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Veteran
Posts: 376
 
| If this is at castle combe on 6th of July I'll be there. Looking at the pics its tight as it gets in the bay but all looks like it belongs true bit of engineering, tap on the back well done |
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Expert
Posts: 2029
Location: sittingbourne, kent | Love it, looks awesome, looks like a very tidy shell too |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | Ians r100 gta vvc - 25/5/2013 11:11 PM
If this is at castle combe on 6th of July I'll be there. Looking at the pics its tight as it gets in the bay but all looks like it belongs true bit of engineering, tap on the back well done
The block is actually @ 20mm shorter than a 'K', but with the adapter plate, is not far off the same.
the tight bits is mainly the turbo actuator arm on the turbo under the 'shelf' and downpipe space between
the frame and the jackshaft, and the ex manifold near the servo, otherwise its prob a bit better than a
'K' due to the engine sloping back which gives more room behind the rad.
I'm deffo aiming to be at Combe, I missed going last year.
Edited by Dave 20VTRO 26/5/2013 7:23 PM
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | Some pics of my rear turrets I did @ 2006
The hole is where the bolt secures the top of the subframe using the thick nylon
spacer shown.
Lower shock mounted through centre of hub, and ARB droplink using brake backplate
bolt drilled out to accept 10mm bolt, same as droplink bush. Also I made adjustable
bump platforms maidway along the radius arm.
Edited by Dave 20VTRO 26/5/2013 7:42 PM
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | Had a gearbox whine, I think its the final drive, so the box is coming out and also
upping the fd from a 3.9 to a 3.6, so 2 birds with one stone. |
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Nutta With An Orange Grille
Posts: 5280
Location: Who put that pit there keep falling down :( | Those mounts are no where near strong enough the spacer needs to locate into the arm ant the bolt should be m14 believe me I've been there |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | muzza - 16/6/2013 7:15 AM
Those mounts are no where near strong enough the spacer needs to locate into the arm ant the bolt should be m14 believe me I've been there
I know what you mean, the spacer is a nice snug fit into the arm , plus, so far its been ok, @ 2006 it was all done
and no probs yet, bear in mind, the car is lighter than a roadgoing version, I would expect the bolt to bend a bit
before failing.
Update on the gearbox: box is out and stripped, there was wear on the crownwheel teeth through the case hardening,
so hopefully that will be the noise as everything else looks ok, just got to re check endfloats of shafts etc, fit
the 3.6 final drive, then drop it back into the car.
Edited by Dave 20VTRO 16/6/2013 6:11 PM
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Nutta With An Orange Grille
Posts: 5280
Location: Who put that pit there keep falling down :( | Ahhh I see il post some pics up if I can find them anyway lol |
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Veteran
Posts: 459
Location: sittingbourne, kent | Awesome build mate, can't bare to think what putting your foot down feels like lol |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | Update on the gearbox, It was the crownwheel making the noise, on closer inspection, the
centre of the teeth contact area was badly worn almost through the hardening surface, the
noise was a loud whine related to road speed that would need ear defenders, I hoped that
it was the crownwheel and not the pinion or diff bearings, as I had fitted steel caged ones
and a new uprate pinion bearing. Also the gearing has been raised from the 3.9 to a 3.6
final drive, the car has enough torque to make it go really well now, plus I dont keep
going for 6th gear, 5th gear is now @ 22.5mph/1000. |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | Ians r100 gta vvc - 25/5/2013 11:11 PM
If this is at castle combe on 6th of July I'll be there. Looking at the pics its tight as it gets in the bay but all looks like it belongs true bit of engineering, tap on the back well done
Just booked the ticket, £136 as a non RS club member. Bring helmet!!
The car tramlines left and right a bit, prob the tyres!!, Dunlop 185/55.
Been 'exploring' the boost curve It swings from 0.6 bar to 1.5 bar
when accellerating, tried it without the boost valve and it boosts to
0.6 bar a stays there, tried a couple of different boost valves, no joy.
may plumb boost signal from inlet compressor housing instead of currently
off the inlet manifold, and mount the MAP sensor a lot closer with a shorter
hose to the inlet manifold, I'm hoping that the surging boost is due to the
hose lengths causing a delay between the map sensor getting a signal and the
wastegate solenoid getting a delayed signal, Its not a missmatched turbo. as
this is the turbo fitted to this spec engine ,(K04), I'm just upping the
boost within the turbos capability. |
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Elite Veteran
Posts: 763
| surging boost is usually caused by the wastegate having too much pressure . on the diesel tdi golfs me and my mates had in the past ,if you upped the boost by altering the wastgate arm it used to have a negative effect on the electronic boost control and flet like it was coming on boost and dropping off boost. the way i got around this was to use the bleed valve before the boost solenoid to fool it into thinking that it was opperating within its normal parameters . if your only wanting to run standard boost then i would think that the waste gate is set too tight or the boost solonoid could be faulty i think it is called an n72 valve and there is quite abit of inf on upping the boost without mapping the ecu act |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | Sorted the boost problem, The boost solenoid I was using was the wrong one, it didn't work
the way I thought it did, I thought That it opened the 3rd port to atmos to make the bleed
but it just shut the 2nd port that went to the wastegate, I fitted a valve that did as it
should, ie have a restriction from the 1st port(plenum) then open to the wastegate (2nd port), the 3rd
port then opens to atmos for the bleed. Took the car up the road and it did the surging but
from 1bar to 1.5 bar this time (an improvement over 0.5 to 1.5 surging). knowing that this
was now the right valve, I had a look at the wastegate map, The duty cycle was 94% Fully open-max bleed
then at the max boost point it was zero%, I reckoned that this was too sharp a shutoff, so I mapped it
gradually down to 25% at the zero point, so I put in 94%, 75%, 50% then 25% as the boost went up, now
it hits 1.5 bar max, the stays there. I will take a better look on Sat when its on the dyno, its easier
to do than trying to look at a screen and drive at the same time.
Will also have a look at part throttle fuelling and ign, as its only doing 30mpg. |
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MP Admin
Posts: 17870
Location: Gloucester | That is a work of art, great to see something different!
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Expert
Posts: 5629
Location: Letchworth/Basildon | Awesome, that's all I really have to say  |
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Veteran
Posts: 376
| Dave 20VTRO - 22/6/2013 11:10 AM
Ians r100 gta vvc - 25/5/2013 11:11 PM
If this is at castle combe on 6th of July I'll be there. Looking at the pics its tight as it gets in the bay but all looks like it belongs true bit of engineering, tap on the back well done
Just booked the ticket, £136 as a non RS club member. Bring helmet!!
Ill be there aint got helmet thou ?  can not wait to get a look around this |
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Regular
Posts: 126
| I will be t castle coombe too this weekend will say hello if i see you guys |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | Got me ticket for Combe, just hope the car doesn't blow up on the dyno tomorrow. |
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New user
Posts: 7
| Mate i take my hat off to you i fort ov the idea years ago but never tryed it insted i put the engine in my polo,,who did you get the bell housing addaptor plate from if you dint mind me asking |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | bantan45 - 20/10/2013 4:35 PM
Mate i take my hat off to you i fort ov the idea years ago but never tryed it insted i put the engine in my polo,,who did you get the bell housing addaptor plate from if you dint mind me asking
Cheers,
The adapter plates are made by Reyland Motorsport, You will also need a MG ZS RH driveshaft as there is not enough
room for the inner pot joint and the block, but it seems some of the racing Elise guys have got around this by
machining the block to give clearance. |
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Veteran
Posts: 482
Location: Meuspath | What sort of power is this putting out? |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | Tracktro - 21/10/2013 6:36 PM
What sort of power is this putting out?
I've been a bit quiet on this front for a while as the initial dyno mapping threw up a problem
that has restricted the bhp, namely that the intercooler I had fitted was not doing a good enough
job, we were seeing intake temps @ 55+deg at 0.75 bar, we were hoping that it should've been @ 40 deg
steady temp, so we left it mapped at 260bhp untill I have a better I/C fitted, I have fitted a bigger
one now,(@ 2x the volume of the original I/C), but I have had to wait untill Reyland has a slot to get my
car in, the only other problem is that on previous engines of this spec, ie Audi 20vt fitted with a
big valve head have produced 'only' 260-278 bhp, I did a bit of digging and found that the small-port
head would produce 300bhp, this has been proved by Reyland setting a customers car up with this spec
of engine and hitting the 300bhp, the power comes in a lot earlier and there is more of it, more info
gathered found this is due to the small-port head having a higher port velocity and works well with
the K04 turbo. The big-port head I have would come into its own with a better ex manifold and bigger
turbo. Although atm at 3700 rpm with the big-port head, its putting 200bhp on the road I will see what
the setup with a better I/C and more boost (@ 1.5bar) will give me a bit later this month with a bit of luck.
Edited by Dave 20VTRO 20/10/2013 8:59 PM
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New user
Posts: 7
| So how did ya go about wireing it up?? Is it on oem or aftermarket management??
Also what's it like for sump clearenace |
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Elite Veteran
Posts: 925
Location: Thinking of vvc'ing my Roadster Brabus :-) | bantan45 - 22/10/2013 5:02 PM
So how did ya go about wireing it up?? Is it on oem or aftermarket management??
Also what's it like for sump clearenace
Its on Omex 600 management, I made the engine loom as the only bit that was OEM was the injector loom as rover
do one that links injectors 1+4 and 2+3 for batch firing that suits Omex 600. There was no point trying to modify a
whole loom because of the different positions and plugs for sensors, none of the loom goes around the back of the
engine as the exhaust is there, so all the loom goes from under the heater blower, the cyl head and around the
front/under the inlet manifold, plus I had to wire in boost control, 2 wire idle valve, oil temp/pressure, map sensor
etc. I've made the loom using a rover MFU which is inside the car with the ecu and inertia switch. The MFU uses the
main relay, starter relay, Oxy heater relay and a relay for the cooling fans. The fuel pump was done by using the
(now) redundant heated rear window circuit as it has a switch, fuse, relay and heavy duty wiring already in, I only
needed to unwrap the wire from the back of the car to the fuel tank in the middle of the car, as the tank is inside
the car. Sump clearance is about the same as the 'K' sump, its the same clearance as the subframe lower cradle height.
The exhaust is a 3" s/s system with 3 silencers, I wanted a quiet system to pass trackday noise testing, it tested at
Castle Combe at 85db.
Edited by Dave 20VTRO 22/10/2013 1:51 PM
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New user
Posts: 7
| Ok am with you so all simple seen as your using a aftermarket ecu,,also I take it reyland sorted you out with the flywheel aswell??
Top man thank you for your time and quick replys |
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My R100 1.8 20vt
