Gen III 3S-GTE WRC build - Finished! Options

[GT4WRC]

What a lovely way to spend a day - pulling the motor and box out of the 4

Dropping the subframe...





Subframe and exhaust removed...





Driveshaft out...





Engine and box just about ready to come out (loom was the worst part!)





Part of the WRC version's antilag system...



With the motor resting on 'supports', the car was hoisted upwards...





Thanks to my mate for the use of his workshop



My, what a big gap!



Uses for Holden Ute wheels #24



Looking a bit sorry for itself right now :cry:



Next step is to start pulling the motor and box apart so the real fun can begin
Gary

This post has been edited by GT4WRC: Jan 17, 2006 - 1:17 AM

[GT4WRC]

Tuesday:
TRD shells finally arrive after their trip from Japan. Though due to a logistical error, only 8 shells turn up, the other 2 are still at the dealer on the South Island. As soon as error is realised, the 2 shells are put on an overnight courier. In the meantime, crank can be neasured up against the new shells and machined to suit.
Wednesday:
Other 2 shells arrive and black and crank arrive back from the engine shop.
Thursday:
I'm at work all day so mechanic who owns the workshop (Mike) where rebuild is being done is tasked with fitting the new pistons and shells to help keep us on track.
Pistons #1 goes in now problem. Piston #4 is being put in its cylinder when disaster strikes. The bottom oil control ring slips out between the clamp and block un-noticed until the piston suddenly goes 'tight'. Immediately obvious that the ring is damaged so new ring is sourced without too much of a problem. However, this has also happened...





Oh dear

By this time, I've finished work and have popped in on the way home to see how things are going. Mike calls the engine shop owner (also a mate) who comes round to survery the damage. He 'offers' several solutions. A replacement block would be a mission to find, especially a good one, a sleeve is not an option considering I'll be running over 20psi and a new cylinder is way too expensive.
So, the block went back to his shop this morning to see if a 1 thou bore will remove the damage. 1 thou being the max we could go to.
Unfortunately, 1 thou isn't enough to cure the issue So, only option we really have is for a set of 1mm oversized pistons and a re-bore. That will essentially give a 2020cc capacity which isn't a bad thing
New pistons have been ordered and will be here on Tuesday when the block will also be re-bored to suit and the new pistons weighed to ensure everything is kept well balanced.
Downside is that I fly to Europe in 8 days so no way the car will be back on the road before xmas. The bottom end will be completed while I'm away and when I return on the 9th Jan, I can hopefully finish the rest and get it running again. I am already getting withdrawal symptoms
Gary