Rolln16 Posted October 3, 2005 Report Posted October 3, 2005 The short version…… Well it all started when the tailgater that had been following us just about all over town pushed Rolln03 just that little bit too hard… One screaming 4k and a lesson to the tailgater taught (smokescreen…well almost) we were left with fried piston rings and a blown head gasket. One week later and after many calls made by Rolln03 a 5k was found at the Maryborough wreckers… the engine cost was $250 and it came with a 5spd gearbox…too good to pass up. As soon as Rolln03 told me about it I started scheming :hmm: with his mates and about three days later a phone call and the co-operation :( of the of the wreckers team – I was now the proud new owner of a 5k engine and a gearbox to suit…One problem – I had no way to get the engine and its gearbox from Maryborough to Hervey Bay before Rolln03 went to get it himself that following day. The next morning I called up his mates once again to see what the go with their input was – and got no reply… two hours and Rolln03 would be on his way to the wreckers…eeek. So in desperation I called my grandfather in Maryborough and asked if he would go to the wreckers – pay them (with his money) and take the engine home to his own house… about twenty minutes after I did this the so called mates turned up with the transport - :hug: boy was I mad… anyway I gave them the money, the directions and goodwill and sent them to my grandfathers place to pay for and get the motor from him… amazingly it all worked out well and the engine arrived at its hideout and was hidden just minutes before Rolln03 and I showed up to visit his mate (the one hiding the engine)…whew!!! :D Well there were two surprises once Rolln03 received the engine - one was that we had only expected a normal gearbox but instead found out that the original was stuffed and the wreckers had proceeded to give us another which was a T50… but the not so good surprise was when Rolln03 took the engine to his fathers place to see if they could get it started. After several attempts the little 5k could only manage a half turnover and wouldn't fire… so after much deliberation off to JACOBSON ENGINEERING she went….. =) Quote
Rolln16 Posted October 3, 2005 Author Report Posted October 3, 2005 Two months later (thereabout) and 3 pushrods are bent as a result of the first firing of the engine :D so Jacobson's called all around Australia to try and find replacements and came up with none, Xany offered Rolln03 some also but in the end… Japan was called and some heavy duty pushrods are imported here to oz for the little k. Four weeks later and we could finally bring home the “beast†– here's what she had done to her; (don't ask for the cost we aren't sure what it was) REBUILT * NEW PISTONS, RODS, CRANK, VALVES, ROCKER ASSEMBLY EVERYTHING BALANCED LIGHTENED FLYWHEEL BORED & HONED 25 / 65 CAM HEAVY DUTY VALVE SPRINGS UNKNOWN IMPORT HEAVY DUTY PUSHRODS PORTED, POLISHED AND SHAVED 5K HEAD NEW HYDROLIC LIFTERS BRAND NEW GENIE EXTRACTORS PORTED & POLISHED INLET MANIFOLD NEW 9MM TOPGUN LEADS NEW BOSCH GT40 COIL RE - BUSHED & RECURVED DISTRIBUTOR LARGER DISTRIBUTOR FITTED NEW WATER PUMP NEW THERMOSTAT & THERMOSTAT HOUSING CUSTOM HIGH QUALITY FAN BELT So on Saturday morning three weeks ago now, Rolln03's Dad picked up the 5k from Jacobson Engineering and we met him at Rolln03's brother's place for the start of a very long weekend… :sad: First of all we had to get to Childers…two jump starts, a set of new jumper leads and a very slow noisy drive to Childers and we were ready to pull out the 4k and prepare for the new engine… Quote
Rolln16 Posted October 4, 2005 Author Report Posted October 4, 2005 Well, all went well with the pulling out of the old engine - there was the odd bolt or two that had seized up in its hole but aside from that there were no problems... We took the 4k out and stripped her of the necessary pieces - Alternator, alternator bracket Starter motor Weber dgv 32/36 carb + adaptor plate Old 4spd gearbox - for now anyway Old radiator - till end of week We had trouble with the engine mount on the drivers side - as it was too small, so the old one was reused, the standard carb was ditched for the Weber and the old 4spd gearbox was mounted to the 5k. Other than the engine mount, the only other problems that had appeared were that the fan belt was WAY to big, so a smaller new one was fitted. also, when mounting the gearbox, the engine backing plate was getting in the way - so the old - chop, chop, hack, hack system was used to line everything up... :D Quote
Rolln16 Posted October 4, 2005 Author Report Posted October 4, 2005 (edited) Well once everything was in..... Rolln03 forgot which way the coil was hooked up :( (luckily i had taken enough pictures to at least have one shot of it and we managed to hook it back up) then we tried to start her.... But she wouldn't click over...just uttered the most hideous sound - "CLICK" and then for some reason she wouldn't even turn over..... so we tried jump starting – numerous times, checked everything millions of times.... and finally got her to kick over, but then of course there was no spark, then there was no fuel, then when we finally got fuel and spark the darn thing didn't want to kick over!!! :D After a day of fiddling around we gave up and rolled the Rolla down to Rolln03's Dads place for storage for the next two weeks and came home...... Last weekend we started again.... first we towed the Rolla back up to Rolln03's brothers shed and - all refreshed with new extractors from wildcat, we got there and pulled off the inlet manifold, and took off the old extractors and replaced them with the brand new ones.... Then we checked every single wire, earth and power wire..... Pulled apart the terminals and filed them all...and finally first go she kicked over! YAY!!! But just because it happened once didn't mean it would happen again - Murphy's Law...grrrr :hmm: So wracking our brains we proceeded to check the timing - which was out...... so we reset it properly and BINGO!!! She finally started! And boy was she loud - the whole shed was vibrating and with no exhaust we all got rather high on the fumes...eeew.....hehehe =) (the reason we had no exhaust was because the other one was so rusted it basically snapped in two when Rolln03's brother was removing it to put on the first pair of extractors...) After all that - when it came to turning her on again she refused to keep running (without the accelerator on), so we ditched the standard carb, because we couldn't figure out where the anti - dieseling solenoid went.....and on went the WEBER..... After a quick tune and a couple of attempts at starting we were finally cooking with gas …time for a spin… :hug: Edited October 4, 2005 by Rolln16 Quote
Rolln16 Posted October 4, 2005 Author Report Posted October 4, 2005 (edited) Well the next thing we had to do was assemble an exhaust from the remnants of the old one (there is no way could have gotten home with being pulled over otherwise) with much sawing clamping and banging we put togehter half an exhaust to tone down the sound just enough to make it bearable and to stop everyone from thinking we were driving a badly tuned rotary...hehehe The best part of course was getting her home... 80ks along the highway fifty million cars banked up behind us and no overtaking lanes for another kilometer...hehehe and when we finally got to the overtaking lane Rolln03 decided to speed up a bit to strecth her legs...hehehe... Well we had to stop about 5 minutes out of Childers otherwise she would have been cooked as she was running hot on two thirds temperature - half an hour later and we were back on the road again... a couple more stops on the side of the highway and then we were on the home stretch...but about 10 minutes from town she got so hot we had to stop for about 45 minutes... then we ran into trouble...Once she'd cooled down a bit we decided to start off again - there wasnt far to go and we thought it would be smooth sailing - unfortunately for us that was a no can do...she would not start - wouldnt fire or click over or nothing...Rolln03 cracked the shits (we had a fight ) then when we were just about ready to start walking low and behold she started to cough over a little - a few more tries and we were up and running once more... So now she is home :D - we still have trouble turning her off but everytime she runs she gets better...This week its a new radiator and exhaust system for her and then on to the interior and the mags, the new paint job, bonnet, sound system, rust killing and the story goes on... :( If you have any comments feel more than free to add your say... :hug: Edited October 4, 2005 by Rolln16 Quote
ROLLN'03 Posted October 4, 2005 Report Posted October 4, 2005 Pictures will follow very shortly...... The only problems i am having at the moment are keeping everything cool. But i think that is only because my radiator is stuffed, and I need some new radiator hoses.... And when you go to turn it off, sometimes it just wants to keep running, is this just because it is too hot? Does anyone else have this problem? Other than that, a new radiator and exhaust system will be on within the next two weeks and new rims will follow.... Quote
NoPsi Posted October 4, 2005 Report Posted October 4, 2005 Run on is because your timing is set too high. I used to get it with an ae82 I deliberately fiddled with. In the end I backed off the timing. I would also check your points/gaps as this maybe the reason why it starts sometimes and sometimes not. Quote
ROLLN'03 Posted October 4, 2005 Report Posted October 4, 2005 Thanks for your input....... Ill check it out! :D Plenty of pics to come...... Right through from start to finish.... :( Quote
ROLLN'03 Posted October 5, 2005 Report Posted October 5, 2005 This is how it looked before we started the journey....! :D Quote
ROLLN'03 Posted October 5, 2005 Report Posted October 5, 2005 And for all those not playing along at home...... This is my Wagon....! :D Quote
ROLLN'03 Posted October 15, 2005 Report Posted October 15, 2005 Hey guys, finally have pictures of the whole project from start to finish so here goes..... =) Here is the first day..... Quote
ROLLN'03 Posted October 15, 2005 Report Posted October 15, 2005 The removing of the front grille, radiator and support assembly..... Quote
ROLLN'03 Posted October 15, 2005 Report Posted October 15, 2005 Old 4k hooked up ready for removal...... Quote
ROLLN'03 Posted October 15, 2005 Report Posted October 15, 2005 Long live the Ol' 4k....... Out and about.... Quote
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