[engine_work] Project Sarty

[kyepan 291]

well done to everyone involved, rich you must be very happy after the long wait.

 

This setup seems perfect, agree that you should leave as is.

 

Cheers

 

j

[GLPoomobile 958]

Tunnel tunnel tunnel!

 

Wonder if I could borrow a camcorder from Argos for the day? LOL. If not, I'll bring our crappy compact snapper to take some low quality vids.

[tom_m 0]

job done! now get out and enjoy it

[jimistdt 1]

Well Done Rich, you got what you were looking for! Bet its shedloads of fun, good work, time to enjoy

[DrSarty 90 1 Cars]

I just realised, I was always lost in Australia when they referred to Newton Metres (Nm) instead Foot Pounds (lb/ft) for torque.

 

So for them and any other metric person:

 

196.1 pound foot = 265.9 Newton meter

 

I'm still going to upgrade to a 306 master cylinder, and in the summer after the EuroTrip, I'm gonna have the engine out and have JP Engineering make up a new mild or stainless exhaust system. I'm 90% certain I'm gonna wang the stage II cam in as was originally planned just for fun, and then have a final remap to perhaps top that 200lb/ft torque goal, but also swing the power a little higher up the rev range and make a true 240-245BHP.

 

The staged injectors I'm still unsure about, but we'll see.

 

Then I will definitely call it quits.

[happygoron 2]

Very nice! I definately have to blag a ride when you next come to wales, that thing looks an animal.

 

Hope you're getting the wheels sorted too!

Edited February 10, 2009 by happygoron

[DrSarty 90 1 Cars]

Very nice! I definately have to blag a ride when you next come to wales, that thing looks an animal.

 

Hope you're getting the wheels sorted too!

 

Using smaller fonts doesn't fool me.

[James_R 3]

Nice result, enjoy it

 

start saving for tyres, can see it eating plenty of them with that much power pulling them about

[platty 1]

Hope you're getting the wheels sorted too!

 

Nice attempt at subliminal messaging

 

I think we need to be more subtle though

[carbers205 1]

What a disaster, 4 torques shy of the target, you must be gutted. And still sporting those dreadful wheels.....dunno how you can still show your face round here!

 

Seriously though Rich, great result, I know the feeling you get when your own creation gets up and running (though Im sporting about half as much power and torque!)

I can also tell how much you've learnt through doing this process and thats just as valuable as the end result.

If you're ever in or around the Yorkshire area it would be good to experience the beast first hand, though at this rate you'll be doing a tour of England just to show the car off!

Congrats again

 

Andy

[DrSarty 90 1 Cars]

Pics & video of mapping session tonight I hope, as I've read that my Casio camera can produce video unplayable on anything but itself.

 

Thanks for the kind and generous comments everyone.

 

I would recommend this style of engine to anyone. Iron XU 10 blocks and diesel 406 cranks are plentyful, so with:

 

£100 on the above 2 items

£700 on pistons plus rework

£200 or so (that's a guess) on rebore, reface and skim

£500 on bodies and inlet

£650 on ECU, £350 on map/set-up

£10 on a standard 106 coil pack

£100 on a new inlet cam

£700 on a diff

£100 on head set and bottom end bearings

£400 on an exhaust system

 

and with you doing assembly, lifter refurb, valve grinding/lapping yourself providing all the rest of the car is sound and you have alternator, oil cooler, rad etc etc from donor engine(s), you can achieve what I've toiled over for less than I paid by not making the mistakes I made, for ~ £3,500.

 

To put that in perspective, if you find a £500 1.9 GTI to start with (due to driveshaft donoring & arguably better brakes - and this is possible at £500, particularly if the engine's blown) - that's £4,000 for ~ 270BHP per tonne fun fun fun.

 

My mate's E46 BMW 330ci M Clubsport has 153BHP per tonne!! Admittedly, bags more comfort, but this is now some seriously quick (and comfortable in mine) motoring. You'd go even quicker if you didn't have my carpet, leathers, stereo system, sun-roof. Christ...you'd get into space .

Edited February 10, 2009 by DrSarty

[projectpug 0]

Awesome result i would be grinning like a cheshire cat . Your engine in a properly setup/lightened track 205 would be absolutely amazing! Would be way over 300 hp/tonne!!

[GLPoomobile 958]

Then I will definitely call it quits.

 

Aye, that'll be right You know what they say about projects never finishing

 

Hopefully it's got enough torque now to spin the TSWs in to oblivion, never to be seen again

[kyepan 291]

£4,000 for ~ 270BHP

 

240/0.895 = 270BHP per tonne

196.1/0.895 = 219LBS per tonne

 

the old pulsar GTI-R was 295BHP and 235lbs of torque @ 1.0 bar of boost.

 

290/1.25 = 232BHP per tonne

235/1.25 = 188LBS per tonne

 

Now, the pulsar was devastatingly quick and would obliterate most things, if you can get the power down, you'll be even quicker. In gear 3rd and 4th gear overtakes were quick safe and decisive, i'd imagine this will be a pretty purposeful a road blaster.

 

J

[hexhamstu 9]

you got any track days planned? you going to come over on the 20th? or maybe come over for the llandow track day?

[GLPoomobile 958]

240/0.895 = 270BHP per tonne

196.1/0.895 = 219LBS per tonne

 

the old pulsar GTI-R was 295BHP and 235lbs of torque @ 1.0 bar of boost.

 

290/1.25 = 232BHP per tonne

235/1.25 = 188LBS per tonne

 

Now, the pulsar was devastatingly quick and would obliterate most things, if you can get the power down, you'll be even quicker. In gear 3rd and 4th gear overtakes were quick safe and decisive, i'd imagine this will be a pretty purposeful a road blaster.

 

J

 

Bet it wouldn't beat a standard Fiat Coupe 20VT though. Once they get in 3rd gear the earth starts to spin in the opposite direction...................................alledgedly

[welshpug 1,657]

oh bugger, I have a spare 2.0 MI engine...

[petert 586]

Superb result Rich and well worth the wait. I have to admit I'd be happy enough to leave it as is, if it was me, given the additional expense of changing cams and remapping. Although the next session will just be a fine tune and shouldn't take anywhere near as long. You're right in predicting the power peak will move, probably to around 7200-7300. I doubt you'll notice any loss in bottom end torque however!

[hexhamstu 9]

oh bugger, I have a spare 2.0 MI engine...

 

do it.

[DrSarty 90 1 Cars]

Before I forget, I've photo'd most of the project, so here's the last bit fitting the trumpets and ITG filter.

 

FYI, I remember joining this forum some years ago, and seeing project threads with ITBs (DreamWeaver's springs to mind), and being over-awed, gob-smacked at what people were doing. It was a whole new science to me. I thought "I'll never do that; I wouldn't know where to start."

 

It's amazing how much knowledge you can acquire if you participate in this forum AND get stuck into the work yourself. How time flies too.

 

This was my first cardboard template based on the dimensions of the ITG back plate (JC_ITG50) which comes with no cut-outs.

 

 

 

I drew in centrelines, and offered them up to the mouths of the bodies and drew around the ITB barrels, then cut out the holes with a scalpel and they slid over the trumpet shafts, which then push fitted into the ITBs. I measured twice and cut once, which is always best.

 

 

 

I had to remove the outer fuel rail because it fouled a little with the back plate - but it looks like this won't be a problem as the 2nd injector set idea is shelved for now - and Dave at Emerald turned up some ally bungs to blank off the injector holes in the bodies.

 

 

 

I then moved the centre line of the holes up nearer the top edge to reduce bonnet clearance issues......(more on that in a mo)

 

 

More in a mo and then some of the Emerald mapping day and a little video.

Edited February 11, 2009 by DrSarty

[DrSarty 90 1 Cars]

It was nerve wracking cutting into £25 worth of backplate, but I'd checked so many times, offering up the metal plate and drawing on that too. I had to buy a £20 hole saw & arbor, but luckily the lady in the hardware shop charged me £8 under...which was nice. 51mm by the way for 46mm bodies with trumpets is perfect.

 

 

I mounted the plate with the Dzuz fasteners on the underside for tidiness and more bonnet clearance issue prevention...(hmmph - see later)

 

 

 

And you should be able to see how the trumpets butt up very close to each other and are off centre.

 

 

Getting the cap head screw holes drilled out accurately was a bitch, as they aren't straight through the trumpet lip. I got it done though, but with some holes more like ovals than circles.

 

 

Then, using a dead-blow hammer and a doggy plastic chew toy (!), I tapped the trumpets in for a tight, friction fit.

 

 

Bonnet strengthener clearance looked ok....

 

 

But it wasn't. So Pronta attacked the bonnet underside with an angle grinder. Job jobbed.

 

 

Edited February 11, 2009 by DrSarty

[GLPoomobile 958]

Rich, dunno how to breaqk this to you mate.....but, errr.........somebody's run off with yer radiator

[DrSarty 90 1 Cars]

And finally (probably), here are a few shots and some footage at Emerald yesterday.

 

 

Grubby bugger

 

 

 

 

What's quite funny in this clip is the speedo needle. Well it seems funny to me, leaping up as it does early on when Dave's only touching the throttle.

 

 

Some of these videos won't be too exciting to many/some, but they are just to show what goes on at a mapping session/rolling road if someone hasn't been.

 

The first (and only) power run you see was the first run. The top right, green numbers are horsepower at the wheels. This was before we lashed the car down as it was wheel spinning. I doubt very much that the sound will do the occasion justice, but you get the idea.

 

Thanks for being with me on this journey.

 

THE END

Edited February 11, 2009 by DrSarty

[Bonzai 2]

after reading up on the theory, its ideal to have a deeper filter than youve gone for. I understand and appreciate that compromises will be made eventually, but it could be hampering you induction slightly having the foam so close to the trumpet mouth's.

[DrSarty 90 1 Cars]

after reading up on the theory, its ideal to have a deeper filter than youve gone for. I understand and appreciate that compromises will be made eventually, but it could be hampering you induction slightly having the foam so close to the trumpet mouth's.

 

Well Colin said 50mm would be fine, and ITG's own website gives clearance guidelines and claims the ITG50 is good for 300BHP.