The pocket rocket

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:44 pm

right time to update this as i've been slacking

Had the aem uego on the car and it was running majorly lean coming on boost and whilst on boost

So took the carb off the car after fixing the rocker cover leak

Striped the carb from the car and a known good carb in my garage

Gave this little bugger a blowy (accel enrichment jet) and it just wasnt performing

So swapped it out with a spare good one, reset the accel pump perfectly paint marked it.

Gave everything a good strip down brake clean and blow out with an air line no dirt to really see as i done it all before.

Then thought bugger it.... a bar of boost sounds nice.... so a few people have run a 1mm air corrector and 1.2mm 2nd stage at the same spec.
So i swapped out the 1.25mm ac jet for a 1mm and then took to drilling out the carb body 2nd stage bush (that if it goes wrong its new carb body time) it quite scary sweat dripping business drilling out the body but it was done quite effortlessly in the end lol

Will get a new fuel filter tomorrow and see what happens fingers crossed at 10psi it overfuels so i can raise the boost up to a bar and its still safe

Few piccys

My bucket of bits all over floor looking for new nuts for rocker cover as their some stupid thread m7x1.00 and i have mostly m6x1.00

Fixed loose arch and it has a face at last

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:45 pm

then we follow with this

Still dont know if its fixed the lean issue as i've not had chance to put the uego on but i know it is clean and polished :mrgreen:

few of the bros mini aswell ~thumbsup~

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:46 pm

and the good old school dial dash

hehe 14-15psi of boost now

before it was on the notch above the letter "o"

Fueling seems ok on boost still a tad lean in the middle for my liking so may have a fiddle with the pump adjustment

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:47 pm

Then at chav nationals i jumped on the rollers

Print outs.

Flywheel power and torque 133.6bhp and 166.7ftlb

Wheel power and torque 109.5bhp and 136.6ftlb

Should be much better and less of a spike of power when i've changed to a better boost controller rather than the 1980's bleed valve i had kicking about and used in a rush

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:49 pm

Then the issues came out of the wood work

i found the reason for my noisy tappets

Yup cylinder 2's rocker shaft bolt was flapping about :S

So re-tapped and helicoiled the hole and put a new bolt in.
But it seems both push rods have bent a little...whoops

Must of been the time before mod nats when i missed a gear coming down a slip road on the a14... 3rd gear high revs into 2nd gear lol thought i got away with it as it still ran lovely but obviously not

Did a compression check and after 600miles i have a perfect 150psi on all 4 cylinders

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:51 pm

Again more problems

The day before i go to modified live at brands hatch....thinking i could get a couple of 20 mins session with the 5

So got to work all good no leaks or problems

Drive home was great, driving it quite quickly on the motorway overtaking and listening to radio 1 loudly..... then slow down for my slip road

WTF is that noise... sounded like a grrrrrrrrr, so change into 4th and noise gone

( pooping pantys at this stage) change back into 5th and grrrrrrrr (Fuck it!)

Still got drive in 5th so thought maybe the nut had worked loose in the box as its a common problem thinking it will be a simple fix lol

Got home jacked it up like f1 pit crew styley

Within 10 mins the cover was off and found the problem.....
It soon came clear that I wont be taking the 5 to brands hatch tomorrow or being able to drive through dartford tunnel on the way home

5th gear nut is tight but 5th gear is missing a few teeth look in the cover and found the teeth and some needle rollers from a bearing in there :mrgreen:

Dunno what the feck this is but it looks pretty battered and was resting in the other shaft

then the count down begun for snetterton

So i need to get a gearbox in for that as a temp fix
or swap 5th gear over from another box and hope the rest of the box is fine ( some golden bits in the oil think the 5th gear syncro took a hit :x )
or find a good refurbed box and put that in

But even with it breaking most of the time it comes out its that much fun i don't care

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:52 pm

Good old ebay

Went over to cambridge to collect my winnings and i've scored alot more than i thought

Got a set of push rods
inlet manifold
exhaust manifold
water pump + housing
fuel regulator
rocker cover
uprated head bolts which i'll bin as new ones are cheap enough
all on top of everything else i won for free

Manky looking Gearbox

Head + manifolds

Rocker cover + push rods + uprated head bolts

T2 turbo going away to be made into a t25/t2 hybrid = more power :biggrin:

Carb that needs tlc

Stripped the head down to a bare head, valves and springs ready for measuring thickness and straightness then of for a crack test and skimming in the future when money allows

Gearbox stripped down
Cover is good and 5th gear is fine

just need to find out how to swap them in situ as this gearbox is too manky internally to put in the car

Taught the bro how to strip a 5 carb and check jet sizes. its all standard jets so i'll be ultrasonic tanking it to make it uber clean through out and treating it to gasket set

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:53 pm

then the fun of having a go trying to get these gears off with no pullers at home

Screwdriver + blow torch and hammer = win

5th gear and everything is off

Now to take the one off the car in situ, this could get interesting.......

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:54 pm

More gearbox storys

Might have an issue
Doner 5th gear's are different sizes, thickness, design. to what i have on the car

The doner is jb3 032 and the one in the car is jb3 014, both have the same diff ratios and gear ratios so they should be the same, yet visually there different gears
So did a bit of checking and i think someone has swapped mine over before for maybe a campus gearset at some point as thats the only guess i have as to why they are different and the reason behind me finding bits of needle roller in the casing with the gears

After finding what other bits i need to swap to make it work without grinding the casing it was all put back together with loctite

Broken needle roller casing

Broken 5th gear teeth

Broken vs new

5th gear difference between new and old

5th gear teeth design difference

Difference between other gear of 5th between old and new

Back together

Good vs bad end covers

Adam_sx · Post by **Adam_sx** » Sat Jul 23, 2011 4:56 pm

And now we are back up to date to today

Replaced all the blowns dash button bulbs and dial bulbs
Strut brace is back on
Fiddled with the carb enrichment pump adjustment
Carried out the "cup" mod which basically you move the turbo actuator boost feed to the bottom of the carb to gain a few extra psi and smoother boost control now its running 15-16psi with a 17psi spike

Took him out today after putting in some millers extra cool and a bottle of millers octane booster

Coolant temps are now alot more steady than before. When giving it some abuise the temp moves up a little but not as much as before as expected with a 20-25-year old coolant system design but the temp comes down alot quicker than before so its doing its job well

Adjusted the brake bias as it was majorly to the rear so i could bed the new pads and disc's in. So now its more to the front.

Changed the oil aswell still using mineral oil for now as its working fine and i want to make sure its bedded in 100% as its still only done 950miles

Hopefully snetterton tomorrow doesn't kill it