What Engine for 500BHP

[turbonutter]

The gold does look good....goes well with the black.

Fog now cleared in the shed, so here are the heads.

[turbonutter]

Started on the engine build,
Assembled the crank into the block, but the bearing clearances for the main & big ends is more than i wanted, so I have ordered some thicker grade shells. Hopefully those will be here this week....

Built up the heads today - well 99% built, of course one of the valve stem seals was the wrong size typical





So thats me at a dead end with the engine - waiting for spares... so I might go back to the car its self tomorrow..

[turbonutter]

OK Christmas is over & the bearings for the engine finally arrived & this time the clearances came out OK, so on with the build, bottom end put together & I managed to find a carbide tip and holder for the lathe, so i managed to put a groove in the liners to help hold things in position.....



That done the pistons were installed using an ARP tapered ring compressor - great piece of kit I must say, just put the tool on the liner and one quick push and the piston is in...



Then The heads were fitted, using spesso racing gaskets & the cam timing set - just one or two bits left, then it can be mated to the gearbox & have the turbo etc mounted, so i can easily do some of the piping & heat shielding...





Before I can get on with the engine though, I have spotted a problem with the rear suspension from some work that was done by the previous owner, so might have to sort that out next...

Edited by turbonutter on Tuesday 3rd January 23:02

[turbonutter]

Starting to assemble the engine and box out of the car at the moment, ready to finish off some bits and pieces while access is easy...



Got so far but need to wait for some parts from the anodisers before doing some more....

[turbonutter]

A bit more progress with the car.....

Brakes installed & brake lines made and fitted..

New fans on the radiator & radiators installed - Cooling pipes finished and cooling system tested.

engine assembled on stand & some pipes finalised while easy to get at , couple more small jobs on the car then the engine can go in.....

[turbonutter]

Just about time for me to head off back to work again (I have to fund this car somehow), so here's a quick update.
The engine is now in the car & all of the fuel system connected and tested, cooling system complete and tested, oil piping complete, engine wiring complete. Gearbox oil cooler and pump 90% done... So if I had a couple more days I could do the final install on the exhaust & to odd other small job & the engine could be tested, but I dont have the time to do that now, so it will have to wait until the end of April

Still a long list of small jobs to do, but it looks like it will be on the road in the summer

[turbonutter]

Also have some new LED rear lights - much better than the normal stratos ones...







Lights are hard to photograph, some more attempts on my website and a short video clip

http://www.turbonutter.net/apps/videos/

Cheers

[turbonutter]

Transmitter Man said:

Same voltage but less current, no?

Phil

Correct still 12V but miniscule current - and really bright

[turbonutter]

Well April is nearly here and Still 3 weeks before I can progress on my car, But one step forward has been made and thats booking the Dyno Session for mapping the engine. The car will be at AET Motorsport on 18th may, so that gives me 3 weeks at home to finish the car...... Nearly there now

[turbonutter]

I think he missed a few pages - Just looked back and the engine choice was settled at the bottom of page 4 way back in 2009 - Have I really being doing this project for so long?!?!

Still the end is in sight - assuming that everything works that is......

[turbonutter]

mickrick said:

Ok so I've been a bit slow posting, but not a lot of interesting photos to post, but since I have been home,

The turbo and exhaust are now installed, I have had the exposed charge cooler pipes powder coated & the Charge cooler system is now connected & tested, The Fire Extinguisher is plumbed & I am now finishing off the Fire Extinguisher piping & working on some heat shielding. There has also been many hours spent finishing off the wiring & I think everything is now connected, ready for me to have a full electrical test next week.

[turbonutter]

Liquid Knight said:

Ready for PPC in the Park?

Would be nice to have another Italian thoroughbred on display next to my Panda.

Thats on the 19th? the car will be spending that day on the Dyno & probably some of the day after as well, so I wont make it this time

[turbonutter]

Just about got the engine finished, just a bit of heat wrap and heat shield to install, so tried the electrics today, now i was sure i had tested the water pumps for the engine before now, but today, when i switched them on manually, one of the fans runs as well and one of the pump controlers seemed to have lost its supply.

A few hour later after unraveling the firing loom from the pump controllers, digging out the relay housings and fuse box and problem found, i had mixed up the green & green/black wires from one of the controllers that would be the fan control signal & the ignition switched supply to the controller. Its all back together now bar wrapping the loom again - just in case i find something else to fix

[turbonutter]

OlberJ said:

Purely from an aesthetics point of view, could you make the left hand chargecooler coolant pipe a 90* angled job that goes around instead of stretching over the engine?

Still loving this though. Can't wait to see a video of it in action.

What's the plans for actually using it? Will it see track and road?

I see what you mean re the charge cooler pipe,I was never really happy with it like it is& now everything else is in place, I can see a possibility of where it could be re routed & still keep a gradual up slope to air venting. I even think i have a 90 deg silicon elbow and a 90 deg alloy pipe that didnt fit somewhere else.....

As for use, this year it will be on the road mostly while i get used to driving it, then next year it will get some propper use, track days, sprints/hilclimbs etc

Edited by turbonutter on Tuesday 8th May 23:38

[turbonutter]

Modified Charge cooler pipe installed.....



I must admit it does look better

and some more heat shielding

[turbonutter]

Managed to get the engine to run today, not very well, as its just a random map, but enough to prove that everything works.
First try was very rough running, but after enabling the filter on the crank trigger it was much better.

A few poor quality videos on Youtube..

http://www.youtube.com/watch?feature=player_detail...
http://www.youtube.com/watch?feature=player_detail...
http://www.youtube.com/watch?feature=player_detail...

Sound quality is really bad as I only had my camera, hope to get somthing better off the rolling road.

It sounds great

[turbonutter]

OK So I lied about a base map, the engine has been on the dyno all day, a few things needed sorting, then the rings were bedded in before a power run..

0.9 bar = 412BHP at the wheels - allowing 12% transmission loss gives 460BHP at the flywheel.

1.25 bar = 450BHP at the wheels - allowing 12% transmission loss gives 505BHP at the flywheel

All the planning paid off - It Works

Cold start and transients to sort out tomorrow......

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To say I am happy is an understatement, and that's a first run on 95 octane unleaded, should be plenty for now

I'm just happy that everything worked out OK, and 500BHP as a starting point is just awesome

The power spread is good as well, on boost from 3800rpm and still strong at 6200rpm

Edited by turbonutter on Friday 18th May 00:17

[turbonutter]

Evoluzione said:

A good result there. Are you using the PWR cooler on its own and have you checked its efficiency?

Cheers, Yep just using the PWR cooler, but the air temp sensor for the inlet to the cooler isnt working, so I cant check efficiency until i find the fault with that

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Evoluzione said:

I didn't think they were very good at cooling (great for air flow rates), but have noted they have altered the internal fin design since the earlier models. I would love to see some before and after (cooler) temps and prepare to be re-educated.

You must be chuffed to fking bits, I bet you can't wait to drive it!

The guys at PWR Europe more or less guaranteed my setup of cooler pre rad and pump, its the same set up they have running in some race cars although with a slightly larger pre rad....

I need to get to AET and see it run, but have a wedding today.... so tomorrow it will be, still have a bit of work to do but it will be on the road soon