1641cc twin scroll turbo

[my_medusa]

After long time sitting on my destroyed 1200 turbo in fact of the broken conrod i decided to end the downzising. it had to much power for that little 1200 parts specially rods and the crank is also not x drilled so not the best option. under 200 nm i would use it but i would max it right there.
some guys have seen 130 hp and up to 160 nm in long use so thats not the problem. but a rod that weights 470g isn't that strong.
all the old stuff you can reed here:
http://www.shoptalkforums.com/viewtopic ... 3&t=133075

so my decision was to build a plug'n play engine with the parts i still have. only the extremly good 1300 34,5/33mm valved DP heads go on a friends 1300 engine because they are made for a small bore. he will use it as N/A high CR E85 first and later 83mm bore Turbo.

new engine:
1300 AB case as41
69mm stock crank ballanced with light 200mm flywheel
87mm mahle forged pistons and cylinders
refreshed stock rods 606g each
041 heads with 39/35mm valves long small spark hole, not really portet just smoth inside and polished+ chamberwork and better valvejob (54cc chamber)
still the close to serial cb 2280 cam with 1,3:1 rockers
double scat valvesprings
cromo bugpack pushrods
stock 86g lifters with hoover mood on them
CR just 7,6:1 for plug'n play

1600i manifold portet to the heads. changed alot to flow more and also to go backwards into the engine
watercooled intercooler
MS1 extra EDIS
bosch ev12 injectors 393cc/min @ 3 bar
want to use E85 again but maybe don't need it
porsche cooling
real twin scroll header (4-2 /3-1) in 35x1,5 to 38x1,5 into turbo 4-2(1) header
borg warner k03 twin scroll from a bmw mini cooper S


block is together again und also header and manifold are now changed for the engine. tomorrow finisching the heads and cut the cromo in size + putting all together that the engine can go into the car again.

thing is the engine has way more potential with an other cam in it but the turbo, manifold, injectors will all max out at about 200-220 hp.
hoping for a flat power and torque curve. and if it holds during the time it will becomme a big one. but for now the jump in HP will be more than enough for me and also for my car. lets see how it all works together and if it holds and how it performs.
pics come tomorrow i just have this one:
alot of work at the moment so it looks very messy on the pic.


wishes chris

[dejan]

Do you think this time it will withstand stock rods.
The cam is very low for 200-220 horsepower.
cb 2280-Eagle Racing Cam
Duration 274° / Dur. @ .050" 222° / Lift @ cam .359" / Lift w/1.1:1 Rocker Arms .394"

stock cam
Advertised Duration: 250° / Duration @ 0.050":214° /Valve Lift (Inch):.334 / Lift w/1.25:1 Rocker Arms .417.5"

Intake Opens -1° Before TDC ---- Intake Closes 35°After BDC

Exhaust Opens 35° Before TDC ---- Exhaust Closes -1°After BDC

can you move on

ntake Opens 2-3° Before TDC ---- Intake Closes 37-38°After BDC

Exhaust Opens 37-38° Before TDC ---- Exhaust Closes 2-3°After BDC

and not have to invest in such glory cam.

[my_medusa]

the stock rods will hold. i hope and belive in them. others put 30psi on it.
and the deal an the low cam is to make it an all rpm power engine. its not a racer. more the "don't shift down to eat porsche engine"

the power will not come out of the cam and rpm. the intercooler, maybe the E85 and stuff will make the jump in extra power.
i want to build the engine so that it performe very similar to the engine the turbo is from.it is an experiment...cam change will be not a problem at the end.

[my_medusa]

plan was to put the engine into the car today bit since sunday i am ill...so hopefulle end of the week.
can't wait...damn.

[Wally]

Cool plan! Could be a torque Meister!
Hope your feeling a little better now?

[my_medusa]

yes i feel ok right now. its like grandma told ...3 days in come, 3 days it stay and 3 days it need to go.
tomorrow i am in the garage again and hope it is in the car end of the day. can't wait to see how it perform. the winter is long so a cam and JCW upgrade could not be impossible for 2012 because would be just bolt on but first lets see what that super small cam can do.

[my_medusa]

played a bit with calculators just to make it visible what i wish from the engine and how i think it will perform.
and also to see at the end the difference in calculation and dyno results. one save street setup and a fun setup.

low boost of 11 psi:
http://www.turbodriven.com/performancet ... rsin=92044&

high boost up to 21psi:
http://www.turbodriven.com//performance ... rsin=92044&

both boost curvs how they could look. dots@(1300/2000/2800/3600/4400/5200)rpm


m virtuel dyno graph:
green is 11 psi: 160 flywheel hp@5200rpm 165 lb-ft@2800-5200rpm
red is 21 psi: 218 hp@5200rpm and 233 lb-ft@ 3600rpm (over 200 lb-ft@2800-5200rpm)


i don't think it will reach that high numbers, who knows what rpm peak will be and also what and where it will become restrictive, even will it need E85 for that? and and and. everything in between of those two graphs is possible.
at the 1200GT the twin scroll started boosting at 1300 rpm in 3rd, but this engine had some very good 35,5/33 heads on it and higher compression ratio....damn can't wait!

[Dan Dryden]

I'm looking forward to seeing your results. Perhaps you could post a video as you did with the 1200....?

[my_medusa]

inside again. oil pressure, easy. just some wiring and starting it. hopefully tomorrow.


chris

[my_medusa]

fu*k. have done everything + E85 out of it and 95 okt fuel into it. first starts, some wiring stuff and than...pump gave up.
damn, could it be, that some pumps don't like standing with E85 vor a longer time? and waiting again...damn damn damn!

[Wally]

..could it be, that some pumps don't like standing with E85 for a longer time?

Oh yes... which one is, euh...was it?

[my_medusa]

Don't remember just that it was up to 6,5 bar and max 270l/hr flow at 3 bar.

[my_medusa]

damn, spend the hole day into searching a pump and fixing some wiring. but end of the story it runns. and that like a champ.
after 2 test drives just low rpm around the block, and short sprint in sec. with 0,5 bar of boost...that scared me. it is a very nice ride now. my ass would say it was like the 1200GT on 1,1 bar but boost comes when put the pedal and very fast.

it was late. but short video.
http://www.youtube.com/watch?v=bKm550D_aWU

[my_medusa]

btw...pump for audi 80/90/100/200 and mercedes w 123 .... std. pump in the 80's-90's

[my_medusa]

so, some video with daylight.
everything is brilliant right now. temps. perssure. no single drop of oil. idle. the map is easy right now but will get some auto tune during the days and fine adjustments.
lets see where the rpm will oes. i hope a bit over 5000RPM peak. but with that small cam...we will see. its a totally street car right now.
and no in front its not a std break. its a csp disk one

http://www.youtube.com/watch?v=6P7FMetnQzU

http://www.youtube.com/watch?v=6ygq3ksbQ1o