200 I6 finally going back togther

finially starting to go back togther after several months ( car's been under the light since the fall, Nov I think ) and the current cost is just over $3,000 but soon to go up...again.

anyway, friday I put in the rear main oil seal, and all the bearings, today I dropped the crank in, torqued it, and started the plastigauge prosess. so far I'v done 3 out of 7 mains. there all coming out at .002 which is ok, hopefully there all within spec. I'll have to pull out the old '74 Motors manual we have, to get the real spec. my teacher said between .001 and .002 was ok, but I seem to remember when I looked at the spec b4 that .003 was the max spec.

Still have to get a fuel preassure regulator ( getting a Aeromotive 1 for $125 ), turbo piping and couplars, and a wastegate, BOV and a intercooler ( a company on Ebay has cheap 1's for $50 but they have 2 yr warranty's )

why use a BOV? a bypass valve will actually bring your performance up a little more, sure it doesn't sound as cool.... but thats not that important... it will also prevent from back spinning your turbo which isn't that common of an issue but it still exists when using a BOV

what does a bypass valve do? force air back into the turbo inlet?

Matt sounds like a really cool project. Don't even think of the money your spending.:3dSMILE:

Sounds like your well on the way. What turbo, int etc...are you using? Maybe you can hit the bone yard for parts? Would the T bird turbo coupe stuff work maybe? Have you looked at ATR for parts? They are expensive but very good. I spent lotsa cash with them in my old GN days. **)

good luck bro!!

G.

yup a bypass instead of just blowing the pressure out into the engine bay, it forces it back into the turbo, which keeps it spinning the right direction and will reduce turbo lag by a small bit..... if the turbo backspins you have a chance of having the impellers disentegrate, eating through the turbo and causing a very massive oil leak at the same time

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Originally Posted by FFR428

Matt sounds like a really cool project. Don't even think of the money your spending.:3dSMILE:

Sounds like your well on the way. What turbo, int etc...are you using? Maybe you can hit the bone yard for parts? Would the T bird turbo coupe stuff work maybe? Have you looked at ATR for parts? They are expensive but very good. I spent lotsa cash with them in my old GN days. **)

good luck bro!!

G.

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I'm using a '78 Buick 231 turbo from a Regal sport, but running an external wastegate, and blocking off the old internal passage ( I don't have the swing valve or actuator ). I bought a lot of goodie parts that I relle didn't need. 1.65 Roller rockers from Yella Terra ( Australlian import ) is among those parts. also a billit dual roller timing chain, Comp cams sells a single roller that would have worked but, I decided to get the good JP performance ( Australlian Import ) timing set. I could have just run a off the shelf Isky cam, but I bought a custom 224/224 .495/.495 ( figured with 1.65 rockers ) from Clay Smith Cams, which has 4* of overlap and should render 300 HP @ 5,500 RPM. the pistions are Speed pro, but not for a 200 6, there actully Ford Tempo 2.3 4cyl High swirl flat tops, .030 over. The 2.3 shares the same bore as the 200 6, they are moderatly related. the cyl head is a later model D7 casting head, bigger ports and valves ( also bigger chambers ). compression will be 8.35:1. the distributor is also a later model, it's a DSII and I will fire it with a MSD 6 BTM which I have.

got finished plastigauging the mains today, everything was .002, so it's all good. started to ring the pistions at the end of the period, got 2 done.

That's right..... I forgot you were using the Garrett turbo. I think i have a aftermarket turbo inlet that's bigger than stock. If I can scrounge it up you can have it. I had a few of them and pretty sure it's in the tool shed.

Everything sounds nice!! Good job and can't wait to hear how it runs!!

G.

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Originally Posted by FFR428

That's right..... I forgot you were using the Garrett turbo. I think i have a aftermarket turbo inlet that's bigger than stock. If I can scrounge it up you can have it. I had a few of them and pretty sure it's in the tool shed.

Everything sounds nice!! Good job and can't wait to hear how it runs!!

G.

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I'll be getting a video cam here soon, initial startup and cam break in will be videotaped at school, as well as the tuning prosess, cause the 'out of the box' Holley 2300 isn't 'out of the box' when you have to pull it apart and modify it to take boost. I will upload the vid's to my website

you're gonna run a carb now? i thought you were gonna go TBI? or is that just something you're going to do later and for now just running a carb?

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Originally Posted by thesals

you're gonna run a carb now? i thought you were gonna go TBI? or is that just something you're going to do later and for now just running a carb?

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I was going to run TBI EFI using a modefied 3.8 CFI TBI and a Megasquirt II ( has ign controls ) but I found out that it wasn't the best idea. because under boost it would have gone lean if the engine was tuned 'right' because the map sensor can only see boost, it cannot see airflow, if it was spooled up at 2k, it's going to use the same values up until the engine blows from running lean. Megasquirt only uses O2 sensor readings below 70% throttle, otherwise it uses open loop fuel tables. it would have had to be tuned rich to get the right mixture's for high RPM boost. so until they come up with somthing that uses a MAF or uses O2 sensor readings above 70% throttle. so for now, I'll run the Holley 2300 2bbl modefied for boost, and use the MSD 6 BTM for the timing retard.

I hope you just forgot to mention the part about checking the end gap on the rings.....

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Originally Posted by Dave Severson

I hope you just forgot to mention the part about checking the end gap on the rings.....

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yeah. I checked them.

today, I got all the pistions ready to go in. #1 is sitting in the bore, compressed, oiled and ready to be knocked in, but I ran out of time.

My website will be updated daily throughout the engine assembly. It's updated to todays progress now.

looking good, i'm glad its going smoothly so far.... hopefully it'll continue on the same way it has

I want to see your turbo piping. I'm going to do a 57 with twins so i'll keep an eye out for you pics when you get them going

SWEET
R^3

Piping should be fairly easy, for the cold side of course. drill a couple 2.5" holes in the front wall's on each side, run piping out, around into the intercooler, and back in through the other side, then up and to the turbo plenum. hot side piping to adapt to the original manifold will get trickey, because the pipe has to go off at an angle in a partial S shape to put the turbo in the correct position, and clear the shock tower.

those darn shock towers are always quite the pain..... i had a chrome monte carlo bar a few weeks ago that fit your car and i didn't even think about it.... i ended up selling it on craigslist for $5

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Originally Posted by thesals

those darn shock towers are always quite the pain..... i had a chrome monte carlo bar a few weeks ago that fit your car and i didn't even think about it.... i ended up selling it on craigslist for $5

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Monte Carlo bar would probably get in the way anyhow, tho it would probably help the flexing that this car is going to get...

today, I got all 6 pistions in, and plastigauged the rods. all came out to .015
rod cap torque spec is excessively light it seems at 19-24 ft/lbs but, I set the torque wrench as low as it would go to 25 Ft/lbs and torqued them. I would have liked to use a 3/8" torque wrench so I could do 3 step torque but, ours is broke ( ratcheting gear is stripped and catches when it wants to ) so I did what I could, put them snug with a regular ratchet, then went back and torqued them properly.

tomorrow the camshaft goes in, which is a Clay Smith 224/224 @ .050 .495/.495 then I can hook up the timing chain, and install the oil pan and timing cover. after that, I'm waiting on the roller rockers for the lifters and pushrods that come with them, and I'm waiting on valve springs and retainers that I ordered yesterday from Clay Smith.

Matt the hot side piping is going to be tricky!! Looking at your pics of the turbo maybe a 86-87 turbo might be easier to adapt? That cam will give it a nice lumpy idle!! Nice progress!!

cam is in, timing set is in, timing cover is on, oil pump is primed and installed, next is oil pan and then I move on to the cylinder head. I have to cut the valves and seats.

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Originally Posted by FFR428

Matt the hot side piping is going to be tricky!! Looking at your pics of the turbo maybe a 86-87 turbo might be easier to adapt? That cam will give it a nice lumpy idle!! Nice progress!!

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yeah, the hot side piping is going to be tricky, but I'm going to put it about leval with the rear of the cylinder head, there are 2 holes drilled and tapped in the side face of the intake log near the back, I'll make a bracket that bolts the Turbo to these ( there's a couple bolt holes that are free, I can use on the turbo ) and then the Turbo can stay there whail I figure out the piping to it, and then after, it will be good to support the turbo.