I've been meaning to put a thread on here for a while but just haven't go to it,
Time for a bit of background and catch up. The project has been on going since Sept 2006 when the car first came off the road. The idea was simple, the car lacked power on track days.. so instead of do the sensible thing and bolt in an Mi or GTi6 lump we went for forced induction, by means of a E45 from a mini.
Right I'll let the pictures do the talking...
How the car looked before.... and where its been sitting since the project started!
Mock up of where the charger could go!
Prototype mounting bracket...
Inlet manifold needed modifying... Its all a little tight for space.
Charger outlet under development...
System coming together in the car.
Charge cooler rad (from a moped) and new oil cooler.
Nearly finished system... Thats until valve meet piston... So engine came out, just before Christmas.
Well I have a baby who will only sleep whilst being held... So I have alot of time just sat around only being able to watch TV or use the computer one handed Tis slowing down project pug. So I'm filling the time doing things like this, and surfing ebay...
Dom has supplied a couple bits and bob for this project, namely the expansion tank for charge cooler, the charger inlet adapter and the charger outlet plate, which I modified into the charger outlet funnel thing. All of which are great bits of kit!
I am going to be running standard engine (which cost me £20) with standard compression ratio, which in theory should be fine for the 0.5 bar of boost planned. The fueling and spark will be controlled by a good old mega squirt, tided into a wideband lambda sensor.
I thought I better post a progress update.... As things have started to happen!
Progress has been slow over the last few months, weather and new baby hampering progress, but we're getting there! The project is only 12 months behind schedule (been working on it 18months!)...
The charger is in, and working! I am currently in the progress of mapping the MS ecu on the road, which is interesting!!!
Boy is it loud! The charger really does wine, and it not from the belt! It seems to be an airflow related noise, still trying to bottom out what exactly it is. So far I have done about 70 trouble free miles in the supercharged pug, ok, not quite! Had front bush / ball joint problems, now fixed, but this showed up a braking problem! I should be able to get this fixed at the weekend, so I can get some more mapping in. In gear acceleration is just fantastic, it pulls like a train! 1500rpm to 4000rpm in 3rd gear you just ride this wave of torque, and this is on an in finished map! We've only hit 1.3 bar (0.3 boost) so far... hoping for a max of 1.5bar (0.5 of boost).
I need to get my knock sensor fitted, and get some miniature k-type thermocouple plugs, suggestions from where please! Oh and some bigger injectors....
Now for the pictures....
Making use of the old Mazda!
The £20 engine and box from ebay! - gearbox for sale...
Its still very much work in progress... Still sorting out issues from where the cars been idle for 18 months... bar an MOT 6 months ago! Sorting out failed bushes, and seized brakes valves! If this rain ever stops, we should get it sorted soon. So far things don't look too bad... The old £20 engine isn't doing too badly, leaks oil which is upsetting as the old one didn't!
The car has taken so long for a number of reasons... One is time in the garage, so most jobs get a lot of thought before I even get started, instead of thinking while doing it!
Its always good to get some feedback, and even better that is positive! With all builds you do start to wonder WHY and I doing this, but positive comments really help!
I love builds like this! Great backyard engineering, done to a high standard too!
If you knew the people behind this ;D you`d know its a long long way from Backyard engineering ;D ;D
Ok, granted I out sourced some manufacturing work to a 'small' 'local' engineer company. But i'm no prof mechanical engineer, hense the need for another engine at the back end of last year!
Things are still progressing, just put an order for all the componets needed to make the knock sensor circuit, and the for bits need to modify the MS to control the idle control valve. That little lot should keep me busy over the weekend.
The mapping shouldnt take too long to finish, its just a matter of finding time, having a knock sensor should help. We're hoping for around 160 - 180 bhp... Which should make it fun.