I'm hating crappy craftsmanship more and more as time goes on...

Jason

Just back from holiday and am very happy your engine issues are actually quite minor and don't cost much to mend :)
I agree with Jason about the no. 1 cylinder: it may just be a blocked injector due to some crap that was in your fuel system (tank, lines, who knows?)
If the spark was at fault, wouldnt the plug show a totally different color?

Damn I feel like and idiot now. No harm done and not much money lost (a wasted trip to the machinist) but I found the source of my problems. Turns out a bad measurement was made and that effected everything. I measured the plate for checking deck height incorrectly, or rather must have read the dial calipers wrong. Probably due to assembling the motor at 2-3am the first time around because I was excited :P

Well I found the mistake today when I double checked the plate thickness. My measurement was off .100" so I had an actual deck height of .171" instead of .071" or a total compression of 6.5:1. So If you're curious as to what kind of power a 2165cc, very low compression motor, running on 3 cylinders makes on 13lbs of boost, it's about 107hp. The low compression explains the hard starting problems and low power so I'm relieved about that. I'm going to tear the short block back down and have both cases machined a total of 4mm (4mm on one block and an additional 2mm on the other). In hindsight, I would have caught this problem early on if I did a compression test, so maybe it's time I got a compression tester.

So going from 6.5:1 to 8.5:1 should be a real kick in the pants with or without boost :) I'll probably be re-re-assembling next weekend and hopefully driving again a week from today.

Sweet!!! Good to hear it was just a learning moment and not a start over! Can't wait to hear about the new numbers.

Jason

Sweet... I'm with Jason,
good to hear it wasn't s HUGE problem and you didn't really hurt anything.


Chris.

Glad to hear it was just that :)

But higher CR also could mean higher IAT's, so I would definately invest in some sort of intercooling while 'your in there' ;)

I already have the water injection in place and since I know the problem now I may not even change the nozzle. The #2 nozzle is good for 250-400hp so it should be fine. Case #1 is at the machinist now getting 4mm shaved off the deck and should be back in my hands wednesday or thursday.

Updates through the weekend!

Haven't had much time in the past couple weeks to work on the car, too many things happening all at once. My sister got breast cancer (thankfully benign and successfully removed), my mom has to go in for heart surgery yet again for her transplant heart (for the medical equivalent of a leak down test), and I've been on edge for over a week with a huge wild fire 3 miles from the house (mostly contained now but still unsettling)

I've been working feverishly on the car since I got home from work yesterday since I now have everything to put it back together. Got the long block assembled last night and hopefully in the car later today. If all goes well I'll be driving her again tonight or tomorrow. Pics coming!

Uploading some pics now, engine is inand managed to fire her up in the midnight hour. Sounds like there's a miss and she was blowing smoke but that could have been assembly oil. I'll have a better ida tomorrow.

Take it easy, don't rush things too much ;-)

It's funny that you say that... Last night after I got the motor in I was turning it over with the starter to build oil pressure and it started leaking oil terribly. discovered that in my rush I forgot to install the oil control valve. That's fixed now but easily over looked!

Some quick pics of the rebuild

http://i93.photobucket.com/albums/l4...6.jpg~original

http://i93.photobucket.com/albums/l4...1.jpg~original

http://i93.photobucket.com/albums/l4...3.jpg~original

http://i93.photobucket.com/albums/l4...5.jpg~original

http://i93.photobucket.com/albums/l4...7.jpg~original

Wrong manifolds but mine were port matched just like this. That's where most of the wait came from.
http://i93.photobucket.com/albums/l4...8.jpg~original

http://i93.photobucket.com/albums/l4...0.jpg~original

Machined the crank pully while I was at it to get some more clearance
http://i93.photobucket.com/albums/l4...5.jpg~original

http://i93.photobucket.com/albums/l4...8.jpg~original

http://i93.photobucket.com/albums/l4...5.jpg~original

This is the one thing I don't like about the DTM shroud, the way the oil cooler installs. First the oil cooler adapter goes on, then the shroud, pull out the top 2 long bolts out of the adapter, and wriggle on the oil cooler while keeping the seals in place. Then thread in the long bolts in through the cooler and bolt everything together. just a pain.
http://i93.photobucket.com/albums/l4...3.jpg~original

new wiring location away from the header
http://i93.photobucket.com/albums/l4...7.jpg~original

Almost there
http://i93.photobucket.com/albums/l4...8.jpg~original

more pics coming!

nice I like the turbo system, how makes it

It's a CB Performance kit that comes with the turbo header, boost pipes, 48mm throttle bodies, manifolds and pressure hats. Overall it's a pretty good setup but if I did it over I'd go with a different turbo header like the one from DRD that has better wastegate placement.

Good to see things are going back together.
I hope all is well with your sister and mother.

Hi

How well do you find your oil cooler works in the inner fender, I'm thinking of doing the same thing on my daily.

Steve