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Offline Os8472  
#126 Posted : 07 March 2010 08:19:41(UTC)
Os8472


Posts: 251

Got quite abit more done to the car, the new 285degree piper cam and adjustable vernier are in and timed up, thanks Handy Andy.

Was gunna spend all out the weekend just gone get it back together but not all went to plan, thursday night while undoing the clutch cover plate bolts 2 snapped off in the flywheel, leading to this
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Ohwell got on with a couple of other bits, the old clutch cable was abit cooked and when I got it out was 20mm longer than the brand new one I got from renault :shock:
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I've fitted a soft pedel conversion to the clutch to make it alittle better to drive, its an easy conversion as Volvo did it as standard on the 480turbo, a quick call to a volvo dealership got me this bits
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Went to a scrappy with a mate to lend a hand pulling a few bits he needed off a motor and had a stroke of luck, found an R5 with nearly brand new headlights
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And it also had a mint condition rocker cover, it even still had the sticker for the plug gap on it
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Got those for 30quid, not bad considering 1 new headlight is 60quid

Had a result on ebay and got a chrome altenator bracket for a fiver
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Offline Os8472  
#127 Posted : 07 March 2010 08:20:25(UTC)
Os8472


Posts: 251

Got alot of stuff yesturday, the head is back on and for the most part the engine is built back up but the stainless gasket I had for the manifold to turbo has gone missing, which is really annoying cus I put it with the turbo elbow gasket and thats still there.

The new clutch arm is very close to the rad fan but clears the rad itself just fine, another 10mm longer and I'd have to move the fan but it should be ok
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I got some new 6mm vacuum hose instead of the 4mm I've been using up to now for the wastegate lines plus I've also routed it in a way so it looks abit less tatty but I'm gunna add some little clips to tidy it up some more
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Here's the new layout albeit still needing some bits finishing
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Had a result on ebay last night, I got a GT Tuning ram raid induction kit for an R5, back in the day these were dyno proven to gain 7bhp, Its gunna need alittle bit of modding to sit behind my airbox but should go nicely
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Edited by user 07 March 2010 08:22:09(UTC)  | Reason: Not specified

Offline foxspeed  
#128 Posted : 07 March 2010 10:23:45(UTC)
foxspeed


Posts: 21,649
Location: retour dans la bulle

really great improvements there - should be a really good motor when finished Approve
Offline Os8472  
#129 Posted : 22 March 2010 19:33:35(UTC)
Os8472


Posts: 251

Update time, I've modded the GTTtunning ram raid kit I got off fleabay to suit my carbon airbox and hopefully improved its flow aswell.

This is the standard GTTuning ram raid induction kit, basically a K&N element for a R5 GTT with a throttle body trumpet in one end.
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But this is the down fall, the trumpet starts a good 2inches up inside the filter
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Stripped down
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Cardboard template
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Bottom plate
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Repositioned trumpet
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And the filter in its new home
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Offline Os8472  
#130 Posted : 22 March 2010 19:34:27(UTC)
Os8472


Posts: 251

After mapping today I had to give it a squirt on the way home and at 14psi it decided to brake its own bonnet mounts at the front and make a bid for freedom :shock:

So abit of modding is in order, the standard bonnet mount with the factory circlip removed for quick release
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Abit of drilling and a clip, job done
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Offline Os8472  
#131 Posted : 22 March 2010 19:35:10(UTC)
Os8472


Posts: 251

I guess its time to report on the mapping

Well it started fairly badly, having damaged an intercostal muscle (I can't spell so don't say it) I couldn't investigate a misfire the car had under a certain amount of throttle, I had to hope it was just down to the fact the car now has a piper 285 cam, ported head and new turbo and needed mapping but alas it wasn't.

At first Dave thought it was the overlap on the cam being to much but a quick check of valve lift disproved that, so he got down to some mind bending mapping work, the guy is bloody impressive to watch.

Although it wasn't a mapping issue Dave was able to map around it as such until a time as I can Id the problem and sort it so he can finish the job properly.

I asked Dave to set the car up with 3 boost levels, 8psi for day to day driving and motorway crusing, 14psi for track use and 22psi for drag use.

Well best get on with the results, can't tell you how much it made at 8psi as I forgot that print out.

At 14psi it made 169.9bhp and 172.4ft lb
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And at 22psi it made 211.5bhp and 203ft lb
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Now straight away looking at those graphs you can see somit ain't right as the power drops off fast after around 5500rpm to 6000rpm, Dave is convinced the cam is too wild to work properly with my efi plenum but I think the cam timing is out so at some point I'm gunna have to whip the timing cover off and go over it to find out for sure.

In the mean time, I'm off, gotta go find me a scooby to waste :D

Offline foxspeed  
#132 Posted : 22 March 2010 19:36:14(UTC)
foxspeed


Posts: 21,649
Location: retour dans la bulle

great work Approve
Offline Gazeratti  
#133 Posted : 24 March 2010 09:56:31(UTC)
Gazeratti


Posts: 8,668

Nice one, should go like a rocket ship Big Smile
Offline PBCup  
#134 Posted : 24 March 2010 23:04:01(UTC)
Phil 172


Posts: 10,735

Bloody hell bet its fun and a handfull!!

3500rpm 100lbft and just over 60bhp

4500rpm 200lbft and 175bhp

That is one hell of a turbo kick!!

Offline Os8472  
#135 Posted : 25 March 2010 23:48:42(UTC)
Os8472


Posts: 251

PB.Trophy wrote:

Bloody hell bet its fun and a handfull!!

3500rpm 100lbft and just over 60bhp

4500rpm 200lbft and 175bhp

That is one hell of a turbo kick!!

It bloody is, the first time I really gave it any at only 7psi I nearly lost it lol

I've only given some at 14psi twice and both times I waited till I had a nice clear straight road and even then it tryed to put me in the hedge with torque steer

Haven't had the balls to try 22psi yet

But the most worring thing is its not running right, there's at least another 20bhp and 30ft lb still to come once I've sorted the cam timing problemShocked

Offline 182petrolblue  
#136 Posted : 26 March 2010 21:24:30(UTC)
182petrolblue


Posts: 84

hey, thats a fantastic result and still not set up to its full potential! well done to u Approve did u do most of the tuning or did you have a specialist do the main tuning side of things? Was it the same company that rolling roaded it for you that has a good knowledge of these cars? as he sounds like he knows his onions.. well done mate, hope you get to iron out those small issues soon Wink

What turbo are you running? was it a tuner bought turbo? I think the 285 cam is good...but the 270 is meant to be a good comprise and not so harsh as another if you think it might have something to do with the setting up

Smile

Edited by user 26 March 2010 21:29:35(UTC)  | Reason: Not specified

Offline Os8472  
#137 Posted : 26 March 2010 23:19:41(UTC)
Os8472


Posts: 251

I built the engine myself, I had certain parts like the crank machined and balanced by a local machine shop but I put it together, I've even had a few peoplecome to me and ask for me to build an engine for them.

I had certain parts made specially, the inlet manifold for example, I can't tig weld so I had to get that done but I fitted it d modded it where needed, as for the actually mapping side of things I had Dave Walker at Emerald do it, I have one his Emerald ECU's so it made sense for him to do it and he feck me he knows his stuff and his ECU has gotta be one of best I've seen and for feck all money, for a motec equiverlant you'd be spending somit like 1500quid where as the Emerald is only 500quid.

Dave doesn't have a massive amount of exsperience with R5 GTT's but he's mapped massive wide range of engines, Lotus even send people to him when they want more power.

I'm using a T28 turbo, nothin fancy like roller bearing or anything just BIG :) cost me 250quid second hand, was used twice before the guy took it off cus he didn't like the amount of lag, which ain't so bad for me, on his R5 it started boosting at 3500rpm, as you can see from my dyno graph its boosting from 2500rpm :) its all about getting the right mods behand the turbo.

I'm not sure that I need to go as far as changing the cam, just need to spend alot of time testing different timing settings, will be abit trial and error until I get it right.

Offline Slippers  
#138 Posted : 06 April 2010 13:55:22(UTC)
Slippers


Posts: 1,874

the one i drove was an absolute monster. torque steering in a straight line when you nailed the power, hurt my wrist! i'd never driven anything with a significant amount of power at the time. I also to this day haven't driven anything with that amount of acceleration! it pictured on the BB Performance site as an example on the R5 page

Edited by user 06 April 2010 13:58:58(UTC)  | Reason: Not specified

Offline mark duffy  
#139 Posted : 13 April 2010 20:49:11(UTC)
duffy


Posts: 1,863

awesome project and thanks for keeping us upto date. Good luck for the continued improvements Eric.!

Offline Os8472  
#140 Posted : 14 June 2010 21:57:32(UTC)
Os8472


Posts: 251

Its been awhile since I posted on here so here's some progress, well I say progress more like doing right what should have been done right first time over a year ago The guy who made the parts for my EFI connversion has caused me nothing but grief and he will get whats coming to him and before anyone makes any comments along the lines 'I told you so' just feck off because that isn't very helpfull.

First off the fuel pressure regulator which I was told was a exspensive quality part that was going to go on his Lancer turned out to be a 22quid job off ebay

Then he over tightened the -6 fuel hose fittings stripping half the threads causing a minor leak

And then to finish it off he drilled and tapped 2 holes in the side for the mounting bracket, these holes went right into the body of the regulator and when I took it off petrol came out, this is the worst bit about it as the regulator was holding the fuel at 3bar of pressure at idle wnd that would rise the boost pressure increased

Next thing he did wrong that I'm sorting now is the inlet manifold that he spent a year designing and making and told me his friend who worked for a wrc team flow tested it. I asked a mate Alex to have a quick look at it on the car and what he said made me take it off and get it checked for myself.

What the guy had to tell me was not good, he looked at it for about 30seconds before saying it was scrap metal and that there was no point flow testing it, I asked him to do it anyway and test a standard GTT inlet manifold, the results that came back were aweful, in his opinion I was better off going back to a carb than to continue with this manifold the the carb manifold although not great flowed better and more evenly across the cyclinders than the EFI one.

You can see from this pic the throttle boddy is not centrel the runners causing the outer 2 to get less air, infact no.4 hardly got any. You can also see that throttle body is not fitted directly to the plenum chamber but on a sort of tube causing the air going in to be aimed at the inner 2 cyclinders.

This is the view down the throttle body hole showing the poor welding that came through to the inside, unfortunaly this is the best bit but I can't get a clear pic of the worst bits.

This is the view just inside the head end of the runners, you can see the inside of the runner hasn't been blended into the flange, infact there is a ridge that causes a flow disruption.

Offline Os8472  
#141 Posted : 14 June 2010 21:58:34(UTC)
Os8472


Posts: 251

To most the problems above would cause the end of a project or at the very least make them go back to a carb, but after getting 40+ mpg and over 200bhp with a dodgy manifold and regulator I figure its best to finish what I've started.

My first job the fuel pressure regulator, a quick call to a supplier and I have a FSE motorsport regulator with -6 fittings sitting on my doorstep, unfortunatly thier idea of red looks more pink to me but hey aslong as it works I'm happy.

I made a decent bracket for that doesn't move around or require drilling holes in the regulator.

This is the new manifold, it use the throttle body from a Lancia Delta Intergrale but needs a few mods to make everything fit right.

Offline Os8472  
#142 Posted : 14 June 2010 21:59:12(UTC)
Os8472


Posts: 251

Some more pics of the new setup.

First off the new throttle cable clamp, see Nigel very simple piece of angle ally with some holes in it.

This bit has all the vacuum ports on it plus the two one way valves at the rear for the brake servo and breather system

The new manifold with my injectors and fuel rail fitted and a much better injector angle pointing almost straight at the back of the valves.

And here you can see how it looks fitted, just gotta get Alex to chop off a pipe from the throttle body and balnk the hole and weld abit of ally on a boost pipe so I can tap it for the air temp sensor and then I can try it.

Offline Os8472  
#143 Posted : 14 June 2010 21:59:50(UTC)
Os8472


Posts: 251

Got a hold of Alex saturday morning, he nipped to his workshop and did the bits I needed even though he wasn't gunna be there, top bloke, cheers fella :thumbleft:

This is what he did, the throttle body with the pipe removed and a proper bung made

The new boost pipe with abit welded on the side so I can drill and tap it to take the air temp sensor

Gave the boost pipe a go with my ally polishing wheel and this is how everything now looks

Offline Os8472  
#144 Posted : 14 June 2010 22:00:45(UTC)
Os8472


Posts: 251

With help from Handy Andy I got the 5 idlin smoothly and the fuelin safe up to 7k at 7psi at full throttle, although its not a perfect map across the rev range at part throttle as I found out on the way to Pod on the friday mornin of the Frog of the Pod RTOC event, as exactly at the right revs and throttle load for crusing at 70mph was abit lean but thanks to my latest ebay purchase a laptop costin 21quid I was able to adjust the map enough to make it safe.
Offline Os8472  
#145 Posted : 14 June 2010 22:02:29(UTC)
Os8472


Posts: 251

Went to Rockingham on saturday afternoon to meet up with a couple of guys from the newly revived Performance French Cars magazine, a couple of hours later and they have my spec, abit of history about the car and enough photos to do a feature in an upcoming issue :)

Offline Os8472  
#146 Posted : 14 June 2010 22:03:16(UTC)
Os8472


Posts: 251

Last update, after the photshoot on saturday I went to Rockingham again on sunday for The French Car Show and came home feeling smug

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Offline Al  
#147 Posted : 14 June 2010 22:11:26(UTC)
Al


Posts: 3,683

Firstly, congratulations on the trophy! What was the award for? I'm guessing something along the lines of best car/division at show.

And double congrats on the feature and photos, especially considering the set backs you've clearly had Angry

Glad you've persevered though. Approve
Offline Os8472  
#148 Posted : 14 June 2010 22:28:40(UTC)
Os8472


Posts: 251

Cheers Al, the trophey was performance moddified car of the show, I knew I was in with a good chance as the next best car was a yellow 106 gti on throttle bodies and stand alone managment but had a full leather interiour which I don't think the judges saw as being performance based, the guy who owned it weren't happy cus when my name was called out he fired up his car and stormed out of the arena apparantly lol

Offline Al  
#149 Posted : 14 June 2010 22:45:14(UTC)
Al


Posts: 3,683

Excellent mate - sorry I didn't know what it was for, I didn't attend FCS and wasn't sure on the categories they have. Make sure you let us know when your feature is out Cool
Offline CarbonLoader  
#150 Posted : 16 December 2010 17:38:59(UTC)
CarbonLoader


Posts: 3

Love this project, almost as mine ;)
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