So following the 300bhp mapping and upgrading of the coils I had a bit of maintenance to do. With the new z32 afm, the air filter wouldn't sit
where it did before so I went to Slide Motorsport to have custom hard-pipe fabricated.
This took something like 4 hours and is made up of over 25 individual 'slices' to get the angle correct. The pipe size goes from 3"
to 2" over the course of the bend.
It worked perfectly and gives an entirely different turbo-stall sound now that the pipe isn't compressing under boost.
I went shopping -
and then booked my second trackday of the year at Blyton again.
I also bought a cheeky private numberplate
With the more hp came less traction, so my hand went in my pocket and I bought some new Nankang AR-1 semi-slick tyres. This is a photo of them side by
side with my previous ones -
The difference is huge. They are so sticky.
Videos from the trackday -
Me getting absolutely destroyed by a 300bhp, 400kg kitcar
Me vs a 400bhp Turbo Reliant Kitten
Overtake Compilation
Oh, the mapper put a bit of 'pop and bang' into my map, which produces stunning flames. I really like flames.
The temperatures of the car at the track did still keep creeping up, so I installed a 'post-turbo' water cooler in the side panel -
I also swapped out my aluminium rear diffuser for a carbon fibre one, saving me nearly 3kg.
Last month I booked on at Anglesey and shared a garage with a car-friend
Some videos -
Me vs Cayman S
Compilation of Sliding
The videos and day at Anglesey highlighted something. I have major, major traction issues. That's going to be pretty obvious given the power and
weight but there's something a miss somewhere. The next job is to do some checks on the chassis, with the possibility of altering the axle
mounts. Swapping the Capri LSD for a "proper one", and altering the spring-poundage to something that is more suitable.
There's always things to do, but I wouldn't have it any other way
Oh, in other news I killed a bird with the car
2007bc Photography - Commercial and Wedding Photographer based in West Yorkshire
i had some new rear shocks fitted by Procomp to try and improve traction - Custom valved Protect..
I cut up the front end bit to get more air in!
Bought some new wheels..
Bought and modified some carbon fibre rear arches
I did a trackday at Croft, managed 8 laps before I broke it I did however manage to get past a GT3rs which I was fairly happy about!
Made a carbon fibre bootlid
Ruined some tyres -
Did plenty of miles on the road...
...and finally some proper mods. Boost pipes replaced with all stainless ones to reduce hose clips and therefore the risk of leaks. Coolant hoses
replaced and improved. Oil cooler moved somewhere more practical too.
2007bc Photography - Commercial and Wedding Photographer based in West Yorkshire
All sat tight ready for the bi-annual update? OK then
After the last trackway I decided it would be a good idea to change the clutch and flywheel. The flywheel was replaced for a 5kg, down 8kg from the
factory 13kg one!! Great weight saving and great improvement on acceleration.
I also replaced the clutch at the same time.
It's a good job I decided to take it out...this could have been very nasty indeed.
I then broke the clutch in, the only way I know how
I did a trackway at Blyton to get the year started
Managed a 1.11 around Blyton, more than happy with that.
Made a car friend and went to the East-coast
Time for some improvements; I'm all about the carbon fibre this season -
Interior done (unless I trip over some CF seats somewhere...)
Now lets look at that mess under the bonnet;
2007bc Photography - Commercial and Wedding Photographer based in West Yorkshire
Ultimate weight saving with a carbon fibre VIN plate -
I was having major problems with over-heating still. I spoke to numerous companies that make bespoke stuff but was told to simply replace the
'copy' chinese radiator I had for a proper one. Out came the wallet
The old rad was replaced for a slightly thinner (but crucially lighter!) Mishimoto version. Temps are hugely reduced, I genuinely can't believe
the difference.
More carbon weight saving in the form of a carbon-fibre coil-pack cover
I then decided to rip the car apart during the 'warmest' weeks we had over Summer. The reason; carbon fibre side panels. Partially weight
saving..partially to save me money when the car gets its new colour. More on that later..
The old side panels were fibre glass so it was a mixture of wood chisels, dreamers and grinders to get it all off.
I decided to 'do it properly' which meant all the front suspension came off.
I had vented side panels before; this time I upgraded them to 'fins' to give further cooling.
Finished!!!
Replaced the headlights for something brighter, smaller and again lighter!
Then went out for a drive with my buddy. He has a Hayabusa powered 'MK' kit car. We did some comparative roll-racing. My car goes past his
like it's standing still; I genuinely thought he'd put the brakes on and given up as I went past!
I'm at the last car-show of the year this weekend and then all the panels that are currently green are coming off to go to the local bodyshop
for a new colour. This will be totally different to the current/previous ones.
2007bc Photography - Commercial and Wedding Photographer based in West Yorkshire
The car made it's trip the most pointless show ever. It was a local Gala/Country Fair that had a stand of Classic and Sportscars. The organisers
for some reason stuck the cars in the corner of the field miles away from footfall and the public.
The outcome of that meant I was home by 1pm so decided to tear the car apart ready for the bodyshop.
Scuttle and bonnet vents off
Rear panel removed (this took so long!)
Panels loaded into the daily for paint. Holes to fill all marked up
Time to paint the cage whilst I've no panels to worry about. Nothing lairy, but I am swopping from matt black to a gloss black to tie in with
the new paint and the carbon side panels.
...and this is just one of the potential new additions. A big rear wing. Currently just thrown on the cage as a test-fit but the end-game is to have
custom CNC brackets off the rear bars. I have a friend in SA that competes in their TimeAttack and the rear wing made a big difference to his traction
in high-speed corners; something I really struggle with.
The Jury is still out on whether or not it will actually go on. But my other on-going project is a big front spoiler/splitter to match from a Formula
3 car. As with the rear one; I'm still not 100% on how I'll progress with this yet.
2007bc Photography - Commercial and Wedding Photographer based in West Yorkshire
I'm never far from 'For Sale' boards on a variety of forums.
Last week I found a reasonably priced steering wheel to replace the Momo Caterham one that I already had.
The old steering wheel was 260mm whilst the new one is 240mm, so a fair bit smaller. (and crucially lighter, ha)
and all fitted into the shell of my car
Good news from the bodyshop - the panels are all prepped and ready for paint -
Now a step-back in time.
This is the development of my front 'aero' - still very much a WIP. Still very much a learning curve for me. Whether or not it will work,
make me faster or slower, or just fall off is all up in the air. It may not even make it onto the car, we will see.
No idea where the front spoiler is from; I suspect some entry level 'formula' racing? Jazzy graphics that's for sure.
Removing the graphics and marking it up
VERY rough idea for a bracket
Original mounting brackets on the wing removed and new ones made. I just needed to make some holes for them
Something like that -
New bracket plates mounted. Sikaflex always comes in handy. Along with some fixings underneath that have been ground off. They aren't going
anywhere!
That's as far as that's got at the moment.
Whilst waiting for my body panels to come back I thought I'd give the car a check over. Around a month ago I smashed the sump pan on a spirited
drive over Holme Moss. I knew I'd hit the floor but, as it wasn't leaking I didn't really worry about it.
On jacking up the car the sump had clearly taken a big hit -
Not ideal - decided it best to take the sump off and find a replacement.
On taking the sump off I found -
Urgh.
Doesn't look better on your finger either!
Best take a look at the bearings then -
Clearly worn but not that bad. Original as they have a 1989 date-stamp on them!
I've examined some of the other oil-ways, checked the filter etc and there is no other gunk or mess anywhere. I'm fairly convinced (or
should that be have convinced myself) that the gunk and mess was in the sump was all dislodged when I smashed it. I also noticed the pickup mesh was
damaged and dented so was obviously resting on the base of the sump itself.
I've ordered some replacement bearings (Clevite) and will of course flush out the engine, change the filter and replace all the necessary
gaskets. I'm not one to spend money un-necessarily being a Yorkshireman and I'd love an excuse to actually rip it out and rebuild it with
uprated parts but until it ACTUALLY breaks SWMBO says that's not an option
2007bc Photography - Commercial and Wedding Photographer based in West Yorkshire
I missed your previous pictures so this is a little bit late...
The square corners in your bonnet may lead to premature cracking.
I sincerely hope I´m wrong.
AA
Beware of what you wish.. for it may come true....
I can't believe it's almost 6 months since I last updated this thread. I'd love to say it's been an amazing 6 months of tyre
shredding antics, track-days, sprints and road-trips but alas it's been half a year of utter crap due to mechanical issues..
Read on...
I finally saved some pennies over Christmas and got the all important Quaife LSD I'd always wanted.
Out came the Ford Capri 2.0 axle and off it went to a chap in Sheffield to have swopped. A bargain at £75
That was fitted nicely back into the car. Bolts all checked and off we went to the local watering hole.
The difference from the Ford 'LSD' is quite simply phenomenal. Where before I span through the gears the car now hunts out even the
smallest bits of traction and when struggling, instead of simply spinning up the wheel 'tramps' as it fights for grip. A serious serious
improvement to the car.
I went to a coffee and cake meet at GBS cars in South Yorkshire
Finally replaced my old and crusty 'caterham' harnesses with some wider Titon Motorsport ones
Went out for some more spirited drives
Now back to the upgrades for a moment. You may recall the large front spoiler from previous posts. I mocked up some cardboard templates of brackets
and a friend at a local engineering firm made me some CNC versions
Quickly offered up on the car
There was far too much side to side movement so I added some wire bracing and also made my own end-plates from carbon fibre.
Cleaned it and went out for some more drives
It was at this stage things took a turn for the worst...
...you can see the dark clouds rolling in.
Since putting the engine in I've always had a strange rattle. The rattle went away when the engine warmed up which implied there was no issue
with the shells. I swopped them out anyway for ACL ones but the noise remained. I ignored it, for a bit but then noticed the engine was breathing a
lot! To the point where people were pointing at it in traffic!
So, before the engine stained the country roads of Yorkshire I decided to take the head off for a nosey.
Pulled out the magnetic sump-plug to find this -
not ideal!
Shells had done just 35 miles and look 'ok'
Cylinders a bit of a mess
I decided at this point there was no going back so out came the pistons..with there rings in pieces
3 and 4 were gone. 4 being the worst
Note the varying fuel spray marks on the pistons which shows the fuelling in each cylinder is different -
My engine spread across my workbench
Engine out
At this point I wasn't sure what to do. I'd priced up forged rebuilds and new management (c.£2k) and even a normal rebuild (£1k) when I
stumbled across a second-hand engine for sale for the right price.
On my way brick from London I called off the M1 and threw it in the back of the daily
..and back at home
The GTiR injectors had to be cleaned; no brainer decision. Off they went to a local cleaner who reported all were 'ok' but one was
'bad'. After cleaning all were 'good' and had matched spray patterns and quality. I also replaced both my fuel filters too.
A few days later the new engine was in the car
Noticed a burnt through vacuum hose going to my boost controller solenoid which I promptly replaced
All back together (just 11 days off the road!)
..and mostly importantly working well
The old engine was clearly dying as the new one felt like a monster in comparison... until on it's second outing to Wakefield the temperature
rose suddenly and water burst out of the expansion tank.
I limped to a lay-by, let the car cool down, topped up the water and then cruised home slowly.
Deciding that the new engine probably had a manky water-pump and galleries I flushed it all out and replaced the water-pump. (old on the left
obviously!)
Coolant refreshed and engine timed up again I plodded around the local area for a test drive. No issues forthcoming so I headed for the local
hillclimb - 'Holme Moss'.
Holme Moss is a 524metre high hill between Yorkshire and Derbyshire with a windy road all the way to the top. A national speed limit of course so
speeds of up to *cough*60mph are achievable
I got less than a third of the way up the hill when I saw the temp sore past 100deg and smoke come out of the bonnet. I pulled over and saw
smoke-machine style effect coming from my exhaust. That'd be the head gasket then
Turned round, rested in a layby and called a mate to tow me home.
Sooo...off with the head again -
Clearly a blown gasket between the waterways around cylinder 4 (the one furthest from the
pump)
The spark plugs show a huge variance in colour and from the image indicate 1 & 3 are running very lean
I've no idea what the actual problem is. The tune hasn't changed. The fuel quality hasn't changed. Dunno, out of ideas.
I took the cylinder head to a local form which has now been pressure tested and skimmed and I've also ordered a thicker Cometic head-gasket to
fit.
The plan is to get it all back together and get it back to my tuner for some runs on the rolling road to check it all over before I melt something
else.
IF, if this engine can get me through the rest of Summer then I am committed to a forged build with proper aftermarket management and a target of
400bhp+ over Winter. If it doesn't, then it's likely to be the end of the road for me and the car.
2007bc Photography - Commercial and Wedding Photographer based in West Yorkshire
It’s been 14 months since I last updated this thread and to say it’s been one hell of a journey is an understatement.
Following the replacement cylinder head and thicker head gasket in my last post, I suffered further problems. Whilst re-fitting the camcovers I
dropped a bolt into the cylinder ?
The head had to come off again to get it. In my haste of refitting I put the head gasket on the wrong way round! I didn’t notice and ran the engine.
Oil couldn’t get from the block to the cylinder and bang. The cams seized and the cambelt snapped. One dead engine.
Not to be put off, I threw all my spare parts together and finally, finally got the car running. But alas, the eBay engine was a bag of nails and
smoked (and clearly had lots of metal floating around in it). I made the decision to do a forged build.
Over the next 3 months I amassed my pile of parts; APR rod bolts, ACL race bearings, cometic head gasket, carillo forged pistons and maxspeeding
rods.
I also bought a new turbo (gt2860rs) along with a tubular manifold. I acquired another cylinder head which I sent off to local specialist AL
Developments to be improved and checked over.
With money (somehow) still in my bank, I invested in proper aftermarket management. My loom was old, maybe 30 years, so I wanted something that would
work well but came with a new loom.
After many many hours of research I plumped for MaxxEcu. It’s a largely unheard of system in the UK but its features largely outweigh those of Link,
especially for the what it cost – sub £800 WITH a loom.
I entrusted the making of the loom with a company near Leicester that will rename nameless. The engine build was entrusted to a good friend from
Kent.
Fast forward to early January and I had a new loom, ECU and a built engine. The engine was built-up in my garage and then fitted to my car over the
period of a few days..
I didn’t want to go through the process of running the engine in on the road. It was Winter, I have no roof or windscreen and didn’t want to risk
breaking down somewhere.
The chap that sold me the ECU and loom offered to run in and map the engine for me at his mates rolling road.
Early April I’m all booked in and trailer the car down to ‘StreetRacers’ so we could borrow the rolling road. The run-in commenced around midday and
we completed around mid-afternoon. Injectors were swopped for 1000cc ones and then proper mapping commenced.
During mapping, I noticed the car was breathing quite heavily but apparently the guy knew what he was doing so I kept quiet.
Mapping stopped around 11.30pm. The car apparently made 299bhp (although I have no evidence of that) but would not respond to increased boost levels.
Boost increase was attempted up to 1.6bar but the power remained the same.
I was told that the poor intercooler design and pipe routing was to blame. We did a quick test drive on the road and the car had huge amounts of lag,
but when boost came in shot went well.
I went back home and was told to get the intercooler fixed and then come back for further mapping.
Over the next few weeks I continued to use the car, fairly hard.
I broke down on two occasions. On the first, it appeared as though my lift pump was not powerful enough to keep up with the new fuel demands. My swirl
pot was ending up empty. A high-powered lift pump was purchased and installed.
The second time, an oil cooler hose split leaving me stranded and required further assistance to get home from a friend.
The car then went over to Clark Custom Fabrication in Barnsley to have the intercooler pipes modified; which at the very least made a good visual
improvement!
It should be noted at no point did the car suddenly loose power or feel any different to my midnight drive immediately after mapping.
At this point, I just wanted the car done and working so went to my regular tuner in Leeds – RS Tuning.
Once on the rollers, Paul attempted to do a power run and immediately stopped. I was told it was knocking [DET]. He took 4 degrees out across the map.
He tried again. Still knocking [DET]. He took another 4 degrees out and just about managed a full pull.
The fuel and ignition maps looked like a mountain range. Paul tidied up the fuel and ignition maps before a figure of 255bhp was produced. Something
wasn’t right.
We pulled the timing cover and found that the timing had jumped 3 teeth on each cam. Mapping was halted and I was sent off to replace the entire
timing belt setup.
I replaced the belt and pulleys but the car still breathed and had smoke emitting from the exhaust. I decided to take off the cylinder head.
On doing so, it was apparent that the head gasket had gone and cylinder 4 had some bore damage. All 4 pistons had evidence of DET marks.
I pulled out piston 4 and it looked like this. Basically scrap from sustained DET. Pistons 1,2 and 3 were all the same.
The pistons went in the bin along the head gasket, bearings and block.
I spoke to the original tuner, who blamed the new intercooler pipework for the cause DET and of course the slipped timing. I drove the car daily since
it was originally mapped and I know it never felt any different. At this stage, I think the timing jumped whilst it was on the rollers whilst it was
being run in and the DET was never noticed.
Of course I have no proof of this so just need to take this one on the chin.
After a few days moping about I picked myself and started ordering parts; pistons, head gasket, gasket set and bearings.
My spare block went to the engine builders and was machined and another friend gratefully came to my house and built the engine up for me.
The engine was fitted, run up to temp and the oil dropped. New running in oil was fitted and I took the car back to my regular tuner; RS Tuning in
Leeds.
A coil pack died during mapping, so a trip to GSF fixed that. Around lunchtime we ended up with 307bhp @ 6,500rpm @ 1bar of boost. The original
standard engine made 298bhp @ 7,500rpm @ 1.1bar of boost. So I’m making more power, at less rpm and less boost.
Throughout the mid-range I have an increased of between 30-40bhp across the board so a huge improvement in that regard.
There was a problem though, the engine was getting hot on boost and wouldn’t cool down. I was told to have a look at the cooling problem, swop the oil
out again and get some road miles on it. Then return to finish the mapping.
The cooling issues was found to be a lack of thermostat. I’d removed this from the eBay engine and simply never refitted it as I stupidly thought an
engine without a stat would run cooler but apparently this isn’t the case.
I’ve dropped the oil again and been out for my first drive which I’m pleased to say went very well.
Over the next few weeks, my plan is to get out in the car as much as possible before heading back over to Leeds to get the mapping finished and see
what she can make. Based on other engines with a similar specification I’m hoping for somewhere in the region of 330-340bhp but it is of course not
just about chasing numbers.
2007bc Photography - Commercial and Wedding Photographer based in West Yorkshire
