My valver/172 project

Matteh · Jan 25, 2008

Yes, another one doing the conversion...

I've had these up on another board for a while, but just noticed this shiney new project section, so thought i'd add mine

I own a ph1 449 16v:

The head gasket has been on it's way out for ages now (as I'm sure Clarkie can point out - he wasn't very impressed that every time I went to Carlton Garage the coolant expansion tank was bone dry

)

I bought a ph1 172 engine off of Joshydee and sent it to Dan for some rebuilding...

so, got to work on the old engine:

Oil cooler is buried in there somewhere (didn't realise I had one) and the 'interesting' wiring on the alternator

engine loom/connectors

Matteh · Jan 25, 2008

16v lump removed:

removed this at night, with rain coming in sideways, as I only had the crane for a short while..

note: always remember to undo the gear linkage from the box!

wrapped it round the steering rack

Matteh · Jan 25, 2008

did some 'derusting' on the front cross member and on the engine bay whilst it was empty..

did some 'freshening up'

I've got plenty more pics of stuff being painted, but you get the idea

Matteh · Jan 25, 2008

I wanted to keep running PAS as I quite like it and I'm a girl at parking

Normally, the 172 manifold runs under the subframe on the 16v, but on the 172 it runs over it (between the subby and the bulkhead)

basically, the PAS pipes are in the way, so have to come off or be relocated...

think this (arrowed) might be the cause of my heavy steering:

Dan sent me these pics of the clearance on his conversion...

Dan said:
Pics as requested.

not much room at all underneath!

so I got the steering rack adjusted (S.P.A. welding, Lancing, Brighton)

Instead of the connection coming straight up and then having the hydraulic line go up a bit more, which would hit the 172 exhaust, I had the connection lopped off and welded on to a 90deg elbow joint, so a very similar height (although a bit chunkier) but now the hydaulic line can run freely!

Painted:

hopefully that will clear the exhaust!

the pipe flarer and bender have been ordered too, so ill make up the remaining pipes to suit

Matteh · Jan 25, 2008

Took the head off the 16v lump...

can see that the head gasket had basically just perished... (it had been 'going' for about a year!

)

My genius method of lifting an engine into MKRs boot on my own!

yes yes, I know all of you could lift an engine 1 handed, but I can't

Beaniemoo · Jan 25, 2008

Brilliant to see, we'll have to start our own club soon!
You know where we are if you need anything

Matteh · Jan 25, 2008

stuff gradually going back on:

2 Bolts securing the inner bushes on the ARB

Subframe in place

Pivot the ARB down (disconnected from the wishbones) in order to easily insert the rear subframe bolt

Front Subframe bolts

Wishbone bolts (18mm)

Subframe to Chassis leg support in place

Bracket for the ball joint and ARB (Williams specific)

2 bolts (18mm) Securing the strut to the hub

2 Bolts securing the caliper carrier to the hub (looking down)

Almost completed assembly (track rod ends not connected)

my dust cover for the other shock has torn, so that's stopping me put the other wheel on

- will hopefully have that sorted soon...

Matteh · Jan 25, 2008

the freshening up of components and altering of the steering rack is pretty much all done now

I'm really just waiting for the engine, so the ball is in Dans court

eek

Dan said:
Now, Matt has kindly given me the task of rebuilding the F4R 730 engine he purchased and had it delivered to mine.

It arrived on a broken pallet, with various bits missing or broken. So after a rather long phone conversation discussing the options. He did not realise that the engine was water damaged hence removal, I knew, but thought The seller would have disclosed such information.

I set about stripping it.

End caps from the cams off:

Oh dear. This kind of set the tone for what else was to be found.

Sump off, and well, it looks like the engine had been driven into the sea. dust/grit found in the sump had me worrying greatly for the welfare of the bearings, or more importantly the crank.

Looks like a bit of a snail shell in the oil pump? ive not fished it out yet for a look to see what it is. but you can also see bits in the sump.

All the big ends off:

Suprisingly good condition. there is only one thats causing me concern, and thats number 2. You can see in this picture the slight dicolouration on the journel, ive yet to clean it up

A close up of No.1.

All the big ends out and on the bench, along with oil pump and cams and cam cover:

A close up of the worrying cylinder(2) bearing:

At this point I had another phone conversation with Matt, to get the go ahead for the head to come off to remove the pistons to check the con-rods. At this point the con-rods appear to be good and true. Time will tell.

Matteh · Jan 25, 2008

Last I heard, he was waiting on the big end bearings

Engine should be good though, with all new belts/pumps/gasket/seals etc..

Now that I get to keep my power steering, the PAS res was bothering me, as they always look old and dirty. Sprayed it up in a can of yellow spray paint I had laying around. Flash makes it look awful, but the photos without show it much better!

Gonna do the driveshafts like this I think - excuse the run, i caught it afterwards...

More bracketry and the PAS pump...

more yellow pipework 8)

Polished magnex!

Matteh · Jan 25, 2008

Beaniemoo said:
Brilliant to see, we'll have to start our own club soon!
You know where we are if you need anything

we'll have to arrange some meets or something

sorry about all the pictures! didn't realise, but they all add up when u cut all the conversation out

mossyv6 · Jan 25, 2008

Awesome project :star:

Please keep it updated

Jay Payne · Jan 25, 2008

Nice Matt, done agood job there so far. look forward to seeing this at the airfield.
Shame about the engine, hope it turns out ok

Matteh · Jan 25, 2008

Engine should be good

just delayed!

was also shocked at 172 prices, would've thought they'd be no more expensive than F7P stuff, given production volume..

Josh@Renparts · Jan 25, 2008

im sorry about the engine, im assuming the water got up the exhaust manifold. I ran the engine for approx 80 miles which is when it started making the rattling. With regards to the comments RE the pallet and broken parts can i stress i gave a full refund on the damaged items and i don't know what the shipping company did to break the pallet, sounds like them tipped it on its side or something. Anyway i hope the project goes well and there are no hard feelings.

Matteh · Jan 25, 2008

oh yeh, sorry - no hard feelings at all - i skipped past all of those details as we sorted them out

it was just in Dans posts [quoted items] that i literally just copy and pasted which still had a mention of them... You've been spot on throughout mate

I knew the engine was 'broken' as I saw the vids... i just didnt know how it had been broken. the plan was to rebuild it all along

Michael172 · Jan 25, 2008

good prodject, keep at it !!!

eternalife · Jan 26, 2008

Awesome car even without the conversion.
IIRC one of the earliest Mk1's with white willy wheels too! (first one that i saw)

Saw this about a year ago at pod when the f7p was alive - thought it was a lovely car then...Then went onto full williams widetrack

which is definitely the first thing i would do (as opposed to the F7R conversion)......and now the F4Rconversion (with a few delicate additions

) definitely makes this my fave mk1 project.

Grrrr makes me want to buy a mk1 again

PS: Can i request a passenger ride in it at the upcoming airfield day? :rasp:

Josh@Renparts · Jan 26, 2008

good stuff then, good luck with the project.

Matteh · Jan 28, 2008

Made up the remaining hydraulic lines on the rack tonight...

looks messy, but I'm reasonably happy with the result, considering it was my first ever attempt!

1st pipe:

2nd pipe:

Different angles:

Broke one of the connectors

(which is why the middle pipe is a bit longer and not seemingly connected

i'll tidy it up to that it all sits more flush with the rack when I put the rack on the car, for now im not sure of the clearance I need for the steering rack mounts...

Matteh · Jan 29, 2008

installed: (flash makes everything look rubbish

)

the middle connection now comes out straight at the gearbox/dogbone mount :roll: so I'll have to make that a very tight bend :shock:

Ads_172 · Feb 2, 2008

Awesome dude, didn't realise you were doing this!

Sounds like there'll be a few Mk1 172 conv's in the SW before too long...

Ryan · Feb 3, 2008

Coming along very nice! Think it would be a great conversion to do!

Nafoff · Feb 3, 2008

keep it up chap

Matteh · Feb 4, 2008

Missed your msn messages mate ^^ - was at hillpower!

I want them pipes!

Nafoff · Feb 4, 2008

ok mate we will sort it later, i should be on msn for a bit tonight so we can have a chat then

Matteh · Feb 4, 2008

got myself a nice diesel gearbox thanks to harvythehippo!

at hillpower:

Cleaning up:

The inner bolts look suspiciously new/clean!

Painted!

grubby hands on the driveshaft

Beaniemoo · Feb 5, 2008

Very Very tidy sir your engine bay is gonna look stunning!

Matteh · Feb 5, 2008

thanks

I bought an ECU today mate - it has the same codes on as yours does (from your text) - hopefully the ecu bloke can work his magic on it like he did for yours!

All I need now is a ph1 throttle body + airbox, fuel rail (with FPR) - though im using a valver one for now, exhaust made up, engine loom and a connector for one of my PAS pipes. oh.. and some form of pipework for this lump too :/

soo much

atleast I managed to get my softclutch bits!

release fork (with old 16v one)