DJ Wilmas 111S S2 T series 400bhp Elise

DJ Wilmas 111S S2 T series 400bhp Elise

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djwilma

Original Poster:

198 posts

148 months

Monday 14th August 2017
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I think it's best to say my motivation with the car is waning, work, travel, family and work on the house have ground me down.

I cant even be bothered to fit some water hoses and sort out the vacuum......its got that bad.

So tomorrow the car is off to HPE Automotive in Bromsgrove for Dan to finish

Monday the engine is then with Specialist Components to map and see what she's got (if the turbo can give it enough air)......

Pick a power figure if your bored, I'm going with 400bhp at 11psi and 8000rpm for a giggle and 480bhp at 23psi and 7250rpm.

But today I suddenly realised I hadnt fitted the rear clam with the new engine in, and I was off to Germany at lunchtime

First fit didn't look too bad at the back



But terrible at the front



So I found the sabre saw and made it fit.



But it hit the wastegate(built when the engine wasn't with the car so can't complain)



I gave accepted I will be losing the boot so will fabricate, sorry asked Dan to fabricate something to lock the hatch too.

Boot will be exhaust as it was way too loud before

hughcam

411 posts

164 months

Wednesday 30th August 2017
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Great thread, I am really enjoying the progress on this epic build!

Would love to do something similar on my Exige but with a Honda k24

djwilma

Original Poster:

198 posts

148 months

Sunday 3rd September 2017
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hughcam said:
Great thread, I am really enjoying the progress on this epic build!

Would love to do something similar on my Exige but with a Honda k24
There is one being built at the moment with a K24 turbo, aiming for about 650bhp



djwilma

Original Poster:

198 posts

148 months

Sunday 3rd September 2017
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Engine lasted 10 minutes on the dyno last week, then started to have a bad misfire at 2500rpm and load. So the head had to come for a re-check

Spoke to the Engine builder today and its pretty clear whats happened

The head was coked up, one of the down sides of direct injection, so the valves were sticking.

An expensive lesson, yet again, but asked them to strip the engine, check and rebuild. They found a few minor issues and have mentioned that it may be worthwhile porting the head..........it never ends

Should be a couple of weeks to get it put back together

djwilma

Original Poster:

198 posts

148 months

Thursday 7th September 2017
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So some good ish news today

I havent wanted to "bother" the engine builder, Damico, as he is manic and fitting in mine between jobs for which i am eternally grateful

Luckily today he called and we had a chat so;

The engine wasnt missing, this is my misunderstood (i was in shock and at Duxford with my 4 year old). The engine was breathing badly, and it got to a point that they were not happy with so they stopped the dyno and advised the problem. With the leakage on the valves i asked them to strip and inspect the whole engine, as i knew the

The engine was coked up, see the photos below. As said this wasnt causing the engine to Misfire but was causing the valves to stick. The valves were sealing when the cams were removed, however they hadnt been lapped or cleaned. The engine just sounded sick and wasnt able to pull through the revs.

The piston rings were on the large side, but in tolerance, however the second ring had a larger gap than the first, all now being fixed

The head was in tolerance for flatness but only just, head is now being skimmed, de coked, cleaned and then ported. Sealing face wasnt as clean as Damico would of liked (polite for had gasket marks, same for the block)

The crank, and bearings, are all fine. Some evidence of a "dirty build" but all can be cleaned up and in tolerance

So I wasnt charged for the engine build (long story), but at least now i know its been done to the highest standards. I just hope the wife doesnt find the bills and this thing had better work !!!




djwilma

Original Poster:

198 posts

148 months

Wednesday 13th September 2017
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Damico have kindly sent some shiney clean photos...........getting closer....again...again





djwilma

Original Poster:

198 posts

148 months

Monday 18th September 2017
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OK results are in and dont know whether to be happy or sad.......i should be happy looking at the curve, i really really should be

Anyway.......

It’s a mixed bag of news

The engine wanted to boost, way above the 11psi set in the actuator. So the dyno removed one of the two springs and got this down to 20psi. The spring should set actuator pressure to 4psi so need to find out why this is happening.

It may be connected to the vacuum pump, this was disconnected and open to atmosphere and caused the crankcase to pressurise. Once disconnected, or sealed up, the engine was fine. Took a while to find out why but hey ho its not been done before.

Weirdly the std gdi injection was ok at 410bhp, auxillary wasnt needed (was tested and wasnt great when injects as the injector opens to much for the need) but does work if needed. Theory is 350wbhp so 400bhp is the limit, which its not as they still had some headroom.

But the major issue was detonation, at 20psi (1.4bar) the sensors were detecting knock, so the ignition was retarded to a point where the egt's got too high......This though should not happen, inlet temps were 30C so even if the compressor was blowing hot air (which its not according to the comp curve) this shouldnt effect detonation.

A theory, which i need to confirm, is that the pistons are higher than the 9.3:1 they should be. This is because i used the 2.3 crank and rods, and the 2.0 pistons. The std 2.0 and 2.3 have the same comp ration, so longer stroke and short rod should ,ake the same as they share (i hope i am right) the same piston diameter. However, the 2.3 and the 2.0 use different heads so i dont know if the volumes change to compensate.

As is normal here Dyno session finished late, so i will get more information tomorrow.

So it may 410bhp, 300lbft at 3000rpm and 350lbft of torque with a flat chunky curve with lots of room under the curve.

So i should be happy, right smile




Toltec

7,159 posts

222 months

Tuesday 19th September 2017
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Looks like you should get over 300bhp through the gears so I suspect it will be quite quick smile

Realistically what speed/gear will you be happy not to be be able to spin the wheels at?


djwilma

Original Poster:

198 posts

148 months

Wednesday 27th September 2017
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Toltec said:
Looks like you should get over 300bhp through the gears so I suspect it will be quite quick smile

Realistically what speed/gear will you be happy not to be be able to spin the wheels at?
with that curve it will be rapid yes, but its still not quite there

Car had 400 plus bhp with the engine before and i never had traction issues. Mainly as its fitted with 4 wheel traction control

Toltec

7,159 posts

222 months

Wednesday 27th September 2017
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djwilma said:
Mainly as its fitted with 4 wheel traction control
That's cheating, though probably not a bad idea! Looking forward to your next installment thumbup