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Plastic Fantastic Coupe

asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Aug 17, 2020 7:55:17 GMT Select Post Deselect Post Link to Post Back to Top
	Aug 17, 2020 6:01:25 GMT spartacus said: Fair play for taking that on, I reckon I'd have been looking for another engine, you're really pushing the boat out giving it a rebuild. I'm in 'Vegas a lot myself so I'll be looking out for you when it's done. Cheers Spartacus I'm hoping to have it done before winter ....at this rate though I'm not sure which winter. I'm not an engine builder by trade but have built before. Keeping things clean, working methodically and check, double check and treble check everything...and ask around If unsure. I'd like to say you don't see many Roadsters yet in the last two days I've seen a silver Brabus Coupe on Derby Rd in Vegas and the day after a red notchback parked up just off Derby Rd in the Vegas. If you catch sight of it rolling, wave me down. Don't forget to say those immortal words " I am Spartacus "
	Last Edit: Aug 17, 2020 8:57:23 GMT by asdajnr current project forum.retro-rides.org/thread/213028/plastic-fantastic-coupe

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spartacus Part of things Posts: 256	Plastic Fantastic Coupe spartacus @spartacus
	Aug 17, 2020 21:49:08 GMT Select Post Deselect Post Link to Post Back to Top
	I try not to get too interested in 2 seaters, as I have twin daughters that I collect from school every so often. These intrigue me though, I read a test some time ago that put them in the same camp as a Lotus Elise handling-wise, are they that good? Is the gearbox a torque converter auto with a manual valve body, or a robotised manual?


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asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Aug 18, 2020 5:00:29 GMT Select Post Deselect Post Link to Post Back to Top
	Aug 17, 2020 21:49:08 GMT spartacus said: I try not to get too interested in 2 seaters, as I have twin daughters that I collect from school every so often. These intrigue me though, I read a test some time ago that put them in the same camp as a Lotus Elise handling-wise, are they that good? Is the gearbox a torque converter auto with a manual valve body, or a robotised manual? I've never driven a Lotus Elise but I have read the same 're the handling. Formula 1 guru Ron Dennis had one and when others around him were accepting the latest Mercedes free by offering he declined and continued with his Roadster. There's a tube of you clip of an interview with him somewhere in which explains why he liked it so much. Handling I believe was his affection for it. However , I surmise that nothing else about its mechanical prowess would compare to a Lotus Elise. Take the gearbox you are asking about...It is indeed a robotised manual. It's slow in decision making when in auto and resists being hustled when in manual. You have to change the way you drive to keep it on the beans. There is a specialist in the Smart scene who has a ecu tuning map that removes the speed limiter, takes the 80bhp model to 100bhp-ish and more importantly speeds the gear selection up.
	Last Edit: Aug 18, 2020 19:43:39 GMT by asdajnr current project forum.retro-rides.org/thread/213028/plastic-fantastic-coupe

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asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Sept 20, 2020 9:48:01 GMT Select Post Deselect Post Link to Post Back to Top
	Now then. It's been a while. Mostly because nobody watered the money tree at the bottom of the yard and it wilted...and the washing machine went boom which took the bulk of coin from my fund. Anyway I managed to shake some passing children upside down and got some loose change which has enabled me to get back on it. So I have a pile of bits ready for assembly... As I was snatching a few hours in the garage thought I'd start with lobbing the lifters, followers and camshaft back in. How wrong was I... Three of the six lifters had passed their sell by date. You can just see in the picture the tapered wear and when you run your fingertip over the top oilway it is razor sharp and brittle. So a trip to my not so local Smart dealer was made who kindly made me wear a mask whilst taking money from me ! I clearly have much to learn cos' when Dick Turpin was operating, he who wore the mask took the money, not the other way round. Gerty indoors insisted on going for the ride to the Smart dealer which is as we all know a Mercedes-Benz dealer too. In a Smart move of distraction I parked in amongst the shiny Merc sales lot and whilst Gerty indoors was all goggled eyed looking at cars we can't afford I stealthily parted with a ton of money for not much to look at. Back in the sanctuary of the 16x8 garage a quick assemble of the camshaft components was made... Bit of torquification was had using the works manual figures... For now the head is done with... I've wrapped it in clingfilm to keep it clean and put it out of the way... In theory I was now ready for refitting the pistons and crank... I had previously checked the crank journals and thought what I had was in good order but I'm no engineer just a Jack of all trades master of none and something was nagging at me in the back of my mind. So after a lengthy consultation with my over the phone guru, aka AsdaSnr, I rechecked the crankshaft... I found a scratch and a tiny bit of ovality in the crank on No3 journal...about 4thou. The scratch was no issue as it has no raised edges and polished up well but the ovality is a pain in the harris. I had left all the old bearing shells in number order and when I checked found the beginnings of witness marks... All the main bearing journals measure at the smallest dimension for a std crank so it will be a regrind and oversize bearings...curse word Anyone need a set of std mains for a Smart 698cc? So it's back to the engine shop. Not the original one solely down to timeframe. I don't want another 8 week wait. Need to find someone on the Chesterfield/Sheffield border. To kid myself I had achieved something that day, the newly acquired OE oil pump was fitted. I re-fitted the old bolts which are flush fitting internal torx whereas the new bolts are external torx. I will use the new bolts to replace the two I snapped from the intercooler shroud bracket. Surprisingly the oil pump was three whole english pounds cheaper than an after market one, so maybe that was the reverse Dick Turpin effect. For the moment everything is cling filmed back up for cleanliness. Here's my motivation for keeping on...
	Last Edit: Sept 20, 2020 9:49:26 GMT by asdajnr current project forum.retro-rides.org/thread/213028/plastic-fantastic-coupe

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asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Sept 23, 2020 18:17:22 GMT Select Post Deselect Post Link to Post Back to Top
	Well no need to break out in a sweat. All is well with the crank. Took it to a engine shop in Hillsborough, Sheffield who has pronounced the crank as fit for use as is. They have polished both mains and big ends and advised that it needed no remedial action. So standard bearings it is. Maybe I should sell my micrometers...
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ballbagbagins RR Helper Posts: 1,534 Club RR Member Number: 164	Plastic Fantastic Coupe ballbagbagins @ballbagbagins Club Retro Rides Member 164
	Sept 23, 2020 18:27:24 GMT Select Post Deselect Post Link to Post Back to Top
	Crack on then.


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asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Sept 23, 2020 18:47:23 GMT Select Post Deselect Post Link to Post Back to Top
	Sept 23, 2020 18:27:24 GMT ballbagbagins said: Crack on then. I will then
	current project forum.retro-rides.org/thread/213028/plastic-fantastic-coupe

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asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Sept 28, 2020 11:15:17 GMT Select Post Deselect Post Link to Post Back to Top
	Now then... I am still on with the engine rebuild, no really I am, think of the tortoise as opposed to the hare. Unfortunately the path to completion has occasional diversions. Today I find one such issue. Please can someone(read someone as stealthstylz but anyone in the know can join in) help me with torque figure for the cylinder bore oiler jet banjo bolts as in the picture? There are three of them that squirt oil into each of the bores. The are no sealing washers to seal the hollow 6mm threaded allen bolts which have inside sprung loaded ball bearing valve. The engine shop that honed the bores removed them, I assume to allow the honing machine to pass into the bores, but even the Smart WIS (workshop instruction system)does not contain this data and they are not available as replacement parts within the Smart EPC(electronic parts catalogue). Probably because they are not meant to be removed. The WIS describes when removing pistons that they (the pistons) should be rotated 120 degrees to miss the oilers/oil jets. So far I've torqued up to 20nm but I don't think that's enough but don't want to pull a thread. A similar banjo for the timing chain oil feed is listed at 30nm. At the moment I am loath to tighten further. There is a perceived risk of them coming loose and playing a tune of destruction within the crankcase and lower bores. I may consider a small dab of thread lock if unable to locate the torque setting.
	Last Edit: Sept 28, 2020 11:18:01 GMT by asdajnr current project forum.retro-rides.org/thread/213028/plastic-fantastic-coupe

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asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Oct 31, 2020 0:17:19 GMT Select Post Deselect Post Link to Post Back to Top
	Now then, it's been a while. I have been working on it as and when able. There have also been a few trips away in the tin tent including the last one to the Lake District to ~~celebrate~~ lament my reaching of 50yrs old... Anyhow, pistons now have rings courtesy of my paupers piston ring pliers which cost a whole £2.49... Bores have pistons - Shiny it looks... Bearings added but not before damaging one conrod set as I nipped the caps up. Managed to catch it on the shoulder of the crank surface putting a groove in. Bit the bullet and replaced them with a set of genuine Smart bearings which had the locating lug unlike the ones I discarded. Lobbed the crank in smeared everything with engine builders sauce... A bit of £1.49 torque angle gauge action... Resulting in something resembling a bottom half of an engine. Whoo hoo! This resulted in a satisfying moment when you look at the engine technicians stud and bolt organiser(aka a cardboard box)to see that progress is being made as can be seen from the vacant holes... That said there are still many many pieces of the puzzle still to go. Note in this image I have introduced cling film to my armour in an attempt to maintain the cleanliness of the build. Seems to work... At this point I find myself faced with fitting the timing chain kit, the very thing that was the catalyst for me dragging the engine out in the first place... I managed at this point to damage the threads on the oil jet banjo bolt. So a new one was ordered. A replacement banjo bolt only comes with the the oil jet which was fortunate as the old one was blocked and the new one with the kit had a wider nozzle end than the OE one... Head and block we're ready for assembly... Heath Robinson turned up at that moment and assisted with locking the cam pulley for torquing to 21 of Newtons finest metres plus 90 degrees plus 10 degrees... Looking good sunshine. Looking good... Bit of Dirko added to the timing cover... Timing marks checked... Whilst Mr Dirko dried off I couldn't resist taking a gander at the turbo and manifold. I wished I'd left it alone as it marred my progress for that day... I already knew it needed a new cartridge due to the play in the shaft. I also knew that the manifolds were prone to cracks which should be seen on the outside of the casting but none could be seen... So cartridge out. Yep deffo needs a new one... Quick picture taken of the ID tag to assist with obtaining a new cartridge... A cursory inspection of the manifold. What the fox is this??... I'll tell you what fox it is. Cracks ahoy... So new manifold also needed. May as well get a full unit with turbo, manifold and actuator. So off inside to console myself with beer of which I had plenty as my neighbour had thanked me with alcohol for butchering her out of control laurel hedge... Numb til next time...
	Last Edit: Oct 31, 2020 0:22:01 GMT by asdajnr current project forum.retro-rides.org/thread/213028/plastic-fantastic-coupe

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spartacus Part of things Posts: 256	Plastic Fantastic Coupe spartacus @spartacus
	Oct 31, 2020 7:27:46 GMT Select Post Deselect Post Link to Post Back to Top
	Good to see progress on this. In response to an earlier post I was going to suggest Sheffield Engine Services, but I'm guessing you found them! How much longer now before you're back on the road?


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asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Oct 31, 2020 8:18:19 GMT Select Post Deselect Post Link to Post Back to Top
	Oct 31, 2020 7:27:46 GMT spartacus said: Good to see progress on this. In response to an earlier post I was going to suggest Sheffield Engine Services, but I'm guessing you found them! I have and very good they were too! I actually rang another Chesterfield based engine shop who said the job was not in their remittance as they only did engines for insurance companies!!... But they did recommend Sheffield Engine Services. Oct 31, 2020 7:27:46 GMT spartacus said: How much longer now before you're back on the road? I would like to be on the road and running the engine in for late spring. The deciding factors for that time table will be: my mechanical OCD, time, money, work, more trips away in the tin tent, the former of which has in recent years slowed things down. [/quote]
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asdajnr Part of things Posts: 67	Plastic Fantastic Coupe asdajnr @asdajnr
	Nov 2, 2020 9:58:00 GMT Select Post Deselect Post Link to Post Back to Top
	Now then... Turbos. I have had very few technical dalliances with said item. In fact none at all. It would seem that a common theme within the Smart scene is to pass the task onto a specialist at a very hefty price indeed. So out with the spanners and cleaning fluids to have a look see. It was very grimey and had suffered at the hands of a six knuckled have-ago mechanical hero. The casting of the cartridge was very rusted and had a damaged edge... One retaining bolt had further evidence of Mr six knuckles involvement... Rounded edges of an 8mm hex bolt head of which I had to file down the flats so a 7mm socket would fit instead. A bit of heat... A light wiggle and a tap with a wooden handled metal headed stick to split the cartridge from the housing... I'm guessing the oil smear is from the blow-by of the poorly sealing piston rings? The boost nipple has issues too... Thinking back the manifold bolts were easily undone, I have something rattling around within the exhaust and the cartridge is very rusty. I wonder if this was a second-hand unit located in a pond or from a breakers and the original turbo had imploded due to lack of oil changes? One will never know... It's a wonder the thing was boosting at all. So now it's cleaned up and in it's component parts... My next task is to work out which is the most economical way forward. There are plenty of Chinese replicas but they don't come with a calibration certificate. Yes I know Garrett have a factory in China but they still come certified unlike the Aliexpress $50 dollar specials and I don't want to undo all my work rebuilding the engine in one spectacular exploding turbo moment. What I want to do is obtain a new manifold, new actuator and a new Mellett cartridge as I've heard good things about them but I'm still searching for a supplier for just the cartridge. The turbo repair industry appears to keep its cards close to its chest and would prefer that they rebuild them...or so it seems.
	Last Edit: Nov 2, 2020 10:00:50 GMT by asdajnr current project forum.retro-rides.org/thread/213028/plastic-fantastic-coupe

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smart Part of things Posts: 134	Plastic Fantastic Coupe smart @smart
	Nov 2, 2020 12:55:02 GMT Select Post Deselect Post Link to Post Back to Top
	Ive driven quite all of the Smart models and actually liked the fact they had dared to be different from everyone else. (whether you think they did that badly is another question!) The manual box in the original Forfour were really good and made making the 3 cylinder engines scream great fun! If the Fortwo and Roadster had a manual gearbox they would have been more popular! Ive driven the Brabus version of all 3 and they are amusing but you get the feeling Brabus did the engine map and put some stickers on but that was pretty much as far as they went! They are not anywhere near as polished as you'd expect from something wearing their badge. The roll and pitch of the Fortwo and Roadster are quite alarming! Accelerate hard and the rear squats so much you think you could actually pull a wheelie!
	1998 Rover 400 Derv

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