Project Ernie

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Re: Project Ernie

Post by rich the mechanic on Tue May 15, 2012 9:03 pm

8bit-ash wrote:2 painted, two ready to paint. Got to take some progress pics soon. Few new bits done.

Is the engine a secret or are you telling us what it is???

Unless it's changed again he said a 1.6 charade although he didn't mention a booster fan.
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Re: Project Ernie

Post by HighlyJetted on Tue May 15, 2012 9:52 pm

Correct, its actually out of a 1.6 efi Sportrak, but pretty much the same but slightly less power, 95bhp as standard. I'm holding off on a bike engine until I get round the lack of a decent cost effective reverse gear.

More of a quick fix "maybe" - and to test to see if you can do the conversion, I can't find anything on the internet about it being done before so it might be a waste of time, money and effort.

When you convert a charade from 1.3 to 1.6, you keep the original 1.3 ecu and just swap to the grey(?) injectors, fingers crossed. While I'm at it I will port out the hijet inlet manifold to the new head - which ever head has the biggest valves and cam, and mate the 1.6 throttle body to the 1.3 inlet manifold. Use the lightest flywheel probably the 1.3 one. Fit some sort of adjustable fuel pressure regulator so I can tweet it a bit. Port out the exhaust manifold. You know, build it nice, all clean, polished bits, and painted casings and mounts etc.
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Re: Project Ernie

Post by Logi on Wed May 16, 2012 6:03 am

Smile the polishing bug has bitten, tis going to be a shiny Jet methinks .


Seemingly scientists have found a substance that destroys a womans sexual appetite





Its called " wedding cake " Wink
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Re: Project Ernie

Post by HighlyJetted on Fri May 18, 2012 12:32 am



Picked this up earlier Smile
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Re: Project Ernie

Post by rich the mechanic on Fri May 18, 2012 6:40 pm

loads of plishing to be done there specially in them black bits.
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Re: Project Ernie

Post by HighlyJetted on Sat May 19, 2012 2:12 pm

Ready for geek talk? Ok...

The hijet injectors are 12.2 ohm and look like this:-



While the sportrak injectors are 13.6 ohm look like this:-



So after some research it turns out that:-



Both have the same flow rating! When doing a charade conversion I read that you swap from the Green 160cc to the Greys 190cc injectors.

That is an increase of 30cc's, also to think scale, 180 over 160 = 1.1875 so times that by my 186cc = 220.875cc

So far the most accessable parts to meet my requirements are:-

195500-4430 from Mazda RX8 1.3 rotory 231bhp primary injectors. Only installed in pairs though.



or maybe a set of these from a early 1990's Mazda MX5 1.6



The hunt continues....
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Re: Project Ernie

Post by HighlyJetted on Sat May 19, 2012 10:18 pm

Another 2 hours and the last one will be done TFFT

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Re: Project Ernie

Post by Logi on Sat May 19, 2012 10:22 pm

Lookin good, can't wait to see them on Twisted Evil
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Re: Project Ernie

Post by EvaInNorfolk on Sat May 19, 2012 10:47 pm

I'm sure Honda use similar low impedance injectors - or they did in some Civics in the 90s (I had a 1979 Honda Civic back in Oz Very Happy ). Anything there to play with?
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Re: Project Ernie

Post by HighlyJetted on Sun May 20, 2012 9:16 am

All the 1.5 1.6 1.8 civic/integra b and d series use 240cc injectors which are a little too big unfortunately as I have a few sets floating about.

I also have some R1 injectors and some CBR1000RR ones and these are way too big too.

I'm going for the MX5 injectors first as a place down the road has a second hand set for cheap.
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Re: Project Ernie

Post by HighlyJetted on Sun May 20, 2012 12:14 pm

And then there were five Smile

Just need to finish the painting...




Last edited by HighlyJetted on Fri May 25, 2012 10:50 pm; edited 1 time in total
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Re: Project Ernie

Post by HighlyJetted on Wed May 23, 2012 11:12 pm

Today I have collect a set of the MX5 1.6 blue injectors, which were quite a bargain and just half a mile down the road so it would have been rude not to have them really.

And I have stripped the 1.6 engine, so its now pending getting the old 1.3 engine out and comparing/swapping the right bits over.

If its even possible that is! I'm thinking of spending as little money and time as possible to see if I can get it in and working. If I blow £300 building this engine up with new this and that and it doesn't actually fit I'd be a bit gutted, nor could I get the money back out of it.
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Re: Project Ernie

Post by HighlyJetted on Fri May 25, 2012 11:00 pm

Thought I'd add some chav bits...

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Re: Project Ernie

Post by HighlyJetted on Sat May 26, 2012 2:48 pm

I'm sure there is supposed to be something under here?



doh! here it is Smile



So you know, you can get to this stage single handed with the help of a few blocks of wood and a trolley jack, and I think that if I remove the inlet manifold and reduce some weight by removing the flywheel and clutch I'll be able to slide it under the chassis without any problems.
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Re: Project Ernie

Post by PFM on Sat May 26, 2012 3:10 pm

You going to deal with some of that brown stuff that shouldn't be there first before you put it back together?

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Re: Project Ernie

Post by HighlyJetted on Sat May 26, 2012 3:19 pm

Awwww, do I have to?

I've had enough brown snot already Mad
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Re: Project Ernie

Post by PFM on Sat May 26, 2012 3:34 pm

Ok, leave it then. You'll regret it later though!

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Re: Project Ernie

Post by HighlyJetted on Sun May 27, 2012 8:41 am

I put some stickers over it Rolling Eyes
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Re: Project Ernie

Post by HighlyJetted on Sun May 27, 2012 2:58 pm

Casting Marks

Sportrak 1.6 efi engine = HD block + 06 C head
Hijet 1.3 efi engine = HC block + 06 B head

Differences

Sportrak water pump pulley flange, but you can use the sportrak water pump and pulley, and it all lines up with the hijet crank pulley
Sportrak block has a drilled hole for a normal dipstick, requires blocking up
Rocker cover, need to use hijet rocker cover
Sump, very different! Need to use hijet sump, and oil pickup etc... will know more when I do it.
Water takeoff pipe fitting in the head is different, still having trouble removing it!
Water pipe fitting near the thermostat is different, same as above Laughing


Use from the Hijet:-
dizzy/cam sensor,
manifolds,
engine mounts,
flywheel/clutch and dust protector plate,
sump, dipstick and pickup,
rocker cover and coils,
crank pulley,
temp sensors,
water blocking plate near the head sensors,
Both water takeoff pipes - one in head, one next to thermostat housing

Hijet Intake side

Sportrak Intake side


Hijet Exhaust side

Sportrak Exhaust side
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Re: Project Ernie

Post by HighlyJetted on Tue Jun 12, 2012 11:25 am

Stripped the sprotrak engine....





Bought some bits!



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Re: Project Ernie

Post by HighlyJetted on Sat Jun 23, 2012 7:16 pm

Check out my new engine......




Well its all there anyway! Tomorrow it's all getting put together into some form of order Laughing
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Re: Project Ernie

Post by rich the mechanic on Sat Jun 23, 2012 8:03 pm

Does the head gasket match between the stock motor and the new one? just wondering if a head swap could be done to get a 16valve without the engine swap.
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Re: Project Ernie

Post by HighlyJetted on Sat Jun 23, 2012 11:43 pm

rich the mechanic wrote:Does the head gasket match between the stock motor and the new one? just wondering if a head swap could be done to get a 16valve without the engine swap.

Sure does, its exactly the same part for 1.3, 1.5 and 1.6

They all have a 76mm bore.

And that IS the 1.3 head, which is a 16v sohc. Which I am using.

The 1.3 has a bigger and longer cam profile than the 1.6 sportrak from my poor measurement/guess game.

Same sized valves and ports, same casting it would appear.
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Re: Project Ernie

Post by HighlyJetted on Sun Jun 24, 2012 8:45 pm

Well it all bolts together with a few tweaks here and there. Because the block is 10mm taller the brackets which mount the inlet manifold to the block don't line up, so they've been drilled out to make the bolt holes line up. You'll need to use a sportrak cam belt too as its a bit longer. Bunging up the hole for the sportrak dip stick was easy, turns out the bit of gear stick that I cut off has a taper that fits perfectly luck has it. You also need to move studs around for the oil pickup and the engine mounts. Nothing too tough really, just takes time. Plus the blue injectors from the MX5 are a bit longer, so you need to remove the studs and use some bolts or something with a few spacers, about 18mm worth.

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Re: Project Ernie

Post by HighlyJetted on Thu Aug 09, 2012 3:56 pm

Check out my Hijets new "limited slip diff"





Twisted Evil Twisted Evil Twisted Evil

Plus I've now refitted the engine and gearbox Very Happy
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Re: Project Ernie

Post by 8bit-ash on Thu Aug 09, 2012 6:11 pm

That back end will be out in no time.
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Re: Project Ernie

Post by HighlyJetted on Mon Aug 20, 2012 9:47 pm

I need to pull my finger out with this Embarassed
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Re: Project Ernie

Post by Logi on Mon Aug 20, 2012 10:01 pm

HighlyJetted wrote:I need to pull my finger out with this Embarassed

Twisted Evil
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Re: Project Ernie

Post by HighlyJetted on Sat Sep 01, 2012 11:09 am

So it looks like I need a new radiator, the metal claws which retain the end caps are rotten and in some places have started to open up a little bit. When it's hot they will seep a little water which will evaporate quickly thus never realising the fault.



plus you can see where the clotting agent has tried to seal the leaks at the bottom, this will be radweld or a similar product:-



Also one of the bottom radiator clips has cracked right in the middle.



Turns out I have a powerflow exhaust! If anyone wants it make me an offer...






And here is a copy of the hijets radiator/coolant filling and bleeding procedure....


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Re: Project Ernie

Post by rich the mechanic on Sat Sep 01, 2012 3:31 pm

I know you dream about these Matt so my gift to you today and the same site offers a 993cc rad for about £105 shipped.

http://www.rockauto.com/catalog/raframecatalog.php?carcode=1118696&parttype=1212
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Re: Project Ernie

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