So, it's been a while. The car didn't make it to Germany like I'd have hoped... in fact, even 5 months later, it's still in no fit state to be driven.
But, progress is being made and there's some light at the end of the tunnel. Dropped the engine back in yesterday, 8 months after it was taken out. At least that's out of the way and I can bolt the suspension back up so it's back on all 4 wheels.
Anyway, on with some pictures.
My flywheel took a while and turned up after something like 6 weeks. It was machined to my specification with a custom trigger wheel so can't complain really. It's nice and light, probably about half as heavy as the original wheel. I couldn't be bothered to get it on the scales to find out but it should allow the engine to rev much more freely.
Even though my new cams were wrapped in bubble wrap and kept in a box in the garage, they were showing signs of slight rusting on the lobes. They were cleaned up with some very light sanding, ready to be fitted. They're Piper 270 cams and for the moment will be used with standard pullies. I'll be keeping my eye out for some verniers to allow me to get the best out of them.
I also tarted up the wood trim by giving it a bit of colour. Should help to modernise the interior when fitted alongside the Momo steering wheel, Recaro seats and a handful of gauges.
My once mint OZ Ultraleggeras also underwent a bit of work. Filled and smoothed any damage and gave the rest a key, ready for paint. I've got a colour in mind but I'll keep that quiet until they're done. Probably won't get round to painting them until after the winter now.
The interior was also gutted ready for some re-wiring. The alarm, ECU and gauge wiring is all integral to the car. Looks nice and neat, but will be a pain to remove in future... which is exactly what I wanted, especially when it came to installing the alarm.
I also noticed that the sound deadening underneath the carpet was quite damp on the passenger side and appear to have a leak from somewhere up front, need to trace that before the dashboard can go back in. Headlining will be recovered in black (currently light grey) and a CB aerial (installed by a previous owner) removed from the roof and a plate welded over.
Before the engine was removed, I had an oil temp sensor in the sump. This worked well when the car was stationary but as soon as you started moving, airflow over the sensor caused the gauge to plummet. I had a mate shot blast the sump and weld some plate to reduce the effects of this. I also gave the sump a few coats of Hammerite to protect it.
After 140,000 miles, the engine was looking a bit manky. It was given a de-grease, several coats of paint and the head mating face cleaned up ready for re-assembly.
A genuine Klinger head gasket (only the best for this car) was fitted and some oil poured down each cylinder to protect the bores while it was sitting.
After lapping in the valves and cleaning up the head, new stem seals were fitted and the head rebuilt. This took a while due to the tiny little collets holding the valve springs in place being very fiddly.
The head was then leak tested using some white spirit. The first few attempts showed some weeping and if I was going to all this effort, it was worth doing right. You can also see my attempt at port matching the exhaust ports, I doubt this will give any noticeable gain but hey, every little helps
After a few attempts, I had it holding fluid meaning that the valves were sealing perfectly. Should make good compression.
With good results on the leak test, I continued to rebuild the head. Valves, springs and collets all in place ready for the cams and carriers.
The head was then bolted down and the cams fitted with new oil seals, the pump housing assembled and fitted with new water and power steering pumps.
The cambelt tensioner was looking a bit worse for wear but being metal usually lasts for a long time. I decided to replace it with a brand new tensioner, fitting a new cambelt at the same time.
And then following onto yesterday's activities, with the help of a mate, the engine found its place back where it belongs.
Along with the obligatory thumbs up picture of me...
So with quite a bit done but plenty more to be getting on with, it feels like I'm finally getting somewhere. I've not done anything with the bodywork yet which due the recent damage from roof tiles, I'm glad about. There are lots of bits (some very rare) to be fitted to the exterior though, I can't wait to see what it's going to look like!