DJ Wilmas 111S S2 T series 400bhp Elise
Discussion
Have had Man Flu and a funeral this week so not had much chance, but managed to wire the Lambda Sensor in properly, but have a loose connect on the 0-5v feed to the DTA so need to check this.
Also the fan knob fell off when i put my foot down, then rattled around so had to stop
Then took it out for a spin today, still awaiting on the Clutch to grip it is getting better but and got the camera on forward facing. The sound for some reason is very quiet to need to re-check this too
https://www.youtube.com/watch?v=jUs35QqmrPk&fe...
Also the fan knob fell off when i put my foot down, then rattled around so had to stop
Then took it out for a spin today, still awaiting on the Clutch to grip it is getting better but and got the camera on forward facing. The sound for some reason is very quiet to need to re-check this too
https://www.youtube.com/watch?v=jUs35QqmrPk&fe...
What a lovely weekend perfect for roof down motoring, especially on my route to Swindon Sunday morning at 7am lovely country roads quiet traffic and even better the clutch has started allowing full throttle in 3rd and 4th
So imagine my mood when 3/4s of the way and full throttle blast and rattle, then oil smell
Drove at 2500rpm in fifth and the rattle started to get worse. Then it wouldnt tick over !
Managed to nurse it to work and let it cool, started again and it rattled, sounds like the big ends have given up. No idea why engine seems to have oil pressure 60psi is showing, however it doesnt change with Revs (assumed dodgy sender)
So it spent the night on the back of a truck, again !
Worryingly i am expecting the worse and googling 2.2 t series...........hmmm
So imagine my mood when 3/4s of the way and full throttle blast and rattle, then oil smell
Drove at 2500rpm in fifth and the rattle started to get worse. Then it wouldnt tick over !
Managed to nurse it to work and let it cool, started again and it rattled, sounds like the big ends have given up. No idea why engine seems to have oil pressure 60psi is showing, however it doesnt change with Revs (assumed dodgy sender)
So it spent the night on the back of a truck, again !
Worryingly i am expecting the worse and googling 2.2 t series...........hmmm
Right looks like i have a Plan
Will be replacing the engine with another forged T series, i was going to try and make a short stroke 86mm by 86mm bore engine but the forged cranks were on a 12 week lead time and would of gone for bigger valves and billet cams and it all got very expensive
Hope to pick the newly built engine up next week, will post specs when i have it
Will be replacing the engine with another forged T series, i was going to try and make a short stroke 86mm by 86mm bore engine but the forged cranks were on a 12 week lead time and would of gone for bigger valves and billet cams and it all got very expensive
Hope to pick the newly built engine up next week, will post specs when i have it
Well i collect the engine on Thursday its a newly built 2068cc T series spec is as follows
Engine/Box
-2067cc forged using aged block, bored with torque plate
-Block decked by several mm
-Ceramic coated Arias Forged pistons with Moly side skirts
-Pauter custom rods (changed rod ratio) rated at 250hp per rod
-ARP Mains, big end and head studs
-Knife edged and balanced crank, fine balanced to 10k rpm
-Alloy sump
-Extra breather on front of block
-Wire ring grooves, stainless wire rings
-Copper headgasket with custom oil sealing
-New head casting taken and ported to the highest level by Sabre Heads, Roger this is Grants old engine
-Oversized valves (Stainless steel one piece)
-Double valve springs with custom caps
-Custom race grind cams
-Special cam belt (kevlar extra wide) with modified lower pulleys to suit
-Vernier pulleys
-Set up with 36-1 pulley and crank sensor for better accuracy on aftermarket ECU (may not fit in my engine bay tbc)
-4.5kg Billet flywheel
-AP Twin place clutch with custom bearing carrier (may use my setup though)
-PG1 220 box ratios, built with new bearings, syncros and type B Torsen. Shimmed correctly have a W4 box so may change the final drive and get a K4 or C6
-Cut down custom engine loom, losing all uneeded wires
-LS7 coils and custom leads with custom bracket
- Daihatsu Charade altenator under inlet (std is under exhaust but my charge cooler is in the way)
Engine/Box
-2067cc forged using aged block, bored with torque plate
-Block decked by several mm
-Ceramic coated Arias Forged pistons with Moly side skirts
-Pauter custom rods (changed rod ratio) rated at 250hp per rod
-ARP Mains, big end and head studs
-Knife edged and balanced crank, fine balanced to 10k rpm
-Alloy sump
-Extra breather on front of block
-Wire ring grooves, stainless wire rings
-Copper headgasket with custom oil sealing
-New head casting taken and ported to the highest level by Sabre Heads, Roger this is Grants old engine
-Oversized valves (Stainless steel one piece)
-Double valve springs with custom caps
-Custom race grind cams
-Special cam belt (kevlar extra wide) with modified lower pulleys to suit
-Vernier pulleys
-Set up with 36-1 pulley and crank sensor for better accuracy on aftermarket ECU (may not fit in my engine bay tbc)
-4.5kg Billet flywheel
-AP Twin place clutch with custom bearing carrier (may use my setup though)
-PG1 220 box ratios, built with new bearings, syncros and type B Torsen. Shimmed correctly have a W4 box so may change the final drive and get a K4 or C6
-Cut down custom engine loom, losing all uneeded wires
-LS7 coils and custom leads with custom bracket
- Daihatsu Charade altenator under inlet (std is under exhaust but my charge cooler is in the way)
Ok, so i have done some silly things in my life. Jumped out of a plane naked, woke up on a dance floor dressed in a sumo suit whilst the cleaner was cleaning around me etc etc
However i have never been so embarressed as when i just got the call about my engine, seems a distinct lack of oil was the reason for the failure. It had a mere 1lt of oil in the sump, which would explain the "knocking noise" from the engine.
Worst still is that the Turbo is pretty much seized solid and as its a roller bearing turbo and looks to be junk !
So a very expensive mistake, simply not checking the oil after an oil leak (return pipe from turbo) and a faulty oil pressure sensor and oil switch (Light on stack doesnt work and ecu display was set to the wrong oil pressure)...... [Censored] s
t [Censored] [Censored]
Anyway the good news is the new engine should be fitted in the next day or so then a replacement turbo needs to be sourced and fitted.
I have bought
A new clutch, helix rated to 425lbft, its a 6 paddle so i hope its more than digital
A custom Inlet with bigger inlet tracks, 660cc injectors still though (may or may not fit)
Placed an order for a 60litre pro alloy fuel tank
New pressure switch for oil
Then we can wind the bloody thing up and break the 450bhp barrier, i can sleep a happy man as long as the wife doesnt find the receipts
I have thoughts of a bigger turbo, EFR Twin scroll but the injectors will need replacing and quite frankly 320bhp was more than the roads needed.........must resist
However i have never been so embarressed as when i just got the call about my engine, seems a distinct lack of oil was the reason for the failure. It had a mere 1lt of oil in the sump, which would explain the "knocking noise" from the engine.
Worst still is that the Turbo is pretty much seized solid and as its a roller bearing turbo and looks to be junk !
So a very expensive mistake, simply not checking the oil after an oil leak (return pipe from turbo) and a faulty oil pressure sensor and oil switch (Light on stack doesnt work and ecu display was set to the wrong oil pressure)...... [Censored] s
t [Censored] [Censored] Anyway the good news is the new engine should be fitted in the next day or so then a replacement turbo needs to be sourced and fitted.
I have bought
A new clutch, helix rated to 425lbft, its a 6 paddle so i hope its more than digital
A custom Inlet with bigger inlet tracks, 660cc injectors still though (may or may not fit)
Placed an order for a 60litre pro alloy fuel tank
New pressure switch for oil
Then we can wind the bloody thing up and break the 450bhp barrier, i can sleep a happy man as long as the wife doesnt find the receipts
I have thoughts of a bigger turbo, EFR Twin scroll but the injectors will need replacing and quite frankly 320bhp was more than the roads needed.........must resist
Well the engine is now apart, the pistons and the head are undamaged
The turbo is stiff, with no play, so its been shipped to Turbo Dynamics to see if they can repair and upgrade to ceramic bearings
Rods have taken the brunt of the lack of oil, NO 2 has spun so the rods are basically junk
The turbo is stiff, with no play, so its been shipped to Turbo Dynamics to see if they can repair and upgrade to ceramic bearings
Rods have taken the brunt of the lack of oil, NO 2 has spun so the rods are basically junk
Clutch is in its a Helix 2.5 from Grant at GBE, hoping it will cope with the 450lbft torque and wont be too digital
Results on the Turbo are in, and its all good in the hood. Basically needed new bearings and a slight fettle and definite lack of oil issue.
Lovely Service from Turbo Dynamics, they even installed their motorsport spec when they re-furbed it. I have no idea why i said yes but the word "motorsport" sounded good. Its basically ceramic bearings which needed replacing anyway. They collected the turbo stripped inspected and had it back within the week and less than half price of a new turbo.
Engines back in and partly plumbed in
Just going to add a smallish intercooler in the side pod to assist the charge cooler, looking at the data log its highest ever temp was 48C but its never been on track so thought we'd pop one in with a little more ducting as well for cold air.
Hopefully be back in action next week.......finally
Results on the Turbo are in, and its all good in the hood. Basically needed new bearings and a slight fettle and definite lack of oil issue.
Lovely Service from Turbo Dynamics, they even installed their motorsport spec when they re-furbed it. I have no idea why i said yes but the word "motorsport" sounded good. Its basically ceramic bearings which needed replacing anyway. They collected the turbo stripped inspected and had it back within the week and less than half price of a new turbo.
Engines back in and partly plumbed in
Just going to add a smallish intercooler in the side pod to assist the charge cooler, looking at the data log its highest ever temp was 48C but its never been on track so thought we'd pop one in with a little more ducting as well for cold air.
Hopefully be back in action next week.......finally
Well I finally got time to collect the car, bit of an epic trip Bournemouth to Carlisle and back in a day about 760miles in total
Good news was it gave me time to run the new 2.1 engine in. Was very tight when i pick it up and with wet roads it felt, well horrible. Looks good too. Need to add some heat shield to some pipework but will get this done.
Good news was that the car loosened up on the journey back, it now has a 60litre Pro Alloy tank fitted (although it only took 52 litres, petrol poured out the filler so knew it was full) and it nearly made it back on the one tank !
Engine now revs to 7760rpm according to the log so i need to re-set the limiter to 7500rpm
Clutch now holds and although a low pedal it grips well, gear linkage needs some adjustment though
Engine now feels lovely, had a little play with a V10 R8 on his way back from the EVO triangle, on low boost, and it was neck and neck, managed to pull up along side in a traffic jam and the driver was a little shocked....as was i..... His comment was this is silly quick and you caught me up. Did mention i had another 120bhp and he just shook his head;)
Curves arent great to be honest, car has too much wheel spin when turning the boost up. And fueling boost etc werent finalised so these are not adjusted
1.34 Bar boost was 386 @ 6200 rpm
1.45 Bar was 412bhp but wheels were a spinning
So will when i get a chance i will get some in car footage and drive by's
Good news was it gave me time to run the new 2.1 engine in. Was very tight when i pick it up and with wet roads it felt, well horrible. Looks good too. Need to add some heat shield to some pipework but will get this done.
Good news was that the car loosened up on the journey back, it now has a 60litre Pro Alloy tank fitted (although it only took 52 litres, petrol poured out the filler so knew it was full) and it nearly made it back on the one tank !
Engine now revs to 7760rpm according to the log so i need to re-set the limiter to 7500rpm
Clutch now holds and although a low pedal it grips well, gear linkage needs some adjustment though
Engine now feels lovely, had a little play with a V10 R8 on his way back from the EVO triangle, on low boost, and it was neck and neck, managed to pull up along side in a traffic jam and the driver was a little shocked....as was i..... His comment was this is silly quick and you caught me up. Did mention i had another 120bhp and he just shook his head;)
Curves arent great to be honest, car has too much wheel spin when turning the boost up. And fueling boost etc werent finalised so these are not adjusted
1.34 Bar boost was 386 @ 6200 rpm
1.45 Bar was 412bhp but wheels were a spinning
So will when i get a chance i will get some in car footage and drive by's
Couldnt agree more
Was noticed that i put up two identical curves
so here is the 412bhp curve and it looks like it just dies at 6200 rpm but notice the boost also drops off. This is due to wheel spin
Engine is happy to pull to 7500rpm, actually hit 7750rpm on my log
Was noticed that i put up two identical curves
so here is the 412bhp curve and it looks like it just dies at 6200 rpm but notice the boost also drops off. This is due to wheel spin
Engine is happy to pull to 7500rpm, actually hit 7750rpm on my log
Edited by djwilma on Thursday 23 October 09:16
Having a busy time at work so the failed alternator bracket / belt has taken for ever
However i quickly realised the bracket wasnt man enough and the belt had been hitting the cam cover, so we have fabricated a new bracket
Still work in progress, but fitted the alternator yesterday fired it up and it hit a heady 11.9 volts. Best bit was the alternator has no numbers and is an unknown origin. One i purchased for the 620 Ti isnt right so i hope second time around to have the right one
Also took the chance to make a few holes to let heat out, as the turbo sits close the bulkhead and high up it has nowhere to exhaust and when stationary i have a fan to circulate air but it just fires it out the drivers side vent, where the air filter is. So this will help
I am thinking about some additional vents on the body but i'd like to keep it vent free and std ish looking
However i quickly realised the bracket wasnt man enough and the belt had been hitting the cam cover, so we have fabricated a new bracket
Still work in progress, but fitted the alternator yesterday fired it up and it hit a heady 11.9 volts. Best bit was the alternator has no numbers and is an unknown origin. One i purchased for the 620 Ti isnt right so i hope second time around to have the right one
Also took the chance to make a few holes to let heat out, as the turbo sits close the bulkhead and high up it has nowhere to exhaust and when stationary i have a fan to circulate air but it just fires it out the drivers side vent, where the air filter is. So this will help
I am thinking about some additional vents on the body but i'd like to keep it vent free and std ish looking
Edited by djwilma on Thursday 8th January 17:43
Couldnt agree more
Was noticed that i put up two identical curves
so here is the 412bhp curve and it looks like it just dies at 6200 rpm but notice the boost also drops off. This is due to wheel spin
Engine is happy to pull to 7500rpm, actually hit 7750rpm on my log
Was noticed that i put up two identical curves
so here is the 412bhp curve and it looks like it just dies at 6200 rpm but notice the boost also drops off. This is due to wheel spin
Engine is happy to pull to 7500rpm, actually hit 7750rpm on my log
Edited by djwilma on Thursday 8th January 17:45
Been asked for a drive by video
15 second of your life you will never get back
http://youtu.be/aH0Pzyb-HB8
15 second of your life you will never get back
http://youtu.be/aH0Pzyb-HB8
Been away for a few weeks so took the car for a spin today in the rain so good time to play about with the traction control. DTA has a a wet / dry setting. Dry is limited to 10% slip, but i can adjust this from the car and this allows the car to slide about to about 10 degrees by cutting up to 75% ignition. Wet is Zero slip etc
Wound the boost up to 1.7 bar, 3rd gear and 60mph and put my foot down. Car accelerated hit the maxboost and the ECU cut all the power to the engine
Same at 0.7 bar and she just accelerated, albeit slightly slower than in the dry
Then i noticed the oil temp, its fitted to the cold side of the water and as i have the EWP it doesnt have a thermostat and was showing 12C
So got home and turned the engine off waited 5 mins, car has a turbo timer that circulates water and turns an engine bay fan on, and the gauge shows this
I think the oil temp sensor is on the cold return so will relocate it to the sump, and if its is running cold will add a thermostat.
Put the hard top on and took the worst photo ever
Wound the boost up to 1.7 bar, 3rd gear and 60mph and put my foot down. Car accelerated hit the maxboost and the ECU cut all the power to the engine
Same at 0.7 bar and she just accelerated, albeit slightly slower than in the dry
Then i noticed the oil temp, its fitted to the cold side of the water and as i have the EWP it doesnt have a thermostat and was showing 12C
So got home and turned the engine off waited 5 mins, car has a turbo timer that circulates water and turns an engine bay fan on, and the gauge shows this
I think the oil temp sensor is on the cold return so will relocate it to the sump, and if its is running cold will add a thermostat.
Put the hard top on and took the worst photo ever
Gooby said:
Seems we have a mutual friend. We will have to arrange to meet!
Ooh cryptic and always up for a meetEnd of year at work is manic so had no real time, even managed to turn 40 but still look 28 so all is good ;-)
Got to the bottom of the alternator belt the lower bracket failed
Have re- welded it and will take it to a friends garage in the new year for a proper go as the rear of the alternator isn't braced so will add a bracket in as it flexes
Also got some quali session used ZZRs from Andy at Maidstone Sports Cars was too good a deal to say no and have a spare set of wheels so will try and get a track day organised
Lol Nick and Sarah, good people
Having a busy time at work so the failed alternator bracket / belt has taken for ever
However i quickly realised the bracket wasnt man enough and the belt had been hitting the cam cover, so we have fabricated a new bracket
Still work in progress, but fitted the alternator yesterday fired it up and it hit a heady 11.9 volts. Best bit was the alternator has no numbers and is an unknown origin. One i purchased for the 620 Ti isnt right so i hope second time around to have the right one
Also took the chance to make a few holes to let heat out, as the turbo sits close the bulkhead and high up it has nowhere to exhaust and when stationary i have a fan to circulate air but it just fires it out the drivers side vent, where the air filter is. So this will help
I am thinking about some additional vents on the body but i'd like to keep it vent free and std ish looking
Having a busy time at work so the failed alternator bracket / belt has taken for ever
However i quickly realised the bracket wasnt man enough and the belt had been hitting the cam cover, so we have fabricated a new bracket
Still work in progress, but fitted the alternator yesterday fired it up and it hit a heady 11.9 volts. Best bit was the alternator has no numbers and is an unknown origin. One i purchased for the 620 Ti isnt right so i hope second time around to have the right one
Also took the chance to make a few holes to let heat out, as the turbo sits close the bulkhead and high up it has nowhere to exhaust and when stationary i have a fan to circulate air but it just fires it out the drivers side vent, where the air filter is. So this will help
I am thinking about some additional vents on the body but i'd like to keep it vent free and std ish looking
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