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

[JP]

So here we are a thread that we thought was coming to an end is being brought back alive.

Various things have been bugging me last year re the engine performance and aesthetics. Not because they weren't good me being me just didn't like the fact it could be better.

So things that bugged me we're

Cylinderhead was a prototype for the original head design for Hamish's SWB and subsequently Jeffers monster. So the good news was it was a good head design and did what it wanted to. But what bugged me is that both Hamish's and Jeffer's heads were far superior to mine which annoyed me as it is my specialist skill set.

Next the intake manifold - perfect flow distribution sized absolutely perfect but done after the head was done and fitted whilst on the car. This meant elongating a couple of holes and a couple of adjustments and the end result being it was never 100% lined up to the ports. So really good but again just not as good as it could be.

Intercooler - was a 450x300x76 core with custom 63mm in 76mm out supposed to be rated at 450hp yet we made 650hp on it great fantastic, but it never sat 100% straight behind the bumper and in warm weather it started to struggle on prolonged high speed runs so yes it worked, ideal for drag strip and not bad on track but could be once again better

Boost hoses - The one that went onto the turbo had a habit of wanting to blow of didn't matter what clamps we used they just wouldn't stay put because there wasn't enough of a lip.

Exhaust wrap - used this funky extra high temp stuff but it only came in white so vht painted it black but this ended up over the year going to a light shade of grey.

Shifted the engine back to make space for an elecric fan to loose the viscous and ended up with a clearance issue to the steering track rod arm.

HKS air filter was a horrible green that clashed with the rest of the bay.

Coilpacks - spark leads and coils of the strut brace looked purposeful but made the bay look too cluttered with the large intake mani and catch tank setup.

Cams - although great weren't making the most of the available flow from the head due to being too low a lift at 10.5mm

Oil cooler - stock oil cooler was just no longer man enough

Brakes - the car went like stink but couldn't stop

There is a couple of other minor bits that bugged me but all in all that was most of them. So I set about carefully stripping the engine bay down and meticulously putting things right bit by bit. Hope to be ready some time this season with the car how I would like it to be so over the next weeks/months I'll gradually be posting updates of the revamp with lots of pretty pictures as always.

For the time being a teaser pic of the head for those of you that are not on facebook



Cheers JP

p.s. and yes various bits will be up for sale during the process.

[jogi730]

Like all projects, they never really end. Great to see more being done to an already great car not least as we can see it and drool. Way to go JP

[Error404]

The bar is raised again! Look forward to seeing you progress

[Rocco]

May Those changes will affect the VE of your motronic setup and you'll require to map again?

I'd say yes

Does it worth for you? After all,like is now is amazing...

[macspring]

The bar is raised again! Look forward to seeing you progress

I agree, word for word.

[andy10v]

You are mad! I look forward to your madness!

Singh grooves?

[driftin jo]

I see you have added some squish area mixing grooves to the combustion chamber.

I remember reading about that guy Singh who patented the idea and everybody was calling him a crack pot, but it seemed to make sense to me, just never seen anybody do it yet, apart from some guy on a Subaru or something and again people just took the piss.
What’s that old adage, often a good idea stars of being ridiculed and laughed at, then eventually those who laughed are all doing it, saying how great it is!

[JP]

Yes Andy and Jo

Been experimenting with singh grooves for a while on personal cars and friends cars. As it's patent pending I can't charge for it.

Will take a pic of the old head for comparison. But I can confirm it definitely aids fuel mixing for a more complete burn. Normally when you look at an I5 piston/combustion chamber you can see spots where there is no carbon build up. This is basically where there is no fuel in the airmix to get burned in that specific spot in the chamber. The heads that have had the grooves on them have a much more even burn distribution and they are very hp sensitive to timing advances. My one was averaging 33hp per degree iirc.

[JP]

Come to the conclusion that a 24hr day is not enough as it's taken me two weeks to get round to continuing the thread with very little achieved

Never got round to photographing the old head which I need to pull out the workshop loft so that will have to be done at one point.

In the meanwhile finally pulled some more photos of my phone.

Intakes Finished



Exhausts



Int Close Up



Exh Close Up



Heat wrapped the oil return pipe and stripped the filter housing for cleaning and element replacement.



Rewrapped the exh manifold as didn't like how the black painted white stuff went over time.



And installed an exhaust pressure sensor take of.



Mocked up in the bay with grey filter element instead of the horrible green awaiting reground cams and 5egt's



Brackets for new radiator made and lined up new larger intercooler to sit hidden behind the bumper. Used a hydraulic press and modded the end tanks to crush the top layer of thins to ensure a perfect fit without bending the bumper and making it look crooked like the old one, which really really annoyed me.
The increase in core size more than outweighs the loss of cooling fins in an area of restricted airflow behind the bumper. Just got to finish of the mounting brackets for the cooler and make up the pipework to mate up with the old ones now.



Hopefully get round to fitting cams and a new oil cooler next.

[AndyP]

With reference to the boost hose coming off, have you thought of trying something like this?

[newsh]

[jsws3]

With reference to the boost hose coming off, have you thought of trying something like this?

These clamshell clamps hold up to 8.5 bar of boost I was going to use them on mine but due to my boost runs being so short there was no point .

[JP]

On my boost run there are the following joints.

turbo to boost pipe, boost pipe to intercooler, intercooler to boostpipe and boost pipe to throttle body.

The 2 intercooler ones are impossible to come of as there is a 1cm gap to allow for a bit of engine movement between the joints.
The joint to the throttle body has a power coupler on it which holds 10bar+.
Which leaves the turbo joint which came of occasionally at 2.5bar on tge turbo side as there wasn't a pronounced lip in the casting of th compressor housing. So for ease I just welded a lip on there this time round which I'm hoping will solve the issue as weldimg any sort of bracket like that would end up tearing a hole in the ally boost pipe as the wall thickness would not have enough strength to stop the weld joint tearing eventually.

[G60Rallye]

[/URL]


These clamshell clamps hold up to 8.5 bar of boost I was going to use them on mine but due to my boost runs being so short there was no point .

When you add up the price for 4 complete clamps you will have a heart attack!

[jsws3]

When you add up the price for 4 complete clamps you will have a heart attack!

I know they are not cheep but look the biz fitted .