* Engine Rebuild

 
   Photo of the original engine installation in the Concept Car. See photos below for the current state-of-the-art 
   engine rebuild for our 'Street Elite' roadcar. 
 
 
  A 'FORCE MAJEURE' created a nightmare problem which led us to an elegant solution and an
  association with some of the most impressive professionals involved in the entire Project.
 
  •   TOTAL ENGINE REBUILD by Reconditioning Services of Auburn NSW
  •   ENGINE COMPONENTRY by ACL (national) and Nason Engine Parts, Dandenong, Vic.
  •   ADVANCED COATINGS by Competition Coatings of Guildford, NSW
 
   It was a version of the good news-bad news joke ... but without the humour.
 
   'The bad news is the factory caught fire. The good news is  we've saved your car ... we think.'
 
   We think ! Hmmmmm....not good.
 
   It was an early a.m. call from the Fire Chief from the local Fire Brigade.   We had only just moved the car into the
   spacious facility and now it had caught fire. But worse was to come....
 
   The car had been 'saved' in principle, but the damage was extensive. And not just from the fire  - which was
   hot enough to bend roofbeams rated for 750degC.
 
   Although the car was on the opposite side of the plant from the fire epi-centre, fireman reported 'fireballs' zooming
   around the factory when they broke the roller shutter down -  so they sprayed everything in sight with high-pressure
   hoses. This included the Nagari and the water jet went in through the grille and filled the partly-dismantled engine.
   You can imagine the result.
 
   And it wasn't just the engine. The fire, water and 'chemical rain' had destroyed the interior trim and penetrated every
   nook and cranny, coating and corrupting all the surfaces - from softgoods (seats etc) to tough hardware such as
   the chassis,brakes and suspension. The grille-mouth was split, there was some heat damage to general paint and
   fibreglass rippling. The smell was worse than a barbecued wet dog.
 
   And then we found the Factory Manager had failed to renew the insurance...
 
   Difficult to imagine but we were in fact 'lucky' - another 15 minutes said the FireChief and the fire would have
   destroyed the factory and the walls would have come down... the Nagari would have been flatter than a possum
   crossing 18-wheeler highway.
 
   Some photos....
 
                                                                    
            
            
               
                                                                                                                                                                            
   (1) RECONDITIONING SERVICES - ENGINE REBUILD
 
   When we finally extracted and cleaned the car, we realised the engine had to be shoehorned out, stripped and
   rebuilt. As the Group A engine is specialised in the first place and this one even more so, we needed very
   experienced professionals.
 
   In the engine reconditioning business it is difficult to find a company with a better reputation than
   Reconditioning Services  in inner-western Sydney at Auburn - with an enviable reputation for road and race.
   The SAAB brothers (Tony and Joe) and their enthusiastic team swarmed all over our crates of rusty remnants
   and it disappeared into the bowels of their massive and well-equipped factory.
 
   A week later, after getting the engine Cinderalla-treatment Big Time, it came out totally transformed into
   a better-than-new machine. We followed and photographed most of the steps as a guide for others. These
   were the major items....
 
  •    Strip, bath all components and blast all relevant surfaces.
  •    Fully mike the entire engine (Reconditioning Services has the original manufacturer specs on file).
  •    Assess damage to componentry and create a machining schedule.
  •    Re-bore the block 30 thou oversize and fit new 30 thou over Mahle flat-top alloy pistons from Nason/ACL.
  •    Machine the heads, instal new guides, and reseat and match valves.
  •    Machine and match crank, rods and new bearings from Nason/ACL.
  •    Strip and rebuild/flowtest injectors
  •    Replace all 'wear' parts including lifters, springs, rings etc. with new Nason/ACL 'Engine Kit'.
  •    Balance
  •    Re-assemble with new Nason/ACL complete engine gasket kit.
          
      ENGINE- BEFORE. A box of bits.                                                       ENGINE- AFTER                                                 
 
   A key advantage of Reconditioning Services is that all operations are performed on-site in clincial
   surroundings with direct-line support from critical parts suppliers such as Nason/ACL. The job is
   project-managed from start-to-finish, down to the logging and storing of fasteners and bolt-on
   ancilliary parts. At the end of the day, the customer is delivered a completed engine, wrapped and
   sealed and ready for insertion. This saves on time and costs and ensures that this quality work
   is done at the most attractive price. This is the best-of-all-worlds engine rebuilding outcome.
 
   This explains why engines are shipped to RS from around the country.
   It also explains why enthusiasts including all kinds of race and rally, street machines and showcars
   gravitate to RS for their premium engine work.
  
                                                                                         
           
       
   SKIMMING & BORING CYLINDERS
      
        
       MACHINING CYLINDER HEADS
                 
       
         MACHINED AND COMPLETED BLOCK
 
     
       
        MACHINING AND MACHINED PARTS COMPLETED  
                                                                  
      
        NASONS/ACL ENGINE PARTS - MAHLE PISTONS AND ACL ENGINE KITS      
                                 
                    
               
          ENGINE SEALED AND WRAPPED FOR DELIVERY AND AWAITING INLET MANIFOLD
              
 
                                                    
        RECONDITONING SERVICES - COMPLETE ENGINE + INLET & PACEMAKER HEADERS                  
                  
                        
     RS WORKSHOP                             ENGINE READY TO INSTAL 
 
   
 
   (2) MANIFOLD PREPARATIOIN - COMPETITION COATINGS
 
   While the core of the powerplant was at Reconditioning Services,  we shuffled the inlet manifold to
   Competition Coatings at Guildford for final finishing.  John Taylor and his team enjoy the best
   reputation in the business for this work and the outcome didn't disappoint.
 
   We delivered a badly acid-corroded aluminium manifold and received back a piece of sparkling
   jewellery. The photos of course don't lie, but the reality is that, good as they are, they don't fully
   do justice to this extremely high-quality finish.
                      
      
      ALLOY INLET MANIFOLD - BEFORE .....                    ..... AND AFTER THE CC 'TREATMENT'           
 
 
   There are two elements to this...
  
   One is the base of the manifold which was prepared to a
   remarkable 'gun-metal' finish in their special 'shaker'. This process is abrasive enough to
   generate a highly-polished surface but gentle enough not to damage or remove metal.
 
   The second is the polished fuel branches. Overall the result looks 'better than chrome' and a
   lot more 'genuine'  too - entirely in keeping with a high quality techno product. In fact it is
   quite sensational and blew everyone away.
 
   We have to note that we scoured Australia for months looking for a suitable supplier to do this
   work and we had a lot of disappointments. It is very difficult to find suppliers who are
   prepared to work with cast alloy, especially in large pieces like this. To end up with this result
   far exceeded our expectations.
 
   This is not the only specialised work performed by Competition Coatings. They are also
   specialists in Exhaust Ceramic Coatings which provide many technical benefits as well as
   improving appearance - for example reduced surface temps, increased gas velocity,
   decreased under-bonnet temperatures and thermal fatigue resistance for exhaust temps
   up to 2000degF.
 
   So the company specialises in a wide range of premium coating products - from Ceramic
   and Thermal Barrier Coatings  (Polished, Black, Translucent, Thermal) to Dry and Solid Film
   Lubricants and oil-shedding polymers.
 
   Another prime and little-appreciated area is in Thermal Dispersants - transferring heat
   to air from coated components such as air-cooled engines, brake calipers, radiators etc.
 
   We will be bringing you further  updates on Competition Coatings as we are planning on
   utilising their finishes for a number of other exciting parts of the Project. Stay tuned!
 
 
 
       TWO PHOTOS TO DEMONSTRATE THE SPECTACULAR RESULT WITH CC TREATMENT ...
 
    
        PHOTO TAKEN AFTER ROUTINE SAND BLASTING
 
 
    
         PHOTO TAKEN AFTER PREP OF MAIN BODY IN THE 'SHAKER'  &
         THE FINAL CERAMIC COATING FOR THE INLET BRANCHES
 
              
    
        COMPETITION COATINGS CAN TREAT A WIDE RANGE OF ITEMS WITH
       A COMPREHENSIVE RANGE OF COATING SERVICES.
 
 
 
   Contacts:
 
   Reconditioning Services
   Unit 1, 28-30 Hampstead Rd., Auburn NSW 2144. PH: (02) 9748 2422  FAX (02) 9748 2811
 
 
 
   Competition Coatings
   10 Ferndell St. Guildford NSW 2161 . PH: (02) 9892 2218 FAX: (02)  9892 1347
 
  
   
 
 
 
  
 
  
 
 
 
 
 
 
 
 
Subpages (1): * Chassis Mods
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