ghetto turbo build page 2

CMF_frank2

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got the 72.5mm bored block done at last (bloody freebie/matesrate jobs get pushed to the back of the que eh lol :) )
he left about 3" thou for me to hone out with grinding paste, for custom piston fit (corsa 3 cyl pistons, so a slight difference in their sizes)

 

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CMF_frank2

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:)

fitted the rods and measured the crown to blockface with a CG13 crank (4.5mm, not a lot different to the CGA deepdish piston, or about 3.5mm with a CGA crank)
which will give about 9:1 c/r @ 1330cc, or about 10:1 c/r @ 1367cc
 

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CMF_frank2

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SSUK WROTE:

"Wow, that's quite an increase in quench over stock......naff all chance of PTV contact there then ;)
Click to expand...

aye :) the stock CGA has a 6.5mm dish eh, so not much of a drop really, the #3 piston is at TDC in the pic (CG13 crank)
you can see how i was able to remove 2 links from the lower chain and skim 2.5 mm off the block and 2 mm off the head on my high comp N/A engine
 

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CMF_frank2

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schoona WROTE:

"So are you bolting the T15 onto the high comp NA frank?
Click to expand...

i think that would be asking for trouble mal :)
i miss the snappyness of the 10.5:1 c/r boosted engine tho (this current one is about 8.75)
i think 10:1 and 1/2 a bar is ideal for a DD personally, but i,m seeking that 1/4 mile title lol :)
 

CMF_frank2

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13.5:1 c/r N/A proved to be a bit OTT lol, so that CGA crank is now fitted to the 1367 corsa piston turbo engine above ^.
and we are currently running a 1.0 coilpack piston 11.5:1 engine @ 5psi :)

 

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CMF_frank2

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thanks majiga :)
and yes paul it stalled when i dipped the clutch, my maf is pre-turbo with no dump or recirc valve installed, so when i wot then lift i get compressor surge, and it sneezes out through the air filter chooo !
(so the maf senses the reverse airflow and thinks the throttle has been opened)
 

CMF_k11_facelift

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Is this the corsa pistoned one, and you reckon the corsa pistons are better suited to boost? Or is this one coilpack pistoned and your giving them a beating? lol.
Loosing track of what engine you have in it.
 

CMF_frank2

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its that 1.0 coilpack piston one i ran for a while last year matt, they have thinner rings and shallow ringlands, so i assumed they would be weaker...............holding up well so far tho :)
and the corsa pistons are a very similar design, and anodised too (like the bulletproof GA ones), tho the c/r is 9 ish (i,ll fit that engine next week)
 

CMF_frank2

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jeeez what an eventfull few days lol :eek:
the corsa piston engine all of a sudden starts sounding like a bag of chissel,s ffs, chick-chick like mad at idle, but not so bad at higher revs !, so in goes an 11.5:1 engine while i strip the corsa piston one (turns out to be a blocked pinhole oil hole in the lower chain tensioner, and its running sweet again now)
then we fit the original hitachi tubby and the car is going like the clappers lol, so i up the boost to 10 psi at work today ***** for brains twat eh :D*
 

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CMF_frank2

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hydro-locked from the ingest of coolant lol :D re-using headgaskets has finally bit me on the bum eh
well its certainly got its mo-jo back now anyway, the garrett shaft had worn that bad that some of the impeller has worn away against the housing, and lost some cfm i guess.
this corsa piston engine has a lot less c/r, and will stand more boost, but high comp/low boost is certainly the way forward for gas milage
 

CMF_frank2

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uk_facelift WROTE:

"oooouch

head gasket fail, so it's not really the result of too much boost.. That's good to hear I guess.

What are you replacing it with?
Click to expand...

too much boost really matt, (and the weakened/rotted gasket around the fire ring eh).
11.5:1 + 10 psi must be equivalent to a c/r of about 17:1 i guess.
and last night must have been my fastest engine change so far lol, and i had to re-assemble the corsa piston engine first ! (head, chains etc)
 

CMF_frank2

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:)
cleaned up the side exit exh today, and painted the 2 silencers (which are,nt s/s)
my bought s/s system pictured too :) (which is too loud n/a, and too quiet turbo,d)
 

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CMF_frank2

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i can barely hear sidey if i wind my window up mal (just how i wanted it)
testing out more spare rebuilt engines atm (2.5hr engine change this morning :) )
i much prefer the high comp/low boost, i think the low comp 1367cc corsa piston one needs intercooling or else a bigger tubby tbh

 

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CMF_frank2

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runnin 4 or 5 psi atm :) it does,nt have time to build any boost in 1st lol, but starts to boost @ 3.5k in 2nd etc, and the boost needle climbs at about the same rate as the tacho needle
v-tec yo :D

 

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CMF_frank2

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this blow-through setup is proving to be flawless in regards of fueling and throttle response :)
and we,ve refined the reg a bit more, by fitting a ghetto vacuum damper to remove the pulses acting on the reg diaphram @ idle and low throttle (the fuel filter that is fitted into the vacuum pipe, and carb jet/restrictor fitted upstream inside the pipe)
 

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CMF_asdame

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baguete WROTE:

"asdame WROTE:

"fantastic :) same power as mine.
got the mapping all sorted out now?"</div>

Yes, as i said before, we must be twins :p

I need to check if i can get the turbo to spool a bit earlier, but its good like this.

How is your forged engine going?
Click to expand...

aye

u could try my electronic boost controller method so the WG stays shut long as possible for the fastest spoolup and lowest boost threshold?

the forged block is deglazed, crank journals grinded, gonna pickup some new 0.25mm oversized main & bigend bearings, and waiting for new piston rings from US.
meanwhile i'm designing my own oil baffle

http://micra.org.uk/threads/pollymobiles-rebuild.35251/page-60
 

CMF_frank2

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we,ve pulled the TD05 off for a few days to do some N/A testing, it gives me a chance to clean up the welds and check it all over (zero shaftplay still :D )
note the open-air wastegate lol, i was gonna encase it but it hardly opens anyway, so cba :)
the 4 psi setting made it quite slow to react (aka laggy) i dont think the wastegate seals properly with the light spring (w/g actuator pipe too close to the turbine/pressure waves or whatever)
so the boost climbed a lot better on the 10psi setting/spring
 

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CMF_frank2

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this one shows the w/g bracket welded to the body, so that i can easily remove the whole core (1 bolt and some pipes) and fit the blanking plate intead
 

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