Building an engine test stand

Started by MiniDave, April 29, 2016, 05:45:38 PM

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94touring

That's pretty incredible actually.

MiniDave

I thought so - I found 10 relays for $25 with no harness, and 5 for $15 no harness, then I ran across these and snapped them up!
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

Merlin

China, that's how they do it!
I have a huge stash of those from eBay that I bought a few years ago. Used a bunch of those all the time. eBay is the king for random shit.
Engineering the Impossible

MiniDave

I've done pretty well on Amazon too, that's where I got the instruments for chepe, cheap, cheep.....
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

Merlin

Ill have to look there as well. I know when it comes to the crap in the paper packages at autozone, eBay has ten of them for the same price.

Engineering the Impossible

MiniDave

#55
Been working on the test stand some more, the block is my old block from Buzz and the head is off Dan's engine - they're just sitting there so I can mock things up.

Got the relays in and most things wired up, final ends to be determined once I have the engine completed so I know how long to make the wires and what sorts of ends to use.....I can figure most of this out ahead of time but it will be good to get everything located in it's proper place. Oh, and it looks like my engine steady will clear the exhaust just fine too.......

I'll tidy up the wiring once it's all done, but I'm going to leave the underside of the dash open.

Dan had some old exhaust pieces he wasn't going to use so I've cut them up and will build an exhaust out of them....got that all mocked up today too.....

Some more parts are on their way so I should be able to start the build soon.

And for those who mentioned it, I haven't hit my feet OR ankles on any of the wheels or protruding metal parts - yet!   ;D
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

MiniDave

#56
Welded up the header, since I have plenty of room it goes in and out in one piece, unlike when it's in a car. It was a bit tricky as the metal was pretty thin and a little rusty.......I had to weld in a series of spots, allowing it to cool a little in between. Doesn't look pretty but it should do the job......
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

94touring

Yeah that y pipe was in pretty bad shape.  Glad it worked out.

94touring

Have you considered getting a wide band o2 and gauge to fine tune on the stand?  I already have one in my rx7 and will have at least a bung in my mini exhaust for a temporary one to tune on the road. 

MiniDave

#59
I'm not that advanced....... ;D

A simple exhaust gas analyzer would probably work better for these engines, I've seen them advertised for about $200.....maybe for Xmas.....

Considering that I'm not on a dyno and just free running, about all I can accurately tune is the idle, right? Don't you need to load the engine to get any sort of accurate A/F ratio readings?

I'm not planning on getting into changing a bunch of needles......I'll let the owners do that.

The plan for the test stand is to run in the cam and make sure there aren't any leaks, then cool it down, retorque the head and readjust the valves and see that it runs smoothly, doesn't leak and is free of "funny" noises. A  dyno would be nice, but way out of my price range......
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

94touring

I wasn't sure if it would be ideal for running engines up for 20 minutes at 2500rpms.  But yeah to tune properly there needs to be load.  All I know is I'm tired of guessing what my AF ratio is.  I tune my rx7 with a wideband so why not a mini.

MiniDave

No question you can get a good read on what the carb is doing, but to effect any changes requires changing the needle - at $20 each experimentation can get expensive - but it would be worth it to get it dialed in well. In England they have plenty of specialists who strap the car to a rolling road and have a supply of different needles to swap out, you'd be hard pressed to find anyone here that does.....the main thing is to make sure it doesn't go too lean.
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

94touring

Figure if I'm spending so much on a fast road engine that optimizing the actual tune only makes sense.  I'd never throw a bigger turbo on the rx7 and guestimate my air/fuel. 

MiniDave

Of course, it's just that all it takes to change it on an FI car is the right software, with a Mini it takes hardware.....I agree that it's important to getting the most out of the engine, but there is enough experience out there to get you started with the right needles, the rest is pretty easy.....
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

94touring

I probably need to grab a few different needles when I build up these twin hs4's.

MiniDave

Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

MiniDave

#66
So, to get ready for the new engine run in, I decided to mount Dan's 1100 in the stand and see if it will run. The engine came to me fairly complete although I will need a few parts before I start it up....it takes a top radiator hose unlike any I've seen, going to have to dig around the parts catalogs and see what I can find. I also need a dipstick.....the rest I either have or can fab up as needed.

Edit: Looks like I need an 850/998 upper hose, anyone have one lying about?

Looks like this....



I had to re-engineer my engine steady, the bolt pattern on the rod change gearbox is different than this remote style, so I simply moved it up to where the slave cylinder mounts, as I won't be operating the clutch anyway....seems to work fine.

I bought a MiniSpares intake manifold and a used HIF 38 carb, and Dan supplied me with an exhaust header and muffler, next up I'll wire and plumb everything, then see if it will crank. After than I'll put some gasoline to it and see what happens! Stay tuned for that!   ;D
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

94touring

I read this and thought...I have an 1100?  Oh right I do lol.

MiniDave

Came out of Vikram's car? I think you said it ran but leaked gasoline everywhere so you didn't run it long. I haven't cleaned it up, just mounted it in the stand. I put the dipstick from my car in it to check that it had oil and it does, and the oil looks really clean too.

My dipstick doesn't fit this car tho, as mine has the O-rings at the top.

Still need an upper hose - anyone have one, even used is OK as long as it holds water - 850 or 998 should be right. Stan?

If it doesn't smoke and the compression's good, maybe just clean it up and use it as is?
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

Vikram

Did come out of mine. Engine should run fine, however I believe the clutch needs adjusting.

MiniDave

Yeah, it may need a clutch actually - I think I'd put one in while the engine's out and it's easy to do. It will need a new slave cylinder too, this one's done.
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

Vikram

That would be a good move. The clutch felt like it was going, eventually it would barely disengage the engine from the gearbox, and the car would pull with the clutch fully depressed. It would only go into gear with the engine off, and I'd have to get the rpm just right when shifting on the go.
I tried adjusting it, but with no success.
I look forward to seeing what the issue/issues were.

MiniDave

#72
I think the issue was that it needs a new clutch!  ;D

I noticed someone has put an adjustable push rod in the slave cylinder - those are rarely a good idea - if the clutch is right you don't need one of those to get it to release. It's not set right either......you can actually push the clutch too far and it won't release.

I wouldn't be surprised to find the clutch arm ball and other linkage is worn badly too.

What happened to the oil dipstick?
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

94touring

That one will be turned into a 1218cc, and once I pull the 998 to swap in my 1275 thinking about combining parts to make it rod change

94touring

Just prior to putting the last plate on my 13b.

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