Post #16
Well ladies and gents, hello! Covid 19 has given us all plenty of time to catch up on our projects and me included, this is probably to first time in 2 years ive had to do something due to taking over a business etc, anyway here is my Rallye, as much as ive always liked this car I must say I found it difficult to modify it much but one day I was tidying up the workshop and gathered up all the parts I had from my previous builds, turned out I pretty much had everything I needed to complete my plan, literally all I had to buy was metal ties for the exhaust heat wrap, seeing as pretty much everyone was closed, Amazon prime saved the day and £7 later I had them!
My last setup was a fully built engine and made almost 370bhp at 14 psi of boost, due to workloads that car gradually was broken for parts, Ross Halpenny bought the engine and I held on to the turbo kit, in the past I have turbo'd stock engines and gained good results. The Rallye had 147k miles on it and I didn't want to open it up and let the magic out lol - normally with a stock motor I would open up the top ring gap but as I had little chance of getting a new head gasket etc I continued on, the spec list includes:
DP engineering exhaust manifold
Custom 3 inch downpipe and system, no mid silencer and still is very quiet
GTX2867 turbo
DP twin pass intercooler with custom piping
Spal 12 inch fan with stock Nissens radiator
Stock water to oil heat exchanger
I wanted to keep the 6 speed box but when I took the quaife diff out of my 5 speed box I quickly realised I didn't have any new diff bolts, seeing as these always tear up the threads on removal I had no choice but to re purpose the 5 speed from a ph2 xsara VTS, 3.6 CWP
Stock valeo clutch
Car already had Baker BM engine mounts
Megasquirt 3 pro ECU (again the car was already running on this and as a rule of thumb pretty much any project car I own I switch to stand alone management)
OE coil on plug setup
GM 3 bar map sensor
Saab Turbo bosch injectors, these flowed out at 420cc so are just about capable for this stage
Stock GTi6 fuel pump
Rising rate fuel pressure regulator with Holley pressure sensor
I have a water/methanol injection kit to go on but so far not fitted it
Slight cam timing adjustment to reduce the overlap
I spent a whole day and worked right through the night converting it all over, I knew if I took a break the car would probably just sit in the corner of the workshop forever more!!
Engine now up and running I carried out a few checks and she was ready for some light mapping, I had modified the wastegate spring to give only 4 psi boost as I wanted to gently creep up on it, so far so good, now swapped to a heavier spring, boost pressure peaking and holding 11 psi I drove around for approx. 200 miles and man it felt quick!! I didn't run at 11psi for long though as my radiator ballooned, luckily the MS3 ecu has lots of spare inputs and outputs so I fitted a Holley pressure transducer to the radiator and I quickly found after a few hard runs the coolant pressure almost had a direct correlation to boost pressure, ill post a pic of the datalog - this meant I was lifting the head, rather than risk hydro locking the motor I lowered to boost and was now seeing a max of 7.4 psi, this along with 14 degrees of ignition timing seemed to be the happy spot.
1040 miles now covered, fuelling dialled in, as this is a high compression turbo engine I am running a richer mixture to keep it alive, 11.5 AFR, it was now time to strap the car down onto the dyno and see what it produces.....
286bhp and with a slight increase in ignition almost 260ft lb, this is a PB for me, previously I achieved 281 bhp on a very similar combo in a 205 GTi.
The car is amazing to drive at this level, normal driving feels just like a standard car with the stock clutch and high compression, as this turbo is so responsive im well into boost at 2200rpm and pulls strong all the way to the redline. To be honest I almost prefer this one to my old forged setup, doesn't give mental torque steer through the mid range yet still enough to have good fun on the back roads! Car still has 195/55 Michelin tyres and i think once they are worn ill maybe go to NS2R's, obviously the brakes are struggling at this point, again just standard pads and discs all round, DS 2500's will be fitted soon.
Other than that I cant really fault the rest of it, water and oil temps are good although ive since ordered an oil cooler, im using normal Shell 10/40 oil, nothing fancy at all, I will fit the WM kit and push it up to around the 300bhp, im not overly concerned about destroying this engine - I just want to slowly push it then cover some miles, if I was to give it aggressive spark advance I know for fact I would bend a rod or 2! I could fit a decompression plate but seeing how well its doing I wont bother, the stock con rods will always be the weak point
Anyway ill include a few pictures and videos of it on the dyno, hopefully David will keep me right here, I cant seem to upload anything right at this minute
Cheers, Seb
The Build Process
Youtube RR Clicky 1
Youtube RR Clicky 2
ECU,..
JWP EFi
Posted 7th Jul 2019 at 21:01
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- (The other half's wheels)
