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Tommy's A-series Misery - Building an A-series engine


Tommyboy12

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The 25 GTI got a run out with it's Rover stablemates from the same era today. A very ropey Metro with a VVC and a deafening exhaust owned by @sharley17194 and a lovely Rover Mini owned by one of our mutual friends. We went to caffeine and machine where we parked our collective scrap pile next to about 50 Nissan GTRs.

I think the GTI has a slightly sticky rear caliper I need to investigate as it feels like the rear is dragging slightly.

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I'm offended! its not ropey, and I can barely hear the exhaust over my deafness.

On 11/02/2024 at 22:09, Tommyboy12 said:

The 25 GTI got a run out with it's Rover stablemates from the same era today. A very ropey Metro with a VVC and a deafening exhaust owned by @sharley17194 and a lovely Rover Mini owned by one of our mutual friends. We went to caffeine and machine where we parked our collective scrap pile next to about 50 Nissan GTRs.

I think the GTI has a slightly sticky rear caliper I need to investigate as it feels like the rear is dragging slightly.

PXL_20240211_112908979.jpg

 

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Some more car related work this weekend. I was going to weld the brown Mini but it's been windy and on and off rain which isn't ideal for welding. So instead I stripped down it's old auto engine.

First off I needed to get the flywheel off. This puller which I borrowed made short work of it and it pretty much fell off.

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I then set about removing the transfer case. Thankfully the engine was full of oil and water which pissed all over my garage floor. My fault for not assuming it was empty...

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However despite the engine being seized the crank nose looked good so I was hopeful about the crank

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I split the block and box and made even more of a mess

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Then started to remove the crank. I had to undo the main caps and move the crank about to get at all the rod caps as the pistons were seized in such a position that I couldn't get at all the rod bolts. Thankfully i could once I had the caps off.

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And then finally one very clean looking crank. There's no burrs or grooves in this one and it measures within tolerance so it's going straight into my manual engine. Saves me paying for a crankshaft grind. I'll still use new bearings in it though. The rest of the engine was collected by the scrap man that day. Block and box were scrap from water damage and I have no need for auto parts.

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I made a real mess and had to buy sawdust to mop up the oil...

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I also took the MGF for an emissions test on Friday and it passed after I fitted new spark plugs and coils. The plugs were pretty bad.

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So it's going for a proper MoT again on Monday! I'm 99% hopeful of a pass this time. Emissions was the only thing holding it back and it's green across the board now. So I washed it in anticipation of getting it on the road! Unfortunately the roof is really bad with mold so it needs more work but it's scrubbed up ok considering there's dents and scratches in every panel. It's definitely a bit of a ten footer.

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  • Tommyboy12 changed the title to Tommy's A-series Misery - Engine teardown and MGF prep

The communal 25 GTI got treated to a fresh cambelt this morning. The old one looked ok but I wasn't willing to risk a 9 year old cambelt when it's meant to be a 4 year interval. Fresh new Gates cambelt fitted at both ends and a new water pump and tensioner. Lovely.

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The old one looked fine but I wasn't super comfortable risking it.

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I also noted an oil leak from the vvc valve block today. Something to look at down the line. I gather they can be changed without interrupting the vvc mechanisms but I'm not willing to risk that while I rely on the 25 as my daily.

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  • Tommyboy12 changed the title to Tommy's A-series Misery - Mini welding

It's been a minute. There hasn't been a lot to report over the last month. I've been travelling with work so the fleet has sat mostly idle. I did enjoy a rather large F150 in Texas for ten days. It impressed me with it's sheer pace considering it's size. Apparently it was the 400hp twin turbo V6 version. Quick in a straight line but terrible ride quality. I did take it off-roading over the weekend and unfortunately it wasn't very good as it was only the RWD version with road tyres. But I still gave it a go.

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Roll forward a week to today and the sun has been shining today so I took out my MGF for a spin. Despite it being a rather rough example it doesn't look too bad in the rolling countryside. It isn't the quickest car with the CVT gearbox but it makes for a nice bumble round the country lanes.

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After I went out for a spin I set about some more welding. It feels like a long time since I last did any welding. Partly because it has been! But today I did manage to finish off the rear panel. When I took off the boot hinge panel the boot floor was also rusty. So I started by cutting all that out.

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Then replaced the central section.

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Then set about cutting out the other corner

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Unfortunately I made the mistake of not measuring twice and ended up cutting the panel too small as can be seen here... A bit of cardboard aided design helped fix that. Although I also had to cut out a bit extra due to thin steel.

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New panel under the rear light too

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Then onto the hinge panel

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Finished off with a lovely coat of brown direct to metal Hammerite

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And that's it for today! There's still a hole in the wheel well to fill which can be spotted earlier on in the pics but I ran out of time today. That'll be next weekends job as well as hopefully starting on the rear floors in the passenger compartment

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  • Tommyboy12 changed the title to Tommy's A-series Misery - RIP Rover 25 GTI

AS I bring sad news. The AS communal bike that is the Rover 25 GTI is dead.

She let go on me on the motorway on Monday night. I lost a cylinder while driving closely followed by plumes of white smoke.

I also gained some serious blowby on the dipstick which is never a good sign

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Five hours later I got recovered...

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I had a delve into the cylinders. Did a compression test.

200. 200. 200. 0.

Oh dear. Bore scope time

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RIP GTI. Long live the GTI.

While I can repair this kind of failure I don't have the time or inclination with this car. However all is not lost. @sharley17194 has decided to take ownership and attempt to fix it/add it to his pile of scrap cars.

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21 hours ago, Tommyboy12 said:

AS I bring sad news. The AS communal bike that is the Rover 25 GTI is dead.

She let go on me on the motorway on Monday night. I lost a cylinder while driving closely followed by plumes of white smoke.

I also gained some serious blowby on the dipstick which is never a good sign

PXL_20240318_174220869.LS_exported_1935_1710792590702.jpg.c24dbe0c401cce7212cc4d860c95220c.jpg

Five hours later I got recovered...

PXL_20240318_231917231.jpg.7056ea3b5aaed98f5c92a8bb97ecc7a4.jpg

I had a delve into the cylinders. Did a compression test.

200. 200. 200. 0.

Oh dear. Bore scope time

PXL_20240320_1732203312.jpg.753860fa88123254c8d87ce5674f7496.jpg

RIP GTI. Long live the GTI.

While I can repair this kind of failure I don't have the time or inclination with this car. However all is not lost. @sharley17194 has decided to take ownership and attempt to fix it/add it to his pile of scrap cars.

Wait what

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On 20/03/2024 at 18:26, Tommyboy12 said:

AS I bring sad news. The AS communal bike that is the Rover 25 GTI is dead.

She let go on me on the motorway on Monday night. I lost a cylinder while driving closely followed by plumes of white smoke.

I also gained some serious blowby on the dipstick which is never a good sign

PXL_20240318_174220869.LS_exported_1935_1710792590702.jpg.c24dbe0c401cce7212cc4d860c95220c.jpg

Five hours later I got recovered...

PXL_20240318_231917231.jpg.7056ea3b5aaed98f5c92a8bb97ecc7a4.jpg

I had a delve into the cylinders. Did a compression test.

200. 200. 200. 0.

Oh dear. Bore scope time

PXL_20240320_1732203312.jpg.753860fa88123254c8d87ce5674f7496.jpg

RIP GTI. Long live the GTI.

While I can repair this kind of failure I don't have the time or inclination with this car. However all is not lost. @sharley17194 has decided to take ownership and attempt to fix it/add it to his pile of scrap cars.

Oh dear. Any idea of root cause or just Old Car Itis? 

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52 minutes ago, grogee said:

Oh dear. Any idea of root cause or just Old Car Itis? 

Not sure. Car was running fine. It had had some spirited acceleration to motorway speed but it let go while driving at around 70mph. Hot spot in the piston from carbon build up maybe?

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  • Tommyboy12 changed the title to Tommy's A-series Misery - Collection caper!

Well as the Rover is dead it's only sensible I buy another inappropriate car as a daily. So collection caper time!

It's not breakfast time so lunch:

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The chariot of choice to get us there is the venerable i10:

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Journey time is approximately 2.5 hours.

I shall post updates as we go. Those observant folk will already know what it is but guesses welcome from the rest of you!

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38 minutes ago, Tommyboy12 said:

And home! It was a fairly smooth drive home. Although there's a few lights missing from the collection. I am really happy with it!

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Yeah sometimes the passenger headlight comes and goes, just give the wires behind a little wiggle or the lens a good whack and it’ll come back, also worth adding to turn the dash lights on turn the headlights on then pull the switch that says P, for the main beam there’s a floor mounted switch left of the clutch 

 

I’m glad it made it home drama free though 

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15 minutes ago, Marshall2810 said:

Absolutely love this, and very pleased you both got back safe and sound. I wish I had half the balls/heroism/lunacy you do. If you run out of space....

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Agree. Bit of an Austin perv myself but regardless got to love a survivor. That's this car in spades.

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