DJ Wilmas 111S S2 T series 400bhp Elise

[Hugh Jarse]

Great progress.
Not a sensible idea but thought id share....it would be cool if you could drive the superchager off the balancer gear.

[djwilma]

Could be done but would be a nightmare as he balancer shaft sits in the sump, so additional heat and getting the air in and out etc

Other issue is I don't have a supercharger

[chuntington101]

djwilma said:

Other issue is I don't have a supercharger

What sort of excuse is that? Lol you could have the first supercharged / turbo'ed duratec Elise! Lol if you hooked it up right you could even do aVW TSI type setup!

[djwilma]

chuntington101 said:

What sort of excuse is that? Lol you could have the first supercharged / turbo'ed duratec Elise! Lol if you hooked it up right you could even do aVW TSI type setup!

Its an ecoboost

Plus i should have enough torque on tap low down that i dont need a supercharger, but i have looked at the TFSI setup simply clever

[chuntington101]

djwilma said:

chuntington101 said:

What sort of excuse is that? Lol you could have the first supercharged / turbo'ed duratec Elise! Lol if you hooked it up right you could even do aVW TSI type setup!

Its an ecoboost

Plus i should have enough torque on tap low down that i dont need a supercharger, but i have looked at the TFSI setup simply clever

Sorry I meant ecoboost! Yeah the TFSI is pretty cleaver. Also have a look at Norris designs supercharger system for the EVO. Think there version 3 is going to be very similar. Interesting but like you say, probably no point in your car!

[djwilma]

These just arrived too so I am happy with that


Also the 2.3l crank has arrived, the joyous moment. The last piece (hopefully and may of said that before) of the puzzle




I was so happy when I dropped it off at Tech1, but Paul wasn't as chuffed. He is normally smiling when I drop something off and his body language was terrible. Long of the short is he and his business partner have decided to part ways and he will be closing the work shop

bks

Good news is he will build the engine for me, this I didn't want to take elsewhere and he has a workshop at home and will finish this. When, was the next question and Paul smiled.

So I now have to find someone stupid, sorry enthusiastic, enough to take on a project half done. I may of found someone but if anyone local knows of anyone (I don't) I would appreciate it.

I'd like to do it myself but don't have the time, or the mechanical know how to make the engine mounts and so on.

I think someone is trying to tell me something, and I think its don't give up

[djwilma]

Some more goodies have arrived courtesy of Speedp3rform6nce, cant praise these guys enough for their support and knowledge

This time its the auxiliary fueling systems, i did want the JM manifold but its taking too long and as i am only going for 450bhp SP advised this kit would be simpler, easier and perfect for what i need. Apparently the std inlet flows pretty well and its also light.

The reasons for this kit are two fold, the GDI engine needs a High Pressure fuel pump(above 200bar) and these run out (depending on who you talk to) at around 350bhp, the injectors run out not far after(depending on who you talk to). Uprated injectors are available but and they need more flow. The 2.3 has 4 lobes, the 2.0 3 lobes, on its cams and a different High Pressure Pump but it was a nightmare to change to this. There are some upgraded pumps, but these cost a fortune and are untested at the RPM i want to go to (saying that the std one is too). This kit has an inlet adpator plate with 4 injector holes, and 4 bottom plugs if i want to run meth/water (which i dont). Injectors are 640cc which are big but they are std FoMoCo for ease. Also combined, ported and direct, i should be able to run about 750bhp (which i wont, yet, maybe, possibly, shouldnt do).

Sounds complicated but Specialist Components already have the software to run both port and direct injection already (so i wont need the additional controller), and most High Power GDI engines, like the Mercs, run both port and direct.

Issue will be with the mapping but i will send the engine back to Specialist Components as they have probably the most experience on these engines in the UK, so need to get an exhaust manifold making and hoping Maniflo in Salisbury can help.

I have also found someone stupid enough to take on the engine mounts, and they are local ish, so having a ready mapped engine will make their and my life easier.

The Complete Kit


The Inlet adaptor


FoMoCo Injector, which is a bosch item


Additional Controller that i dont need

[djwilma]

Engine is being built, all parts fit......so far

[djwilma]

So progress at last, Engine builder got a new job (after needing a break) and engine was in one place and tools in another

Anyway a month later the three of them got re-united and the engine is being built (again)

Issue i had was the Main Bearing studs, the OEM items are stretch bolts and once used you need to measure the stretch and then change the torque accordingly, so i rang Speedperf6manc3 and asked what this should be. The ever helpful, if busy, Pablo explained that i needed to fit ARP bolts.

Next problem was searching for the correct bolts, ARP catalogue number came up at £270 and no one in the UK had any, and they were 6 weeks delivery. Rang Pablo again, and asked him to ship some. Turns out the ARP bolts for the 2.3MPS DISI engine are the same as the ECOBOOST, and £175 ! Luckily i found a supplier in the UK, who also sent sweets with the delivery.....





Pauls managed to fit them this week and cams are next



Cams are on lifters as per the Duratec but they are not shimmable, instead the buckets come pre-sized. Great idea but Paul needs to fit the cams check the gaps and then order some buckets.......more delays ffs

Good news on the cams, i decided to fit the full blown 12mm lift cams capable of 650bhp and 8000rpm........just need a bigger turbo, chargecooler, radiator, bigger tyres, more cooling and the head porting.........hmmmmm

[e8_pack]

Great read, hope this engine works out. Get the feeling there will be a lot more fettling to come!

[djwilma]

e8_pack said:

Great read, hope this engine works out. Get the feeling there will be a lot more fettling to come!

i agree but we all like jiggery pokery

Well its Christmas soon.......

Engine progress is slow, the last (please for the love of god) challenge is the cam followers. Ford in their wisdom made the ecoboost (like the duratec) with mechanical followers. They then made cam followers "un-shimmable" so you have to buy the correct followers shimmed accordingly.

Luckily i only need three, and these have been ordered direct with Ford

Then the engine needs building and dressing, flywheel, clutch and gearbox then ship it off to get a manifold made then off to get dyno'd

1. nevergiveup

[djwilma]

Well New Year, New Engine !

Its finally been built, well almost the flywheel, clutch and box need to go on and the gearbox.

Engine with the external oil filter bracket and PCV delete and breather



Without the inlet fitted



With the new auxillary fuel manifold, basically a spacer with ports for 630cc injectors and ports for meth injection




Engine Fully built




I then need to make an exhaust manifold adapter (engine has on internal exhaust manifold) which needs to have an external wastegate something like this



If anyone can make one for me let me know as the USA is the only place to get them and they only sell them as kits with upgraded turbos ffs

Worst still Garrett have released a GEN II GTX2867R which would be perfect for this engine, the current GTX2867 will run out of puff above 7500rpm.........and the internals are not interchangeable

However good and bad news, the tartan carpet has gone and we now have Brimstone

[djwilma]

Had a mad thought today as i realised i havent fitted the custom flywheel, helix clutch (Rover T series) and gearbox (PG1 but C4 u spec) all together

Good news is it all fits, gearbox input shaft meshes with the clutch friction plate and everything seems to be ok

Obviously wont know its all perfect until its in and i have pressure on the clutch. But the signs are good

Good news is the engine is now pencilled in for the dyno with specialist components, and i have found a nice man to make the turbo adaptor. Plan is to have one made in stainless steel, to the best guess, get the engine dyno'd and hope it fits when the engine goes in. Then make one out of inconel for the long term.

[djwilma]

Today is a good day

Custom dash is nearly ready and i was asked if i wanted a custom screen so i got a pen and a fag packet and drew, like a 5 year old, what i'd like on the back.

a few weeks later and this is what has been done, at startup the 111ST logo is shown on boot up (not for long but if first boot it takes a few moments longer i am told), at the redline the welsh dragon appears in the middle (something the designer and I share heritage from so seemed apt and its a dragon !!) and the third and last screen is as per my request. 1st is copy of std dash, for road use but all the parameters shown on 3rd screen (track screen) can be show also on the 1st screen.

Oil pressure gauge is duplicated a few times but will be replaced with air temp, battery voltage and something else.

Its all plug and play with the analogue inputs, fuel etc and plugs directly to my ECU and will show all parameters it does.

Could not be happier, and i cant thank Alex enough for doing this


https://youtu.be/rBSeaTqIS0U

[djwilma]

So today i have the, first production dash fitted to the car and wow....just wow....i mean like wow

First off was the box


Then the contents, the dash on the top and the wiring below




I've spoken to Alec about how to control, and whilst you can use the trip reset and indicators he asked if i would like a small joystick for moving around the dash, i said yes a small discreet one with a push button so he supplied this. Idea is to have it mounted on the dash or just use it when you need it and plug it in



Next was fitting it to the standard mount


The original dash was taken out a few months ago and sent to Alec so fitting the new dash took about 30 mins




Fit and finish are pretty damn good and the graphics are awesome, the dash can take up to 6 screen designs (one of which i designed myself and Alec made for me), and then the 7th is the data logger


Took some photos, from afar, sun light was straight ahead but not direct sunlight but the dash was more than bright enough





https://youtu.be/qGOj5vBujCg

Overall very very happy and it has more features that you can shake a stick at, everything was plug and play and worked

However i dont have an engine in the car, so couldnt test drive it

[djwilma]

Finally getting the manifold made, this was the first attempt. I didnt like how much it stuck out and how the turbo was rotated



So second attempt looks a lot better

[djwilma]

I now have the engine at home, I need to add in some oil and water pipes to the turbo and tidy up the breathers



JEK Fabrications made the exhaust manifold, oil return and also the brace which is rose jointed to allow movement due to heat.





I have also looked at the PCV breather and added in an oil pressure sensor (only comes with temp as std) and I need to seal all the joints



Then I need a TMAP sensor, Lambda sensor and stuck whether I ship it back to Specialist Components for mapping (where their normal dyno has a long waiting list) or book it in to make the engine mounts, get the engine running (2 month waiting list) on the std map and then drive to SC to have it mapped.

Ideally I ship it to SC and they get it back in 2 months and I get the engine installed but I don't think the way the project has run its that easy

[djwilma]

Wow, you go away for holiday and leave the car with a man and st gets done.......why didnt i do this before

Anyways, engine mounts are now made and engine is in the car. Turbo hasnt been fitted but i see no reason why it wont fit

Drive shafts fitted all ok, no rubbing (unlike duratecs so i am told)












No idea what this lug is but seems to be ok



Wiring next

[djwilma]

The new fuel pump turned up today, big thanks to Gaz at Spitfire Engineering. This (small) pump should provide enough fuel for 500bhp at 3.5bar and Gaz kindly sent me a complete unit, i have to send my old unit back. I went for the Deutschewerks pump

This will save me a swirl pot, lots of fuel pipes and i dont need the Bosch Motorsport pump i had on the T series.




Hoping to have the car wired up to the ECU and Ford Loom next week

[djwilma]

Got the Elise out today and did some work at home



Put the engine cover on and it will be tight but the HPFP pressure sensor and the wastegate both it (when level) but need to get the rear clam on to check

I have the Duratec Silicone Hoses from Essex Autosport and tried to get them to fit. I got very confused until i realised the Ecoboost water inlet and outlet are on the opposite side to the Elise so after doing some searches (yes i know) of the Duratec builds i saw the swap of water pipes. With some pipework from the rover i managed to get it all set up

This makes it a little congested under the inlet, as the water pipes Swap over, the oil cooler water pipes, the remote filter pipes and the throttle body inlet.



Fitted the starter and it fouls the bell housing adaptor, bit strange but an easy fix



Also looked at fitting the fuel pump, and the hole is too small, i think i will go for the easy option of cutting the top rather than dropping to the tank (as no ramp)