Fury "Egoboost 2.0" - CBR1000RR to Ecoboost

[shirt]

what other sbd goodies are you going for and what are the power/torque targets?

[MagicalTrevor]

shirt said:

what other sbd goodies are you going for and what are the power/torque targets?

It's the Gemzoe goodies I've got to be careful of!

I don't have my eye on any more SBD bits but Dave Gemzoe makes some useful bits for the Ecoboost. I'm generally trying to build it and then see where I might need the extras or whether they can be fabricated as I can't just buy every single nice to have.
A lot of the builds so far have been for Caterfields and their narrow body means you need some clever solutions for packaging, my Fury has a wide body so I don't have the same issues. That said, the turbo placement is still an issue that needs addressing once the engine mounts are done.

There's a power/torque dyno chart further up the thread. I bought the turbo knowing it was capable of 315bhp and 265lbft, the Elite IL200 5S Extended gearbox has a limit of 250lbft so that dictates the target.

[shirt]

We have very similar targets then. My box is limited to 240ftlb until I can get the cam and pawl diff upgrade. Stage one is around your figure, stage 2 will come once that ceases to scare me...

I’ll check out gemzoe, hadn’t heard of them before.

The peron manifold is about the best off the shelf one ive seen

https://peron-automotive.co.uk/products/nortech-pe...

[MagicalTrevor]

shirt said:

We have very similar targets then. My box is limited to 240ftlb until I can get the cam and pawl diff upgrade. Stage one is around your figure, stage 2 will come once that ceases to scare me...

I’ll check out gemzoe, hadn’t heard of them before.

The peron manifold is about the best off the shelf one ive seen

https://peron-automotive.co.uk/products/nortech-pe...

https://www.gemzoe.com/ but you're better off finding 'Gemzoe Motorsport' on Facebook. He does lots of Caterham Ecoboost stuff and generally makes stuff that makes the installation neater, easier... and more expensive!

I can't afford a manifold like that so my intention is to try and add an extension that twists the turbo so it faces slightly outwards. It's my biggest concern right now actually.

Here's a crude drawing. The current cast manifold is represented on the top. It's all fed into the central downpipe to the turbo. What I want is an off-set outlet to give more room for the turbo.


Basically, this but with Ecoboost flanges.

[MagicalTrevor]

A bit more progress this afternoon.

Loose fitted the gearbox just to make sure it would go in the tunnel and start to work out where to weld in a plate for mounting.

It's not level in this photo, but when it is, it lines up perfectly with the end of the pedal footwell.


Loads of room


Not a great photo but it's here for some sort of reference


I've mentioned the turbo placement. If I can move it forwards then it sorts all my problems out so I've started speaking to a fabricator who can make a log manifold that brings it forward.






Hopefully it won't be too expensive though.

Edited by MagicalTrevor on Friday 18th September 20:02

[jase_llan]

MagicalTrevor said:

A bit more progress this afternoon.

Loose fitted the gearbox just to make sure it would go in the tunnel and start to work out where to weld in a plate for mounting.

It's not level in this photo, but when it is, it lines up perfectly with the end of the pedal footwell.


Loads of room


Not a great photo but it's here for some sort of reference


I've mentioned the turbo placement. If I can move it forwards then it sorts all my problems out so I've started speaking to a fabricator who can make a log manifold that brings it forward.






Hopefully it won't be too expensive though.

Edited by MagicalTrevor on Friday 18th September 20:02

You're going to love driving this when it's done, I dread to think how quick it'll feel! I've done my own job of showing an Ecoboost where it shouldn't be - I took my old MK6 Fiesta 1.25 (first car actually), pulled the engine and a load of weight out of it and dropped in an Ecoboost. Currently at 235bhp/???lbft (Collins CP2 remap with custom 3" > 2.5" exhaust and homebrew induction kit) and it will see off most things on the road - also did a good job out on track, with wheelspin in 4th in the wet coming out of the Shell Oils hairpin and up the hill at Oulton Park!

[MagicalTrevor]

I've found somebody to make me the turbo manifold that I need and that'll help with packaging of the turbo and the pedals. Shouldn't be too expensive to do.

I've decided on the gearbox, it's an Elite IL200 5S Extended
Key points are that the torque capacity increased from 270Nm (200 lbft) to 340Nm (250lbft) from the standard IL200 which is common in my competitive events.
My engine, with the turbo I've got, is capable of 312bhp and 265lbft and it's easy to restrict the boost so I can maintain a 250lbft limit and protect the gearbox. 300bhp+ here we come... this is going to be mental!

I celebrated by adding some engine vajazzle...



I'm a tart, I admit it! It dresses up the engine bay and makes it 'appear' like a built engine despite my *current* policy of not modifying the internals.

[MagicalTrevor]

Loads of progress today.

Got the engine back in today and in position ready for making engine mounts. The sump barely peeks out below the chassis so I don’t have to worry about the sump getting damaged.

Go say it’s tight is an understatement. Had to cut parts of the chassis around the wishbone mounts but it’s trivial to weld up new braces.

When in its proper position, the oil pump from the dry sump is much closer than in this photo.


And a photo showing how close it is


Here’s a photo with the engine in place . I didn’t get a photo of the underside but I’ll get one next time.


Engine mount next. Sat on Vibra Technics mounts. Had to be positioned to avoid oil pipes.


There’s plenty of strength in that with thick walled box section and thicker tube for the vertical section.
Again, but of a rush so didn’t get photos of the finished article but I’m very pleased with the result.

Hot side of the engine is also looking positive. This is how it looks with nothing fitted.


Turbo fitted


Very relieved to say that it looks like there might be room to fit a 90deg bend for the exhaust outlet without having to get a custom manifold which is really good news as it means more money for the gearbox!



This diagonal chassis brace is going to need to be modified so the exhaust can pass through

[MagicalTrevor]

I’m waaay ahead of myself here but today I made a logo and experimented with how it might look against the wrap I’m considering

[MagicalTrevor]

Here's a photo of the first engine mount. It's just bare metal at the moment but we're planning on black galvanising it or just paint or powdercoat it. It'll also have the end plugged up and a gusset made on the top.

Note how it avoids the pipes of the dry sump pump.

[Fastdruid]

That really is an awkward place.

I think I'd probably have made it kind of as a triangle shape and so the pump outlet went through the middle. Not that would have been easy either.

Then again my engine mounts are massively overkill so what do I know!

[MagicalTrevor]

Fastdruid said:

That really is an awkward place.

I think I'd probably have made it kind of as a triangle shape and so the pump outlet went through the middle. Not that would have been easy either.

Then again my engine mounts are massively overkill so what do I know!

Coincidentally I sent this to a mate earlier



I think it won’t hurt to add the triangular brace

[shirt]

How do they do it on the gemzoe caterhams? Is it not possible to put an additional chassis member in and use that method?

[Fastdruid]

MagicalTrevor said:

Fastdruid said:

That really is an awkward place.

I think I'd probably have made it kind of as a triangle shape and so the pump outlet went through the middle. Not that would have been easy either.

Then again my engine mounts are massively overkill so what do I know!

Coincidentally I sent this to a mate earlier



I think it won’t hurt to add the triangular brace

Great minds think alike!

[MagicalTrevor]

shirt said:

How do they do it on the gemzoe caterhams? Is it not possible to put an additional chassis member in and use that method?

Gemzoe mounts are like this. I plan to mimic those albeit with the gusset piece above

[MagicalTrevor]

Decent progress made at the weekend although nothing that really warrants a photo.

The second mount location was decided upon and I've begun fabrication of the legs. I'm probably going to add a 3rd engine mount at the front and incorporate that into the replacement chassis bracing (that I cut off at the start of all this). Despite having more metal to mount to, the packaging is event trickier than the 'hot' side of the engine! For that reason I'm using thicker wall square tubing and hence the 3rd mount.

Finally the ultra tight bend exhaust bend arrived. It's Chinese as that's all I could get with a 0.84D bend. All the quality UK brands could only supply a 1D bend.

I just sat it on the exhaust flange to measure up so it's not been welded.


This is the location it's going into. Note that there's a 110mm gap between the turbo flange and the footwell


So rough measurements show that it ought to fit... just! I'll be using a lot of heat protection in this area, that's for sure.


This will actually curve down to avoid the chassis brace (which I don't really want to modify) so fingers crossed it will fit.

[MagicalTrevor]

Further progress on the engine mounts.

Here's a photo in-situ before being fully welded (I couldn't take a photo of the welded item in-situ, before finishing last night, because it was still hotter than the sun).




The silicone elbow needs to be trimmed down to avoid the chassis member but there's a good chance the chassis member will be re-routed anyway.



I took a video for a mate, it's not particularly interesting but it does show a quick tour around the engine bay as that helps give context to the task at hand

YouTube - Engine Tour