Looking very good Duncan

 

cheers Bob - hopefully will fire it up today

 

What a giant leap forward!

Why not fit new rubber hoses all round?

 

Just the M word

The existing hoses are fine though as they are only 2 years old and any that werent have been binned I believe.

 

Fair enough, just thinking of reliability as you race away from the rest!

The field of cars looks awsome in both classes....

 

Yeah, the field of cars looking blinking intimidating

If I get to 500 bhp for the first couple of rounds it will put me fairly in the middle of the field. The game has moved on big style this year. It will be fun playing with the big boys.

I have done way more than I should have at this stage to be honest, but whilst the engine was out it made sense to do the stuff I have. There is still a huge list of things that need to be done aswell as things that I could do either sooner or later such as heads and cams that would take it that much higher.

The step over 400bhp is a big one to get some degree of reliability and hopefully this spec will do the job and make the engine future proof as well as making it less worrying in competition. It would have been too easy to just stick some pistons in it and hope for the best.

I think you will follow a similar path when you decide what to do with yours Graham, getting the torque that you want is expensive and you end up overspeccing some parts for the sake of peace of mind even if you dont use the full potential at this time, it is useful in the future to know you could change the characteristics of the car in a very short period of time by bolting on a new turbo.

 

Dead right.
My Sti is sitting all cool and calm in the garage now less it's racing seat which is in my 911 for this year.
Will wait to see how the rest in my 'old' class fair, esp Rob and the battle with 2 EVO's and the Big V8 Audi. there are at least 2 more Impreza's joining in.

All too much competition and I don't want to spend on the car and still be uncompetative.
I have other plans, but the wife is not too enthusiastic at the work required, so waiting to see if a part finished car will appear in the small ads.

I would expect about 20% of that entry list not to make it to the first TA round.

 

The 911 looks great fun though or the Murtaya for next year

Would be a shame if 20% drop out of round one - i guess some drop outs/failures is to be expected. But it would mean more space on track

 

can i ask who done the sleeving job on your block and have they garrantied the sleeves wont drop .

reason for asking is im about to build up and ej22 odb and thought about sleeving it

 

Scoobymania / Area 52 Autosport have done the liners/sleeves.

ScoobyMania Online Shop

They are top hat liners so wont slip down.

 

That's a bold statement there Duncan, good luck!

 

Never say never in this game but best of luck Duncan...

How much did it cost for the o ring in the heads?
and what was the exact reason for that?

Regards

 

To make the head gaskets seal even tighter between block and heads around the bore, should also help to lock the bores in place

 

Do the rings (are those 'Wills Rings'?) stand very proud of the head surface?

 

It depends on the definition of 'very' but they are proud of the heads - I would be guessing at how much though tbh.

 

Having dropped Annabelle off at Triathlon club I headed up to nottingham with a boot loaded of things that I could do today and to see the progress of the car (more important really).

Got the usual great welcome and a cup of coffee thrust into my hands by Mike, who I have to say publicly makes a good brew Jase does too but it took him almost all day to find the kettle, something to do with 'Tigers' was stopping him

Anyway... walking into the workshop and finding my car transformed is a lovely feeling but I could tell something wasnt quite right. The car was up on the ramp and had been running but was not making oil pressure at idle like it should be. .... hmmm Not good. Mike, Jase, Mark and Dan couldnt understand why thy would be as the engine was built as they would normally but this one was not holding pressure.

Much head scratching and debating later narrowed it down to the baffle plate being the only element that was different in this build so up with the engine and sump and baffle removed, MORE new oil, and back together to see whether this could be the culprit. Fired up (once primed) and the oil pressure was immediately bang on target for it. Hmm.

We decided that the baffle tray will stay out of the car until Cosworth can confirm what testing they had done on it and confirm why it would lower oil pressure to 10 psi at idle

I do have to say that it purrs beautifully and sounds proper with the characteristic twin plate clutch rattle at idle

Anyway some pics:

An engine bay:



The front now with the FMIC in there:





One thing ticked off the list now is the drivers seat, the adaption of the rails done by Jason (sidewaysfletch) on my measurements worked perfectly:





6 Point harness fitted:



Passenger harness fitted:



Superb

I left the car with them whilst the last few jobs needed finishing, but almost there now. 8)

 

looks a proper job.

 

Those arnt wills rings Graham, they are just a thin wire, which digs into the stock design head gasket. Ive used them on NA V8's in the past but found them no better than a good quality metal head gasket, they may be more beneficial in a turbo app but havnt been needed on engines like in the Zen car. It will be interesting to see how they work out which is why threads like this are good to read.

Wills rings totally replace the head gasket fire ring, they are gas filled rings that are 3mm or so wide and deep, you then cut a groove in the head to locate them. Some WRC engines use these, they also have gas ports on the outside of the rings, so if the heads lift the gasses get expelled out of the head into atmosphere and dont presurise the water system, very clever little feature that is. The water jacket is sealed via a thin paper gasket that is the same thickness as the protrusion of the wills ring, often you use rubber o-rings for the oilways if they carry presure, so you effectively end up with 2 or 3 gasket methods in one aplication.

The risk with these type of sealing methods is if you get the dimension of the cuts wrong, you can end up cracking the heads as the localised presure may be too high for the head bolt torque, you can also end up with water leaks until the engine is up to temperature closing up the gap on the paper waterway gasket.

I'm not keen on that cosworth baffle plate arangement, it seems very restrictive in getting the oil into the sump, certainly a very poor substitute for a proper baffled sump which you can get made for £300ish.

 

That was certainly our findings today John. Pressure would be good to start with then reduce down as oil was trapped on top of the tray and oil starved out of the sump. Not good and very disappointing.

 

Possibly need to run higher volume of oil with that plate, just to compensate for the slower return to the sump.

 

John:
It was that thought that prompted the question on the rings. The studs are 'miles' away from the very localised ring pressure which must potentially bend the heads. If the rings were (say) 0.1mm aove the head face then the head will be stood off by that ammount and the suds at the corners of the heads would be trying to close that gap when torqued down..

Must admit that cosworth baffle plate looked wrong even to my eye with only gravity to open the flaps to allow oil to pass.
Surely a labarinth of plates would be better?

Certainly is a good read!

 

Glad it is interesting.

Looking at the new narrow sump (as per the spec c 06) and refined oil pickup pipe side by side with the pre 06 equivalents, there are definite improvements.

All that is there without the baffle is gravity Graham, if you pressed on the flaps yourself you would know how little effort (ie none) is required to open them, it 'shouldnt' be an issue. Obviously something was though.

 

Did you try pressing down on those flaps when they had a coating of oil on them?

As soon as you get a liquid on the contact face you increase the force needed to open them significantly due to stiction and surface tension properties.

Ive never seen that type of baffle flap used horizontally, they are usually mounted vertically. To work as a baffled sump you need to suround the oil pickup as quickly as posible, ideally with a surge tube feeding the pickup directly from the top, with the sides being fed via a baffle arangement.

 

The flaps are effectively hanging open when the plate is fitted so no pressure should be needed.

We did wonder about the surface tension of the oil or even the running in oil versus normal oil.

The pickup on the 06 is partially shrouded unlike the earlier versions - It looks much more efficient.

This is still on the list of things to solve though.

 

sad to hear that the baffle plate did not work as i was interested to see how it performed...

Great read ..

Thanks

 

Cheers mate.

Not sure that I mentioned the TGV delete done aswell by Area 52 Autosport. Getting rid of the obstructions in the inlet should help flow.

 

The list as it stands now:

Power:
- Engine (DONE)
- Turbo (DONE)
- FMIC (DONE)
- GT Spec Gen II Headers (DONE)
- Clutch (DONE)
- Baffled Sump (to be decided finalised)
- Mapping
- Fuel swirl pot (to be done in March)
- Oil Cooler (tbc)

Handling:
- Whiteline camber bolts (DONE)
- Suspension set up & geometry (6th March)

Brakes:
- Fit Ducting

Interior:
- Seats (DONE)
- Rails (DONE)
- Firewall & fittings (DONE)
- 6 point cage (ordered)
- Harnesses (DONE)
- fit Phormula Knock Sensor

Tyres:
- Toyo R888 to be ordered soon

Exterior:
- Fit front splitter (next weekend's job)
- other aero stuff (next weekend's job)
- new Graphics (5th March)
- Bonnet catches (this week)
- Tow Hook - need to buy one as the std one wont fit now

 

What bhp/torque will you beast be?

 

We are hoping for around 480bhp and 500 + lb/ft on pump fuel in its set up for Donington and Knockhill with more on more exotic fuel if I run on that.

We will change turbos after that and try something a little wilder for silverstone

 

As used by RCMS, theres some nice pics on their website if you want examples

David