[engine_work] Project Sarty

[DrSarty 90 1 Cars]

interesting with the method of keeping overall inlet tract the same. Do you think thats more important than the throttlebody position along the runner??

 

I haven't a frickin' scooby Kev. I think accurate/fairly close tract lengths is important though. Dunno why; just makes sense to me.

 

It was either you or Pug Power Dave who mentioned the possible effect of the TBs being nearer or further away from the head. Personally I can't see it making any difference. But I've been proved wrong before, so I have no fear of it happening again!

 

Here are a few snaps of test fitting flanges ( ) and runners.

You may note the blue hose connector, which is now one of two t-pieces for breathing off the crank case gases. The top (blue) one goes to my catchtank and the red one feeds the hose to t-piece (currently copper, but being replaced) 5 o'clock in the photo which is a pressure feed for the CV plungers on the bike bodies.

 

Theory is, as crank case pressures increase on acceleration etc, the plungers rise to de-restrict the TB venturis, just like a second choke. The pressure but works for sure, as if you blow in the CV plungers do exactly that. Now all we hope is that this feed method works, as these restrictors apparently help idle and throttle response.

 

Pronta is collecting the nicely discounted ECU from Emerald today, so all that is left is the welds on all 4 runners to be ground back and tidied up, the runners to be cut level and square where they'll meet the bodies via the silicon joiners, a sand blast and a red enamel/powder coat. Should look sweet; just hope it'll go. All systems and wiring have been checked and the ECU tailored by Dave and the Emerald gang to run the LS1 coils 4 cyl wasted spark.

 

Yamaha FPR has been looked up to be 2.84bar, which may be a little low, so an udjustable FPR maybe on route.

 

The LC1 (lambda sensor) has been calibrated and is ready to go aswell.

 

Crapping my pants from 3,500miles away.

[kyepan 291]

from the wiki on the mx5

 

The BP-4W engine remained at 1.8 L (110 cu in) but received several minor updates. The engine compression ratio was raised from 9.0:1 to 9.5:1 by adding slightly domed pistons; the intake cam was changed to a solid lifter design with a stronger cam; the intake runners in the head were straightened and the intake manifold was mounted higher up. Mazda's Variable Intake Control System was introduced, which effectively gave a long narrow intake manifold at low rpm for better swirl, changing to a short, free-flowing manifold at high rpm for maximum breathing. Power output of the new engine was quoted at 106 kW (142 bhp) with 116 ft·lbf (157 N·m) of torque.

 

interesting...

 

less interesting than the answer to this question, when will it first breath life? bark and spit flames?

Edited August 26, 2008 by kyepan

[DrSarty 90 1 Cars]

less interesting than the answer to this question, when will it first breath life? bark and spit flames?

 

One would hope by this weekend.

 

Guy (Pronta) needs to finish off the manifold, make the support bracket for the TBs off the plate at the rear of the starter (knew that would come in handy - most people remove it), cut the silicon and fit the bodies to the runners and bracket.

 

Then connecting fuel and electrics up to TBs & injectors is piss easy, as I've set up all the wires, labelled and ready to plug in. The slightly complicated issue is the need to increase the diameter of the TB throttle cable cam, such that it's closer in size to the Mi/6 cable cam, to help give correct pedal travel and ability to contol RPM. It would be very jumpy and twitchy as is because the bike body cam is approx half the size of what's required.

 

Guy then just needs to pop all the labelled wires in the cabin, which used to go into the MS DB37 connector into the new Emerald 36pin (different layout - 3 rows) connector. They're almost identical to the MS requirements except the Emerald is asking for a dedicated VR/crank sensor earth as opposed to a common earth shared by the other sensors such as IAT, TPS & coolant temp. This also seems to be the case for LC1, and Guy was to ask Dave Walker today how important these separate connections are.

 

As the Emerald is much more flexible too, we are adding a third, ECU controlled measure for switching on the cooling fan, which needs one more wire inside the car.

 

Then, it's GO GO GO...........we all hope.

Edited August 26, 2008 by DrSarty

[DrSarty 90 1 Cars]

Tiz ALIVE!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

 

 

Meet my mate Pronta, giving the 2.2 it's first start up. Thanks Emerald; thanks Guy; thanks PeterT; thanks QEP; thanks Anthony; thanks Miles; thanks Tom, Kyepan, Batfink, Josh, 16v205....the list goes on - thanks everyone.

 

Click Me Baby

 

Only gotta wait 2 months before I can drive it. Talk about chuffed. When I come home it should be all red (note the auto bonnet), clean, shiny and running sweetly.

 

I'm on a high, but am realistic enough to know there'll be some teething issues and maybe even disappointing RR results on mapping with Dave Walker and team. Let's hope not eh?

 

Rich - Chuffed to f*&k in Afghanistan.

 

Note to self - Don't get shot or blown up.

[Super Josh 4]

Nice one Rich, you must be as chuffed as punch She certainly sounds good Mate.

 

 

Josh

[kyepan 291]

that's got a nice lumpy tickover, sounded like a bass line from a club at one point..... th th thump th th thump th th thump.

 

congrats you must be pleased as punch.

[welshpug 1,657]

YAY! is that just on a base map and a tight newly built engine? stay safe!!

[Sandy 191]

that's got a nice lumpy tickover, sounded like a bass line from a club at one point..... th th thump th th thump th th thump.

 

congrats you must be pleased as punch.

Needs setting up

 

Glory!

[DrSarty 90 1 Cars]

Needs setting up

 

Glory!

 

Indeed it does Sanders me old mucka. And how could I have missed you out from my 'thanks' list above, as you've been one of the most selfless contributors? Cheers buddy.

 

This was the first start up, without Guy even connecting the laptop; it fired up straight from the base map. It's way too rich and the TPS hasn't been calibrated. Pronta will make it sing before long.

 

He said no leaks; got oil pressure up nice and quick and wasn't tappety at all. It's only run as long as the video clip so will be running better when he's made some tweaks.

 

Sounded deep and throaty, and I'm hoping - and I'm going to steal a line from a movie here - it's 'gonna be one bad mutha f***a!'

 

Edited September 7, 2008 by DrSarty

[Henry 1.9GTi 36]

nice one engine and bay look sweet, hope it performs as well on the tarmac. gl with the mapping.

[westy 0]

Wow, congrats Rich, bet you're chuffed.

[pronta 1]

More to follow soon . I've been playing !!!

 

wts

[kyepan 291]

More to follow soon . I've been playing !!!

 

wts

anything?

[pronta 1]

In between ducking in and out of hospital with my dad i did this.........

 

 

[pronta 1]

I swapped the tps leads about as we discussed on the phone sorted the leaking injector with new seals.

 

I have been looking for a suitable way of connecting an off board fpr and i may have a solution, but need to look further into it buit the viper will require my attention sooner.

 

I will plug the lappy into it tonight and then range all of the sensors .

when it runs it runs with a lovely little burble, its rich as hell and shtings the eyes, I'm off to buy some pipe today to shove over the exhaust to vent it off elsewhere.

the smoke from the engine is just build oil burning off, and it settling in. stinks though.

no tappety noises, its very willing on the throttle. ha ha i cant wait to get it up the road, its gonna make you really smile alot.

It sounds like it really has purpose.

 

One concern.................

 

master cylinder on the rocker.

 

I take it you have a solution for this or are not bothered about it. I personally dont like it. things should not rub on the brakes as you kind of need them. alot.

 

post here sarts.

 

G.

[DrSarty 90 1 Cars]

I have been looking for a suitable way of connecting an off board fpr and i may have a solution, but need to look further

I thought about this, and would suggest removal of the R1 FPR from the rail, tapping in a pipe take off. Then remotely locate the FPR over near the 106 GTi fuel filter, extending the vacuum hose over to it and rejoining it to the fuel return system. We know the R1 FPR is only 2.84 bar, which is less than 205/Mi standard and may well be choking the fuel system; although that doesn't add up with it running rich at the moment and secondly I don't know enough about fuel pressures and injector duty cycles to comment or advise. An adjustable FPR may be the best route to give flexibility and they're about £60.

 

It sounds like it really has purpose.

As it bloody should!

 

 

One concern.................

 

master cylinder on the rocker.

 

I take it you have a solution for this or are not bothered about it. I personally dont like it. things should not rub on the brakes as you kind of need them. alot.

Thought that might be coming. A common and acceptable fix is to remove the rocker cover and grind a bit off. I'd be happy for you to do this, as tilting the master cylinder would be a bitch.

 

Thanks for the work and video Guy. I know what you're going through at the mo with your Dad and I'm amazed you're showing such enthusiasm and commitment to getting my car going. It does indeed sound very meaty and burbly, but I'll leave comments on whether that's right or not to experts like Sandy, Anthony etc. However it does sound like it has some bollocks and is ready to go.

 

I know you're going to remake the inlet manifold, using the current 'industrial' version as a guide, but it seems the TBs plus hose plus runners are a lot longer than the advised 300mm. Perhaps that'll leave some room for shortening of the metal runners which will also ensure good bonnet clearance. Perhaps there'll be more bonnet clearance WHEN IT'S RESPRAYED RED?

Edited September 10, 2008 by DrSarty

[kyepan 291]

sounds great, and willing like you say, keep up the good work guys

[pronta 1]

red ? i thought you said i like that duck egg blue !!

[DrSarty 90 1 Cars]

Well Guy's cracking on with pre RR tune up & ironing out tiddly issues. He's doing a great job as you all now know.

 

I can't believe I'm fantasizing about driving a car! I've even made up 2 x MP3 CD's (7.5hrs each!) with my type of driving toons. Sad tw@.

 

On the phone the other day he told me he's making a new inlet manifold out of thinner metal stock, which instead of being slant cut and welded will be bent into shape using a mandrel; much like the GTi6/Mi16 exhaust manifold where the pipes mate at 90deg to the flange. (Flange ..... )

 

One thing he also told me which made us both chuckle - and could potentially result in a few more horses being unleashed - is that the inlet manifold runners were so cold, even when running, that they were condensing moisture on and were almost too cold to touch .

 

If reducing inlet temps is a good thing, then this must be a good omen. It's due partly to the injectors being in the R1 TBs rather than firing into the head.

 

I'm not sure how this effects things in reality, as I've read positive things about both mounting locations for injectors, and Sandy favoured the near head approach for that 235bhp 205 that was on sale just a few days ago. We will just have to wait and see. But Guy couldn't believe that he could not hold is hand on the runners when the engine was running. Most bizarre.

 

Injectors will be cleaned, serviced and flow tested before RR day at Emerald, just as the TBs will be balanced.

 

These are exciting times n'est pas?

 

Edited September 18, 2008 by DrSarty

[welshpug 1,657]

too damn right its exciting times Mr Sarty!

 

I found a nice solution to the master cylinder clearance yesterday, tis a bit fiddly but I unbolted the servo and ground away at the holes in the pedal box so that the whole assembly could be moved up and across a touch, then placed some small pieces of plate with holes in over the studs and tightened the nuts back down (couldn't use washers as they drop into the hole)

 

how long till you're back in the country?

[DrSarty 90 1 Cars]

how long till you're back in the country?

 

49. Not that I'm counting.

 

Nice solution to the cam cover clearance issue; maybe Guy'll read/use it?

 

There's only one solution to the 'giggling like a big kid & can't wait to drive it issue', it's called pedal mashed into carpet.

 

Oooh. On one of the walls of our delightful wooden s*itters out here in Afghanistan, someone's written an 'A-Z' of sexual positions, prompting people to write suggestions next to the letters. My favourite at the moment is for 'I': the 'inverted sleeper hold'.

 

When I drive down the M5 to drop in to see Bonzai, d'ya fancy meeting up with us Merruz? I was thinking of tying up with Rob Thomson too as he's in Weston. Just a thought.

[GLPoomobile 958]

Does Rob know you are planning to drop in? He might need a bit of time to prepare his argument if you are going to re-ignite the moon landing conspiracy debate LOL. You f***ing retard

[Bonzai 2]

 

and thats all i have to say about that!

[Mattsav 1]

It runs at last

[16v205 9]

Awesome Rich, ive just re-read this thread from way back and im really pleased youve got it up and running If you want some emerald maps give me a shout and ill email you mine.

 

Rich