4.4 rv8 build thread (Doc evil need not post)

[fett]

hello right been and had a butchers at the inlet and got the waterpump back on.

it seems to me when I looked down the first bolt hole which is one the bolt would not go all they way in (but i did torque it up using a nut as spacer if you remember) and is pointed to by a yellow screwdriver in this pic:

wholeengine.jpg Photo by fett8 | Photobucket

that the thread is cutting in to the lower face on the manifold bolt hole as per this pic:

yellowscrewdriverside.jpg Photo by fett8 | Photobucket

so removed the one on the opposite side on the engine which had gone in all the way but none of them were easy to start if you remember I mean really not easy! and it seems it has done the same. (This is the bolt pointed to by the orange screwdriver in the first pic btw)

orangescrewdriverside.jpg Photo by fett8 | Photobucket

although it is not quite as bad they are both cutting threads in to the inlet on the bottom side of the hole, making me think that its because the heads were skimmed making that distance more shallow for a std inlet manifold to fit in to, any suggestions or other ideas as to why?

If I am right it is hard to decide what to do as it seems down and sealed but bar marks good idea of a pressure test how would I ever know without taking it back off ? lol

I have new bolts of various lengths and taps and dies, I am thinking of reaming out the inlet bolt holes on the bottom face a little to allow the bolts some clearance? thoughts

I dont want to pull off the whole lote, there is £50 worth of permatex on it for a start, I understand in an ideal world I would get on my mill which I dont have and skim the inlet to an indeterminable size but this isnt really feasible for me.


one final sideline, I think the valley cover may be on back to front as there is a slot on the inlet where a bolt hole should be (middle bolt in this pic)

slotinmanifold.jpg Photo by fett8 | Photobucket

and a slot in the valley cover where the middle bolt hole is (in this pic below the middle hole and black as full of permatex)


http://s1189.photobucket.com/user/fett8/media/inlet fun/slotingasket.jpg.html?sort=3&o=4


does anyone have a clue what its for? is it essential as i cant see what it could do except make a leak

Nearly there now guys, despite every possible problem!

 

[jamesmartin]

if heads sit to low then the top side of threaded hole will be evident through manifold hole, reaming out manifold might well be a good fix

 

[fett]

only question is how well is the manifold sealed now its down? ans why mor probs one side than othe, does it men its not down right? it was a race against parmatex curing time to get any of the bolts to start initially lol

 

[discomark10]

if heads sit to low then the top side of threaded hole will be evident through manifold hole, reaming out manifold might well be a good fix

Thats right. By tightening the manifold you bring it down and relieve the bolt fouling.
If it where me I'd tap the holes as you say to get a decent amount of thread in ali head. Just hover and air blast the swarf out.
if I remember right the slots are not anywhere a seal was needed.

I'd be tempted to leave the manifold holes if you can get the bolts started ok, once its in it won't hurt.

 

[fett]

got everthing taped up just to trim the holes a little as they are too tight on the bottom on the inlet hole no matter what, noticed when temp putting rocker covers on that top edge tin valley cover just fouling rubber rocker cover gasket on one head- what to do and why lol

 

[discomark10]

Where is it fouling? Got a pic of some sort?

 

[fett]

Yeah if you look in my long post above you can see in the pic of the holes the thread has cut itself in to the underneath of the manifold bolt holes is the closest edge to the sump

 

[zen]

ever wonder why things are sometimes just sooo bloody hard???

cos i do.....

 

[discomark10]

Yeah if you look in my long post above you can see in the pic of the holes the thread has cut itself in to the underneath of the manifold bolt holes is the closest edge to the sump

Still not sure.. lol

 

[fett]

ever wonder why things are sometimes just sooo bloody hard???

cos i do.....

Yes lol!

I am sure then next joy is that none of the ancilleries will fit on the p38 heads but we shall see

 

[Dr_evil]

Not been looking at the pics, what stage are you up to now ?

 

[fett]

Mark, the bolts are fouling on the bottom of the inlet manifold holes, the side closest to the center line of the engine.

been held up on fences and got to do the rad on the trooper so may be a while before i get the die grider on her but its covered up ready when i do get to.

 

[fett]

doc, inlets on, just need to adjust the manifold holes then its ancilleries , rocker cover carb and flywheel

 

[Dr_evil]

Oooh getting close to firing stage then!

 

[discomark10]

If there on the inside (towards centre) it shouldn't matter as it will pull down anywho

 

[fett]

I agree mark, if I could get the bolts in all the way lol

 

[fett]

5 manifold holes dremmeled out, holes tapped again and new correct length bolts put in, they go in really nicely too.

it still didnt add up why some were off and others were good, I hope the manifold is sealed well, I guess I will find out on start up

 

[fett]

For James Martin

 

[MattMatt]

Whatever happened to Doc Evil?

 

[fett]

he thought he was good, we knew he was ****, sometimes he convinced people he was good with his crazy projects but none of them achieved more than wrecking a couple of running series and keeping a big block in the boot of a disco despite his guarantees of certain dates for project completion - am I right?