1. Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

bensalf's 4 year caferacer build

Discussion in 'XJ Modifications' started by bensalf, Dec 26, 2015.

  1. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    the edges were smoothed using 320 grit paper then gradually decreasing to 400,600,1000,1500, then buffing wheel
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    now to start masking up for spraying
    [​IMG]
    [​IMG]
    [​IMG]
    discs also masked up and sprayed
    [​IMG]
    new hi-max tyres arrived
    [​IMG]
    [​IMG]
    stu
     
  2. jayrodoh

    jayrodoh YimYam Premium Member

    Messages:
    2,522
    Likes Received:
    1,102
    Trophy Points:
    113
    Location:
    Cleveland
    Great attention to detail! Looking forward to the finished project. I'm about 1 yr into a similar build on a 650 Max.
     
  3. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    ------------------------------------------------------------------------------------------------------------------------------------------
    Great attention to detail! Looking forward to the finished project. I'm about 1 yr into a similar build on a 650 Max.
    --------------------------------------------------------------------------------------------------------------------------------------------
    yes, thanks,! so you're probably like me , a bit timid to start posting pictures in case the whole project collapses?
    I've seen so many projects on here and other forums that never come to a conclusion because the builder hits a snag.
    at least mine's up and running , just needs a little more dialing in ,when the weather improves.
    cheers
    stu
     
  4. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    so I finally got around to bolting some pieces together.
    [​IMG]
    next, the engine
    stu
     
    Joris and k-moe like this.
  5. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    oh!, also ,above, note the 6 little up-stands I had welded onto the rear top frame , these are to mount the seat rails on , also to bolt
    the new under-seat tray to house the electrics.
    stu
     
  6. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    so, engine lifted onto bench, and paint stripper applied
    [​IMG]
    [​IMG]

    [​IMG]
    stu
     
  7. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    after an initial steam clean, and wipe down.
    [​IMG]
    overdid it with the steam a bit.
    [​IMG]
    stu
     
  8. jayrodoh

    jayrodoh YimYam Premium Member

    Messages:
    2,522
    Likes Received:
    1,102
    Trophy Points:
    113
    Location:
    Cleveland
    I starting posting a build thread, but it's taking longer than I thought so I figured I would just do a full thread once done.

    Keep the pics coming!
     
  9. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    did'nt have a compression tester at this stage, but did a valve shim check.
    only 3 were in spec, managed to swop one around, which left me needing to buy 4 more.
    obtained these and fitted , all valves now in speck.
    here's a tool I made to hold the bucket down , while the shim is extracted with tweezers.
    [​IMG]
    [​IMG]
    I made the tool out of a 1 foot steel rule, and stuck an old wire brush handle on,
    after seeing a similar thing in the Haynes book
    [​IMG]
    [​IMG]
    stu
     
  10. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    this was before I read about the zip tie /bent wire methods.
    didn't like the home made tool very much ,as it had a tenancy to cock over whilst holding the bucket down,
    although it did work.
    I used the bent electrical wire at subsequent times.
     
  11. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    obtained a compression tester, like this one.
    [​IMG]
    run a compression test on all 4 cylinders.

    with the following results

    1---- 0
    2---45
    3---100
    4---85

    with a tablespoon of engine oil in each cylinder

    1---110
    2---155
    3---165
    4---100

    re-tested the day after

    1---25
    2---75
    3---105
    4---90

    left a week after

    1---0
    2---100
    3---240 eh?
    4---85

    dunno what happened to the no3 cylinder test above, probably me, getting used to the guage.
    so these results would indicate a fault within the cylinders, so decided to pull the head off, to have a look.
     
  12. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    I could fit a .178mm feeler guage between the piston and cylinder, which is slightly out of spec, but I reccon rings are stuck.
    cylinder bores look good ,with still some cross hatching showing, so I pulled off the cylinders
    [​IMG]
    [​IMG]
    pistons themselves looked good ,after a clean up
    [​IMG]
    but some of the rings were stuck in
    [​IMG]
    stu
     
  13. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    also found no, 1,2,and 3 exhaust valves were leaking through, after filling the head with oil
    [​IMG]
    stu
     
  14. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    so stripped the head completely to regrind the valves in
    [​IMG]
    [​IMG]
     
    mnrider likes this.
  15. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    cleaned up bottom crankcase, and masked up ,and sprayed with simoniz engine enamel
    [​IMG]
    [​IMG]
    [​IMG]
    new camchain installed, also note the black plastic protectors on the cylinder head bolt shafts.
    originals disintegrated whilst dismantling, these new ones are actually heatshrink tubing
    [​IMG]
    stu
     
  16. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    cylinder barrels cleaned up and sprayed
    [​IMG]
    pistons cleaned up and refitted, barrels slotted on
    [​IMG]
     
  17. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    note the clear air passages, through the middle of the cylinder block,
    compared to this picture, before cleaning, shows the passages almost completely blocked.
    [​IMG]
    stu
     
  18. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    NOW------here's where I made a monumental f-up, yes stupid imbecile, me,----
    after grinding in the valves I decided to refit the cams ,and redo the valve clearances, with the head on the bench.
    whilst I know xj's are "interference engines ", in that the valves can come into contact with the pistons, when manually turning the cams , without the camchain being fitted and timed up. so that wouldn't be a problem ,with the head on the bench. OR SO I THOUGHT.
    what I didn't realise is that the valves also "interfere" with each other when turned separately, as in the photo
    [​IMG]
    so whilst turning the cams with a spanner on the hexagon, I managed to bend all 4 exhaust valves.
    you can see here the light shining through the bent valve, this one is supposed to be closed.
    [​IMG]
    I didn't even know I had bent them till I turned the head over, after doing the clearances, as it took remarkably little effort to do the damage.
    here's one of the bent valves
    [​IMG]
    stu
     
  19. bensalf

    bensalf Well-Known Member

    Messages:
    1,267
    Likes Received:
    254
    Trophy Points:
    83
    Location:
    yorkshire ,england
    so after sifting through ebay, I couldn't find any replacement valves on their own.
    but I did manage to find a complete engine, at a reasonable price "£75" complete with starter motor, and generator.
    and only about 30 miles away.
    so I got the engine ,and stripped the valves out of it, reground them into my head, and re fitted them back in.
    now masked up and sprayed the head
    [​IMG]
    [​IMG]
    head now refitted back on, with the new camchain threaded through and linked up and timed.

    [​IMG]
    chain riveted over
    [​IMG]
    all timing marks lined up, with crank shaft set at t.d.c.
    [​IMG]
    stu
     
  20. jayrodoh

    jayrodoh YimYam Premium Member

    Messages:
    2,522
    Likes Received:
    1,102
    Trophy Points:
    113
    Location:
    Cleveland
    Good on ya admitting to the mistake and the consequences. Another person will read this thread and save their valves :D
     

Share This Page