You should definately get it mapped up to 1.8bar (will very likely need the 16vt injectors) as you now have the strength to take this boost and the turbo is good for it You then need to get Paul to look at the fueling running 1 bar and map accordingly and I would also check fueling for an everyday setting of about 1.4bar I reckon you'll get an easy 350-380bhp and hopefully with minimal lag i.e. at least full boost around 4200-4500rpm. I also reckon you'll get an easy 300bhp at 1bar as the torque will flatline all the way to redline at that boost so no probs there. I managed to achieve 298bhp at my last PTS session running 12.5psi or 0.85bar

I can see you becoming on first name terms with your local tyre fitters Nige!

Aaaaaargh!

First set-back

Iceberg has been working really hard and had got to the point of putting it all back together today. He got the brand new crank from the box that Fiat sent last week and found that they had put a 16vt crank in the 20vt box.



Paul now has to find a new set of big end shells to go on my existing crank. Delay means I won't get the car back on Saturday, although he reckons he'll have to do it on Sunday, as he's desperate to get his ramp back.

I know he's desperate to get his ramp back you ramp hogger

Bad news there though Nigel, i thought iceberg said the Fiat place he got his parts from was good and reliable! but i guess they are still fiat.

Nigel, you are certifiable...!!

I know for a fact that you'll be able to run it in fine, and very quickly no doubt!! Random needless mileage ahoy, which you are a veteran at anyway...

Look forward to hearing all about it when she is back on the road 'proper'.

Any news on this monster yet Nigel - or is Iceberg working into the night to get it finished? Did he get those big end shells?

I can't wait to hear the first reports!

Hey Nigel, when are you getting the new turbo properly mapped? Looking forward to see your results, I should get mine back wednesday with the 2871rs, and then is off to mapping...cant wait

Lots of minor setbacks mean that I still don't have the car back.

Paul and John at Motormech worked all weekend on it. the engine is now fully built, along with fully matched exhaust ports (there's a 2-3mm step into the exhaust manifold).

It should all be fitted back inot the car tomorrow, so should be collecting on Monday night or Tursday morning

remap is booked at PTS for 22nd July @ 9:30am

Good to hear it is nearly there Nigel.

Paul and John are total legends! Can you imagine ANY other company (in any trade) working straight through the whole weekend to get a job completed?! Well done guys.

James

Aaaaaaargh!

it never even crossed my mind

the inlet on the GT2871RS is 3", not 2.25"

this means three things

1) The wonderful ProAlloy straight induction pipe won't fit

2) The standard induction pipe won't fit

3) I can't pick the car up until at least Wednesday

I'm in London tomorrow, and I'd even bought the train tickets to get me back to Birmingham instead of all the way to home.

Ar$e!
the suspense is killing me

Nigel, Samco or SFS will sell you a silicone adaptor,.. Barbz or even PTS may have one! .

SFS are only 50yds up the road from PTS.

Isn't Luton on the London to Birmingham line

joe

Barbz does a full 3" straight induction pipe.

So does ProAlloy, £45+VAT I believe.

its already ordered, but it won't be made and despatched until tomorrow

I guess I should have checked

another day of running in gone

Cool - nice one Nigel. Are you sticking with the supersprint?

So, my car is ready for picking up today at the mechanic, the GT2871rs was fitted yesterday, and he was making the induction side when I called. Today was down to fitting the walbro and then its ready Cant waittttttttt

AT LAST!

Iceberg and John have been complete stars. I arrived at Motormech at about 5pm tonight, ready to pisk the car up. It wasn't quite finished, so I hung around. When Paul finally started the car up, it didn't sound very nice, with lumpy running and hunting for stable revs.

We instantly put this down to the 16VT injectors. Paul hooked up his diagnostics to find it was ridiculously rich and the ECU couldn't cope. Paul removed the 16VT injectors and replaced them with my old 20VT items - now runs fine.

So - some initial observations:

Clutch is a bit grabby - I'll get used to it. However, Phoebe's tune springs to mind - "Smelly clutch, smelly clutch, what did they make you from....."

Engine is smoooooth - probably feels good because it was a bit rough before, and also because I've just had to do 500+ miles in a rough 1.2 Clio.

I've only taken it to 4,000rpm on the 30 mile trip home, with only a light throttle load. However, I decided to see what spoolup was going to be like. With the boost controller turned off (ie getting base boost only) Its giving me 0.25 bar at 2000rpm, and 0.7 bar well before 3,000. Once I'm aiming for 1.5 bar, I reckon I'll be seeing above 1 bar by 3,000.

Bottom end seems nice and responsive, but again, after nearly two weeks in a small capacity normally aspirated car, the throttle feels a bit woolly. The remap will undoubtledy help get some response back.

the straight induction is waaay quieter than having the Ramair on the standard induction pipes.

I soooooo want to plant the throttle and get the car to sing, but I just have to wait until its all bedded in nicely. Boost controller is turned off and I'm just going to have to exercise superhuman self-restraint

All promising so far



So, I've

Great news Nigel,... she lives!!!

Are you able to say what clutch you went for in the end?

Are you still going to map with the 16vt items ?

joe

Great stuff Nigel, hopefully turn out to be a good 'un. I think you may have to give the ecu some time to adapt to the 16vt injectors as the lambda should slowly acomodate. I know Barbz had no real problems with these after they had bedded in.

@ Joe, irc Nigel has an organic Helix clutch which is rated pretty high circa 280-300lbs/ft.

Joe

I'll get PTS to doa power run on the stock injectors first. If they cope, I'll keep them. However, I'll take the 16VT jobbies and if they think it needs them, they can fit them.

Clutch is an organic Helix with a Walkers cover plate. Slightly grabby and juddery, but its on a refaced and lightened flywheel, so it may need a bit of bedding in. It certainly bites hard and I'm sure its going to be good for the power I'm aiming for. For some reason, I'm extremely light on clutches (wish I could say the same for brakes) so I think it'll be good for 350+

Sounds like a good clutch, Barbz was suggesting these as a strong alternative to the GTA plate

If mine gives up the ghost I might kill the piggy bank and do the same

Now time,.. will seem like an eternity before you can floor her

joe

YEY good news, i feel sorry for the guys as its taen them an age to do it but they have probably worked thier ass's off to get it ready in time I think i should go for the sticker sponsership option on my next bill! LOL

Anyway good to hear about the spool up, still a bit behind what i have mind but we would have to compare side by side sometime Nigel, maybe when i pick my car up before your remap

One thing i would say is get a tiny bit of old carpet or door matt and cut 2 small 10cmx10cm chunks out of it. glue them together and stick them on the backing plate that the loud pedal hits when floored. this should help you keep from straining the engine, i tend to move my standard floor matt over a bit for the same effect

Will - the loud pedal has an adjustable stop on the underside of the pedal.

So far i've managed to stay under 4,000rpm and I've hit 0.7 bar once, but stayed under 0.5 bar for the rest of the time.

The engine feels better this morning after another 50 miles - clearly its loosening up nicely.

Clutch also feels lots better, less juddering now its done a few miles in stop-start traffic.

I can now also feel the effct of the lightened flywheel - the engine is noticeably quicker to pick up from a dead throttle, especially when pulling away from a standstill.

On the couple of runs I've had from 2,000 up to 4,000 rpm, with about 0.5 bar showing, the engine feels silky smooth and very strong.

Can't wait....

Quote:

---

the straight induction is waaay quieter than having the Ramair on the standard induction pipes.

---

Thats an interesting comment Nigel. One of the reasons, Ive held off on the straight induction is a fear of creating loads more noise, but looks like I need to get on and do it, especially now the Apexi intake has arrived.

I'm really hoping this will give me some spool up back.

I know nigel but it only goes so far

The flywheel lightening sounds like another thing ill need to get done on my next clutch change as i dont reckon it will last another 2 years with my usage and locallity...

The note about teh straight induction pipe is good as well

I didn't notice a frickin thing when I had my flywheel balanced and lightened

Good to hear that you've got it back on the road Nigel. I'm not looking forward to the running in on mine either, as it is going to be so tempting to give the throttle a bit more than would be prudent ! But, will power will have to prevail .

Phil

Things are getting better...

I'm up to about 300 miles since getting the car back - everything is loosening up nicely. The engine is clearly going to be nice and revvy, but there's definitley going to be some decent low down grunt as well.

I'm still running at base boost (1 bar actuator - shows about 0.8 bar at the gauges) and I still haven't gone above 4,500 rpm (apart from one brief excursion to 5,000 to overtake a couple of dawdling caravans)

The car is soooooo smooth (although I bet it turns out a bit more peaky when I turn the boost up)

The REALLY good news is that my very un-Nigel-like gamble with the turbo appears to have paid off. I can get 1/3 bar at about 2,000 rpm. By 3,000 I can get 0.8bar (which I'm sure would be higher if I turned up the boost). by 4,000rpm, its all pulling very strongly and at 4,500, the engine note goes very noticably harder as the cams start to have an effect.

I've only had one heart stopping moment - Friday, on the way home from work, the car suddenly started misfiring and cutting out, then surging up to 3,000rpm (with no throttle) and just general misbehaving.

I managed to get it home OK, and hooked up my code reader to see that the lambda sensor was fubar'd.

£45 for a sensor and £5 for a special socket and I'm away again.

Previously, my air / fuel ratio meter used to rise and fall every second or so, as the ECU hunted for stochiometric. Now its doing it about three or four times a second. I reckon my fuel consumption may end up being better, as the ECU was clearly staying too rich for too long, a theory which is borne out by the state of my pistons when Iceberg removed them. VERY clean underneath the inlet valves, but quite coked up for the rest of the crown.

Remap is booked for Saturday morning, at which point I'll know whether its all been worth it. I'm hoping for something like 300bhp @ 1bar, and 350 - 360ish peak at about 1.4 or 1.5 bar.

I'm concerned about mapping to very high boost figures, as I'm still on standard rods. I guess if PTS say its safe, I may go as high as 1.6 or 1.7, just for pub-talk bhp.

Nigel

Interested in the Lambda sensor bit. I think these have a life of about 80k miles in a Coupé so maybe more of use should change them, as you say the over fueling does not help, especially on a modded engine.

Bet you are so wanting to plant that right foot