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Copied from a post elsewhere

Pictures of the car it's going in can be found here........

http://www.tigerstyle.co.uk/poloforum/v ... php?t=8414

Opel Monza GSE 3.0 12V 5 Speed manual - actually my track day tool

Right so I had a spare 3.0 24V engine and I can get a reliable 250 bhp out of one of these lumps but I wanted the Monza to look like the engine was factory fitted so

Had a few bits powder coated - you've seen these threads before

(bear in mind here I want this engine (24V) to sit in a monza and look like it was made to be there so bright silver and red it isn't gonna be)

We talking Black - like a monza engine I was tempted to mat black it (like a stealth plane - I rarely polish the car so it would be in keeping with the overall look) but it actually marks worse than shiney black so settled for this

I might polish a few bits but black is back

24V sump (black - it might be alloy but it's black now) shot blasted and powder coated



Exhaust manifolds (shot blasted and Sperex'd - 1250 deg C)



Inlet manifold - (normally silver it might be alloy but it's black now) shot blasted and powder coated



Other ancilaries (all shot blasted and powder coated - err black!!!



Rocker cover and spark plug cover plate - normally silver and red respectively - now black and black.... don't worry bit of detailing will brighten it up



Yep - the lettering on the front will be powder free and polished



I might polish another spare cover plate if I don't like the all black look

Fuel rail and cover plate - very rare Opel logo one



Hmm strip back the powder coating on the lettering so its polished and you'll see what I'm going for

Bores honed and ready for the pistons



Block painted already (I know it's not black - I did one before black and you couldn't see an oil leak)



Pistons All balanced up to within 0.2g (pre polished)

1-3



4-6



Heres where they remove material to balance them

1-3



4-6



Rods have been blanced too

And the crank

And the flywheel (althought thats because it's been made from scratch EN24T Billet steel)

Bottom end is now rebuilt

Pistons installed before the crank

1-3



4-6



Crank installed and all the big ends closed down



Both ends of the con rods had to have a bit of shaving to balance them up - one had nothing removed all the others needed plenty taken off to get down to the same weight



10mm double doweled crank



Sexy EN24T Billet Flywheel lightened (std 24V flywheel is 16.5kgs - this is less than half that) and balanced - Clutch face



Same but engine side - bit of lightening went on Tig welded ring gear for extra security



About this much lightening......



Damn I could look at this thing all day but no one is ever gonna see it!!!!

Timing cover back from chemical clean

Repainted and ready for rebuild



Oil pump cover - stripped rebuilt cleaned painted and ready for fitting



No explaination needed for pic below - uprated timing chains

The link you have provided is gash!

Sounds like a proper awesome car though!!

2Fchris wrote:The link you have provided is gash!

Fixed..... Sorry

2Fchris wrote:Sounds like a proper awesome car though!!

I like it - nice that a car built in 1985 can worry modern stuff

All looking very nice How much longer before it'll be going in the monza?

GroovyCarrot wrote:All looking very nice How much longer before it'll be going in the monza?

Next track day is 4th September....................

Blimey You going to have it run in by then?

GroovyCarrot wrote:Blimey You going to have it run in by then?

If I'll have it running - I'll run it in on the way

I have a slightly unorthodox approach to running in and the only thing that will need running in is the rings - everything else is sized to mid clearances

wow...... no wonder you've been mouse-like.... that looks like a hell of a lot of work

can we have pics of the finished thing in the car then?

Tahrey1043 wrote:wow...... no wonder you've been mouse-like.... that looks like a hell of a lot of work

It's a few evenings for sure

Tahrey1043 wrote:can we have pics of the finished thing in the car then?

you can have a before and after pic of the engine bay when it's done and judge for yourself if it looks factory fitted or not - with the bonnet down no-one will know It'll look the same as the picture in members rides

I love Lotus Carltons

dino wrote:I love Lotus Carltons

well it's not going in that...........

nice work! That flywheel has made me go ever so slightly weak at the knees

btw I love lotus carltons too, but i love a good sleeper more!

Hope it all goes together well

Ste

SteB wrote:nice work! That flywheel has made me go ever so slightly weak at the knees

I've been drooling over it too - have to be carefull cos it'll go rusty

Seems such a shame to hide it!!!

SteB wrote:btw I love lotus carltons too, but i love a good sleeper more!

Yeah well the car (Monza) and I have a bit of history and this is my way of resolving one of the problems I have with it on track days - slow on the straights but quick in the corners means I get overtaken on the straights and then often the same person that overtook then gets in my damn way in the next corner.

I'm not trying to make a sleeper but I don't plan on advertising whats under the bonnet if you get what I mean

SteB wrote:Hope it all goes together well

So do I

very cool mate!

keep up the good work! would love to have a noisy at em when its all done!

Bottom end is now completely built

Chains fitted

Front timing cover and water pump in

Front pulley on - remind me to tighten the bolt!!!



Sump on (can hardly see it cos it's black!!)



No offence but most of you won't know what a Monza GSE engine bay looks like - that has black lettering and polished/machined strips going from front to back... Just for interest like below



So I'm trying to get this (a 3.0 Litre 24V engine) that normally looks like below to a similar look to the picture above..... ie looking OE or at worst like it was meant to be there.....



So I have some choices

This (the all black minimal look)



Or this with powder coat stripped from the lettering



or this with a polished spark plug cover plate and lettering



With this WIP (work in progress)



And here it is finished





And a bit of trick photography to finish - both side by side WTF!



not really trick photography - i had two rocker covers and 1 cover plate powder coated in black at the same time so I could play about with the look and finish (it made no diff to the price of all the bits I had done)

The fun bit tonight was finding I couldn't fit the flywheel - not enough clearance on my engine stand to get it over the dowels so i had to improvise and make some clearance

The Engine stand is now modified with several parts from a Lotus Carlton



Head work continues at a pace....

Valve throats opened out to maximum



Seats cut to 0.5mm Inlets and 1.0mm Exhaust (good for power - not so good for long term reliability)





Inlet Ports opened and blended





Modified alternator Bracket and tensioner fitted





(Reason is to reduce the width of the engine/alternator so I don't have to cut the chassis rail to give the required clearance - this set up is 20 mm narrower than std)

Head is back from skimming today...... So should be on by the end of today