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.

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.

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.

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.

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

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.

Ok quick update as a few bits have arrived.
Block and heads are complete and ready to be picked up.
Now I have the pistons, the small end bushes can be replaced.
Not pictured is a new oil pump, crank timing gear, ACL race bearing and gaskets.
hopefully if maddat get back to me I will do a steam pipe exhaust manifold as well.

New CP Pistons below, this should take the compression ratio up to around 10.5:1.



Ross Racing Balancer, needs to go back as it didn't come with timing marks :(



Adjustable Cam gear, going to run two exhaust cams so need to adjust inlet timing.



did some work to fix the broken dump pipe, added a divider, enlarged the wastegate area to allow it to open further.



Also fixed the cracked section and added a stiffener between the flange and the O2 sensor mount, will also put a flex pipe in the exhaust to further reduce the load on the dump pipe.



Inlet manifold went on a diet with all excess mounts removed (close to 400grams removed from this heavy beast).



Ka24de throttle body attached. easy bolt on upgrade.



Sump started to be modified ready for wings and gate



Threaded insert machined to replace welsh plug on back of head for head drain.

Took the other 3 pistons/rods apart the other week and found another bush spun, with it spun there is no oil feed to the bush/pin, which would have caused the failure.
Only way that can happen is if the clearance wasn't correct/checked when the engine was put together originally. Oh well, will get it right this time.

rebuild is turning into a monster build.
Hoping to net about 10-20% extra torque out of this build.
Machinist seemed to think last build it wasn't torque plate honed and a couple of bores were very slightly out of round, he has fixed that this time.

Most parts are now ordered.
Custom CP high compression pistons 4 weeks lead time are the next thing I need to progress.
Order thicker Gudgeon pins on this as well.
Decided to re-bush the rods in lieu of buying new ones. This way I can get the gudgeon clearance spot on and hopefully not have the same problem. Was significantly cheaper then new rods too.

Will keep you posted when things start to come together. Looking forward to the rebuild phase on this one.

Quick update.
Engine iwas dropped off at the machinist today.
On the cards for a rebuild:
Block bored, decked and torque plate honed
Head pressure tested, stripped, cleaned, valves seats reground, new seals, rebuilt
New oil pump
Exhaust cam on inkale side, adjustable cam gears
Custon high compression pistons
Ross racing balancer
New rods
New bearings
Balanced
Injectors cleaned
Retune

Will be replacing all pistons and rods, with the bore damage to No. 3 & 4 (Pre-existing damage in 4 due to a bolt ingestion a long time ago) will oversize the lot to 84mm.