[engine_work] Project Sarty

[BusEngineer 7]

Grey speedlines hey!!! I wonder where you got that idea from in a pub car park in manchester!!!

 

Im sure iv seen that idea before <<<<<<<<<<<<<<<<<<<<<<<<<<<

 

[kyepan 291]

get c5 alloys they are the magic cure all to handling

[DrSarty 90 1 Cars]

Alternatively, stick with crappy TSWs and remember to put everything back on the car you took off.

 

THEY'RE STAYING THE F*CK ON YOU LOSERS!!!!!

 

[Rom 0]

Lol.

 

Glad to see you sorted out the issues.

Ill have to drag my sorry ass along to some meets at some point. Reading about yours guys antics provides lots of entertainment

[DrSarty 90 1 Cars]

Rom>

 

Bonzai and I are going to make a regular thing of Cardiff antics, so I can meet you and other Bristolites before or after I cross, OR you lot can flash £5.30 and pile over the bridge with me into sheep 'dip' land.

 

Next time we could meet up with Spiky perhaps and other Welsh puggers who didn't come to the last meet.

[Rom 0]

Id definatly be up for that mate.

Ive only been to wales once, and it was a flying visit in the middle of the night

Guess i could give it another go.

 

Ill try and keep my eyes peeled in the meets section.

[DrSarty 90 1 Cars]

Well I'm now down in Oz, complete with my Mi inlet cam ready to meet PeterT on Monday and do an exchange/business meet, over a beer (or two) naturally. I'll start a Slut Adventures thread soon to show what I'm up to down here, as it's already been an adventure.

 

As for the project, the homemade inlet manifold went off to Eeyore and Sandy, along with the R1 bodies a few days ago and has arrived safely. We already knew an improved set of inlet runners was coming, but now we've upgraded from the 40mm R1 ITBs to new 46mm jobbies, as their mutual consultation has concluded we were most likely starving the poor 188lb.ft / 196bhp engine. It was under-pushed anyway the engine; let's face it.

 

So Colin & Sandy will design and manufacture this fuelling and inlet system (to include the staged XU7JP4 injector sets) to compliment the inlet (stage II) and exhaust cams (stage I) to take advantage of more duration from the cams to unleash more than likely what this Frankenstein of an engine is perhaps capable of. Only mapping will say.

 

[EdCherry 34 1 Cars]

Sounds f***ing amazing. Loving this thread.

[roland rat 11]

Just taken me 4 hours to read this thread from start to finish and all i can say is OMG!

 

Dr S i take my hat off to you and all the members whom have got the car to this stage,what an awesome project and build thread!

 

Let me know next time your in Wales and i'll bring my Supercharged GTI-6 along for a leisurely jaunt

[DrSarty 90 1 Cars]

Thank you Roland. I think it's getting better too.

 

Would love to see you next time I'm in Wales, as Bonzai and I are pretty good mates.

[Ron_Jaegers 10]

DrSarty, since I am planning on building a similar spec'ed engine as yours I was wondering what the exact specifications of the pistons are. By how much have you changed the gudgeon pin. Since it are still S16 pistons can you use the small end bearings from the S16? What kind of big end's do you use?

[magic 1 1 Cars]

This is DrS at Magic's house in Brisbane .

 

I'll have to ask Matt Saville at QEP for you my friend.

 

I've been discussing my engine amongst many others with Magic today (and he is certainly a fan of Mi/S16/GTI6 hybrid, larger displacement engines BTW) and he's raised the issue of S16 rods (big ends) matching the journals (without modification) on the 2.1 DT crank. Now I'm pretty convinced Matt didn't have to do any extra work, as I only remember him mentioning some work on the small ends to make them work correctly with the gudgeon pins. As for the new gudgeon pin height, I can only assume QEP did some dry, test assembling and measuring based on the cam I provided to ensure adequate starting valve to piston clearance was achieved.

 

QEP are building/have built a few of these 2.1 - 2.3 hydrid engines now and I'm sure Matt would be quite approachable, providing he got a little business out of it.

 

My pistons are Wiseco by the way, who I've since learnt are made in Asia to keep costs down and profits up I guess, and were I to do this again I think I'd choose Wossner (sp?) as I suspect being made in Germany will be of better overall quality.

 

One of Magic's favourite N/A engines to date has been his 2.1, made with S16 block & head but Mi16 crank to up displacement. With Wossner standard 11:1 pistons, a block deck, head skim and pretty wild cams running 12.4:1 CR, he's had masses of torque from really low down, a smooth idle and 260 BHP from a 7,500 limited engine. He also has 45mm bodies on 8 staged injectors and a Haltech ECU with LS1 coils (like mine) .

 

Let me know if Matt doesn't reply and I'll ask him for you.

Edited December 22, 2008 by magic

[B1ack_Mi16 67]

I'm pretty sure S16 rods have ~24mm ish wide big ends as it has the standard cast crankshaft.

 

All the forged crankshafts though, like T16 and XUD11 (2.1 TD) have ~26mm ish wide big ends.

At least this is what I've found out after measuring some of these engines..

[monty69 6]

Does anyone know the ew 2.2 crankshaft big ends width?

Edited December 22, 2008 by monty69

[DrSarty 90 1 Cars]

In which case then perhaps I misheard/misunderstood Matt, and this is the modification he had to make (at the big end) rather than at the piston end. My engine build was 2,400pounds (no pound sign on Magic's PC) which was more than just assembly on several counts, such as this mod, the valve work, rebore, deck/skim, pressure test and the machining to make the DW8 pulley fit & rotate freely on the inlet cam.

 

The latter means a little more work will be needed to fit the second DW8 to the exhaust cam.

 

I've also never considered solid lifters, but am pondering the idea of even more cam, i.e. stage III inlet / stage II exhaust, as it seems I still may not be liberating the potential of this capacity engine with this planned cam swap.

[DrSarty 90 1 Cars]

Buck me fackwards with a stick: 31,000 views!!!!!! OMFG.

 

Well after my trip to Oz, Colin Satchell aka Eeyore produced the goods as ever. What a designer and fabricator.

 

Behold my new 46mm throttle bodies and new inlet manifold:

 

 

...and fitted:

 

 

Me's a like. Thanks Colin.

 

The bodies are inverted which hides the (currently unused) outer fuel rail and injectors, which won't come to life until all of the injectors are lower flow

XU7JP4s. So still to happen is the cam swap (as per my sig), the staged injectors and associated complete remap with good 'ol Dave at Emerald. I think we'll see some serious figures then, before the Eurotrip .

 

I think it's still running a little rich, which is totally based on the first mapping session with Dave at Emerald being with almost a different engine, which means truthfully it's not really mapped correctly now. Bonzai and I are going to have a little play on Monday (after the Welsh meet) although it runs just fine.

 

It's getting more air in now due to larger bodies, and the inlet is so much better shaped, but this means of course 35% throttle on the 40mm bodies was letting through less air than 35% on the new ones, so effectively it could be way off. And also bear in mind the old inlet had the injectors on the mapping day in the bodies themselves, whereas now they're firing straight down onto the backs of the valves.

 

It sounds different again now too, although it still goes like stink.

[Peetypug 5]

lookin good rich

when can i cast my beady eye over those beautys

[DrSarty 90 1 Cars]

lookin good rich

when can i cast my beady eye over those beautys

 

Thanks. Tomorrow if you like?

[pip470 61]

That looks very nicely made, What a nice pressie to come back too.

[welshpug 1,657]

has it got that throttle body bark now Rich?

[DrSarty 90 1 Cars]

has it got that throttle body bark now Rich?

 

Errm, still no really. Runner length maybe? No trumpets (yet )?

 

As SuperJosh said, 'it sounds like a f*ckin' spaceship' . I can live with that though.

 

See you Sunday Meirion.

[maxi 36 1 Cars]

Rich, I really think you are insane to drive this engine unmapped. Anything could be going on in there and potentially you wouldnt know about it until too late. Dont want to see all that hard work destroyed mate.

 

Maxi

[Peetypug 5]

Thanks. Tomorrow if you like?

 

yeah thats fine

 

i'll get the bacon butties on for lunch

[Tom Fenton 1,541]

I agree with Maxi, if these new bodies are flowing more air than the old, (which hopefully they are or else you wouldn't have changed them) then it could well be running lean, coupled with an advance curve tailored to the old stuff COULD mean you really are on the edge. I'd stick to below 4000rpm or better still don't drive it at all.

[DrSarty 90 1 Cars]

Sound advice Tom & Adam. Thanks.