baffled and gated sump is coming along nicely, a few progress shots below.

the plug is just in there so I don't loose it :) and yes they are 50mm door hinges with the holes welded up :)




Basically new sump section is segregated into 4 sections, surging oil has to go through the pickup area, which is gated to minimise outflow. When I was checking it for leaks I was sloshing water around, doing this filled to pickup point which is exactly as intended.







Ready to finish it off next weekend.

Hey mate great thread will be keeping an eye on this one.

things are ticking along nicely at the moment.
have most of the gear now. Was waiting on gaskets and replacement balancer.
Engine machining will be finished this week.
Small end bushes are done.
Block is finished.
Head is machined, was awaiting valve stem seals.
They cut new valve seats, reground the valves, replaced the exhaust valve guides.
Crank will get a final grind and everything balanced.

Have all the pipework for the exhaust manifold and picked up a bellow for the exhaust pipe.
Finished (except paint) the sump today. Pics below.










tab at the back is to lockwire the sump plug.

Things are progressing albeit a bit slowly.
Have all the parts back now.
Head - All the exhaust valve stems were replaced, two valves were slightly bent so were replaced.
Block is back and painted.
Crank was polished and rods have new small end bushes.
I got some ACL race bearings. Rods were 0.0015" oil clearance which I am happy with.
Main clearance was 0.003" which is on the loose side. This will mean I have to find some 0.025mm oversize bearings to bring the clearance back down and may have to run half of each.
Interestingly my previous build had standard plus 0.001" race bearing, so the mains must have been really loose. Even with the crank being polished it doesn't remove that much material. This may have contributed to lowish oil pressures.
Anyway with ACL closing down, bearings are hard to come by, still in the hunt. Else I might have to go back to OEM.

Sump is finished, painted and ready to install.



Exhaust manifold - I got the collector finished and it is mounted in the jig, however in its current state the collector will hit on the head so will have to be put this on hold till the engine is back together. I will have to move the turbo position slightly from standard to get the collector to clear. This will have a flow on effect to the dump pipe angle.

made some more progress today.
bottom end is back together.
Had to use a combo of two difference size bearings to get the clearances correct.
Should make some good headway tomorrow with reassembly.
looking forward to seeing the numbers on the dyno with the higher compression.






somehow I managed to convince my wife to let me get one of these :) should fix that pesky diff issues.

looking good. Did you go with the 1.5 or 2 way lsd? I Havent put my mine in yet. interested to see the results.
Some ideas for the block; Weld up the side heater port on the large water line. Ive got mine rubber capped which i regret could fail on high water tempertures.
The rear water two port post, cut in half and weld a -6 on for turbo. Change over turbo side oil, water fittings to speedflow parts. The 90deg fitting on top of the oil filter side upgrade for flow.

I use that port as a bypass when the thermostat is closed and also for the oil cooler.
I am moving to speedflow fittings for the turbo now.

Oda70, it is a 2 way LSD. They don't a 1.5way for the hilux. Actually they don't make one for the hilux, you need to use a combo of supra and hilux bearings to make it fit or machine a 4mm spacer for the ring gear. I'll post photos when I get up to installing it.
Back to the rebuild. Made some more progress today.
Almost all back together now.
Head is on, cams are in.
New cam gears bolts hit the timing cover back plate bolts so will have to fix that.
Missing one oil filter bolt too, so need to do a bit of bolt shopping.

Bottom end ready for sump



Head studs back in. Bought a couple of second hand torque wrenches for the build. My new favourite tool, snap-on 3/8 torque wrench. Calibrated at work on Friday it was less then 0.5ft.lbs out across the entire range. 4-75 ft lbs. lovely tool.



Nice clean head, the top cylinder is no 4, you can still see the damage in the quench pads from the bolt it ingested about 6 years ago, went strong even with this damage. You might also note the fitting at the top, this is the head drain. I had a threaded insert made up to replace one of the welsh plugs. This goes around the back of the head and returns to the sump under the oil filter (Can see the fitting in a later photo.)



Now it's starting to look like an engine. New cam gears took a bit of work to fit, and as above the bolts are too long so need to be replaced, glad I noticed it before buttoning it up further.
I'm running 2x Exhaust cams too, so need adjustable gears.
New oil pump & water pump while I was at it.



Cam covers back on just to keep the dust out, will probably go for a mat black this time. Sump looking good too.



last one for this weekend, oil filter and cooler installed and can see the nice work done on the inlet side. some porting was done when I first had it build, no more port work done this time.

A few updates from today.
Mostly all Bach together now.
Will work on the exhaust manifold next weekend.

did a bit more today.
Exhaust manifold is coming along nicely. Ran out of gas on the tig so have to wait another week to finish it.
turbo site closer to block now, which will give more room to the strut tower (always been a problem for me).
Will have to modify the dump pipe to get around the gearbox.