Engine finally ready for Dyno test

[Gadgeroonie]

Where did Terrys post go ?

---

is that the stock exhaust system we can see on the car ?

did you fit GT2860RS turbos ?

Edited by Gadgeroonie on Wednesday 19th September 17:18

[sundance002]

Hi all,
Just a quick list of the spec and parts used in the Development of Sundances M400 Engine.

To set any Ecu to this level takes time as we spent 7 days on the dyno calibrating in-depth everything from the knock control
to hot and cold starting. It can be a long process but is needed for road drivability.


Parts Used:
.F88 Life Racing Ecru with ability for Knock Control, full traction control, closed loop lambda, closed loop knock, and twelve position map selection.


.Race prepared wiring harness with military connectors throughout and facility to control fans, gear box oil pump, fuel pumps and dash and gauges.

.2x Wideband lambda sensors for accurate closed loop lambda corrections at all rpm sites.

.Boch Tap sensor which incorporates manifold pressure, air charge temperature and key on barometric pressure.

.Individual fuel and oil pressure sensors with fuelling corrections on low or high fuel pressure and engine trip at low or high oil pressure.

Results
I am very happy with the results as we achieved everything that we set out to do. our aim from sundance002 was to create a map to beat his power figures from the MBE ecu but more ethicist was put on creating a package that is reliable for both the engine and car. We achieved greater engine reliability by adding better boost control facilities alongside closed loop lambda which has never been run on this engine and also self learning knock control. To help with car reliability we have incorporated a twelve position calibration switch which coupled with our upgraded boost control strategy means that you can switch between boost levels allowing you to turn max power and torque up and down( even though on sundances engine the bottom power figure is 475hp with full duty to the wastegates). Also as an added conveniences is that in one of the positions he can run a fuel saving map, by running a lean burn mix and keeping the boost levels down, we added this feature for them moments we all have when the nearest petrol station seems to be further than the moon.

I will be posting all the charts and grafts, plus pictures and videos of the first fire up in the car and also of the first on road running.

Cheers Terry


And for those who's interested , this is a small list of some of the other things that have been done on my car, and now I've written it out, I think I may of gone a tad mad when I started


Pro alloy, oil breather, fuel tank, hard pipe kit, inter cooler , rad.
Gearbox oil cooler, and pump,
Oil cooler
Roush exhaust,
Zertec coated alonux manifolds
RSGT28 garret turbos
Uprated valve springs
Uprated. Valves and stems
Forged pistons
Uprated main bearings
Re profiled crankshaft
Gas flowed head, inc port and polish .
Uprated fuel pump
Uprated fuel rail
Uprated fuel injectors 
Electronic boost control
Uprated waste gates
Uprated bov
Oil cooler and pump
Life ecu F88 bespoke software.
Hand made racing spec loom car and engine
Wheel speed sensor
AP grooved discs
Pagid pads
Adj wishbones fr and rear
Twin plate clutch
Uprated gear box
Tunnel mod
Heat shield bags turbos
All hoses and pipes upgraded to a high spec
All engine bolts changed to race spec lock nuts

Sundance

Edited by sundance002 on Thursday 20th September 12:48

[sundance002]

Gadgeroonie said:

Where did Terrys post go ?

---

is that the stock exhaust system we can see on the car ? No Roush system

did you fit GT2860RS turbos ? Yes

Edited by Gadgeroonie on Wednesday 19th September 17:18

[2.5bluenob]

that car of yours is going to awsome when you get to drive it. i wish everyone would stop tuning theie cars its making mine seem very slow.

[Hollowpockets]

Hey Craig,

Any idea how long we might be talking for gears being available for purchase?

Cheers

Graham

[joust]

Ballpark cost?

Sounds awesome!

[sundance002]

Hollowpockets said:

Hey Craig,

Any idea how long we might be talking for gears being available for purchase?

Cheers

Graham

Hi Graham, it's not good news, I have just been told today that it will be 6 months before there are ready for sale, im really not happy, but bugger all I can do, they will not let us be the guinea pigs and need to do lots of develment tests. And track tests. Any suggestions are welcom

Craig

[Hollowpockets]

Well thats odd, how do they intend to test them? Purchase a noble, tune to our levels and track for 6 months over winter?

The only way to properly develope them is to build gears to a spec using existing technology that they think is upto the job with the power we are running. fit to a couple of cars with data logging (ours) and we send them the info to review with real world conditions, i live in a cold climate, you live in a hot climate. After a set number of miles on road /track we send them the box back for inspection. If changes are needed then get it done. We pay something now to cover material costs and the rest once inspection/changes are made. ??????

Or do they just want us to forget the idea and go elsewhere?

[Gadgeroonie]

has anyone contacted quaife and asked them to develop a gear kit ?

they do already make gear kits for other gearboxes

Bernie at CTS is a quaife dealer and would be a good person to deal with

we at least will find out how many gearsets they need to build to be interested in a production run

i am happy to discuss this with them

[GTO600]

Gadgeroonie said:

has anyone contacted quaife and asked them to develop a gear kit ?

they do already make gear kits for other gearboxes

Bernie at CTS is a quaife dealer and would be a good person to deal with

we at least will find out how many gearsets they need to build to be interested in a production run

i am happy to discuss this with them

Already been done a long time ago, Quaife already offer a dog gearset but no known duty.

[playalistic]

I have a box at Jetstream with the quaife gearset in it. Apart from it being completely the wrong ratios and butting the limiter at 130mph, oh and the fact it screams its tits off at motorway cruising speeds it was great

[Hollowpockets]

playalistic said:

I have a box at Jetstream with the quaife gearset in it. Apart from it being completely the wrong ratios and butting the limiter at 130mph, oh and the fact it screams its tits off at motorway cruising speeds it was great

How did that come about? Built for a reason or someone cock up the ratios?

[playalistic]

Hollowpockets said:

playalistic said:

I have a box at Jetstream with the quaife gearset in it. Apart from it being completely the wrong ratios and butting the limiter at 130mph, oh and the fact it screams its tits off at motorway cruising speeds it was great

How did that come about? Built for a reason or someone cock up the ratios?

Thank one of the previous owners of the car. He lunched a box and needed a new one, despite being told by Kerridges (who performed the work) that the ratios he chose were mental he went ahead with the rebuild and installation of the box on the premise that it would be a 'track only' car. I think he drove it after for a month or so then sold it on the tool. It cost an absolute packet too. The first few gears are mega mega short so you had to row through them like lightening. I think with a very high final drive you could even it out I suppose. If anyone wants to buy it off me then make a bid! The gearset alone cost over £3k! Ouchie.

[ThatPhilBrettGuy]

playalistic said:

I think with a very high final drive you could even it out I suppose.

Or really really big wheels? Yeah, that'd work

[playalistic]

ThatPhilBrettGuy said:

r really really big wheels? Yeah, that'd work

Monster Nob. You could drive over other road users at will. Could be useful!

[Gadgeroonie]

does the low ratio gearbox have the straight cut gears ?

is it 5 or 6 speed ?

---

Sundance

what type of pistons and rods have you fitted ? what is the cr ?

[playalistic]

It's only a 5-speed and I suppose they must be semi-helical not fully straight cut.

[Gadgeroonie]

ok - so do quaife do a gear kit for the 6 speed box ?

[chuntington101]

Sundance, intresting to see that the proally intercooler was used not a larger custom item. Was it sufficent at keeping intake temps down?

[sundance002]

Hollowpockets said:

Well thats odd, how do they intend to test them? Purchase a noble, tune to our levels and track for 6 months over winter?

The only way to properly develope them is to build gears to a spec using existing technology that they think is upto the job with the power we are running. fit to a couple of cars with data logging (ours) and we send them the info to review with real world conditions, i live in a cold climate, you live in a hot climate. After a set number of miles on road /track we send them the box back for inspection. If changes are needed then get it done. We pay something now to cover material costs and the rest once inspection/changes are made. ??????

Or do they just want us to forget the idea and go elsewhere?

I agree completely, it's done my nut in, I was told wks not months.

Speaking again on Monday to see if we can do the testing.

Regarding Quaffe, and others they can do it but at a crazy cost 20k plus.
This seemed to be the best way for cost and time, the others said it could take a year.
The company who are developing it are top of there game, and the cost compared to others is a 1/4 of the price,
Just need to see if I can get them to move a bit faster.