The '2 ton bugswatter' - back for a gentle stroke

[Bram]

cool stuff. Great project to follow

[Billman]

Oil pump stripped down for clearance inspection and cleaning

JP, what did you checked for in the oilpump? Visible signs of wear or something measurable?

[JP]

Damage to casing/teeth. Lash on the teeth and clearance to the cover plate and main casing. Height clearance can be machined and fixed lash and casing clearance unfortunately cannot.

In the interim the car is almost back on the road. Engine and gearbox are back in the hole with just gearbox fluids, coolant and front end to go back on.

Will @ VRS has sorted me a very nice rebuild box with 1st 2nd carbon synchro upgrade. And is getting me a nice set of grooved discs with yellow stuff pads to fit on Friday which should leave me with enough time to bed in the brakes, clutch and gearbox along with a remap before ADI.

[Error404]

What is considered too much clearance on the pump JP?

[AndyP]

Updates?

[JP]

Hopefully be driving again tomorrow had to walk away from it as just not enough time to be dealing with it due to workload. One of the reasons I also haven't been on the forum of recent.

[chaloux]

So I saw a little MRC dyno video!!! Fill us in!

[JP]

I'll do an update with full spec later today/tomorrow when on a computer and my own vid however in the interim my sig tells a bit more ;-)

[A80Avant]

let us know what turbo you ended up with. 572hp is mental!! with dual mass flywheel as well! as many thought that it cannot handle that much torque/hp!

[Jamo]

if it's the same turbo I talked to him about is a hybrid from owen developments. glad to see the planned thinking behind it has given good results.

Nice work sir

[JP]

Thankyou for kind words gentleman

This is the spec I've ended up with for the time being. I'm going to run the car like this till either the dual mass packs it in or the end of next season so I can enjoy it instead of having it of the road for the main race season like this time round.

- Engine 2.5ltr stroker using diesel block - Pretty much as per build

- Except lightweight flywheel and triple plate clutch has been temporarily change to a Dual Mass with spec 3+ clutch

- AAN intake manifold port matched to head

- Wagner K26 Evo exhaust manifold ported polished

- 3" Downpipe and system with stock AAN backbox on the dyno the power starts to tail of after 6800-6900rpm on the road I got an actuator opened bypass valve and it pulls strong to 7800rpm.

- Boost run 63mm to 450x300x76mm bar and plate £60 ebay intercooler with 76mm boost run to MAF and then throttle body

- Overbored 69.5mm throttle body

- Custom breather system, oil seperater/catch tank setup

- Cams are Audi 7A ones that have been modded and dialled in to personal spec for turbo use

- 034 coil packs with custom quadcore leads made in the UK by performance leads

- Owen Developments GT3079r with steel bearing races and uprated billet heatshield fitted with a 0.82 K26 hotside and HKS mushroom filter. (Basically a 3076 with an 82mm billet wheel machined into it)

- Stock AAN wastegate ported with reprofiled seat and valve

I think that's most of it

and a couple of pretty pictures

New billet wheel vs old one




Figured I'd be safe as I grenaded the bearings in the last turbo so I went for the steel bearing race and billet shield upgrade




Turbo in all it's sealed glory




Intercooler setup




Engine bay in all it's glory courtesy of Quattro Coachworks




Car on the dyno last night




Finished power curve




As for driveability in first gear I've got to catch it to stop it bouncing of the limiter at 8000rpm as once the turbo comes alive at 4k it rips round. 2nd it still tearing it's *** of and by the time we get to third well I haven't found anywhere that I would consider safe to try it's strictly track day only in the upper gears till redline.

The intake manifold can do with being a bit better now there is a tiny bit of surge in the higher gears as it starts to come onto boost just before 4k if pulling from 2k it's there for just around 50-100rpm which can be resolved by downshifting (eventually a better intake though).

Really happy with how it's turned out it's coming on power the same as it did with the smaller 3076 with a 0.63 housing on the 2.2 @ 2.1bar and carries on to make more power for longer running 1.75 bar dropping to 1.65bar, I did force it to hold 1.75 till the 8000rpm redline at one point but the exhaust/wastegate became such a restriction it lost 20hp so I got the controller to trim it at 7000 and 7500rpm.

Will try and do a vid later on when I get a moment to sift through the footage.

[mcandmar]

Great to see this back on the road JP, it was impressive before on the old turbo with a temporary map, must be a riot now. Would love to hear it with exhaust bypass open and wound up to 8k rpm

[Jonnybravo]

Good results. I bet that shifts on somewhat.

[Sonic]

As for driveability in first gear I've got to catch it to stop it bouncing of the limiter at 8000rpm as once the turbo comes alive at 4k it rips round. 2nd it still tearing it's *** of and by the time we get to third well I haven't found anywhere that I would consider safe to try it's strictly track day only in the upper gears till redline.

Awesome news

[JP]

Just got Doug to overlay my old plot with the new one and you can really see the difference on paper across the whole range. It comes in sooner, goes higher and carries on for longer. Can't wait to go pod now ran 12.4 on the old setup so would be nice to break the 11sec barrier.