Fuel Tank Breather
The breather that comes with the kit may not be ideal for injected engines, the tank pressurises during use to a very high level. As it is only a one...
On the road again!
On the road again: Sorry you'll need Flash installed to view this video!
Mudguard Stay
New bits of steel for mud guard holders Spacing for the carbon wings - ended up using 1/4 of one of these as space. Steel bent and fitted to the...
Bracket + Nose Cone
Finally bit of construction. The original bracket that held the header tank was a bit floppy so Richard welded up a new one - nice and solid now! Plan A...
Windscreen part 1
To fit the windscreen you'll need some masking tape a pencil, rule and maybe a tape measure! Put some tape down and mark a centre line on the scuttle -...
Carbon Wings
Carbon wings next to original Carbon weave! Pretty! The new wing is not quite a wide as the original and follows a slightly tigher curve. You can hardly see any...
Engine in
Rear cover plated attached to block, sump bolted on and the flywheel on read to be bolted. The bolts need to be tightend up in a specific order and covered...
Head on block
Final clean up and degrease of the head. Mmm shiny! Also double check that the cam pulley is turned to the timing mark on the head. Belt tensioner now also...
Bottom end assembly
2.8 crank installed in the block with new bearings, bolts are torqued up. Crank spacer in place Many hours later all the pistons are installed with new bearings, all moving...
Parts!
New parts! Conrod bolts, main bearing shells, big end shells, water pump, cam belt and piston rings.
Camshaft in and head assembled
Camshaft inserted New oil seal and o-ring for camshaft Rocker shafts and rockers on their way back into the head - the head needs to be propped up so there...
Valves
Got the head back from the machine shop on Friday, they took 4 thou off to remove the warp: Starting a bit of valve lapping 2 down only 10 to...
Blue! And oil pump
Silver is so last month, so blue it is this time! We used red hamerite on the exhaust plugs and those didn't discolour until we welded something on it -...
Piston this
Cleaned up all the pistons today, but manage to snap one of the piston rings in the proces - doh! Andy, the chap who came up with the conversion severl...
Finished the crank spacer
Spacer machine down to size, about 17.90mm with in 0.1mm of the original. Cam belt pulley test fit, this a very tight fit so it will need the "the tool"...
Crank spacer
Crank spacer taking shape on the lathe One step left is to machine down the spacer to the correct size - about 18mm
Test fitting
M20B25 piston fitted with M20B20 conrod and M52B28 crank! Moves well. Piston / conrod / crank combo at top dead centre - looks good :)
Its off!
Puller-me-jig in place. The metal plate is bolted to the bit that needs to come off. In the middle a long bolt (out of an M52 block!) and a nut....
M52 crank sits neatly into the M20 block
M52B28 crank shaft sitting in the M20 block - this end will need some kind of spacer for the oil seal. Crank sits in the block like it was meant...
More engine work
The head is off to the local machine shop for crack testing, we'll know if everything is good on Tuesday. If it is then it'll get a bit of clean...
Engine Rebuild
Rather than buying a new valve spring compressor we decided to make an extension for the curent one. After lathing the tube to the correct size with a suitable amount...