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Discussion Starter #1 (Edited)
Well, it all started when I dropped some cams in my 2.0 without checking clearances or upgrading springs. Lesson learned. About a year after the install, I overrevved my car passing an "I love Jesus" box truck (it was a big boxtruck that said that on the side.) I did not drop a valve or anything but I did weaken my valve springs enough to make the car undriveable in a few days time. Determined to learn a thing or two about the internal workings of a motor, I made the executive decision to source a 2.3l and build that sucker up. Yes I could have bought a 2.5 and built that up, but for simplicity I stuck with the 2.3.


I realize that I probably should have had someone experienced help me out with my first build but hey, thats what you guys are here for! I asked a ton of questions on the forum that probably seemed really stupid like, "how do you remove the crankshaft or remove the crank pulley bolt" lol, etc. I wanted to be as well informed as possible so I have probably put a bunch more time into researching the assembly of engines and how engines work than I have actually building mine.

On to the build[wrenchin]



I am halfway done with my build and should have it completed and ready to drop in as soon as my cossie timing chain among other small things gets in.

My build

Head:

2.3 head
Arp head studs
Crane Cams stage 2
Crower springs and titanium retainers
Stock valves
3 angle valve job
EGR delete
Cossie friction washers and cam sprockets

Block:

2.3 block bored to 88mm
line honed
Arp main studs
Keyed ranger crank and sprocket
Eagle rods
Supertec 11.6:1 88mm pistons
Clevite race main and rod bearings
Massive BSD and Baffle

New oil pump, water pump, 34lb ford racing injectors etc.

Exedy stage 1 clutch with 9.5lb flywheel

Cossie Intake Mani

Power steering pump retrofit for Cossie
And much more.


I have the short block put together and am going to install the head later on this week pending upon my valve to piston clearance and final cylinder compression numbers. This is my first build and I have done most everything myself with thorough research! Although Nate (420svt) did help me finish pulling my old motor.

I have a few pictures but to be honest, I didn't take many as I am not a picture type person. I promise to get better as the thread/build goes on.

The motor is going lime green/ massive purple... Hulk theme (the lime green is much nicer in person and trust me, I meticulously prepped this thing so fingers crossed it holds up)











Basically all that is left is to finish assembling the motor, drop the motor in, install Cossie intake, install all misc accessories (ps pump, etc.), wires and hoses and install my new oil pressure and oil temp gauge. Took the easy route and bought a sandwich plate to install them.


After that I will upload my initial start up tune from Tom and prime my motor hopefully getting adequate oil pressure from my new pump that I packed full of Redline assembly lube.


The goal is ~200whp and 160 wtq




Please feel free to ask me questions or offer me advice!
 

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Discussion Starter #5 (Edited)
Well, I took all of my measurements for my final compression ratio and it came out like this:

Bore 88mm / 3.465 in
Stroke 94mm / 3.7 in
Head 43 cc's
Deck Height 0.014 in
Piston Valve pocket -2cc
Stock Felpro head gasket 0.016 in

When I enter all of that into CFM's Cometic calculator and zealautowerks calculator I get 12.51:1

However Summit Racing outputs 13.5:1 and when I calculated it out by hand I got 13.5:1.

Why am I getting lower numbers using their calculators?

If the 12.51:1 compression is the correct one then I should go with a .045" Cometic gasket to get 11.56:1.

How do I lower the compression enough if 13.5:1 is the right compression?
- Messing with summit's calculator, it looks like if I machined the pistons to have 0.032 deck clearance and used a 0.050 Cometic I would be at 11.64:1
 

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FUBARCUS
2003 ZX3 2016 FoST
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Very nice. I really want to build a motor but financially cannot right now. Color looks awesome!
 

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Discussion Starter #7
I am found myself at a stall in my build process. It comes down to either machining the rods down a bit and getting everything rebalanced or buying a custom cometic .066 head gasket (thanks Tom for the advice); turns out machining the combustion chamber will not provide enough increase in volume. The gasket has a few days lead time and a week or so to ship. I will keep this thread updated and hopefully everything goes smooth after I get all of this sorted.
 

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Discussion Starter #8
Had to wait over a month for Cosworth to get me all of my timing stuff.






Got my custom HG from Cometic

 

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Discussion Starter #9
And today was get things put together day.
























Next weekend I hope to have time to install it with a buddy or two. In the meantime I am going to be putting together the cossie manifold and a few other preliminary things.
 

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Looks terrific, make sure you build oil pressure in the motor before you fire it up, ours took a long time before it got pressure, so much so we actually started taking things apart to double check.
 

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Pieces are coming together, like seeing a thread on your project.
 

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Discussion Starter #12
Forgot to mention that i had decided to just buy the stage 2 cams instead of waiting. They came in a few weeks ago giving me plenty of time for valve adjustments.

Also there is suprisingly a lot more valve to piston clearance than i would have guessed. These pistons must have relatively deep relief pockets. Not completely happy with the pistons however as 3/4 of them were off weight out of the box.
 

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Discussion Starter #14
We will probably work till 6 or 7 pm. Unfortunately i work friday, sat, and sun nights from 9pm to 7am. It will be tough on me to be awake during the day but i am determined to get my car done.

On a different note, i have tuesday thru thursday off so if anyone wants to stop by, shoot me a text. I will be wiring up a few oil gauges this week, finishing putting together the cossie im (have to clean all the threads first as they are all too tight) and somehow tapping in the metal coolant tube that goes on the block in the thermostat/wp housing.

Also, i want to get matts new cams installed here shortly! And ofcourse i have many little things to do on the wifes svt
 

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br/o/stang
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yes.
 

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FUBARCUS
2003 ZX3 2016 FoST
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I can't wait to see this build come to an end. This is an awesome thread!
 

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Discussion Starter #19
The neon green is a little bleh for my taste but very nice job



I haven't seen that stuff since I was a kid. The actual color looks pretty nice and in the bay, you can hardly see it. I will post some more pictures of updated progress tomorrow
 

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Discussion Starter #20
Here are a couple pics from Sunday. You cant really see the green block from the front view, pretty much only from looking at the timing cover side. It is more subtle than previous unistalled pictures make it look.






I was too busy yesterday to do anything more. Still have to wire up my oil pressure and temp guages, find a silicone coupler that will replace the accordion for my steeda intake, install battery, headlights, grille, upload tune, and go over the wiring and hose clamps one more time.

One thing is for sure, the stage 1 exedy clutch with the lightweight flywheel is going to be a lot different than stock.
 
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