The awkward third block
The story so far.
Original block wrecked due to a failed head gasket allowing water to sit in the bore.
Replacement block found to have been over bored for first size Pistons. This wouldn't be a problem usually but the block was a non turbo version and therefore had higher compression Pistons. This block also need a small amount of machining to turn it in to a turbo block.
So. Last weekend the good people of the TDC (thema dedra consortium) of which I have become a fully paid up member pulled out another engine and striped it down to the bare block for me!
This time it comes with the turbo oil drain pipe already machined (boo!) and the pleasant addition of piston skirt oil jets.
Interestingly the piston crown design is different to that of my originals ones in that there is a depression over a greater surface area. I assume this is to lower the compression ratio? I should add that this is a block from a 16v turbo engine. So what should I do? Install my original Pistons or use the Pistons that were with the block?
Doing some research into fiat / lancia engines ( as you do). It appears that there is a top level basic matching of Pistons to cylinder bore dimensions. I.e. A cylinder that is slightly under nominal ( but still within overall tolerance) is stamped up 'A'. This might typically be with a new tool / start of the day. As the tool wears and the machine warms up, the size the machine cuts might change and is now on nominal. These are marked 'B'. This carries on to a 'D' catagory dimension.
When the engines are assembled a similar process has happened with the actual Pistons themselves, being marked 'A -D'. So as the block is assembled, an A piston is used in an A cylinder bore. This is to reduce the chance of piston skirt wear on the bores (so I believe).
The issue that might crop up is that if i use my original Pistons in the 'new' block these were marked 'A'. The 'new' block has bores marked 'c'.
Will nuns and kittens die? I'm not sure. But at the moment I am going down the route of sacrificing OMGMAXPOWER for let's get it on the road and taxed!
Enough with the theory, we aren't here to look through text books and poor over engineering drawings. What we want to see is ferrous oxide Italian style, man against rust.
Luckily the Dedra chassis was fully galvanised when assembled so there isnt really a lot to show.................... who am I kidding, what follows is an orgy of rust, patches, sacrifices and months and months of work. Sit back, relax and be glad it wasnt you.
Rear corner, Sun roof drain pipes
Removing the Gear change tin work
Rust where the cable management clips are
Front wheel arch, rust cut out and the dreaded expanding foam seen behind!
Another patch cut out, but importantly the Foam has been removed.
This doesn't look to bad, Front wheel arch,
Cutting out the rot still, but now we are the root of the problem
Mmm, maybe not.
Front Bumper hanger and oil cooler support. Looking a little battle scared.
The area around the jacking point was just universally condemned. It was all just Urghhh. Therefore the decision was taken to cut out and reinstate in a simplified manor. That’s quite easy to say, but what maybe doesnt come through in the picture is that most of the jacking point is sunk between the sill and the chassis member meaning that the disc cutter was only of some use and a pad saw had to be deployed.
Jacking point partially removed, undersea lifting off, every thing red raw with rust.
Almost out, more rot under the ‘as new’ underseal!
Other jacking point.
Jacking point completely removed, and more rust removed from behind it. The jacking point had rotted out part of the chassis member so this was cut out as well.
Passenger side, worse than the drivers with gaps along the sill / floor. Cable management holes cause of rust patched seen felt tipped for removal.
Rear Floor perforation in evidence.
Front floor perforation in evidence.
Sill end, rear wheel arch.
Continued wheel arch woes
Other sill and wheel arch.
Random rust spot
The outside of the sill look very good, would you consider changing it? Cutting it out and looking inside reveals a very different story!
Whats in the box? Only pattern parts! God bless the internet and all who surf in her.
Bumper hangers!! 16euros each!