450-500 Crank Horses

[epic]

You'll also need much better brakes than the standard ones if you don't have them already!!!

[MikeLarwood]

Righty - well, here's a load of input! Basically, the whole lot is going to be as new, so it'll all be brand spanking, hence new pistons/rods etc. It's also got to be daily drivable on that power - so it doesn't want to be fragile!

Keep them coming though guys...

[S2central.net]

If money is no object (as it seems on your project of increasing scope) - then go mad, but you don't need to upgrade the pistons here for reliability at the target power level. Having lighter ones is great for a free-revving machine - get it all properly balanced with the new rods, lightened crank and I'd suggest an SM flywheel here as it gives more options for uprated clutch.

You have a few main choices of turbo to get 400-450bhp and beyond :

2871R
3071R
3076R

Other exotic choices are out there too of course - like a hybrid KKK26/27/29 dinosaur or something from CompTurbo, but there is a lot of experience with the Garrett family here these days. Oh there is also that turbo from Applied Turbo Dynamics - some sort of KKK & Garrett hybrid - search out posts from DJones on the peformance in his machine. I can't remember its product name / number but it is well matched to the I5T at those power levels.

For that sort of power you will need minimum injector size of 440ccpm at 3bar. Using 4bar FPR gives plenty headroom. RS2 injectors wont cut it here. You could go even larger Siemens 550cc injectors if you like.

I would personally choose the 2871R for this as it can run with standard cams and compression to be perfectly nice and driveable with plenty of smooth torque for daily driving - and it goes well into 400-420bhp territory with precious little lag and sufficient G-Force to give you a nose bleed !

A left-hooked IM will reduce lag further, but thats getting into more significant surgery... I'd say RS2 IC as a minimum but would strongly recommend something bigger like Carstens RS2 IC upgrade. The air temps at 1.8-2bar are pretty significant.

[MikeLarwood]

Yes, the scope does seem to be growing... Lol!

I'm taken with the 3071R, as it seems capable of up to 500bhp crank with not too much in the way of lag. 3076 gets a bit laggy doesn't it, and shifts power further up the rev range? I was considering the K26/27 hybrid, but wasn't sure on it? Ah, never mind. As I know all too well, it can get very silly, very quickly.

I guessed fuel would need upping. I'm not sure on the whole upside-down inlet manifold - it doesn't look so factory, but at the sime time it comes with a whopper of an advantage. I'd probably be looking at the Wagner intercooler as it bolts to the normal crossmember? But would that be sufficient?

I dunno... Hell of a project to take on with very little knowledge!

[repo]

Don't skim the pistons, keep the compression stock, if "only" 500 hp is goal.

Wagner evo, ct350, 1 x 044, siemens deka006, adjustable camgears, new clutch (forget spec)...

Might do the trick with proper rehaul and spot on remapping.

Not seen too many +500hp motronic remaps though. Big maf is not an easy one to calibrate to motronic, so not all remappers can do it.

If You PM me, I can make You a suitable offer. I am not the cheapest though, but most likely have made more 500hp setups than most.

You may save some dimes with ordering bits from here and pieces from there, but if You get a whole bunch from one single supplier, You save a lot in headache pills.

e: make sure supplier is up to the task, iow sells parts with first hand experience.

[Rocco]

Don't skim the pistons, keep the compression stock, if "only" 500 hp is goal.

Wagner evo, ct350, 1 x 044, siemens deka006, adjustable camgears, new clutch (forget spec)...

Might do the trick with proper rehaul and spot on remapping.

Not seen too many +500hp motronic remaps though. Big maf is not an easy one to calibrate to motronic, so not all remappers can do it.

If You PM me, I can make You a suitable offer. I am not the cheapest though, but most likely have made more 500hp setups than most.

You may save some dimes with ordering bits from here and pieces from there, but if You get a whole bunch from one single supplier, You save a lot in headache pills.

e: make sure supplier is up to the task, iow sells parts with first hand experience.

Repo , the stock 9´3:1 compression ratio its recomended always for projects under 500hp at crankshaft??

and if someone has skimed a little the plane of the head x2 times??? the compression will be bigger and than it will need something for reduce it... ( skimed stock pistons , shorter rods, metal head gasket thicker...)


what do you think about Repo???


-Tomas-

[repo]

Compression ratio is not 9.3:1 in stock, but closer to 8.9, which is not a bit too low, if You have proper engine management and ignition devices.

Best I've done, and on daily use, is 630hp/760Nm with 1,9bar. Held like that for 15 000km year round daily use, and hevy trackday misuse. Rods swapped, stock pistons.

Thick headgasket messes up the squishband -> bad

Short rod messes stroke/rodlength ratio -> bad

Only proper way to drom C/R is to skim off from pistons, but only at the bottom of the dish, not from the squishband OR custom pistons. Also, You cannot grind off too much from the oe pistons without compromizing the strenght.

So for 500hp, as stock pistons as they are, are totally safe, I wouldn't touch the C/R.

[aelred]

Compression ratio is not 9.3:1 in stock, but closer to 8.9, which is not a bit too low, if You have proper engine management and ignition devices.

Best I've done, and on daily use, is 630hp/760Nm with 1,9bar. Held like that for 15 000km year round daily use, and hevy trackday misuse. Rods swapped, stock pistons.

Thick headgasket messes up the squishband -> bad

Short rod messes stroke/rodlength ratio -> bad

Only proper way to drom C/R is to skim off from pistons, but only at the bottom of the dish, not from the squishband OR custom pistons. Also, You cannot grind off too much from the oe pistons without compromizing the strenght.

So for 500hp, as stock pistons as they are, are totally safe, I wouldn't touch the C/R.

Totaly agree!!!!!!!!!!