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 Ricou's French Cappuccino (currently 3134 views) |
| Ricou |
| Posted on: Wednesday, November 14th, 2012, 6:19:51pm |
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Hmm, didn't think about the space it would free, I'll look into it, thanks 
Other than that as I'm using the Adaptronic the EGR shouldn't be working anymore, unless I've missed something. |
Last modified Wednesday, November 14th, 2012, 6:20:24pm by Ricou |
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Reply: 40 - 84 |
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| Ricou |
| Posted on: Wednesday, February 13th, 2013, 10:28:21am |
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A lil' picture of the ported head :
I've had the front subframe and wishbones painted.
Before :
After :
Also polished the headlights with a 3M kit.
Before :
After :
Fitted back the exhaust manifold with its new EGT sensor :
Then I emptied delicately the cat with a hammer and a big screwdriver.
Still got a lot to do... |
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| Andy |
| Posted on: Wednesday, February 13th, 2013, 10:34:11am |
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Very nice progress  |
Drop me a PM if you would like to be added to the ClubCappo Member Map. More details can be found here.
We now have an official Facebook group as well as a page! See here |
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Reply: 42 - 84 |
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| Ricou |
| Posted on: Tuesday, February 19th, 2013, 10:05:06pm |
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Yeah Andy, I'm finally making some progress, it's a relief after all this time.
I was fortunate this sunday, 3 other french Cappuccino owners came to help 
I'll let the pics speak for themselves :
nc30pete's gearbox here !
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| Capposteve |
| Posted on: Tuesday, February 19th, 2013, 11:59:23pm |
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| Avar |
| Posted on: Wednesday, February 20th, 2013, 8:36:30am |
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| Yep, good job, nice to see my coolant kit partially fitted too |
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| Capposteve |
| Posted on: Wednesday, February 20th, 2013, 8:39:54am |
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| I was just thinking the same thing about your coolant system. |
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| doodlepugg |
| Posted on: Wednesday, February 20th, 2013, 1:41:18pm |
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looking good! I really should start my progress thread...  |
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| Ricou |
| Posted on: Wednesday, February 20th, 2013, 1:52:50pm |
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Thanks guys
Kei, about your nice bleed kit, did you get any results from installing it the right way (apart from the engine warming up correctly) ? |
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| Avar |
| Posted on: Wednesday, February 20th, 2013, 7:21:58pm |
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| Once it was fitted to the correct pipe (engine coolant return pipe) i've noticed no change to anything which is exactly as hoped, its purely a bleed to ensure No.3 doesn;t stagnate, without serious analytical equipment its a job to say anything else. Its one of those things that will only tell after extensive engine use and punishment and then a breakdown to check the condition of internals. But its generally agreed that its working as intended. |
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| Ricou |
| Posted on: Wednesday, February 20th, 2013, 8:08:04pm |
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I was expecting an answer like this, but I asked anyway
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But its generally agreed that its working as intended.
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Good ! |
Last modified Wednesday, February 20th, 2013, 8:08:20pm by Ricou |
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| Ricou |
| Posted on: Monday, February 25th, 2013, 7:02:31pm |
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This sunday, lyric and 2 other friends helped me put the engine where it should be
As usual, it was quite fiddly getting everything to fall in place (steering column, gearbox, subframe mounts...) but we finally got everything back in place.
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| lord |
| Posted on: Monday, February 25th, 2013, 7:19:00pm |
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Looking clean and tidy... that engine will be good for another few years....
Was all that a hard job to do?? |
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| Ricou |
| Posted on: Monday, February 25th, 2013, 8:34:41pm |
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What exactly do you mean by "all that" ?
If you're talking about the engine removal + reinstallation, I'd say it's definitely not an easy job.
But of course it depends on your personal references and your skill level |
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| Ricou |
| Posted on: Thursday, March 7th, 2013, 1:50:21pm |
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This saturday I finished fitting and wiring the gauges, it wasn't very fun but needed to done.
I wired them from the audio head unit wiring because it was the simplest way and it had all the necessary inputs (permanent +12v, switched +12v, headlight signal).
The result
Sunday progress was less visible, but it was some pain-in-the-back stuff.
We replugged the fuel hoses, put back in place the wiring for the injectors and stuff that goes around intake manifold, fitted the new alloy rad, replugged the boost control valve.
I also ordered some silicone 90° elbows to improve the new intercooler fitment, and to make an unrestricted intake for the HT-07. |
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| Al Cappuccino |
| Posted on: Thursday, March 7th, 2013, 3:20:32pm |
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| Very nice and almost done! |
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| Ricou |
| Posted on: Wednesday, March 13th, 2013, 3:14:38pm |
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Thanks !
MOAR PROGRESS !
Yesterday, I didn't go to work because of the snow, and very conveniently the hoses I ordered were just delivered, so here's what I did.
Unrestricted intake for HT-07 :
Six Sixty's engineering shiny airbox
The intercooler I bought from Lars, now sitting in its final position :
Oh, and the engine runs !
But not well, it can't even idle for long. I hope it's only because of the old fuel in the tank, not something more annoying to fix. |
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| mattjohns |
Posted on: Thursday, March 14th, 2013, 9:11:43am
 Attachment: wastegatecontrol.jpg - 43.38 KB (852 views) |
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| EDIT: This isn't what I first thought it was but may still pose a problem in the future |
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Last modified Thursday, March 14th, 2013, 9:17:53am by mattjohns |
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| Ricou |
| Posted on: Thursday, March 14th, 2013, 10:42:43am |
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Yep, it's a water pipe, if I remember correctly I checked and it is not going to leak or come off, but I'll double check.
Thanks |
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| Ricou |
| Posted on: Monday, March 18th, 2013, 12:05:31pm |
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Well my Cappuccino is officially in the engine break-in phase 
I had a few issues (the engine wouldn't start with 9 grade plug, but that was a mistake, I planned on running 8s) but most are sorted or getting sorted. |
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| mitogeri |
| Posted on: Monday, March 18th, 2013, 1:53:59pm |
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| can't wait to see some new on-board videos |
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| Ricou |
| Posted on: Monday, March 18th, 2013, 2:32:12pm |
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When the engine is ready to handle it, I'll do some 0-60 runs videos
And later will come some trackdays hopefully.
Anyway it's looking promising, with the unrestricted intake for the HT-07 it seems the lag have been reduced and it's making boost quite earlier, as Don described it
The Suzuki Sport clutch isn't that bad, but combined with a shitty idle (I'll need to work on that later) and the lightened flywheel, it's quite tricky not to stall. By the way, I like the low inertia the new flywheel gives, it's a bit more like a racing engine now. |
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| Ricou |
| Posted on: Monday, March 25th, 2013, 10:43:07am |
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I've done 500km of break-in (~300miles), I'm starting to apply some boost and rpm (6000 and 0.5b), and it seems very promising
Two crappy pics because I haven't found the motivation to use the reflex camera :
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| doodlepugg |
| Posted on: Monday, March 25th, 2013, 1:49:34pm |
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| Looks awesome! What is it that you did with the intake to de-restrict it? I'll need to do it with mine... |
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| Ricou |
| Posted on: Monday, March 25th, 2013, 2:27:28pm |
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| doodlepugg |
| Posted on: Tuesday, March 26th, 2013, 2:55:18pm |
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Ideal, thanks buddy. Pretty much just a bigger bore inlet? I may just make one and save the aggro
~Andy |
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| Ricou |
| Posted on: Tuesday, March 26th, 2013, 4:47:00pm |
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| Yeah, it's just a bigger bore inlet for the turbo, but it does make a difference |
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| doodlepugg |
| Posted on: Monday, April 1st, 2013, 8:51:19am |
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| Thanks buddy |
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| ycming |
| Posted on: Wednesday, April 3rd, 2013, 11:36:09am |
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Doodlepugg, i'll got a spare of that inlet pipe which you need to modify. IF you need it!
Ming |
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| doodlepugg |
| Posted on: Thursday, April 4th, 2013, 7:14:33pm |
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No thanks Ming. Only have use for one  |
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| Ricou |
| Posted on: Monday, May 13th, 2013, 10:57:45am |
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| Ricou |
| Posted on: Tuesday, November 19th, 2013, 10:49:03pm |
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Right now the engine is at my mechanic's place. It burns 1L/500km of oil on the 1st cylinder alone, and after stripping it down we're unsure about why.
He is going to hone the cylinders and install new segments to be on the safe side, as well as changing the valve stem seals. |
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| doodlepugg |
| Posted on: Thursday, November 21st, 2013, 8:11:16am |
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oh no.... Have you moved the engine breather to somewhere not under vacuum? You'll get 'blow-by' or something like that if the head becomes pressurized from lack of vacuum on the breather.
Each time I see your thread it makes me a little jealous because it's how I should've done mine  it is a lovely looking car you have! |
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| Ricou |
| Posted on: Thursday, November 21st, 2013, 4:30:08pm |
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“ |
Quoted from doodlepugg, posted Thursday, November 21st, 2013, 8:11:16am at here |
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oh no.... Have you moved the engine breather to somewhere not under vacuum? You'll get 'blow-by' or something like that if the head becomes pressurized from lack of vacuum on the breather.
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Yeah I did, exactly. I hope it's just something as stupid as that, but another french owner is using a similar setup on his cappuccino and he doesn't have any oil consumption issue.
Anyway, if that's the issue and not something wrong with the rings or the cylinder head, it's not all for nothing because the engine will be put back together with a 2mm headgasket (instead of 1.4mm) and ground camshafts (Palsports).
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Quoted from doodlepugg, posted Thursday, November 21st, 2013, 8:11:16am at here |
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Each time I see your thread it makes me a little jealous because it's how I should've done mine it is a lovely looking car you have!
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Thanks mate.
I think you took a more reasonable way by buying an engine already tuned, it's a shame it turned out how it is but you couldn't have foreseen Fairfax were a bunch of idiots. |
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| doodlepugg |
| Posted on: Thursday, November 21st, 2013, 8:25:43pm |
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it's always good to have something to check I suppose! I was going to have just a filter on my engine breather, but I really didn't like the idea of not having it under vacuum. There's a reason it was designed like that, so to me it's best to leave it like that!
I really wish I did have an engine built myself (or built one myself) just so I know exactly what's going on and what I've done. After spending so much time and money on it, It's the only grey area which I'm unsure of. All I can tell for sure is that it has brand new pistons, and a thick head gasket...
Truth be told, I wish I bought an ae86 corolla and done some N/A tuning. Or stuck with my MX-5 and done N/A tuning to that. I love a good, simple & tidy engine bay...
It'd be nice to have a 4ag engine in a Cappo, I think it'd suit it well. |
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| Ricou |
| Posted on: Saturday, November 23rd, 2013, 3:07:36pm |
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| A 4AG would be nice power wise, but I'd hate to throw away the Cappuccino's very good balance and 50/50 weight distribution... |
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| Ricou |
| Posted on: Tuesday, February 4th, 2014, 10:41:56pm |
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I was at my mechanic's place yesterday, we made some progress.
As he thinks the issue I was having with the cylinder 1 is because of pistons rings not sealing properly, we're just changing the rings and re-honing all cylinders.
JE pistons and News GT1 rods, reusing them of course.
Engine head with uprated springs from News GT1.
Cylinder bloc, with honed cylinder (clickable). Isn't it pretty ?
Oil pan and engine head to get cleaned.
Cleaning !
Cleaned.
Putting the pistons back in.
2mm headgasket from Suzuki Sport with some sealant adhesive paste.
We also installed the regrinded camshafts from Palsports, but I forgot to take pics.
Engine should be ready next week |
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| lord |
| Posted on: Thursday, February 6th, 2014, 8:28:01pm |
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I'm loving the engine work you have put into this mate....
How long has this taken you to complete and what kind of gains will you get from all this engine work mate? Don't see many people do internals like what you have done. |
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| Ricou |
| Posted on: Thursday, February 6th, 2014, 11:54:51pm |
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Cheers mate.
This engine build took a lot of time for various reasons (adding more parts from Japan to the build, waiting to get enough money...). I also had to find another mechanic during the build. And I wasn't in a hurry most of the time, so all in all it spread on more than one year, but I guess it's possible to do that in 3 to 6 months if you know what you're doing and you don't get unlucky.
And just to be clear, I didn't do much on the engine myself, the mechanic did all the work while I took the pics
If I get 130bhp out of this I'll be ok, and if I get 150bhp I'll be very happy. Might have to switch to a turbo bigger than HT-07 for that though.
I think this engine should be able to withstand 180bhp, but it would need some supporting mods (custom intake, bigger turbo) to get there, and probably a reinforced gearbox too.
Also, I don't know how much power and torque the standard crankshaft and bearings can take, so pushing it too far could get very expensive.
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Quoted from lord, posted Thursday, February 6th, 2014, 8:28:01pm at here |
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Don't see many people do internals like what you have done.
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If you're talking about the forged conrods, to be honest they're a little overkill, I bought them a bit on a whim. News GT1 told me standard conrods break at 180bhp, whereas these are supposed to hold up to 280bhp.
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| Ricou |
| Posted on: Monday, August 18th, 2014, 10:57:45pm |
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Wow, it's been a while since the last update
The car has been on stand-by for a while now, she needed some work before being able to start breaking-in the engine.
I recently discovered (thanks to Dave660) that the little washers I got with my reground cams were supposed to go under hydraulic lifters.
That mistake should explain the noticeable ticking sound the engine head is making.
That, with a tired HT07 turbo, a slow oil leak around oil pan and a lack of money explains why the car has been sitting in my garage for almost 6 months.
But a few days ago, a mate and I started working on it, and it went quite well
Turbo and intercooler piping off, coolant drained, engine radiator removed : now there's some space to remove the timing belt.
We also removed the HT07 turbo, which was leaking oil in the intake, as I suspected.
Then we used an old timing belt to block camshaft pulleys in order to remove them. Then camshafts went off too (no pics, sorry).
It's time to install those damn washers !
All that for these 
One by one, we removed valve rockers and lifters and put the washers under the latter.
I can say we were quite happy after all that as we were expecting all sort of trouble getting crankshaft and camshaft pulleys off
I'll be soon putting back a stock turbo while I figure out if I'm buying another HT07 or getting mine rebuilt (which seems not an easy job as the parts for that aren't made anymore).
It won't be anywhere near it's full potential with a stock turbo, but at least it will get me through the engine break-in  |
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