Doug's EA81 Rebuild stuff.

Subydoug · Post by **Subydoug** » Sun Jun 30, 2013 8:08 pm

Cheers Fella's

Little bit of an update, Pictures tell more words then my dribble,

Once you've gone black, you'll never go back

.

Throwing around a few idea's. What do you guys think, Twins?

Heads still to be painted, wont paint till I finish messing around with them or Il scratch the precious

.

So, feedback from you all, Twin? Custom spfi intake? ITB with injectors? dedicated weber intake? ea81 hirise? Things you'd like to have tried but haven't? FEED ME!

Regards

Doug

steptoe · Post by **steptoe** » Sun Jun 30, 2013 10:38 pm

water feed, er , sorry, coolant feed... surely a very simple task for some of the talent we have within - to make a mounting block with coolant ports and hose fittings, especially clever would be not mirror image babies, like a left and right, but one same, flip the other way up for the other side - a guy on subaruxt moulded a Vortex dash trim in alloy ....I can almost hear it snort Dougy !

Subydoug · Post by **Subydoug** » Sun Jun 30, 2013 10:53 pm

If you look closely at my last picture you'll notice Ive got some steel spacers under the carbies. Plan was to make those into some water bypass adaptors. Problem with the carbies like that is my power steering pump will be in the way, same for the alternator on the other side. Not a big deal to fit a different unit but still a bit annoying. I plan on messing around a bit with carbon or glass fibre.

Regards

Doug

Tweety · Post by **Tweety** » Mon Jul 01, 2013 10:07 am

if you get one of these small alternators and make a bracket up it can be mounted just above the water pump and look smick. letting the world see your engine more. thats my plan with the alt.

http://www.ebay.com.au/itm/ALTERNATOR-M ... 3a7db6626e

Subydoug · Post by **Subydoug** » Mon Jul 01, 2013 10:16 am

They look mint mate!

YouTube · Post by **El_Freddo** » Sat Jul 13, 2013 2:42 pm

Subydoug wrote:Problem with the carbies like that is my power steering pump will be in the way, same for the alternator on the other side. Not a big deal to fit a different unit but still a bit annoying.

Have you thought about going down the road of the same setup as the EA81T for it's auxiliaries?

It's basically the same setup as the EA82. It'll keep everything out of the way of your twins

Also, having a short runner between the carb and the inlet valve is good for high revving applications rather than reliable bottom end torque. The longer the run between the butterfly and the inlet valve the better low down torque you'll produce, but your top end will struggle because of it. You need to work out what it is that you want to use this engine for, then work from there.

Or just go with this because you can

Cheers

Bennie

Subydoug · Post by **Subydoug** » Sat Jul 13, 2013 7:32 pm

Bennie,

Yeah Ive looked into not only the ea82 PS pump but ones from other cars as well. The one in my brothers hiace would squeeze in there nicely. Nah what Ive decided to do is make a manifold, or manifolds that move the carbies out of the way and into the middle. It will make for easier throttle linkage setup as well. Also plan on making a new manifold with some fuel injector holes in it

. Gotta at least try these carbies first though.
As far as runner length goes, haven't really thought about it much. Im not making a race car or anything, just a daily with some mean induction noise. That being the case Il probably go for the longer runs. I think a lot of the manifold ram effect is corrupted by the single inlet for both valves so even if I were to dyno it with different manifolds I doubt there would be much in it.

As far as engine construction goes, haven't done much, plan on getting the heads on tomorrow. I was too busy having fun today, though clearly not enough, she too clean

.

Regards

Doug

Subydoug · Post by **Subydoug** » Sun Jul 28, 2013 8:31 pm

Hey fella's.

Pulled out the rubber gloves and had a whack at making up some short intake adaptors for my 34 ICT's. Only ever dabbed into fiberglassing in the past so it was pretty much a new experience for me. Results were messy to say the least.

Anyway here is my hotwire bow I use. Have a bit of experience with cutting foam like this. Used it to make flying wings and other foam things.

Pretty simple thing. I use a little 14v AC/DC power adaptor to drive the wire. Note the foot switch on the top

Sort of results.

So I made up some parts. The angle is to clear the PS pump and the alternator. Even like they are I may have to get creative.

And wrapped them in glass,

Now I need to lay up the inside of the tube to match the port size. That should be pretty easy. Then I need to make up the water outlets which will be going to my external thermostat from a Fiat 124. That's the plan anyway.

I made up a tube of glass out of the same matting. I can happily stand on it an it wont crush. Seems tough enough. Should be interesting anyway.

Regards

Doug

Silverbullet · Post by **Silverbullet** » Sun Jul 28, 2013 9:07 pm

Neato! Good old hobbyking to the rescue for a hot wire power supply, I always burned mine out doing this sort of thing

Are those plywood flanges laser cut? It certainly will be interesting seeing if these "composite" manifolds hold up

Subydoug · Post by **Subydoug** » Sun Jul 28, 2013 10:14 pm

Yeah laser cut. Too lazy to sand the ash off. They are laminated ply and soaked in resin. bit like you find on wooden rudders on yachts. Yeah, not sure yet. Its very rigid and Im a little concerned about fatigue and cracking but oh well. So be it!

Doug

Post by **Bantum** » Sun Jul 28, 2013 10:20 pm

Query : Won't the heat, oil & coolant decay this ?

Subydoug · Post by **Subydoug** » Sun Jul 28, 2013 10:46 pm

No Idea. Guess ill find out. The resin I used is meant to be fuel resistant and rated for high temp. Il just try it and see what happens.

Doug

YouTube · Post by **El_Freddo** » Tue Jul 30, 2013 8:48 pm

Subydoug wrote:No Idea. Guess ill find out. The resin I used is meant to be fuel resistant and rated for high temp. Il just try it and see what happens.

That's the best way to learn/discover new things!

Cheers

Bennie

Subydoug · Post by **Subydoug** » Tue Jul 30, 2013 10:48 pm

Its about the only way to discover and learn new things. Put it aside for the moment. Hoping to finally get the new motor into the car this weekend. One thing that occurred to me though is my stock manifold probably isn't going to fit

. Shaved 2mm overall....could be tight. May need to get creative again

. Anyone know from experience?

Regards

Doug

steptoe · Post by **steptoe** » Wed Jul 31, 2013 1:15 am

yeah, maybe, I have had to redrill the manifold to block bolt holes in a larger size to make things fit nice

Post by **TOONGA** » Wed Jul 31, 2013 7:17 am

Yes I've encountered the same problem, redrilling the manifold solved the problem and got my brumby back on the road until the EJ was ready

a drill 1-2mm bigger than the hole will solve the problem.

TOONGA

Subydoug · Post by **Subydoug** » Wed Jul 31, 2013 9:10 am

Ok fella's easy as pie

. Wagon getting a nice little birthday this weekend then. New clutch, driveshafts and engine. Waiting on one part in the mail and its show time.

Regards

Doug

Tweety · Post by **Tweety** » Wed Jul 31, 2013 4:58 pm

Looking good Doug.

Subydoug · Post by **Subydoug** » Thu Aug 01, 2013 7:58 pm

Cheers mate, cant wait to drop her in. Did a number on the heads ay, tidied up the ports, port matched all the water jacket passages and block passages. Valve seats are a bit of an experiment in progress.

I have a theory on the crappy stock valve seats too. Does anyone know if the later ea81's with the larger valves actually have larger valve seats? To me it looks like they have exactly the same port and seat size and to fit the larger valve, they just cut the 45 deg angle further up on the seat. This meant the original back cut was recessed underneath the seat giving that crappy ridge. EWwwwwl.

Im also going to have a spare ea81 in decent condition after this....and a 3spd auto.....beach buggy

.

Looking forward to your post telling us all how well tweety purred when you turned the key for the first time in a few days, no pressure though mate

.

Regards

Doug

Subydoug · Post by **Subydoug** » Sun Aug 04, 2013 12:17 am

Howdy,

Unfortunately I forgot to get some new valve stem seals

. Ordered some today so they should turn up next week.

Still did a bit of work to the heads. All the valves are lapped in, ports looking good. Tomorrow Il give them a paint job.

Just thought Id throw this up here too, maybe some other people rebuilding these engines may find it interesting. How to measure a cylinder head combustion chamber.
I used a pipette. My brother got this one years ago when He was messing around with his yz250's squish band and comp ratio. It has since been snapped in half

. Still good for 5ml though so it will do the job.

With the heads all lapped and ready to be assembled. Put the valves in with a thin bit of grease on the seats to seal it.

Stick the valves in and push them down to make sure they are all the way down. Then I usually smear some grease around the combustion chamber to create a seal.

Then a piece of something like acrylic with a single hole in it at one end. I didn't have any scrap so I used this antenna I built which. Nice and flat and already had a hole.

Push it down into the grease hard to make sure its right down on the head.

Then simple fill it up with the pipette until there is no air left and write down the amount.
The pipette is capable of being accurate down to fractions of ml's, but for practicality reasons I just went by 0.1's of a ml.

Readings came out as;

cylinder 1 = 43.4ml
cylinder 2 = 43.4ml
cylinder 3 = 43.3ml
cylinder 4 = 44.1ml

Mean average = 43.55ml

Pretty happy to be honest. Might give No:4 a light sand and re-measure. Not bad for a guy in a garage with an ancient shaping machine

.

Static CR going by the ea81 FSM engine capacity of 1781cc comes out at 10.2-1. Realistically with the thickness of the gasket, and the small volume associated with the block it will be somewhere between 9.5 to 10. Gonna be mad that's for sure!

Anyway, spewing about the stem seals. Oh well.

Regards

Doug