Honda K20 Super Light R Build

[bourne power]

Hi All, We are currently undertaking the refresh of sundances Caterham/Honda K20. This time around we are pushing the the button harder by adding some upgrades over the original power unit. We have added Cosworth pistons, Arrow Rods,Lightweight crank (1.5kg) Removed,High Flow injectors,Wild Mugen Camshafts and a lightend flywheel. As Promised we have started a link and will update through the engine build, Mapping and engine instalation stage. If you are after any technical info you can pm me or comment on the link, im happy to answer any questions. Cheers Terry.

Edited by bourne power on Monday 2nd March 23:06

[bourne power]

Bottom End

[tomwoodis]

Bookmarked. Looking forward to reading all about this.

[bourne power]

Edited by bourne power on Monday 2nd March 23:15

[bourne power]

[bourne power]

[bourne power]

As you can see engine build is nearly complete, a few finishing touches to go but she's starting to come together!

[Gingerbread Man]

How nicely does this sit in the engine bay? Is the sump standard Honda, or is it modified or dry?

Always thought a Honda engine would be a nice choice, interested to see how it installs and it's output.

I'm assuming it's mated to the Caterham 6 speed or Ford 5 speed box?

[Martin777]

what a great post! Really curious to see how it's done! Thx!

[nigelpugh7]

Looks excellent !

Looking forwards to the full story and pictures of the build!

[james7]

Very nice
Please update with pics of it fitted in the car and spec etc

How is the fit in a series 3 chassis?

I was going to do a turbo one in an SV but had a bit of a change of plan in the end. Only recently just sold the engine etc.

[bourne power]

Gingerbread Man said:

How nicely does this sit in the engine bay? Is the sump standard Honda, or is it modified or dry?

Always thought a Honda engine would be a nice choice, interested to see how it installs and it's output.

I'm assuming it's mated to the Caterham 6 speed or Ford 5 speed box?

Hi there, First of all can i say many thanks for the intrest, more than happy to answer any questions any time. The rate of acceleration of revs that you get from a Honda power unit really compliments the Caterham, the sound is also amazing, we will be using our own engine control unit and software to map on which gives us full control of the VTEC and when we bring it in. As we are mapping this engine for track use we will be activating the VTEC early on in the rev range at around 3500RPM, this allows you to be constantly be running on the big cam and give you more torque and power all the way out of the corner. Also as a fix for the Hondas jumpy characteristics as in the standard road car ECU it doesn't activate until 6500RPM.

Last time around we achieved 286bhp and 185NM of torque, this time around with the new engine spec we are aiming for just over 300BHP and 190NM of torque, also the mods that we have carried out this time should increase our rate of acceleration of revs quite dramatically i.e lightweight crank and con-rods etc. Its not always about what top figure numbers you achieve, with a lightweight car such as the caterham chassis ripping through the rev range is key. For this setup to be a true hyper car track day killer we are concentrating on getting the car out of the corner as quickly as we can to gain on larger GT cars that are heavy and take a while to build their momentum. There are other engine control unit tricks we use to help with this as well from the standard set up such as taking full control of the VVT (Variable valve timing) which gives us greater control on where we deploy our power through the straight allowing for optimum traction at all times. Yes we are currently running the caterham standard 6 speed box, but there is a possibility to use a sadev sequential if desired alongside our own pneumatic paddle shift system.

Edited by bourne power on Tuesday 3rd March 20:20

Edited by bourne power on Tuesday 3rd March 20:21

[bourne power]

Hi All, Here are the install pics before this seasons engine mods. Just to fill those of you in on the history of this project, we Complete the original engine build and instal pictured here at the beginning of 2013. Since then in this configuration the car has run problem free. The car has been mainly used for track days, topping many elite track day time sheets and with out sounding big headed has upset a lot of ferrari/Lambo owners lol. The car is also road legal. This build Started out as a an engine refresh, but as these things always go once apart it seemed rude not to try to push her on and gain even more laptime!

Edited by bourne power on Tuesday 3rd March 18:15

Edited by bourne power on Tuesday 3rd March 18:15

Edited by bourne power on Tuesday 3rd March 19:58

[bourne power]

[bdev]

What was the original donor car chassis ? - an S3 Metric ?

[sundance002]

bdev said:

What was the original donor car chassis ? - an S3 Metric ?

Originaly it was a 98 Superlight R,
Build No4 on the regester. S3 chassis.
As you can see from the pics, with the engine cover on you could not tell it has been changed, other than side air scoops and badges.

[e21jason]

Really like this esp as living in this part of the of the world a stock s2000 motor is the best value if the K series goes bang.

My main question is the sump dry or modified.
I presume you made you own engine mounts and exhaust manifold do you sell these.

Jason

[sundance002]

e21jason said:

Really like this esp as living in this part of the of the world a stock s2000 motor is the best value if the K series goes bang.

My main question is the sump dry or modified.
I presume you made you own engine mounts and exhaust manifold do you sell these.

Jason

Hi Jason, The engine is a K20a Honda 2 ltr, not an S2000.
Yes we run a dry sump, and fitted the Mugen upgraded Honda manifold, straight swop. The engine mounts have been bespoke made and very strong, to stop the vibration from the engine transfering to the chassis,
All is on the shelf at Bourne racing.

[e21jason]

That makes things easier i run a DC5 24hr endurance car here so plenty of k20 bits around. Was it a DDMR bell housing or was it made to suit.

[bourne power]

e21jason said:

That makes things easier i run a DC5 24hr endurance car here so plenty of k20 bits around. Was it a DDMR bell housing or was it made to suit.

Hi Jason, The exhaust manifold, Bell Housing, sump and engine mounts are all our own. We Can supply all these parts. We also offer engine managment options to go with the package.