emo The story of our Carol a.k.a. 'spud'

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10 Jul 2014 09:38 #21976

Good to see the progress, keep on persisting with the lil carol and soon it will all fall into place :)

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31 Jul 2014 15:03 #22158

What's the latest on Carol? Do you think she'll be making an appearance at the meet?

Last Edit: 02 Aug 2014 08:48 by wh1teleopard.

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05 Aug 2014 07:56 #22196

Em, I've just had a thought on your terbo to cat problem. Could you post a pic of the original cat, if it's the same shape as the AZ-1 one I've got one in the loft that mates directly to the cappo turbo.

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05 Aug 2014 20:49 #22201

Sorry for not replying Adam, wasn't intentionally ignoring you...

I'm not sure, it's a bit hit and miss if she'll make the meet. Certainly she won't have been to the bodyshop in time for a repaint. However we've got to get her through an MOT... which means new tyres, new lower arms, new link arms, new springs and anything else we find with the backend.

I ordered some lowering springs from SPAX yesterday, so hopefully they'll fit (they're for an Alto).


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05 Aug 2014 20:52 #22202

Hi Don, that's very kind of you.

The cat sits behind the engine on Carol, not on the down pipe like a cappo. The downpipe on Carol goes through the engine mount which is where we are having some problems. We've got to grind a mount off the back of the down pipe as it's hitting the block and won't let us marry the turbo to the exhaust manifold.

Jamie's got to take the turbo back off to try modify the down pipe (don't fancy trying to separate them again)... so I'll ask him to take some photos if he does that while I'm at work.
:)


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06 Aug 2014 18:58 #22207

Sorry for not replying Adam, wasn't intentionally ignoring you...

I'm not sure, it's a bit hit and miss if she'll make the meet. Certainly she won't have been to the bodyshop in time for a repaint. However we've got to get her through an MOT... which means new tyres, new lower arms, new link arms, new springs and anything else we find with the backend.

:lol: I knew you weren't ignoring me! You were busy making KKITP 4.0.

Whenever she's ready she'll be the star of the show.

Last Edit: 06 Aug 2014 18:59 by Adam Kenney.
The following user(s) said Thank You: wh1teleopard

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01 Feb 2015 13:03 #23679

Time for an update...

So just to recap because I lose track of what I've told you and what I've forgotten to post up haha

So we bought Carol as a non-runner... though we were told it was just a head gasket failure, but turns out she'd been in a ditch for 5 years... the perils of buying blind. Anywho, we bought her home and rebuilt her original single cam engine.
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1165
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1460

The single cam engine didn't seal, it had obviously been run really hot until the head warped.

With sourcing a new head near enough impossible we decided to swap in the twin-cam engine from our cappuccino. On the books they're near identical engines, in reality there's a little more to it than that.

Anyway, we both worked together, rebuilding the bottom end first (might I also add we moved house twice during this haha). New oversized pistons, new oversized rings, new everything really. Swapped things over as we went between Carol and Cappuccino (the bottom end is near enough identical, so that makes things easier).

http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1244

So on the bottom end we have...

Cappuccino block
Cappuccino pistons
Cappuccino piston rings
Cappuccino crank shaft
Cappuccino bottom end auxs
Cappuccino oil filter
Alto oil pump
Alto water pump
Carol oil pick up pipe
Carol sump
Carol flywheel
Carol clutch
Carol gearbox

Then we had to swap over the heads from a Carol single cam head to a Cappuccino head. This is where the fun starts.

Basically, the carol and cappo engines have are no electronics switches or sensors on the engine itself, everything is controlled by the inlet manifold assembly and the distributor, with some input from the exhaust and cat.

So with that in mind I figured we could use the Carol inlet and electronics, especially as they are such similar engines. The injection pattern would be the same, timing would be dictated by the distributor, so there's no reason why we can't use the carol inlet. It also meant not having to rewire everything, and also a big factor in why we couldn't use the cappuccino inlet was that the cappuccino inlet would be where the RH front strut sits... so can't start taking air in from there, well not without forgetting the turbo altogether haha.

So with that settled we rebuild the head with the carol inlet manifold assembly. Unfortunately this meant stopping work for a few months while uncle Bob very kindly made us an adapter plate. The centre of the holes on the Carol inlet, and the Cappuccino head are lined up which is very helpful. Sadly though the water jacket is completely different. On Carol the water exits the head between the inlet ports into a cavity on the inlet manifold. On the Cappuccino engines it's one hole to the RH side of the engine (or front, if it's mounted on a cappo). This means on the Carol the thermostat sits on the LH side of the engine, on a Cappuccino it sits on the RH side. The adapter plate Bob made allowed us to fit a hose on the RH side and run it to the LH side, and into the correct part of the thermostat (that took a bit of working out haha).

http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1255
http://kkitp.com/index.php/home/gallery/image?view=image&format=raw&type=img&id=1258



The next issue came from the manifold side. We would have to use the Cappuccino exhaust manifold so that it would marry up to the turbo. Sadly for us the triangular flange on the turbo is roughly 180 degrees different, like the triangle is flipped over - no logical reason for this is obvious other than to sell more turbos haha.

With the Cappuccino head, Cappuccino exhaust manifold, Cappuccino turbo we next had to mount the downpipe, on a Cappuccino this also houses the cat, on a Carol this downpipe goes through the front engine mount which is not big enough for the Cappuccino cat to fit in. So we had to use the Carol down pipe... however as we've become accustomed to now the flange for the turbo-to-downpipe was ever so slightly just a tiny bit, but enough different that we could only use 3 of the 4 holes for now.



With that fixed in place we went to mount the exhaust to the downpipe... low and behold we can't fit it on because the downpipe is angled closer to the engine and there isn't enough physical space to fit the flange of the exhaust.

So we had to ask uncle Bob again to make us a spacer that would push the manifold further out and give us clearance to fit the exhaust on the bottom.

Unable to fit the exhaust we were able to build up Carol to approx 80% completion and fire her up. She ran perfectly, so that at least was good news. We also jacked her up and checked to make sure she had drive to the wheels, which she did, so that was great news too.

We couldn't run her for long though as the noise was deafening and we were being gassed to death.

We then had to wait for the spacer to arrive.

Once we had the spacer we were able to build up the exhaust again, only this time we found that even with the extra 18mm it's only just barely enough, and we can only fit 1 bolt in the exhaust as the angle is thrown out, so plan going forward is to cut the cappuccino downpipe above the cat and get a stainless steel exhaust bolted on to it there... it's the only way we can think of doing it as the cappuccino downpipe ultimately will head off towards the LH wheel rather than the back of the car as the Cappuccino engine is mounting longitudinally not latitudinally like the Carol.

We finally managed to run her up to temperature last night and were pleased to see her fan kick in, maintaining her own temperature and at the moment no oil leaks... sadly there's a water leak but I think I know what that is as it's got oil in it and the only pipes we couldn't flush out fully were the ones for the heater matrix, so they'll still have oil in from the previous rebuild that couldn't seal.

However - Jamie's already not a big fan of Carol for all the trouble she's caused us, and today she electrocuted him with a high voltage shock which could've caused him a lot of pain and trouble. Thankfully he wasn't holding on to it at the time and managed to pull his hand away before any serious damage could happen.
:angry:

It seems the intercooler is not only sitting on the HT leads (we knew about that) but it seems to be arching out on one of them or something in that area that's high voltage. When it does start arching the engine begins to stall and eventually cuts out... so that'll need sorting out pronto, can't be electrocuting people...

Plan for next weekend if Jamie hasn't set fire to her by then is to remove the A/C gubbings from the front inc the radiator and pump and move the intercooler down there, seeing as it's just the right size to fit behind the hole in the bumper. This will hopefully stop the arching problem and stop people being electrocuted when touching the intercooler... though I will investigate the wiring down there and make it safe so if someone grabs the dizzy it won't be the last thing they do!
:angry:

So things to do:
Sort out the vacum hoses, we've lost one haha
Rip out the A/C
Move the intercooler
Get a new exhaust made
Replace the exhaust side of the turbo as the manifold flange is mullared
Find the water leak and fix it

Then I think we're done for the engine side of things





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Last Edit: 27 Apr 2015 14:53 by wh1teleopard. Reason: typos

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01 Feb 2015 22:29 #23684

Awesome to see the progress that you guys have made. It's clear to see a huge amount of effort has gone into her. B)

Shame about the intercooler though. Are you going to relocate the current intercooler or go for something else?


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