Bit of a summer clean (Now with mot and all work completed!)

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Henry
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Bit of a summer clean (Now with mot and all work completed!)

Post by Henry » Sat Jun 13, 2009 9:10 pm

Right hear we go, over the last few weeks myself and Baxterszuk have been slowly stripping down the SJ for a bit of a spruce up under the engine bay. I’ve been watching AndyB’s engine conversion for his zook, and thought i would do a bit to mine, now that i have finished my exams. After our last event at toms farm my engine was far from good. The water pump was growling, oil was pouring out of the exhaust and the piston rings where cracked with some evidence of water in the oil. The exhaust manifold was also cracked so this will be welded up and painted in BBQ paint. The rear axle was also leaking oil and the breaks well and truly shot, so a new axle will be sourced and rear disc fitted. The rear lights where smashed and needed replacing, so i plan to stick the original ones in the back door.

So a new engine will be sourced out of a Vitara. This will have my SU carb put onto it along with the manifold and the electric fuel pump with a boat tank positioned in the back. This will be mated to the Sammy gear box as before. The gear box will be steam cleaned, and painted prior to fitment and so will the engine. The bulkhead will also be painted as will all the inside of the wings and the underside either stone chipped or under sealed. On top of this i hope to get some 31” rubber under her with some 15” Weller wheels painted black and gun metal grey! The axle will be painted after a thorough steam clean and wire brush with some rover 600/400 callipers on the rear so i have a handbrake. The local garage offered to set up my carb on their emissions tester, so it is running just right. After all this work, it will be put in for an MOT and fingers crossed, it might just pass!

DAY 1
Today was spent mostly taking the front end off the SJ ready for washing and painting and should also make life easier when fitting the replacement engine. The front end came off without a hitch, luckily the door hinges had already been taken off when i cut the hinges to make the removable doors. So all went well and the front end came off well, and luckily its in great condition with no welding needed, just a good rub down and paint. The surface rust will be treated before painting.
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It was then pushed back into the shed for the next stage.





DAY 2
Went to pick up the donor Vit today. Found a nice example with low mileage and mint condition. So went to pick that up today. It is fitted with the 8V Injection engine. I will strip my old engine of its manifolds and transfer these over. The Donor Vit also came with some nice 8 spoke Wellers. These are going to be shot blasted and then painted up.
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I also took the manifolds off the sj. Its pooring oil out of the exhaust manifold and the water chambers look corroded.
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So I popped down to the local garage and ordered some new Gaskets and filters. These will be fitted on the new engine after I have painted it up with the old gaskets in there. This also came the other day, the new rear fuel tank.
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Spoke to the guy in the garage. No fire wall is needed, but it has to be securely bolted down. So im going to knock together some sort of glorified battery clamp. I also plan to fit the original fuel sender into this tank so I still have a fuel gage.
I will update more as more happens. Henry
Last edited by Henry on Sat Sep 26, 2009 2:07 pm, edited 1 time in total.

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Henry
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Re: Bit of a summer clean (Now with mot and all work completed)

Post by Henry » Tue Jun 16, 2009 12:29 pm

I was bored of Chemistry revision, so i popped out and decided to paint one inside wing to see how it looked...

Had the wire brush on the drill, being careful not to damage that plastic/rubber covering. Think they are better like this, even if it didnt really need it.

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Dont think they look too bad, compared to the dirty and un painted side. Will leave it to dry and might give it a second coat later.

Henry
Last edited by Henry on Sat Sep 26, 2009 2:07 pm, edited 2 times in total.

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Re: Bit of a summer clean (pre mot)

Post by Henry » Wed Jun 17, 2009 5:24 pm

Had a nice exam this morning, so couldn't wait to get home and just do a little bit to the sj! :D

Only small bits mind, still got one more exam to go!

So i got the other wing painted
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Got the exhaust manifold off and got the wire brush on the end of the drill, cleaned it all up and inspected it for cracks. Also gave the mating surface a good going over with the wire brush.

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The garage dropped these off too,

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So all that is left is to clean the ally surfaces, but i felt that the wire brush
maybe a bit to harsh on them, so would fine emery cloth do the job?


Henry

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Re: Bit of a summer clean (pre mot)

Post by ScottieJ » Thu Jun 18, 2009 12:41 pm

Yeah just use very fine emery paper, like 1200 or something finer or for more stubborn stuff i usually use a stanley knife blade but you need to be very careful not to score the surface.
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Re: Bit of a summer clean (pre mot)

Post by Henry » Thu Jun 18, 2009 2:40 pm

Yes i will have to see when i take the new engine out the Vitara, what sort of condition the gaskets are in before i determine how i remove them.


Im all geared up for tmo now, just got to persuade the tractor to start so i can lift the engine out

Henry

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Re: Bit of a summer clean (pre mot)

Post by Henry » Fri Jun 19, 2009 7:49 pm

More more more today! Last exam today so im in a good mood!

Engine and gear box came out with ease

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Just need to remove steering box then steam clean the front end and paint


Engine in the shed for timing and removal of clutch ect ect

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Water was present in the rocker cover

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Made these too. They will be part of the fuel tank container.

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Henry

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Re: Bit of a summer clean (pre mot)

Post by Henry » Tue Jun 30, 2009 6:14 pm

Well its been a busy few weeks but ive not stopped work on the sj.

I have got the old engine stripped of everything. All of the stuff stripped has been cleaned, ready for some lovely paint!

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These will be black, (steering box red) and put onto the new engine block. The starter and alternator will also receive a good clean and service before refitting.



Myself and George took the engine out of the Vit yesterday, it is apparent that it is going to need a new rocker cover seal and a new rear cam shaft seal.

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These have been ordered and should be with me in the morning. I will then fit both of these before painting the block. While im doing the cam seal the dissy will also be swapped for the 1300 one.


I then stripped this engine of everything, and make some chip bored plates to cover the inlet and exhaust ports. With these fitted i spent a hour steam cleaning the engine and the gear box. With a liberal coating of Traffic Film Remover...

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It came up lovely!

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Ive also finished the fuel tank holder, fitted it, along with the pump and filter. The fuel lines still need fitting and securing and the fuel pump wired in.


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Henry

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Re: Bit of a summer clean (pre mot)

Post by deathbus » Tue Jun 30, 2009 6:22 pm

comin along grand mate 8-)

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Re: Bit of a summer clean (pre mot)

Post by Henry » Thu Jul 02, 2009 5:06 pm

Done some more today...

The seals came the other day, however the lip seal isnt right. There looks to only be a square ring seal type thing in the back of the dissy housing. I have managed to find a new one, so this should stop the oil leak. This seal will be fitted to the 1300 dissy then fitted.
I also got the rocker cover today. This will be fitted to the engine once it is fully sprayed up.

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And the cover that i have started to clean...

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I had a root round in the shed, and found my top coat for the engine and gear box...

Carnt beat a bit of Massey Ferguson ;)

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Went to halfords and got all the other paints i need... Some high temperature undercoat (only came in black :roll: )
So after more cleaning with the tooth brush i started to spray up the Gear box.

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And the "Very High Temperature" spray paint for the exhaust

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So fingers crossed i should get some more painting done tomorrow! :)

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Re: Bit of a summer clean (pre mot)

Post by Henry » Mon Jul 06, 2009 7:12 pm

More done over the last few days...

My new tires came 31/10.5/15 :D
Less aggressive than the ones i have on now, but they will be seeing more road miles and should be better for that.
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They will be put on my 7J wellers, im still undecided on colour, but i think that they will be black.... (suggestions welcome)

Just taking the old tires off.
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My read disc kit from Muddyzook also arrived the other day..
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Ive also painted the gear box with its red top coat. This will be filled will oil and then fitted before the engine.
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More to come soon!
Henry

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