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Your Saxo Photos / Videos / Progress Reports Please share photos/videos of your saxo in this forum.

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Old 5th October 2020, 14:57   #161
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First check in, in a while and happy to see a build still going - mines coming out of 'storage' soon so I'll have to get some pics up. Where do you find your parts these days? I want an engine!
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Old 6th October 2020, 12:42   #162
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Quote:
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First check in, in a while and happy to see a build still going - mines coming out of 'storage' soon so I'll have to get some pics up. Where do you find your parts these days? I want an engine!
Wheres the thread for yours?

Parts... hmmm... facebook groups I guess. It has dried up though. Luckily OEM style stuff for service items are still plentyful from motorfactors.

I'll soon be just a case of going to the remaining tuners for bits I reckon. Depending on what you're doing with it, of course.

I have the guts of a J4 in various pieces, just in case.
I'm sure I've seen some complete engines going for circa £400 over the past 12 months.
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Old 13th October 2020, 20:49   #163
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Awesome work man. Nice to see a project still actually being projected rather than the dobbers on facebook who take a Saxo, pull the seats out it for a track car m8 and then thats it.
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Old 16th October 2020, 13:29   #164
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I've been chipping away. No rush.

Engine is all timed up and belt cover is on.
I painted the block.
Then painted the cam covers and they look ace.



I sold my old 4 paddle and bought a new 6 paddle. I decided not to go for the extra expense of a lug drive and just turn the boost down, if this doesn't like it.



Will continue with the ancillaries and inlet this next week. I'm cleaning up all the bolts etc, just because I can. Might as well make it look half decent.

Then onto making a turbo support bracket.

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Old 22nd October 2020, 08:21   #165
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The previous build of this engine maybe ran about 100 miles, if that.
Yet the water circuit was full of rust. Like a very fine bright orange dusting everywhere. Water pump, galleries, thermostat. The coolant was probably 75% antifreeze as well.



It was very bizarre. If you've bothered to read this far, you may recall there was constantly air in the coolant after a spirited drive. Not sure if that was a contributory issue to the corrosion. Anyway, the engine and head have been pressurised and cleaned, so maybe what was once there, is not now.

In the throws of making a support bracket for the turbo. It was previously just hanging from the collector and I'm sure it will break soon. This might help prolong it a little. I've also added a brace on the downpipe to attach to the gearbox. Although you can't see anything on this photo.

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Old 8th November 2020, 21:44   #166
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I wrapped the manifold and test fitted a turbo blanket.



Going to be running actuator pressure (8psi) for a few miles when the car is ready. So I've removed the MBC. Just to let the engine run in. Then, will switch to an EBC (already got it) when I want to creep up the boost back to it's heady power days of 270+ bhp.

The Turbo support bracket is also complete. It fits across where the mount point for the crankcase breather (bottom section) and dip-stick (bottom section) and then into the corner of the block, in a hole that was already there... but nothing ever went into!
The horizontal section mounts to the bottom two downpipe bolts and is welded to the support brace on the block. It is very rigid, so that is a concern, but it is taking some weight off the manifold, which has to a bonus.



Hopefully you can see it in the photo above.

The only issue with the bracket, is that when it came to fitting the crankcase breather (lower section), it is in the way. Luckily I've got another pipe - they must have changed the design. This has a different orientation, yet mounts to the same point. It doesn't meet the top section properly, but I'll just make an adapter. Should look OEM+.

Hoping to get the alternator fitted this week and then get the engine off the stand, to fit the loom, coolant pipes, clutch and gearbox.

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Old 13th November 2020, 23:06   #167
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Made a small heatshield with what I had left. Not ideal, but better than nothing.
Sufficient air gap left, hopefully combined with the heat wrap, it'll save the alty.



The crankcase breather took ages, had to make a 90 degree elbow for it to route properly.

Engine is off the stand, flywheel (skimmed) and new clutch has gone on.



Gearbox, coolant pipes & loom to attach next week.
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Old 14th November 2020, 10:43   #168
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Why not just put a support bracket at an angle down the the boss to the right (gearbox side) of the oil filter?

More vertical support, less likely to crack because the load is going down the bracket and not into the 'flat' part (loads should be sent along a panel, not into it) and out of the way of the case breather/head oil return.
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Old 15th November 2020, 12:43   #169
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Quote:
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Why not just put a support bracket at an angle down the the boss to the right (gearbox side) of the oil filter?

More vertical support, less likely to crack because the load is going down the bracket and not into the 'flat' part (loads should be sent along a panel, not into it) and out of the way of the case breather/head oil return.
Which bit is the boss? I can always add this, just need to see what you mean.
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Old 21st November 2020, 18:57   #170
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Quote:
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Which bit is the boss? I can always add this, just need to see what you mean.
The sticky-out lump with a hole in it just above your oil return.
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Old 8th March 2021, 09:11   #171
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Still looking good and if you still want sell it I'm here hhaha but ye I love to have it back after all these years but epic progress
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Old 12th March 2021, 14:17   #172
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Still looking good and if you still want sell it I'm here hhaha but ye I love to have it back after all these years but epic progress
Haha, You'd need deep pockets mate.
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Old 6th April 2021, 11:56   #173
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It's safe to say, that I wouldn't have made either a good mechanic, nor a good paint sprayer.
However, I've been 'over' the engine bay and both wheel arches/tubs, in the last couple of months.

Wire wheel, screwdrivers, chisels etc.

Suprisingly the shell is solid. Even the bumper hangers have survived and although the metal is thinner in places, no welding at all, is required on the front.





Arches are now a few layers deep in Dinitrol, which seems to be excellent stuff. Any cavities have been filled with dynawax also. That should see it for another decade or so.

In other news, the engine now has it's loom attached and plumbing ready. I'm putting the ECU in the car, along with map sensor and injector relay plug thing.



The engine will be installed this coming weekend. Which leaves only the radiator and intercooler setup remaining to be completed.
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Old 16th April 2021, 13:26   #174
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The engine is in.

I've positioned the rad, where I want it and created the plumbing to/from the header tank.
ECU, map sensor, fuel injection relay are now inside the cabin.



Instead of running the extremely overly large intercooler, I have gone for a more simplistic solution from our oriental cousins.

It's billed as a side-mount for an MR2 and I'll mount it vertically next to the radiator.
It's a chunky thing, but being a single pass with a direct in-line route from the turbo to the inlet, I think it's actually going to work out great. Famous last words.



I had lofty ambitions of running the car this weekend, but I'm admitting defeat.
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Old 14th May 2021, 11:07   #175
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I'd love to sit in this, looks amazing mate. Don't forget to update in here cause I'm still keeping tabs
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Old 28th September 2021, 15:53   #176
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Some months on, how goes this with progress?
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Old 1st October 2021, 15:45   #177
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Some months on, how goes this with progress?
Funny you should say that. My dad said yesterday "want me to help get the Saxo going".

What happened was, I positioned everything where I thought it should go, then my old man said "no no no.. you don't want to do it like that" in a Harry Enfield voice. So I spat my dummy out, as I'd already cut and shaped the coolant pipes etc. Then left it and focused on other stuff.

It's now going to be winters project, as the motorcycles get put away.
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Old 14th November 2021, 00:26   #178
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Stil coming along treat this saxo build..
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