M42 rebuild and upgrades help.

[Massimo]

UPDATE 14/19/10

I have posted this on R3V want optinins from you guys as well.

As the title states I am thinking of rebuilding the M42.

Reason: Well over the weekend while I was looking inside her, I noticed a water leek from an odd spot (on the air conditioner compressor). Anyways upon further inspection it seems to be coming from the head gasket . It’s a very small leek, but one none the less.

So if I am going to replace the head gasket I might as well do a performance rebuild.

Experience: Well non this will be my first ever engine rebuild I am confident, in my skills and hope I have read enough to do a good job. This is also part of the reason I am posting here. I have devised a list of parts I need and the machine work I will get done. I know what the prices are for the parts and was wondering if anyone could give estimates on the machine work required that I have listed.

Goals: Well I would like keep the price under $5000 and hopefully achieve 180hp without any real bottom end modifications beside 360Degree Thrust Bearings and oversized pistons, focusing more on the head.

Anyways here is the list

Metric Mechanic
-Rod Bearings $60
-Main Bearing 360Degree Thrust $120

Total From Metric Mechanic = $180

Vac Motorsport
-Titanium Valve Retainers $289.95
-Hardened Valve Locks $71.20
-1mm Over Sized Stainless Steel Valves $479.95
-Duel High Performance Valve Springs $447.95
-Vac 269/269 Cams $949.95
-ARP Main Stud Kit $149.95

Total Option 1 From Vac Motorsport = $2334.95

Possable Option 2
-Stage 2 Cylinder Head $1399.95
-Vac 269/269 Cams $949.95
-ARP Main Stud Kit $149.95

Total Option 2 From Vac Motorsport = $2499.95

Pelican Parts
-Head Gasket Set $106.75
-Hydraulic Lifters $276
-Chain Tensioner $39.75
-Timing Chain $56.25
-E28 Motor Mounts $44
-Bottom End Gasket Set $65.50
-Oil Pressure Relief Valve $10.75
-Cam Sprocket x2 $108.00
-Crank Shaft Sprocket $67.25
-Deflection Wheel Sprocket $145.00

Total From Pelican Parts = $909.35

Bav Auto
-Oversized Pistons $439.95

Total From Bav Auto = $439.95

Total Option 1 Cost of Parts = $3864.25

Total Option 1 Cost of Parts AUD = $4293.61

Total Option 2 Cost of Parts = $4029.25

Total Option 2 Cost of Parts AUD = $4476.95


So this dose not leave me with much room for machine work so I am just going to list the things I want done and if anyone can put an estimate to the cost that would be good. Then I can review my parts and see where I could save a bit.

Block
-Crank Shaft Alignment Honing
-Decking Surface
-Hone Cylinders

Head
-Deck Surface
-Increase port and valve seal size to suit new valves

Crank
-Probable fix spun main bearing journal
-Chrome journals

There will also be inspection for cracks and repairs but that is an unforeseen problem which I can not list and will just have to see what happens there.

So that is what I have come up with so far. The car has done 190,000km so I am hope there will not be any major problems but you never know.

As you may have already noticed I have not really done much with the timing components, when I last looking at the cam gears and chain it looked in very good condition, so I am hoping that the guides will be in good condition. But if there any evidence of problems then they will be replaced.

I would like peoples comments and any help with what I have listed, also an estimate on the cost of the machine work would be a great help.

Cheers Massimo

PS I should add i am going to try my hand at replicating the Metric Mechanic Pulse Chamber.

[e304me]

I would skip on the parts from vac, just not much to gain with the valves. Look into getting used m44 crank and pistons and you will be in business. I dont think even metric mechanic messes with the valves sizes. If you were trying to build a 300hp race motor then yes but there is not much if anything to gain with stock internals, and will add A LOT to the machining costs. ALso look into VW lifters you can find info on m42club.com. They are lighter and cheaper, and I believe what MM uses in their motors.

Even better performance per dollar would be finding a used DASC kit, or even buying one new. I would look into this and just swapping in a lower mileage engine. Its really just a much better alternative than rebuilding an engine, which can be a pain in the ass.

[Massimo]

I would skip on the parts from vac, just not much to gain with the valves. Look into getting used m44 crank and pistons and you will be in business. I dont think even metric mechanic messes with the valves sizes. If you were trying to build a 300hp race motor then yes but there is not much if anything to gain with stock internals, and will add A LOT to the machining costs. ALso look into VW lifters you can find info on m42club.com. They are lighter and cheaper, and I believe what MM uses in their motors.

Even better performance per dollar would be finding a used DASC kit, or even buying one new. I would look into this and just swapping in a lower mileage engine. Its really just a much better alternative than rebuilding an engine, which can be a pain in the ass.

Didn't think about M44 crank and pistons that could be a good option I will have to do some investigating on prices. Being here in Australia it will proabably be more then the VAC stuff though.

Forgot about the VW lifters would much prefer them thanks.

As for the Vac stuff I want good quality long life stuff for the head as a once off upgrade. I know they are a bit pricey but like I said before I want to focus more on head work then bottom end. I want a soild high flow head for possable race applications in years to come.

A DSCA would be fantastic but I am trying to keep the engine stock looking for insurance reasons.