Jesse888 Forged/stroker turbo ek9

Discussion in 'Builds & Projects' started by jesse888, Mar 8, 2014.

  1. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    Too right! Give it a strong 1.5bar until i can sort some valve springs.
     
    EK9 Matt likes this.
  2. ellb123

    ellb123 Member

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    that rad looks a good bit of kit! coming on well mate, be good to see how much difference that makes with the bigger turbo too
     
  3. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    Yeah i cant wait to find out how the new turbo is!
     
  4. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    Abit more progress today.
    First things first i forgot that id need new fans with the new radiator, rywire designed the mounting system around a fan thats only available in the USA. Naturally i didnt want to pay $100 plus shipping and taxes for a pair of rad fans.
    So i took a punt on a pair of universal jobbies at like £40 for the pair. Fits perfect!
    20170713_102438.jpg

    Then thought id finish up wrapping the downpipe to get that off the list.
    20170713_112303.jpg

    Then it was the radiator ducting, id already made templates for left and right of the rad so i got those cut out in some thin stainless steel sheet and welded them in along with blocking off the gaping hole at the bottom. (More "welding")
    20170713_123304-3456x1944.jpg

    Then i used some duct tape as a seal for the blocking plates to the radiator.
    20170713_141237-3456x1944.jpg

    Ive left the top of the rad open for now but i will sort something for it once ive decided the best/easiest/cleanest way of doing it.
    Then it was time to fit the intercooler back on and make some air guides to stop the air hitting the rad/intercooler and moving either left or right around the car. I didnt get far but ive decided to go "gobstoppper" style with the intercooler and essentially make a scoop for it to grab more air. This is only the first piece 20170713_145203.jpg

    Will become more clear to everyone tomorrow, i also need to make a blocking plate between the chassis and the bottom of the intercooler to stop the air going through the cooler then escaping under the chassis.
     
  5. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    So alots happened (might not look it but feels it lol) in the last 2 days.
    I got to work on the rest of the air guide/ram plates for the intercooler and radiator.
    Abit of cardboard templating
    20170714_104525-1944x3456.jpg
    20170715_164932-3456x1944.jpg
    20170715_172550-1944x3456.jpg

    Chuffed with how these came out! As you can see my plan is to trap the air infront of the radiator so that it cannot escape around the car or get through any gaps etc. Im heinsight i should have gone larger with them so that they are flush with the front bumper. My "welding" seems to be improving alittle bit aswell. I dont feel ashamed to let people see these welds lol
    Gave them a quick shot of matt black to keep them fresh and somewhat hidden. I decided to block the top of the rad with duct tape for now, i didnt want to weld more metal in on the slam panel and pull all the paint off of it, i see no issue with using the tape other than it might break and let the air out. Would prove im making good pressure infront of the rad though.....
    20170715_173800-3456x1944.jpg
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    Here is the only place i could think of to put the oil cooler, its such a tight squeeze in there! Not helping that the cooler is 25row, and that i couldnt really go infront of the intercooler. Hopefully it will work out ok there.

    Next up was wrap the hotside boost pipe in cool tape, ive done this aswell as wrapping the downpipe because now the downpipe is 3" it comes pretty close to the boost pipe and i wanted to minimise heat transfer between the two.
    Offered up the front bumper, knowing it was going to need some serious chopping to "fit"
    20170714_192132-3456x1944.jpg

    As you can see not much left of it at all! I made the mouth of the bumper abit bigger in the hopes of hitting more radiator with unblocked airflow and obviously gave the oil cooler a hole to cool from.
    Ran the new oil lines back to my inline thermostat
    20170715_195851-3456x1944.jpg

    Thats about as far as ive have got.
    Will re-attach my front lip and make sure that all fits fine tomorrow then its waiting game for turbo to arrive i think.
    Turbo news
    Turbo-men got to work on my turbo today, they said they couldnt use the antisurge housing that i currently have on my turbo because they need to take too much material away when fitting the larger compressor wheel.
    This leaves me with a standard gt28 housing, if i start gettimg surge issues then i can possibly source a gtx2871r compressor cover. My issue with this is the inlet is 4" on that housing and tjat is likely to cause clearance issues with the bleed nipple on the clutch slave.
    I also confirmed exactly which parts where going into the turbo and they are
    Gtx30 71mm compressor wheel
    Gtx30 60mm turbine wheel

    So basically my turbo will be a gtx3071r crammed into a gtx28 frame.
    Thats all the news i have so far. Hopefully have a turbo mid week!
     
    King Sir, Mark Mckay and EK9 Matt like this.
  6. EK9 Matt

    EK9 Matt Well-Known Member

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    Serious re-modelling of the front end there dude! Can't wait to see how efficient this is.

    Bigger turbo = massive smiles!
     
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  7. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    What started as a simple fit new rad job has turned into a full on rebuild of the entire cooling package and front end!
    Really getting somewhere now though, i must not forget i need to find a way to block airflow from going down behind the intercooler and under the chassis.

    Yeah the turbo is basically 1 size up on the cold side and 2 sizes up on the hotside according to garretts current line up.

    Exhaust flow shouldnt be a problem with this turbo, i suspect i was getting to the end of the old turbo and ive learnt now that hondas need a large turbo!
     
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  8. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    20170718_204012.jpg Picked up the turbo today!!
    Probably going to need the gtx compressor housing if im going to hit the big numbers.
    This current housing (chosen because it will defo fit in the space i have) has only a 3" intake, the gtx housing has a 4" one.
     
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  9. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    So i managed to get the turbo on, started tuning for it and instantly get missfires, real bad aswell it wouldnt even pull through the rev range on full boost. Some consulting with madmike had that fixed along with afew other niggly issues i was having.
    Had the wastegate set at 1bar thinking it would hold 1bar like the old turbo did....nope, pretty much instant 1.4bar. Im wondering if this is an efficiency thing or perhaps the wastegate is too small for the amount of gas trying to come through it at that kind of boost now. Old turbo would hold it perfect so its defo in the turbo.
    Anyway that was abit too mental so i pulled a spring out the gate which left it at 0.6bar creeping up to 1 bar at redline. No boost controller means thats what im stuck with although this meant i had half a chance of driving the car should it turn out to be a wet trackday.....
    Which it did. Absolutely pissed it down most of the day, standing water all over the track.
    The only video i got is abit poor tbh, i set the angle of the camera wrong so got mostly the dash and the windscreen mists up quite badly in the rain so you cant see out the front at all for the majority of the video lol
    Hopefully @B16Swt will have some footage to show you how the track was.

    First impressions are abit mixed tbh. Ive lost a good 6-700rpm of powerband with the larger turbo which is what youd expect jumping up 2 turbine wheel sizes, a compressor wheel size and also a larger AR exhaust housing all at the same time! you can really feel that on the road, it should be fine on track on all but the tightest of corners(possibly use 2nd gear if its that bad).
    Ive yet to play with the tune properly and am relying on the wastegate to control boost so i may be able to bring that down some more yet.
    The brief period i spent at 1.4bar feels promising as far as power goes though and it feels as if it carries much better in the higher rpms than before.
    Heres afew shots pre trackday
    IMG_20170724_223849_113-3456x1944.jpg

    IMG_20170725_223934_891-2720x1944.jpg

    One of the causes of my missfire issue was the ignition wires, they corroded inside the dizzy cap and one set of leads i had was also shorting out, it would shock me everytime i touched it! This isnt great obviously and was running the engine with the leads spaced away from eachother as best as possible lol 20170723_155747-3456x1944.jpg

    Fixed it with a new set of leads from nology, was recomended these and the write up seems good so hopefully theyll live up to the hype. Ill need the strongest spark possible once i try running it on ethanol.
    20170727_163342-3456x1944.jpg

    Will be fairly quiet for alittle while, the rad and turbo have drained funds for the car pretty bad! Hoping to get out at brands late next month, hopefully with more boost and go for another PB!
     
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  10. B16Swt

    B16Swt Boosted Staff Member Donator

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    It was rather wet!
    I'll post it here mate.
    I really need to update my thread
     
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  11. DC17

    DC17 Member

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    been following ur thread and everyones turbo builds, with the power levels u r at is there a possibility coil packs will be better for ur build or the dizzy fine and give a strong enough spark, also ur old rad setup are they easy to install as im thinking when i finish off buying bits for my turbo build on my dc2 either get a tripple core half rad or the vw rad, any help would be appreciated
     
  12. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    Personally i think coil on plug is better than dizzy but not needed unless clean over 600hp on pump fuel, others will say differently but i know guys that run big power and are still on the dizzy(madmike for example) Im not a fan of the coil pack retro-fit and im not keen on the price of it either tbh which is why i havent bothered.
    My only real concern as far as spark energy goes is on the ethanol, because you need 30-35% more fuel flow for the same boost level as pump fuel it means the engine has alot more fuel going in and that can cause an issue with ignition. Time will tell on that one!

    I have the VW rad for sale if your interested? It was a custom mount job so youd need some fab skills(or a friend with fab skills) to make it fit.
     
  13. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    Right so weve been alittle lazy with the updates.
    So i mentioned above that i would aim for a nice 1.5bar with the engine still having standard valvetrain in it.... well i got alittle carried away with that... 20170816_025227.jpg

    At nearly 1.7bar(boost controller is in different units but works out at 1.68bar....)
    The engine is mega powerful now! Easily the most powerful its ever been and it really chews through the rev range, with my road tyres on its spinning 4th gear(rainsport 3). Ive managed to pull that "lag" down a decent amount aswell, we now have nearly 1.5bar and vtec at 4500 rpm which considering it revs to 8800 leaves a wide powerband to play with. If im being picky its still alittle slow to pick up that first 0.5bar of boost but once it has that the rest comes flying in, i guess this is unavoidable really as its fairly large compared to my old one.
    I feel this turbo is far better suited to the engine though if im honest, esp at higher boost pressures. The old gtx2867 was giving its best at 1.3bar and i really had to work hard to keep the turbo going at full rpm. By the time the engine was at its most efficient the turbo was struggling so it was never a perfect match really. This new turbo though just chews it up, even at 1.7bar and 8800 rpm its no problem at all and you can really let the engine breathe!

    Brings us to the latest trackday, quick sparkplug swap and a minor tune tweak(more about that later) the day before.... 20170830_131539.jpg

    20170831_172014-1944x3456.jpg

    Started the car to leave for the track evening and the car was running very rich(remember that tune tweak?) Well turns out i managed to save over my tune with a basemap id written for someone elses car. This map was for a injectors and a bigger motor so the fueling was way off for my setup.
    So throughout the evening i ran the car and tweaked it until it got somewhere reasonable. Meant i could only run low boost as i wasnt willing to push the car with what was really half a map on it. Not worth the risk really.

    So all going fine then 15 mins from the end of the evening this happens....


    Yeah the car wouldnt stop lol turns out id hit a coolant slick from the bmw. Right in the braking zone at like 100-110mph! Very lucky it was on that corner really as anywhere else the barriers come up pretty quickly!

    Damage assesment the next day reveiled
    20170902_152752.jpg 20170902_153348-3456x1944.jpg IMG_20170902_152922_445-486x486.jpg

    So yeah. A smashed up splitter and a bruised exhaust basically.
     
    Last edited: Sep 3, 2017
  14. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    I also found my air filter in abit of a state, im not sure if it was hit in the accident, i think so tbh as it has loads of room to move about should it need too.
    Its abit "sucked in" wondering if it got abit clogged or perhaps its too small?
    IMG_20170902_153834_451.jpg

    Also good news! Coolant stayed perfect the whole evening and i was out for a fair amount of time each session!!
    So thankfully that seems to be over now.
    All i need is a good dry day, new brake pads and to run it at more than wastegate pressure and im hoping to make another PB
     
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  15. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    been awhile since the last update(again) not too much gone on tbh.
    jumped from the last trackday, into the next one other than making a brake pad and fluid change. Replacement RC6 pads for my wilwood calipers are £250! home ownership got me abit skint so i took what i felt at the time was a gamble and bought my first Ferodo pad, DS1.11...
    20171011_130649-3456x1944.jpg
    20171017_092207-3456x1944.jpg

    trackday went OK. no issues with the car really other than afew exhaust housing bolts coming out, meaning a larger exhaust leak pre turbo left me with about 13psi boost at redline. Brakes are fantastic for the price, very happy with them. still locking the rear quite often but its controllable so im not massively concerned with that just yet.
    Really not liking these R888Rs they just feel like theuye no initial bite and the ultimate grip is alittle lower than id like.
    Despite feeling this and the boost leak i did manage a new PB of 54.1....


    Thats very promising for next year tbh as that all felt very slow, considering i have a passengers weight and the majority of the cars power left on the table i should come closer to my goal of matching the Time Attack UK FWD times of mid 52s.

    Since the coolant incident i decided enough is enough when it comes to the front end of my car, its been in a comically bad state for far too long!
    so i bought a very used and very fake Airwalker bumper and set about fixing the damage and modding it abit...
    20171011_134120-1944x3456.jpg 20171013_165051-3456x1944.jpg
    20171025_160047-3456x1944.jpg
    20171025_161401-3456x1944.jpg

    so as you can see, ive glued the whole thing back together, sanded all the cracks down and made the passenger side air vent larger to fit my oil cooler behind it! This should look much much better than it has done for along time so im excited to get this done and on the car!
     
  16. King Sir

    King Sir Apex Master Donator

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    Why do we have the same ideas ffs. I just bought a airwalker bumper aswell to fit my intercooler in god dammit :eek2:haha ah well

    You bought a chargespeed just after i did too haha
     
  17. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    they say great minds think alike...
     
  18. jesse888

    jesse888 Ek9+Turbo+Nurburgring= Heaven Staff Member Donator

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    so i made my first winter purchase
    ported cylinder head from Agra engineering in scotland. A wise man tells me they're very reputable so when this came up 2nd hand relatively cheap i snapped it up.
    was part of a no-expense spared b16 NA build making 220hp and spinning to nearly 10k rpm.
    20171120_162313-1944x3456.jpg 20171120_161948-1944x3456.jpg 20171120_162207-1944x3456.jpg 20171120_161847-1944x3456.jpg

    my build needs valve springs pretty bad anyway so ive decided to overhaul the entire head whilst im at it.
    ATM im looking at using
    ferrea 6000 series valves
    ferrea 80lbs dual valve springs with Ti retainers
    ill be keeping the Type R cams that are in my current head as these are well known too be one of the best cams for a boosted bseries under like 600hp but the setup will handle an aggressive cam should i want too go that way eventually with a larger turbo/sleeved bottom end.
     
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