A 33 is Reborn

[33gold]

Thought I'd start a thread of my 33 mk1 rebuild, I'll start with the engine.
Engine was deburred, note high spots on casting marks, these need to be removed as they are a weakness, see attachment 1:

Attachment 2-4 shows deburring.

Attachment 6 shows the con rods having the forging marks removed, prior to polishing; this was not to remove weight but rather to strengthen and again avoid any high spots that could have caused a crack. after this the rods were weighed at the big and small ends rather than just weighing the rod to create a balanced bottom end.

[33gold]

Note the chamfering of the bearing oil ways, although these are new original bearings they were very hit and miss with then chamfering; this creates a pool of oil to increase lubrication.

Engine is now just ready to go back together (minus heads that I am working on).

New oil seals are a must when rebuilding, crank was lightened and balanced, new std piston rings, luckily the bores and pistons were good as you can see the original honing marks are still visible in the liners.

[Spooty22]

That would be the first boxer motor I have seen that still has a hone in the cylinders Normally they are smooth as a mirror, with a huge step in the bore. (and oil consumption to match )

This block looks like it could take a serious power hike

[m.jansen]

this is a very nice project,cant wait to see the result.
good luck.

[33gold]

Rods were weighed and material taken off accordingly, not ethe scales i was using weight the paper towl at 4g, pretty accurate. you need to weigh each end of the rod with the caps in place and get the rod down the same weight as the lightest piston.

[33gold]

new big ends were installed as well as new rings, note the compression rings need to be installed opposite each other (180) and at 90 degrees to the oil rings. The budget won't stretch to new pistons at present, so originals used.

[33gold]

New crank seals went in along with a new water pump. Plus a couple of snaps of the bodywork, sprayed by yours truly (after practising on my mates mini ) I'll post some more body pics after engine pics. Note the 16v enameled calipers and new 16v disks.

[33gold]

300 degree billet cams took 5 months on a special order from Italy (cost more than I paid for the car!), 1.7 journals are larger than 1.5 (which is what the cam boxes came off) so I had the boxes machined.

[33gold]

Now the donor engine is a 1.7ie with hydraulic followers. The cam boxes as stated are off of a 1.5ti. Because the heads in the i.e. have a combustion chamber the valves are shorter, that combined with the different cam centre of the "hydraulic" cams means that the ie valves are too short and don't reach the cam; the 1.5ti valves are too long and at fully closed on the cam are still open! So I ground back the top of the stem and measured so that the clearance was at specified .4-.5mm (will do final adjust with different shims). The collets are still fine with some stem still above to touch inside of bucket.

[33gold]

Check out the lift on those cams
Cling wrap stops nasties getting into the cylinders, picture of the honing marks that were already there, I just hand deglazed with 400 grit after seeing this. I would love to have seen the km of the donor vehicle, as bore and bearings are all still standard.

[33gold]

oops forgot photos - must stop drinking now