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5 GT Turbo R5 GT Turbo - Complete strip down and re-build #1

Almost certainly will be for sale @Big Steve - Raider not sure just how soon mind as super useful and few things to tick off still.

@brayboy if your not in am urgent rush might be an option as Steve mentions...also converted to a car dolly as a bonus and can use as both 👍
 
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So, managed to put a few quid away and paid a visit to Mr Dullforce down south! I picked up th gaskets and bits to put the engine back together.
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First off, I had to clean and hone the cylinders.
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Then on to fitting new big end bearings and rings to the pistons!
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I got the seals on the cylinders, and gave them a liberal covering of sealant! and then got the pistons into the cylinders and then the cylinders into the block as per the @sparkie C1J build post.
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Then I fitted the new seal and applied liberal amounts of sealant, got the new timing chain and tensioner on then got the cover on!
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Next for the cam followers, I gave them a smothering and dropped them in!IMG_0624 Large.webp

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Then after a clean up, I got the head gasket on!
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I gave the face of the cylinder head a clean and then laid it on!IMG_0635 Large.webp
and got the rail cleaned up and on!
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Then gave the dipstick tube a blob of sealant and got it in.
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Then on to the water pump, and as per Sparkie's recommendation I split it and gave it a smothering of sealant!
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I then got it fitted!IMG_0645 Large.webp
Then on to the distributor drive, I had a bit of a fiddle with this before I managed to get it in! but got it in there!!

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and the distributor on!
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The I put the new plugs in after gapping them to 0.8mm as per the Haynes manual!
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Then I gave the exhaust manifold a good clean up and got that on!
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and then on with the inlet manifold!
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I then loosely bolted the turbo and carb on. I think the carb will need to go to Sparkie for him to work his magic on it! I will send the turbo off to Midland Turbos for a service!
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Thank you @sparkie for your guide to rebuilding this!

thanks for reading guys!
 
So, been pottering about with it, mainly trying to get the bloody gearbox back together after stripping it again when I realised it was stuck in third gear!! I have been messing with this for a couple of months now, but finally got it back together yesterday with all gears operational! TF!!IMG_0700 Large.jpeg
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Also during the week, the turbo came back from Midland Turbo, can't recommend these guys enough!
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Brilliant sevrice and honest people, they called me and told me that there was not really anything wrong with it other than slight wear to the bearings, which they were changing anyway as part of the service! woohoo!!

Today I finished putting the gearbox back together, fitted the flywheel and then the new clutch! Had a bit of a game getting the clutch centralised, but got there in the end!
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Then I wrestled the gearbox back on to the engine, managed to slice my finger on the gearbox ID tag and bled like a bitch, must be something to do with the 37C heat in the garage!! :)
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I then got the starter on and loosely fitted the turbo. Then lowered it and covered the turbo!
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@sparkie has also finished my carb now so will get that next weekend!! Thank you sparkie!

Thanks for reading guys!
 
Excellent work! Is it even a day in the garage if there isnt blood?

How much did the turbo cost mate? I might need to send mine off, running it without the oil drive key on the 9 might have goosed it :(
The turbo service was £230, they send a courier to collect and drop off!!
 
I collected the carb from @sparkie yesterday morning. A big thank you to him, what a blinding job he did, a true gent!
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I also got a delivery from Autodoc during the week, should keep me in service bits for a while. 5 air filters and 7 oil filters £80!IMG_1131 Large.webp
I managed to get a few hours in the garage today, I continued fitting bits back on to the engine, spent a lot of time looking through old photos to see where things go!
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I then got the engine loom out and fitted that!


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Getting through this now, at what point do you guys think I should put the engine back in the car, and is there anything I should make sure I do before I put it back in?

Also, any suggestions for tidying up the wiring?

Thanks for reading guys!
 
Getting through this now, at what point do you guys think I should put the engine back in the car, and is there anything I should make sure I do before I put it back in?
Lots and lots and lots of sheets to protect the engine bay as you drop it back in!!

Ref the engine loom, a good clean, new conduit makes wonders. Any nasty bits, you can replace. I’ve seen your work, know you can make it fabulous!!
 
Guys,
Suggested ‘first start’ routine please. Michael Dullforce kindly gave me a sequence but I’d like your views on it. Which oil to run first and for how long before changing the oil and filter!!
 
Many different thoughts on this, so take your choice..

I’ve recently filled the engine with mineral running in oil, and started it up, ran to temp with mixture of speeds, not just idle, then turned it off. Before changing the oil to the right stuff and then sending it.

It’s basically all down to changing the oil after startup to make sure you get rid of any remaining grot.

They like load better than just idling..

@Brigsy has got some good experience of this.
 
Many different thoughts on this, so take your choice..

I’ve recently filled the engine with mineral running in oil, and started it up, ran to temp with mixture of speeds, not just idle, then turned it off. Before changing the oil to the right stuff and then sending it.

It’s basically all down to changing the oil after startup to make sure you get rid of any remaining grot.

They like load better than just idling..

@Brigsy has got some good experience of this.
Thanks Steve, any particular brand & viscosity?
 
I collected the carb from @sparkie yesterday morning. A big thank you to him, what a blinding job he did, a true gent!
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I also got a delivery from Autodoc during the week, should keep me in service bits for a while. 5 air filters and 7 oil filters £80!View attachment 212794
I managed to get a few hours in the garage today, I continued fitting bits back on to the engine, spent a lot of time looking through old photos to see where things go!
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I then got the engine loom out and fitted that!


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Getting through this now, at what point do you guys think I should put the engine back in the car, and is there anything I should make sure I do before I put it back in?

Also, any suggestions for tidying up the wiring?

Thanks for reading guys!
Looks Lovely, I was speaking to Mark fish when collecting My Cup Car and he went into detail about how the Elf stickers on the oil caps were never straight. Seeing yours made me think of it…
 
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