that came back good off it went for block prep!
Here is everything that was completed on the block
- block was ultrasonic cleaned
- old frost plugged punched out
- cylinders bored 0.020″ over for new pistons
- PTW clearance was checked, double checked and then checked again
- head surface was decked flat and a quality surface finish for a MLS gasket was achieve
And then the headache began….mainly because i like to complicate things and be slightly different and use different parts. i’ll describe that in the next post and hopefully have some pictures also for you guys.
So my first post, what to write…….. Guess will start with some background of what Brightside is and what i hope to post in this blog in the future. Brightside started out 5yrs ago now in my home garage where almost all my tinkering happened (sometimes it even spilled out onto the driveway). This blog will be exactly that, posting the projects were tinkering with, trying out, experimenting and the projects we take on as a business and personally. You’ll find I jump around a bit in the projects as I’m always juggling time, commitments and deadlines for customers, family and events that come up throughout the year so unfortunately not many of the projects I write will show completion from beginning to end. This is especially true for personal projects because as the business goes the customer always comes first and therefore you’ll see that customer’s projects go through the doors quickly but the personal projects tend to linger.
Nothing is more famous for this than the never ending project of my 1993 Eagle Talon TSI AWD that is going on 5yrs since it last left my driveway……. A lot has happened in those 5yrs though, I finished my engineering degree, got a job as a design engineer, started Brightside and progressed to what Brightside is today at 701 Brock St North! I’m very proud of all those achievements but unfortunately the car hobby got left behind…… The passion is still there and that is the reason the car is still with me and not going any where! I’ll make a separate post about the talon and give some background of that car and my daily so look forward that to soon.
That’s the end of my first blog post! I’m soo proud about myself! Hope you guys stick around and check out all the cool things Brightside will be up to in the near future!