clubstylus

rossco61 wrote:Hi all, still watching altho not doing much these days. Too many other irons in the fire !!
I see that Matt needs info on Intercooler placement.
Photo included with my install onto the Nissan CA18DET and a redesigned front mount frame.
Both the Radiator & the Intercooler are rubber mounted to the frame, in compression, not tension.
Air inlet to the Turbo will come over the Turbo to Int/cooler pipe, then turn to the center & into a Pod Filter,
mounted to the new frame. There is 8" clearance to the front body oval air intake from the frame.
NO Body Modding required !!!

Rossco

Like you work Rossco

I'm retaining the original cheapo intercooler for now, which is considerably smaller than yours !
The throttle body outlet is also at the firewall end, so the pipe routes & lengths to the front end wouldn't be pretty.
I'll be ducting air through a NACA on the bonnet into an airbox, with the cooler mounted at an angle behind the passenger front wheel, exiting into the sill.

Not ideal.. but it should work.

Well then bit of an update...

Zetec is out ..
New Engine has been in & out a few times, mainly due to bellhousing/tunnel mods & engine mount making.
The tunnel mods mean I've had to cut the new pedal box a little.. but all fits now.

Spent £400 on "bits" at Stoneleigh - so will crack on this weekend.
All got heavy, so never made it to the JPSC club area

Master Cyls now fitted, New brakes & fuel lines to run, bit of BiltHamber & Hammerite, then the engine can go in for final fitting. Matt.

i wish i had the guts................................. maybe over the winter bigger engine me thinks!

Looking Good Matt!! Is it going to be back on the road this year?

She turned over on the key at about half past midnight last night.
(& in case I forget to mention it, I hate automotive wiring )

With a bit of luck she'll fire up over the weekend, & about time too !!

Awesome, Good work

good work, and so do i!

Well then.. I had a good Saturday afternoon

Was too knackered the other night to start tracing why it wouldnt start.
But a fresh, logical look on Saturday sorted things out.

Basic checks showed she had fuel, had spark, so why no go ??
A quick study of the wiring diagrams - & I guessed right first time - injectors not firing.
Follow though on the connections showed that a single pin had been pushed down out of its connector body & wasn't making contact. This was the injector +ve supply pin (the ECU supplying the switched earths when required).
Fixed that & "Vroom" ! Very happy.. big step forward

Followed that with a short drive round the field - clutch & gearbox works, but finding out I had no brakes (new pipes/no fluid) made it interesting !

Short startup video here : http://www.youtube.com/watch?v=YByw2TqZyYg
Now need to sort the alternator mounting, mainly cos the water pump isn't turning either at present
This has to be relocated to low down near the steering rack/column linkage, as the original location was above the oil filter housing. This had to changed as it interfered with the near side front wishbone pickup, the new Integrale one has the filter on top (as apposed to Thema original, with the filter on the side). Oil cooler feed pipe outlets are totally different too.
Oil cooler will be inverted from how it is in the pics, the unions under the rad are the lowest point of the car... too low !

Got to make the front flip & bonnet fit now too

All part of the FUN !

Looks good Matt. When is the next track day? Have you thought how you are going to duct your intercooler?

Hi Tony

I have a provisional entry for a charity trackday at Castle Combe on the 5th Oct.
Dont think I'll be ready though realistically.

If I get my act together & have big enough balls - there's a club sprint at Eelmoor in late Oct - the same one that Rob met a tree at in '08 ! Not good if its wet, & not a good place to learn where the boost comes in.

So... most likely road use this side of xmas.

Yep, got plans for the intercooler. NACA duct in the bonnet/flip, then ducting into an airbox above the cooler, with similar below - air being sucked either through the lower sill (holes in the underside) or pushed into the exhaust cutout area. Something like that - got any better ideas ?!
Main thing will be to separate the turbo area from the intercooler area by means of a vertical barrier on the chassis rail between the inner wing return & the passenger footwell.
The exhaust now passes through a cutout in the lower forward chassis that has the steel sheet infils.

H'mmm ----- and now you've got a 2lt Turbo , that boosts your class capacity by 40% so maybe you'll end up in my class (probably not though --- Simon Besant gets in the above 1800cc roadgoing )

stylussprinter wrote:H'mmm ----- and now you've got a 2lt Turbo , that boosts your class capacity by 40% so maybe you'll end up in my class (probably not though --- Simon Besant gets in the above 1800cc roadgoing )

Capacity gets upped by 1.5 for turbocharged - so its now classed as a 3 ltr - but also still roadgoing.
So if I'm right I'm in with Simon's V8 & Brian's Rotary Beastie.

No , Brian's rotary rocket is in sports libre with me --- he beat me at Abingdon Runs slicks and has no mot etc

stylussprinter wrote:No , Brian's rotary rocket is in sports libre with me --- he beat me at Abingdon Runs slicks and has no mot etc

Yep, just checked the entry, Brian's the only sport libre entry so far. Presume his westie has been log booked then ?

have you thought about a chargecooler? you could get one about the same shape/size as your i/c and put it where you like. Then run a nice little rad up front, modern plastic rads weigh next to nothing. I am now running a charge cooler. At least that way you wouldnt have to change all your pipe work. There is a little bit of weight added but for every degree you reduce your intake temps by, you gain 1 bhp so well worth looking into.

Either that or look to run a front mount but it will be more work redoing all your pipe work.

Is that a new cage? Who did made it?