Not OT: Actual automotive related crap

[Noddy]

Vehicle talk in a car group. Who would have thunk it.

As some of you may be aware, I have a small petrol powered Forklift. A
little Mitsubishi FG15 built in the late 1990's. It's a little 1.5 tonne

https://ibb.co/M5sSt15

(Not the actual machine, but the same model. I don't have a pic of mine)

It came from a Potato farm in Bendigo a couple of years ago, and as is
typical of a lot of farm equipment, it's had the living shit abused out
of it and is fucked off it's nut :) It's had *lots* of "farmyard mods"
to keep it running. The engine sits under the sit as you would expect,

https://ibb.co/P1kkdNq

All neat and tidy like. But they're not all like that. When I got it,

https://ibb.co/s5LH2nG

A whole lot less neat and tidy. Typical farmers :)


These little forks run a variant of the venerable Mitsubishi 4G15
engine, which is a little 1.5 litre engine that's been around for
something like 40 years and has been in Mitsubishi cars like Lancers in
boths single and multi valve variants with either carbs or EFI, as well
as some Korean vehicles and Chinese cars under licence. They were also
used in industrial applications like Forklifts.

However, the forklift variant differed from that used in cars. In cars
the engine sat on a 15 degree tilt to allow for a lower bonnet height,
and the carbureted version used a long, angled inlet manifold to suit.
The Forklift application didn't have the same hight clearance issues,
but *did* have a very narrow engine bay so the engine in the Fork sat
straight up and used a different cylinder head and inlet manifold to
make for a narrower package.

At some point in it's life the previous owners of this machine have
replaced the original forklift engine with one from a car, and this is
where all the problems began. Virtually nothing fits well, and to make
it all work, to a degree at least, the previous owners removed one of
the engine mounts and jacked the engine up on one side with a piece of
wood, they moved the air cleaner outside the engine bay for more room,
and had to grind the shit out of the left side of the chassis to the
carburetor would clear and not squash the wiring loom, which it had
already done once and melted half of it, hence the block of wood and
additional relays.

Fucking farmers :)

You can see the differences in the pics of the two engines shown above.
You can also see that the original fork engine had the top water outlet
at the front of the engine near the timing belt, while the car engine
has the water outlet at the rear near the clutch. Hence the messy "over
the top" water plumbing. I've had to modify the inlet manifold, relocate
the air cleaner and redo the water plumbing to make all this work, but
that''s another story.

Onto the purpose of this post. How people fuck shit up :)

When I bought this mess I paid fuck all for it, and despite appearances
it does have some redeeming features although right at the moment I've
forgotten what they are. However one of the things the previous owner
mentioned was that the engine had trouble holding a head gasket. They'd
had it out a couple of times to try to sort it, and even took it to an
"engine specialist" to get it fixed but they never did.

And while I had it apart to do other things I saw why.

When I was fucking around modifying the inlet manifold I had the
cylinder head on and off a few times while I was trial fitting stuff as
I was welding, and I noticed something on the front corner of the engine
block. You can see in this pic here right under the number 1 spark plug
there is a pad there with the engine number stamped into it, and a

https://ibb.co/Drdp1kg

Turns out that in chasing the head gasket issue someone had machined the
gasket face of the block a few times, but to preserve the engine number
they'd set their cutter back from the front and rear pads and left them

https://ibb.co/fGDq0D9
https://ibb.co/HtDXwhF

They'd clearly had a few goes at it, as they'd cut 20 tousandths off the
top of the block, and I cant imagine anyone doing that in one sitting
unless the block was severely damaged and there was nothing to indicate

https://ibb.co/HtDXwhF

So, I looked at that for a second and thought "hang on...." and then sat
the cylinder head back on to double check that I wasn't imagining
things, and I wasn't :)

https://ibb.co/ZWGK3xc

Yep. The cylinder head manifold bolt boss is bottoming out on the non
machined pads and is being held off the gasket at the front and rear of
the block. It was effectively tilting the head over towards the opposite
side, and preventing the gasket from being compressed properly. The more
they cut off the top of the block the worse it got, and the gasket was
never going to seal no matter how hard they turned the bolts.

Fucking idiots :)

I spent this afternoon setting the thing up in my mill and giving it a

https://ibb.co/W554szM

I nearly wasn't going to cut any more off the block than what already
has been and just grind some off the bottom of the head for clearance,
but I'm glad I did as the top of the block wasn't exactly flat and it

https://ibb.co/bswcLc2

You can see where all four corners have touched off with the cutter, but
the back side of the head is shallow. It only needed 5 thousandths and

https://ibb.co/MN89Q7b

When I first got thing thing it would barely run. After looking at this
like this I'm surprised it ran at all.

Oh. Did I mention that Farmers are rough cunts? :)

[Clocky]

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.
As some of you may be aware, I have a small petrol powered Forklift. A
little Mitsubishi FG15 built in the late 1990's. It's a little 1.5 tonne

https://ibb.co/M5sSt15

(Not the actual machine, but the same model. I don't have a pic of mine)

<snip fascinating>

Post by Noddy
Oh. Did I mention that Farmers are rough cunts? :)

Good luck with that engine. They are notorious for cracking heads at the
best of times.

Since it's essentially already scrap you have nothing to lose and you
can't really fuck it up any worse.

Then again...

[Xeno]

Post by Clocky

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.
As some of you may be aware, I have a small petrol powered Forklift. A
little Mitsubishi FG15 built in the late 1990's. It's a little 1.5

https://ibb.co/M5sSt15

(Not the actual machine, but the same model. I don't have a pic of mine)

<snip fascinating>

Post by Noddy
Oh. Did I mention that Farmers are rough cunts? :)

Good luck with that engine. They are notorious for cracking heads at the
best of times.
Since it's essentially already scrap you have nothing to lose and you
can't really fuck it up any worse.
Then again...

Oh yes he could! Remember Les' engine? It's not for nothing that he's
called passion fingers!

[jonz]

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.
As some of you may be aware, I have a small petrol powered Forklift. A
little Mitsubishi FG15 built in the late 1990's. It's a little 1.5

https://ibb.co/M5sSt15

(Not the actual machine, but the same model. I don't have a pic of mine)
It came from a Potato farm in Bendigo a couple of years ago, and as is
typical of a lot of farm equipment, it's had the living shit abused
out of it and is fucked off it's nut :) It's had *lots* of "farmyard
mods" to keep it running. The engine sits under the sit as you would

https://ibb.co/P1kkdNq

All neat and tidy like. But they're not all like that. When I got it,

https://ibb.co/s5LH2nG

A whole lot less neat and tidy. Typical farmers :)
These little forks run a variant of the venerable Mitsubishi 4G15
engine, which is a little 1.5 litre engine that's been around for
something like 40 years and has been in Mitsubishi cars like Lancers
in boths single and multi valve variants with either carbs or EFI, as
well as some Korean vehicles and Chinese cars under licence. They were
also used in industrial applications like Forklifts.
However, the forklift variant differed from that used in cars. In cars
the engine sat on a 15 degree tilt to allow for a lower bonnet height,
and the carbureted version used a long, angled inlet manifold to suit.
The Forklift application didn't have the same hight clearance issues,
but *did* have a very narrow engine bay so the engine in the Fork sat
straight up and used a different cylinder head and inlet manifold to
make for a narrower package.
At some point in it's life the previous owners of this machine have
replaced the original forklift engine with one from a car, and this is
where all the problems began. Virtually nothing fits well, and to make
it all work, to a degree at least, the previous owners removed one of
the engine mounts and jacked the engine up on one side with a piece of
wood, they moved the air cleaner outside the engine bay for more room,
and had to grind the shit out of the left side of the chassis to the
carburetor would clear and not squash the wiring loom, which it had
already done once and melted half of it, hence the block of wood and
additional relays.
Fucking farmers :)
You can see the differences in the pics of the two engines shown
above. You can also see that the original fork engine had the top
water outlet at the front of the engine near the timing belt, while
the car engine has the water outlet at the rear near the clutch. Hence
the messy "over the top" water plumbing. I've had to modify the inlet
manifold, relocate the air cleaner and redo the water plumbing to make
all this work, but that''s another story.
Onto the purpose of this post. How people fuck shit up :)
When I bought this mess I paid fuck all for it, and despite
appearances it does have some redeeming features although right at the
moment I've forgotten what they are. However one of the things the
previous owner mentioned was that the engine had trouble holding a
head gasket. They'd had it out a couple of times to try to sort it,
and even took it to an "engine specialist" to get it fixed but they
never did.
And while I had it apart to do other things I saw why.
When I was fucking around modifying the inlet manifold I had the
cylinder head on and off a few times while I was trial fitting stuff
as I was welding, and I noticed something on the front corner of the
engine block. You can see in this pic here right under the number 1
spark plug there is a pad there with the engine number stamped into

https://ibb.co/Drdp1kg

Turns out that in chasing the head gasket issue someone had machined
the gasket face of the block a few times, but to preserve the engine
number they'd set their cutter back from the front and rear pads and

https://ibb.co/fGDq0D9
https://ibb.co/HtDXwhF

They'd clearly had a few goes at it, as they'd cut 20 tousandths off
the top of the block, and I cant imagine anyone doing that in one
sitting unless the block was severely damaged and there was nothing to

https://ibb.co/HtDXwhF

So, I looked at that for a second and thought "hang on...." and then
sat the cylinder head back on to double check that I wasn't imagining
things, and I wasn't :)

https://ibb.co/ZWGK3xc

Yep. The cylinder head manifold bolt boss is bottoming out on the non
machined pads and is being held off the gasket at the front and rear
of the block. It was effectively tilting the head over towards the
opposite side, and preventing the gasket from being compressed
properly. The more they cut off the top of the block the worse it got,
and the gasket was never going to seal no matter how hard they turned
the bolts.
Fucking idiots :)
I spent this afternoon setting the thing up in my mill and giving it a

https://ibb.co/W554szM

I nearly wasn't going to cut any more off the block than what already
has been and just grind some off the bottom of the head for clearance,
but I'm glad I did as the top of the block wasn't exactly flat and it

https://ibb.co/bswcLc2

You can see where all four corners have touched off with the cutter,
but the back side of the head is shallow. It only needed 5 thousandths

https://ibb.co/MN89Q7b

When I first got thing thing it would barely run. After looking at
this like this I'm surprised it ran at all.
Oh. Did I mention that Farmers are rough cunts? :)

~~~~~~~~~~~~~~~~~~~~~~~~~

 Good result, good write-up!.

[Daryl]

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.
As some of you may be aware, I have a small petrol powered Forklift. A
little Mitsubishi FG15 built in the late 1990's. It's a little 1.5 tonne

https://ibb.co/M5sSt15

(Not the actual machine, but the same model. I don't have a pic of mine)
It came from a Potato farm in Bendigo a couple of years ago, and as is
typical of a lot of farm equipment, it's had the living shit abused out
of it and is fucked off it's nut :) It's had *lots* of "farmyard mods"
to keep it running. The engine sits under the sit as you would expect,

https://ibb.co/P1kkdNq

All neat and tidy like. But they're not all like that. When I got it,

https://ibb.co/s5LH2nG

A whole lot less neat and tidy. Typical farmers :)
These little forks run a variant of the venerable Mitsubishi 4G15
engine, which is a little 1.5 litre engine that's been around for
something like 40 years and has been in Mitsubishi cars like Lancers in
boths single and multi valve variants with either carbs or EFI, as well
as some Korean vehicles and Chinese cars under licence. They were also
used in industrial applications like Forklifts.
However, the forklift variant differed from that used in cars. In cars
the engine sat on a 15 degree tilt to allow for a lower bonnet height,
and the carbureted version used a long, angled inlet manifold to suit.
The Forklift application didn't have the same hight clearance issues,
but *did* have a very narrow engine bay so the engine in the Fork sat
straight up and used a different cylinder head and inlet manifold to
make for a narrower package.
At some point in it's life the previous owners of this machine have
replaced the original forklift engine with one from a car, and this is
where all the problems began. Virtually nothing fits well, and to make
it all work, to a degree at least, the previous owners removed one of
the engine mounts and jacked the engine up on one side with a piece of
wood, they moved the air cleaner outside the engine bay for more room,
and had to grind the shit out of the left side of the chassis to the
carburetor would clear and not squash the wiring loom, which it had
already done once and melted half of it, hence the block of wood and
additional relays.
Fucking farmers :)
You can see the differences in the pics of the two engines shown above.
You can also see that the original fork engine had the top water outlet
at the front of the engine near the timing belt, while the car engine
has the water outlet at the rear near the clutch. Hence the messy "over
the top" water plumbing. I've had to modify the inlet manifold, relocate
the air cleaner and redo the water plumbing to make all this work, but
that''s another story.
Onto the purpose of this post. How people fuck shit up :)
When I bought this mess I paid fuck all for it, and despite appearances
it does have some redeeming features although right at the moment I've
forgotten what they are. However one of the things the previous owner
mentioned was that the engine had trouble holding a head gasket. They'd
had it out a couple of times to try to sort it, and even took it to an
"engine specialist" to get it fixed but they never did.
And while I had it apart to do other things I saw why.
When I was fucking around modifying the inlet manifold I had the
cylinder head on and off a few times while I was trial fitting stuff as
I was welding, and I noticed something on the front corner of the engine
block. You can see in this pic here right under the number 1 spark plug
there is a pad there with the engine number stamped into it, and a

https://ibb.co/Drdp1kg

Turns out that in chasing the head gasket issue someone had machined the
gasket face of the block a few times, but to preserve the engine number
they'd set their cutter back from the front and rear pads and left them

https://ibb.co/fGDq0D9
https://ibb.co/HtDXwhF

They'd clearly had a few goes at it, as they'd cut 20 tousandths off the
top of the block, and I cant imagine anyone doing that in one sitting
unless the block was severely damaged and there was nothing to indicate

https://ibb.co/HtDXwhF

So, I looked at that for a second and thought "hang on...." and then sat
the cylinder head back on to double check that I wasn't imagining
things, and I wasn't :)

https://ibb.co/ZWGK3xc

Yep. The cylinder head manifold bolt boss is bottoming out on the non
machined pads and is being held off the gasket at the front and rear of
the block. It was effectively tilting the head over towards the opposite
side, and preventing the gasket from being compressed properly. The more
they cut off the top of the block the worse it got, and the gasket was
never going to seal no matter how hard they turned the bolts.
Fucking idiots :)
I spent this afternoon setting the thing up in my mill and giving it a

https://ibb.co/W554szM

I nearly wasn't going to cut any more off the block than what already
has been and just grind some off the bottom of the head for clearance,
but I'm glad I did as the top of the block wasn't exactly flat and it

https://ibb.co/bswcLc2

You can see where all four corners have touched off with the cutter, but
the back side of the head is shallow. It only needed 5 thousandths and

https://ibb.co/MN89Q7b

When I first got thing thing it would barely run. After looking at this
like this I'm surprised it ran at all.
Oh. Did I mention that Farmers are rough cunts? :)

On one hand its not all bad when people have a go at fixing things but
if they don't know what they are doing enormous stuff ups happen and it
take a lot of work to sort it.
Your finished block looks perfect now, it should have a bit more power
with all that extra compression:-)

[Clocky]

Post by Daryl

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.
As some of you may be aware, I have a small petrol powered Forklift. A
little Mitsubishi FG15 built in the late 1990's. It's a little 1.5

https://ibb.co/M5sSt15

(Not the actual machine, but the same model. I don't have a pic of mine)
It came from a Potato farm in Bendigo a couple of years ago, and as is
typical of a lot of farm equipment, it's had the living shit abused
out of it and is fucked off it's nut :) It's had *lots* of "farmyard
mods" to keep it running. The engine sits under the sit as you would

https://ibb.co/P1kkdNq

All neat and tidy like. But they're not all like that. When I got it,

https://ibb.co/s5LH2nG

A whole lot less neat and tidy. Typical farmers :)
These little forks run a variant of the venerable Mitsubishi 4G15
engine, which is a little 1.5 litre engine that's been around for
something like 40 years and has been in Mitsubishi cars like Lancers
in boths single and multi valve variants with either carbs or EFI, as
well as some Korean vehicles and Chinese cars under licence. They were
also used in industrial applications like Forklifts.
However, the forklift variant differed from that used in cars. In cars
the engine sat on a 15 degree tilt to allow for a lower bonnet height,
and the carbureted version used a long, angled inlet manifold to suit.
The Forklift application didn't have the same hight clearance issues,
but *did* have a very narrow engine bay so the engine in the Fork sat
straight up and used a different cylinder head and inlet manifold to
make for a narrower package.
At some point in it's life the previous owners of this machine have
replaced the original forklift engine with one from a car, and this is
where all the problems began. Virtually nothing fits well, and to make
it all work, to a degree at least, the previous owners removed one of
the engine mounts and jacked the engine up on one side with a piece of
wood, they moved the air cleaner outside the engine bay for more room,
and had to grind the shit out of the left side of the chassis to the
carburetor would clear and not squash the wiring loom, which it had
already done once and melted half of it, hence the block of wood and
additional relays.
Fucking farmers :)
You can see the differences in the pics of the two engines shown
above. You can also see that the original fork engine had the top
water outlet at the front of the engine near the timing belt, while
the car engine has the water outlet at the rear near the clutch. Hence
the messy "over the top" water plumbing. I've had to modify the inlet
manifold, relocate the air cleaner and redo the water plumbing to make
all this work, but that''s another story.
Onto the purpose of this post. How people fuck shit up :)
When I bought this mess I paid fuck all for it, and despite
appearances it does have some redeeming features although right at the
moment I've forgotten what they are. However one of the things the
previous owner mentioned was that the engine had trouble holding a
head gasket. They'd had it out a couple of times to try to sort it,
and even took it to an "engine specialist" to get it fixed but they
never did.
And while I had it apart to do other things I saw why.
When I was fucking around modifying the inlet manifold I had the
cylinder head on and off a few times while I was trial fitting stuff
as I was welding, and I noticed something on the front corner of the
engine block. You can see in this pic here right under the number 1
spark plug there is a pad there with the engine number stamped into

https://ibb.co/Drdp1kg

Turns out that in chasing the head gasket issue someone had machined
the gasket face of the block a few times, but to preserve the engine
number they'd set their cutter back from the front and rear pads and

https://ibb.co/fGDq0D9
https://ibb.co/HtDXwhF

They'd clearly had a few goes at it, as they'd cut 20 tousandths off
the top of the block, and I cant imagine anyone doing that in one
sitting unless the block was severely damaged and there was nothing to

https://ibb.co/HtDXwhF

So, I looked at that for a second and thought "hang on...." and then
sat the cylinder head back on to double check that I wasn't imagining
things, and I wasn't :)

https://ibb.co/ZWGK3xc

Yep. The cylinder head manifold bolt boss is bottoming out on the non
machined pads and is being held off the gasket at the front and rear
of the block. It was effectively tilting the head over towards the
opposite side, and preventing the gasket from being compressed
properly. The more they cut off the top of the block the worse it got,
and the gasket was never going to seal no matter how hard they turned
the bolts.
Fucking idiots :)
I spent this afternoon setting the thing up in my mill and giving it a

https://ibb.co/W554szM

I nearly wasn't going to cut any more off the block than what already
has been and just grind some off the bottom of the head for clearance,
but I'm glad I did as the top of the block wasn't exactly flat and it

https://ibb.co/bswcLc2

You can see where all four corners have touched off with the cutter,
but the back side of the head is shallow. It only needed 5 thousandths

https://ibb.co/MN89Q7b

When I first got thing thing it would barely run. After looking at
this like this I'm surprised it ran at all.
Oh. Did I mention that Farmers are rough cunts? :)

On one hand its not all bad when people have a go at fixing things but
if they don't know what they are doing enormous stuff ups happen and it
take a lot of work to sort it.
Your finished block looks perfect now, it should have a bit more power
with all that extra compression:-)

Perfectly fucked.
These heads crack like there is no tomorrow when running stock!

[Noddy]

Post by Daryl

Post by Noddy
When I first got thing thing it would barely run. After looking at
this like this I'm surprised it ran at all.
Oh. Did I mention that Farmers are rough cunts? :)

On one hand its not all bad when people have a go at fixing things but
if they don't know what they are doing enormous stuff ups happen and it
take a lot of work to sort it.
Your finished block looks perfect now, it should have a bit more power
with all that extra compression:-)

Lol :) The engines make between 60-90kw depending on what car they're
in and the configuration, but in the forklift they make 25kw at just
under 3000rpm thanks to the governor. The governor sits under the carb
and has it's own butterfly that is activated by both spring pressure and
manifold vacuum to regulate airflow, but like everything else on this
thing it's fucked and doesn't work :)

When they fitted the car engine the original fork carburetor wouldn't
fit the car manifold, so they used the car carb. The original carb was a
single barrel industrial thing, but the car carb is a variable stage two
barrel so I have to shut down the secondary and stop it from working. I
also need to use the governor body to maintain correct carb height and
align cables and fuel lines, so all I could do was machine out the guts
of the governor and put a sleeve in it to block off the vacuum and shaft

Post by Daryl
https://ibb.co/C5nLVvp
https://ibb.co/KWBDhsL
https://ibb.co/6WNshzj

I wanted to put the air cleaner back under the engine cover where it was
originally, so to make it all fit the carb needed to be at the right
height so the air horn cleared the exhaust manifold heat shield (which I
also had to make) and had enough of a path to make some ducting back

Post by Daryl
https://ibb.co/3s49Yc0
https://ibb.co/2d8N1bw

And doing *that* would allow me to run a fabricated coolant passage over

Post by Daryl
https://ibb.co/XJjSXS5

It's definitely a can of worms with everything being connected to
everything else. I wanted to move the top water outlet to the front of
the engine as per original, but it just wasn't possible with this inlet
manifold as there wasn't enough room between the number 1 inlet passage
and the distributor. The original Fork engine ran a different port
spacing and manifold to allow it.

Fun and games. Still, if I wasn't doing this I'd be wasting my time
talking shit in here :)
--
--
--
Regards,
Noddy.

[Xeno]

<snipped bullshit and lies>

Post by Noddy
manifold as there wasn't enough room between the number 1 inlet passage
and the distributor. The original Fork engine ran a different port
spacing and manifold to allow it.
Fun and games. Still, if I wasn't doing this I'd be wasting my time
talking bullshit and lies in here :)

I fixed it for you! HUGE increase in accuracy

[Daryl]

Post by Daryl

Post by Noddy
When I first got thing thing it would barely run. After looking at
this like this I'm surprised it ran at all.
Oh. Did I mention that Farmers are rough cunts? :)

On one hand its not all bad when people have a go at fixing things but
if they don't know what they are doing enormous stuff ups happen and
it take a lot of work to sort it.
Your finished block looks perfect now, it should have a bit more power
with all that extra compression:-)

Lol  :) The engines make between 60-90kw depending on what car they're
in and the configuration, but in the forklift they make 25kw at just
under 3000rpm thanks to the governor. The governor sits under the carb
and has it's own butterfly that is activated by both spring pressure and
manifold vacuum to regulate airflow, but like everything else on this
thing it's fucked and doesn't work :)
When they fitted the car engine the original fork carburetor wouldn't
fit the car manifold, so they used the car carb. The original carb was a
single barrel industrial thing, but the car carb is a variable stage two
barrel so I have to shut down the secondary and stop it from working. I
also need to use the governor body to maintain correct carb height and
align cables and fuel lines, so all I could do was machine out the guts
of the governor and put a sleeve in it to block off the vacuum and shaft

Post by Daryl
https://ibb.co/C5nLVvp
https://ibb.co/KWBDhsL
https://ibb.co/6WNshzj

I wanted to put the air cleaner back under the engine cover where it was
originally, so to make it all fit the carb needed to be at the right
height so the air horn cleared the exhaust manifold heat shield (which I
also had to make) and had enough of a path to make some ducting back

Post by Daryl
https://ibb.co/3s49Yc0
https://ibb.co/2d8N1bw

And doing *that* would allow me to run a fabricated coolant passage over

Post by Daryl
https://ibb.co/XJjSXS5

It's definitely a can of worms with everything being connected to
everything else. I wanted to move the top water outlet to the front of
the engine as per original, but it just wasn't possible with this inlet
manifold as there wasn't enough room between the number 1 inlet passage
and the distributor. The original Fork engine ran a different port
spacing and manifold to allow it.
Fun and games. Still, if I wasn't doing this I'd be wasting my time
talking shit in here :)

LOL.
Looks at bit like mods that need to be done when you take a FWD engine
and use it in a RWD Clubman.
In a FWD car thermostats are often at the rear of the engine which is a
pain when you put that engine in a RWD car.

[Noddy]

Post by Daryl

Post by Noddy
Fun and games. Still, if I wasn't doing this I'd be wasting my time
talking shit in here :)

LOL.
Looks at bit like mods that need to be done when you take a FWD engine
and use it in a RWD Clubman.
In a FWD car thermostats are often at the rear of the engine which is a
pain when you put that engine in a RWD car.

Yeah, definitely a pain. The clearance is so tight that I couldn't even
get a hose outlet on the manifold and use a remote thermostat. It just
wasn't going to work. Plan B was to use the rear outlet and run a solid
pipe under the inlet manifold and around the front of the engine but the
starter is directly under the rear water outlet and would be in the way.
So I just had to live with the top radiator hose going over the top of
the engine.

I don't like it, but it was the only workable solution as trying to
track down an original Forklift head and inlet manifold wasn't happening.
--
--
--
Regards,
Noddy.

[Xeno]

Post by Daryl

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.
As some of you may be aware, I have a small petrol powered Forklift. A
little Mitsubishi FG15 built in the late 1990's. It's a little 1.5

https://ibb.co/M5sSt15

(Not the actual machine, but the same model. I don't have a pic of mine)
It came from a Potato farm in Bendigo a couple of years ago, and as is
typical of a lot of farm equipment, it's had the living shit abused
out of it and is fucked off it's nut :) It's had *lots* of "farmyard
mods" to keep it running. The engine sits under the sit as you would

https://ibb.co/P1kkdNq

All neat and tidy like. But they're not all like that. When I got it,

https://ibb.co/s5LH2nG

A whole lot less neat and tidy. Typical farmers :)
These little forks run a variant of the venerable Mitsubishi 4G15
engine, which is a little 1.5 litre engine that's been around for
something like 40 years and has been in Mitsubishi cars like Lancers
in boths single and multi valve variants with either carbs or EFI, as
well as some Korean vehicles and Chinese cars under licence. They were
also used in industrial applications like Forklifts.
However, the forklift variant differed from that used in cars. In cars
the engine sat on a 15 degree tilt to allow for a lower bonnet height,
and the carbureted version used a long, angled inlet manifold to suit.
The Forklift application didn't have the same hight clearance issues,
but *did* have a very narrow engine bay so the engine in the Fork sat
straight up and used a different cylinder head and inlet manifold to
make for a narrower package.
At some point in it's life the previous owners of this machine have
replaced the original forklift engine with one from a car, and this is
where all the problems began. Virtually nothing fits well, and to make
it all work, to a degree at least, the previous owners removed one of
the engine mounts and jacked the engine up on one side with a piece of
wood, they moved the air cleaner outside the engine bay for more room,
and had to grind the shit out of the left side of the chassis to the
carburetor would clear and not squash the wiring loom, which it had
already done once and melted half of it, hence the block of wood and
additional relays.
Fucking farmers :)
You can see the differences in the pics of the two engines shown
above. You can also see that the original fork engine had the top
water outlet at the front of the engine near the timing belt, while
the car engine has the water outlet at the rear near the clutch. Hence
the messy "over the top" water plumbing. I've had to modify the inlet
manifold, relocate the air cleaner and redo the water plumbing to make
all this work, but that''s another story.
Onto the purpose of this post. How people fuck shit up :)
When I bought this mess I paid fuck all for it, and despite
appearances it does have some redeeming features although right at the
moment I've forgotten what they are. However one of the things the
previous owner mentioned was that the engine had trouble holding a
head gasket. They'd had it out a couple of times to try to sort it,
and even took it to an "engine specialist" to get it fixed but they
never did.
And while I had it apart to do other things I saw why.
When I was fucking around modifying the inlet manifold I had the
cylinder head on and off a few times while I was trial fitting stuff
as I was welding, and I noticed something on the front corner of the
engine block. You can see in this pic here right under the number 1
spark plug there is a pad there with the engine number stamped into

https://ibb.co/Drdp1kg

Turns out that in chasing the head gasket issue someone had machined
the gasket face of the block a few times, but to preserve the engine
number they'd set their cutter back from the front and rear pads and

https://ibb.co/fGDq0D9
https://ibb.co/HtDXwhF

They'd clearly had a few goes at it, as they'd cut 20 tousandths off
the top of the block, and I cant imagine anyone doing that in one
sitting unless the block was severely damaged and there was nothing to

https://ibb.co/HtDXwhF

So, I looked at that for a second and thought "hang on...." and then
sat the cylinder head back on to double check that I wasn't imagining
things, and I wasn't :)

https://ibb.co/ZWGK3xc

Yep. The cylinder head manifold bolt boss is bottoming out on the non
machined pads and is being held off the gasket at the front and rear
of the block. It was effectively tilting the head over towards the
opposite side, and preventing the gasket from being compressed
properly. The more they cut off the top of the block the worse it got,
and the gasket was never going to seal no matter how hard they turned
the bolts.
Fucking idiots :)
I spent this afternoon setting the thing up in my mill and giving it a

https://ibb.co/W554szM

I nearly wasn't going to cut any more off the block than what already
has been and just grind some off the bottom of the head for clearance,
but I'm glad I did as the top of the block wasn't exactly flat and it

https://ibb.co/bswcLc2

You can see where all four corners have touched off with the cutter,
but the back side of the head is shallow. It only needed 5 thousandths

https://ibb.co/MN89Q7b

When I first got thing thing it would barely run. After looking at
this like this I'm surprised it ran at all.
Oh. Did I mention that Farmers are rough cunts? :)

On one hand its not all bad when people have a go at fixing things but
if they don't know what they are doing enormous stuff ups happen and it
take a lot of work to sort it.

Like when you and Darren worked on Les' engine, right?

Post by Daryl
Your finished block looks perfect now, it should have a bit more power
with all that extra compression:-)

[Clemmie]

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.

I suppose if think that decrepit forklifts, geriatric Yankee trucks and
hideous Rangers are "vehicles" then anything is possible.

And thanks for yet another instance of you kicking your own arse. You'll
provide multiple pix of irrelevant & dreary subjects, but *one* photo of
the fabled NAoA, or you 'working' on an expensive Euro exotic... Nahhhh.

Just change your name to Darren Bozo and be done with.



alvey

[Xeno]

Post by Clemmie

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.

I suppose if think that decrepit forklifts, geriatric Yankee trucks and
hideous Rangers are "vehicles" then anything is possible.
And thanks for yet another instance of you kicking your own arse. You'll
provide multiple pix of irrelevant & dreary subjects, but *one* photo of
the fabled NAoA, or you 'working' on an expensive Euro exotic... Nahhhh.

And not one shred of evidence to prove his *multiple claims* of being a
*qualified* tradesman and, ultimately, that would be one of the
*easiest* to prove - *if* - he was actually qualified since those
records are online.

Post by Clemmie
Just change your name to Darren Bozo and be done with.

Noddy Bozo would be more apt.

Post by Clemmie
alvey

[Mighty Mouse]

Post by Clemmie

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.

I suppose if think that decrepit forklifts, geriatric Yankee trucks
and hideous Rangers are "vehicles" then anything is possible.
And thanks for yet another instance of you kicking your own arse.
You'll provide multiple pix of irrelevant & dreary subjects, but *one*
photo of the fabled NAoA, or you 'working' on an expensive Euro
exotic... Nahhhh.

or claimed automotive qualifications..

Post by Clemmie
Just change your name to Darren Bozo and be done with.
alvey

[Xeno]

Post by Mighty Mouse

Post by Clemmie

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.

I suppose if think that decrepit forklifts, geriatric Yankee trucks
and hideous Rangers are "vehicles" then anything is possible.
And thanks for yet another instance of you kicking your own arse.
You'll provide multiple pix of irrelevant & dreary subjects, but *one*
photo of the fabled NAoA, or you 'working' on an expensive Euro
exotic... Nahhhh.

or claimed automotive qualifications..

Yeah, you'd think a person who managed to amass two *claimed* trade
qualifications would be proud to show off those achievements. But not
Darren. His reasoning why he doesn't front up with the proof is so
implausible as to be downright inane. FFS, were he able to present *any*
trade qualification he'd be shooting *me* down in flames and you'd have
to imagine that the puir wee Darren would *love that*! Somehow I don't
think he's trying to spare me the humiliation - hasn't any form for
that! ;-)

Post by Mighty Mouse

Post by Clemmie
Just change your name to Darren Bozo and be done with.
alvey

[Mighty Mouse]

Post by Mighty Mouse

Post by Clemmie

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.

I suppose if think that decrepit forklifts, geriatric Yankee trucks
and hideous Rangers are "vehicles" then anything is possible.
And thanks for yet another instance of you kicking your own arse.
You'll provide multiple pix of irrelevant & dreary subjects, but
*one* photo of the fabled NAoA, or you 'working' on an expensive Euro
exotic... Nahhhh.

actually there was a pic of one exotic.. the one he lifted wrongly, lol

Post by Mighty Mouse
or claimed automotive qualifications..

Post by Clemmie
Just change your name to Darren Bozo and be done with.
alvey

[Clocky]

Post by Mighty Mouse

Post by Clemmie

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.

I suppose if think that decrepit forklifts, geriatric Yankee trucks
and hideous Rangers are "vehicles" then anything is possible.
And thanks for yet another instance of you kicking your own arse.
You'll provide multiple pix of irrelevant & dreary subjects, but
*one* photo of the fabled NAoA, or you 'working' on an expensive Euro
exotic... Nahhhh.

actually there was a pic of one exotic.. the one he lifted wrongly, lol

Yes, the Elise who misidentified the lifting points on and then then
tried to backpedal saying it didn't matter.

If potentially structurally damaging a vehicle, increasing the chances
of dropping it off a hoist, risking you and other peoples safety and
suggesting that using the incorrect lifting points doesn't matter then
you have no business working on *any* car.

The incompetence he so blissfully displayed in total ignorance was as
astounding as it was revealing. Given he never admits he's at fault he
would be the very worst person to ever take your car to for anything as
I have said many times.

[Xeno]

Post by Mighty Mouse

Post by Clemmie

Post by Noddy
Vehicle talk in a car group. Who would have thunk it.

I suppose if think that decrepit forklifts, geriatric Yankee trucks
and hideous Rangers are "vehicles" then anything is possible.
And thanks for yet another instance of you kicking your own arse.
You'll provide multiple pix of irrelevant & dreary subjects, but
*one* photo of the fabled NAoA, or you 'working' on an expensive Euro
exotic... Nahhhh.

actually there was a pic of one exotic.. the one he lifted wrongly, lol

Exotic for Darren maybe, to the rest of us, not so much. It was powered
by a *reliable* Toyota engine, reliable until Darren got his sticky
fingers into it - and that took it to the next level - of destruction.

I must say, I was amused by the fact that Darren couldn't look at a
*mid-engined car* and work out that what he thought were the *rear*
hoist points were in fact the *side* jacking points. That the jacking
points were in line with the seat backrest, and close to the car's
longitudinal centre of gravity, should have told him they were side lift
points and to *look further rearwards* for the *rear hoist points*.
Better yet, he could have RTFM. After all, it was *available*. Daryl had
it, remember?