K-Series Engine Build

[@ndy]

After the disaster I had with my previous engine (linky) I seriously considered sticking a Honda or Duratec in the Elise, However 18 months and 10 track days later with my £350 ebay engine I’m still loving the ‘K’

 

So earlier this year when Martin R offered me a low mileage 145 VVC engine I snapped his hand off -

 

 

 

 

Head looks good and no fire ring indentation -

 

 

 

 

Block and liner heights good to –

 

 

 

The plan was to get the head ported, fit my Newman ph3 cams from existing engine and build a new bottom end, Well the things may of got out of hand a little –

 

 

 

• Piper 285 cam kit (cams, springs, spring caps, vernier pulleys & blanking kit)
• Lightened (3.7kg) flywheel
• AP clutch
• Geotze liners
• Omega forged pistons
• Malhe VP2 big end bearings
• Malhe motorsport main bearings
• New OE oil pump
• New OE water pump
• New OE rod bolts
• New cam belt tensioner
• Front pulley machined
• New belts, gaskets etc.

 

The entire bottom end (crank, flywheel, clutch cover, front pulley & rods) have been dynamically balanced by Jason (Hellier performance) who also did the head work.

 

I will be building it up over the next few weeks and hopefully installing over Christmas….. I’ll keep you updated on progress -

[Martin R]

Im glad its a good one Andy. Is the crank ok? Send the liners back and get some Westwood ones. Do DVA,s oil pump mods as well. Im going to enjoy this    

 

Edit, the latest Geotze liners have been know to crack in use.

 

http://www.westwoodcylinderliners.co.uk/

 

They are only in Droitwich. The standard ones should do you fine.

[AlanS1]

Andy - Great start and write up. I look forward to reading the next chapter. 

 

Looks like you are already well on the slippery slope

 

I would do a little write up on mine, but i have never uploaded photo's to this site? (i have lots of photo's)

[@ndy]

Im glad its a good one Andy. Is the crank ok? Send the liners back and get some Westwood ones. Do DVA,s oil pump mods as well. Im going to enjoy this    

 

Edit, the latest Geotze liners have been know to crack in use.

 

http://www.westwoodcylinderliners.co.uk/

 

They are only in Droitwich. The standard ones should do you fine.

 

Crank was good Martin..... 

 

I was advised to go for Goetze liners, However may consider getting some Westwoods now as I dont want any chance of a failure

Andy - Great start and write up. I look forward to reading the next chapter. 

 

Looks like you are already well on the slippery slope

 

I would do a little write up on mine, but i have never uploaded photo's to this site? (i have lots of photo's)

 

Very slippery slope, I will be refreshing and upgrading a few other parts during the build once the clams are off !

[JonS]

Good luck with the build Andy.

 

I had Geotze liners in my DVA fully rebuilt K13a back in 2012. This may be a previous version from what Martin mentions, but I can say that mine ran absolutely fine since then. Honestly didn't miss a beat - and it was pushed quite a bit on occasion! ;-)

[Martin R]

http://forums.seloc.org/viewthread.php?tid=393407&page=1

[JonS]

Ouch, that's quite a read!

 

Nice to see Dave & Rog working together on that.

[@ndy]

Westwood liners purchased.....

 

[@ndy]

Managed to complete a couple of small jobs today -

 

 

As recommended by Dave Andrews (DVA) Took the Dremel to my new oil pump and flowed the oil ways -

 

 

 

And bloted the block to my engine stand.... Nothing to stop me now apart from time !

 

 

 

I also checked over the car in prep for Donny at the weekend and managed to get a short run in the morning sun

[Alex B]

Looking very good Andy.

Mega clean n Shiney!

[jody391]

Very nice Andy!

[@ndy]

Managed to get a few hours in the garage over the weekend to work on the engine, First job was to double check the liner heights are OK with the new liners before re-fitting with sealant, Thankfully all were at a consistent  0.003" height difference -

 

 

 

Before re-fitting liners with sealer I wanted to get the crank in, I used Millers competition assembly lube on the main bearings and crank that should hopefully protect the metal to metal surfaces during initial start-up -

 

 

 

Next was to apply the flange sealant, I used Loctite 574 as recomended by Dave Andrews -

 

 

Now to drop the crank in place and tighten to 5Nm then 30Nm in the correct sequence -

 

 

And back to the liners..... After applying a bead of Blue Hylomar I dropped them in and held them in place with my home made liner clamps -

 

 

 

 

 

[Martin R]

Andy, nice. Im presuming you did not forget the crank thrust washers?

 

Edit, ignore that i can see them now. God in getting old   

[AlanS1]

Great work mate.

 

Should all be done for the end of the month then

[russelld]

Good work Andy,

 

My engine is out at the moment waiting for new parts ! It looks like you are using the standard con rods, have you had the pins press fitted to the little ends or machined to make them fully floating ?