The Ginetta Project
By Robert Furness, Head of Technology
In the summer of 2007 the Technology Department was approached by Richard Cooper, father of Andrew in S6 and David in S2, to see if we would like to provide a temporary home for a Ginetta G15 sports car from the 1960s that was in need of some tender loving care and restoration. On June 7 the car arrived on a trailer, along with two Hillman Imp engines and two gearboxes.
Great to see the engine finally running after so many years. I found the engine rebuild very interesting I was particularly interested in seeing what was inside and getting a greater understanding of how the engine works.
In the autumn we began dismantling one of the Imp engines with our S6 Car Maintenance group, which takes place one lesson a week. The engine had not run for 27 years, and in the process of dismantling it, three of the cylinder head bolts snapped off, leaving their remains in the cylinder block. We could see that refurbishment was going to be a challenge! Repairs to the cylinder block required the help of friendly mechanics and Hillman Imp enthusiasts, and were only successful after a number of attempts. Meanwhile the pupils were busy cleaning up the cylinder heads and regrinding the valves. The valve clearances were carefully measured, and the appropriate shims ordered and fitted. Once the cylinder bores had been honed, new piston rings were fitted, the pistons tapped into the bores, and the crankshaft and bearings refitted. By now the school year was drawing to a close, and the summer examinations curtailed our progress.
I have applied to study Electrical & Mechanical Engineering at University, and the chance to do real hands-on engineering at school was a chance I couldn't pass up.
In autumn 2008 a new S6 group started work on the engine. The cylinder head was refitted, and this time the cylinder block repairs were successful. Now we could start to see progress. Over the weeks the engine reassembly was completed, and we were just about ready to try the engine again. With quite a few parts both given and lent by members of the Imp Club, and filled with new clean oil, the engine was made ready to try out. Our first attempt to fire up the engine on a test rig from the Imp Club ended in disappointment - the engine fired, but would not keep going due to a faulty fuel pump and carburettor. Replacements were lent to us, and this time the engine burst into life and kept going. And after 27 years lying idle, and our considerable efforts, it certainly sounded sweet.
Being able to pull it apart, and view all the small parts inside the engine made it that little bit more special. My knowledge about internal combustion engines has increased dramatically since coming along to work on this engine every week.
Our attention will now turn to the rest of the car, which needs work on the brakes, the steering, the suspension, the wiring, the instruments - well, on just about everything. But perhaps the most complicated and challenging part - getting the engine running again - is now behind us.
It was great to rebuild a car engine from scratch and it was worth every minute when we finally got it to work- a great sense of achievement. It is very rare to be given an opportunity like this one.
