WIP Nova turbo 1.6i SRI

[Green16v]

Nearly at the end now should be on the road in two weeks. off to get exhaust this week and full samcos in engine bay.
What do you think?



http://i102.photobucket.com/albums/m89/Makwal/STP60355.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60356.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60357.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60358.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60359.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60362.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60364.jpg
Chrome sump!
http://i102.photobucket.com/albums/m89/Makwal/STP60365.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60366.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60367.jpg

[craig0120]

looks like a std engine to me lol

are you having the afm after the turbo?

[Green16v]

Couple of pics of my mates astra aswell who is helping me
http://i102.photobucket.com/albums/m89/Makwal/STP60361.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60360.jpg

[Green16v]

I started the engine up with the turbo off so thats why the the airflow meter is on the mainfold

[n0va_dan]

note to self..not enough room for cars...knock down wall lol.looks mint pal,im jealous.

[General Baxter]

note to self..not enough room for cars...knock down wall lol.looks mint pal,im jealous.

there would be more but i had the clio lol

chris, do you know if coopers got the engine back running yet?

[draper]

looks good matey, astra looks nice aswell

[Green16v]

Coopers just waiting on sev to put some cooling pipes into his transfer box then the engines going back into the astra mate

[nova ian]

Nice work, I like that looks spot on

[Green16v]

Got the boost gauge in and the digi dash now, going for exhaust fri then samco the engine bay the weekend.

http://i102.photobucket.com/albums/m89/Makwal/STP60375.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60370.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60369.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60384.jpg

http://i102.photobucket.com/albums/m89/Makwal/11-09-06_1826-2.jpg

Cheers for the comments will try to update as much as pos.

[Iain]

Looks brilliant :cool:

[craig green]

looks good. Very interested in the manifold. Hope it works well.

Should be really nice when she is all cleared out & the finishing touches are done.

[macc nova]

good work there, looks mint

[Green16v]

Went for exhaust yesterday but they didnt have any with a rolled out tip so i've ended up with a rolled in tip dont really like it but will change the back box later. Car now at a friends unit getting full samco hosing in the engine bay and the oil feeds to the turbo connected. still waiting for grill and boot handle back from painters who are messing around. will post more pics in a min.

[Green16v]

http://i102.photobucket.com/albums/m89/Makwal/STP60391.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60396.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60397.jpg

Just uplaoading pics of exhaust now. not that happy with it but will get changed later on. car is at the moment getting a full samco fit and little finishing jobs done round my mate unit becuse his got a 2 poster ramp. going for alarm fitting next week then mot. so not long to go now. nice xmas gift from myself.

[Green16v]

http://i102.photobucket.com/albums/m89/Makwal/STP60398.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60399.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60400.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60401.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60402.jpg

[Mike.]

very, very nice mate :thumb:

[Adam]

Very nice indeed, like how you've modded the front bumper for the IC,to keep it looking almost std.

What did you use to turbo the 1600? Did you buy a courtney/mvaux turbo kit? Or get the bits together yourself?
What are you using the control boost etc? Aftermarket ecu?

[craig green]

I think its all bits he has sourced. He's had the manifold made for him.

I beleive its having the Courtenay style microswitch on the std ECU as I was answering some Q's about the TPS wiring via PMs.

looks sweet though.

[Green16v]

Cheers craig, yes as craig says ive sourced bits from all over mainly the courtney kit i.e. sandwhich plate and micro switch. then got the mainifold built brought a new turbo and just hunted around, will have some more pics tomoz and hopfully fully running aswell ready for the alarm to be fitted, which ive just found out i've got a bargain. my mate works for BMW and was asked to take off a clifford G5 950 which when i phoned the alarm place asked how much i had payed and told him nothing i got it for free and he says it's normaly around ?900 fitted, and he'll fit mine for ?160 (mate rate)with door poppers so bonus!!!

if you look quick craigs old engine is for sale for ?900 in the for sale section.

[Green16v]

Got all the piping done yesterday looks ace and its run for the first time with the turbo YEAH!!! how good does this feel, i'm off back to the unit now for some tweeking bits.

Pic of mainifold and turbo
http://i102.photobucket.com/albums/m89/Makwal/STP60403.jpg


http://i102.photobucket.com/albums/m89/Makwal/STP60413.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60414.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60416.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60417.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60418.jpg

[Dave.]

looking good mate

what bhp is it putting out?

[Green16v]

I think courtney say 150bhp standard but were thinking about 175bhp or around there. Got all the oil feeds to the turbo now. Got an FSE kit but gave me the wrong adaptor for the top of the fuel rail so waiting to get that today, when we started it with the turbo plumbed in the mainfold went red within mins so we think theres maybe a lack of fuel. No other problems everyhting seams to be going to plan at the moment. Next comes the alarm.

http://i102.photobucket.com/albums/m89/Makwal/STP60415.jpg


http://i102.photobucket.com/albums/m89/Makwal/STP60419.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60420.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60421.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60422.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60423.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60424.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60427.jpg

Does craig or anyone else who knows about courtney conversions know if this micro switch is wired up correct? this is how it came on the loom. cheers.
http://i102.photobucket.com/albums/m89/Makwal/STP60426.jpg

[Adam]

when we started it with the turbo plumbed in the mainfold went red within mins so we think theres maybe a lack of fuel.

What turbo is it?
A oil cooled/fed T2?

Whats your fuel pressure set to?

[Stuart]

id go with needing a properly mapped ECU rather than "fooling" the std one with that switch..... but hell what do i know lol

[Green16v]

Will get omex on in jan, but wanted to run engine in on this man system. Turbo is T25 oil cooled dont know what fuel pressure is but will do tonight when i get FSE plumbed in Because ive got the gauge with it. Without the turbo plumbed on the engine ran sweet so i must be that the turbo is pushing to much air into the engine and the engine cant get the fuel in fast enough???

[Stuart]

id also be inclined to ditch the FSE setup you have and get a proper SARD pressure reg that holds the right pressure across the rev range....

[Adam]

Will get omex on in jan, but wanted to run engine in on this man system. Turbo is T25 oil cooled dont know what fuel pressure is but will do tonight when i get FSE plumbed in Because ive got the gauge with it. Without the turbo plumbed on the engine ran sweet so i must be that the turbo is pushing to much air into the engine and the engine cant get the fuel in fast enough??? It will be making hardly any boost idling/ free revving as theres no load on the engine.
If the turbo is glowing at idle, i don't think i'd risk driving it tbh, its going to be melting under full load/boost.

Whats that switch do? Trick the ecu so it chucks a load of fuel in?

[Green16v]

i was told the the switch tricks the ecu into throwing more fuel in ( i think or i could be air ) it was only the mainfold that was glowing not the turbo. where going to try throwing more fuel in and see if the tick over comes down from 1300- 1600rpm.


SARD pressure reg that holds the right pressure across the rev range
where do i look for these?

[Adam]

You can adjust the idle speed manually on the side of the throttle body, also if it was cold when it was started the idle will be high until the coolant warms up.

It will be putting more fuel in, it can't add more air as thats not possible as it can only flow whats coming through the air flow meter/tb(apart from at idle)

Any "proper" fuel pressure regulator will be fine, one that holds constant pressure, it will need to be set to the same pressure the engine runs at originally as thats what the ecu is set for, so it injects the correct amount.

[Stuart]

google SARD fuel pressure regulator and see what comes back...

you wnat a constant 3bar (for exmaple) fuel rpessure difference between the inlet manifold and the fuel rail, an FSE isnt the best at holding this... the SARD is better. Or even a cossie weber one (look on the burton power website)

[craig green]

You want 3 bar at idle with the vac hose off (back on when set).

The chrome will not last on that manifold (it is chrome yes?), dont worry about that. I swear the nderbonnet temps are higher with a turbo installed even without boost, just idling.

This is making me want mine back...dammit!

[Adam]

With the manifold being shiny/chrome i'd imagine it would get hot quicker/glow, compared to normal cast iron/mild steel jobbies.

[Green16v]

Mainifold was just polished but sinice it went red its gone that burnt colour which doesnt look that bad. but im goning to use exhaust wrap to keep the temp down in the bay and get a turbo heat sheild.

cheers for the advice, im off to london tomorow but will be back on car wed so will update then. just off to help my mate drop his turbo lump back in his astra 4x4 after he melted a piston will get some pics so you belive its a 4x4.

[craig green]

All good.
Chrome Motorcycle manifolds are a good example of when they discolour. just wrap it as you say.

[s14a]

what intercooler is that mate??

[Green16v]

one of custom made intercooler. trying to get stand a TV show to show off what work and chroming we can do

[rc]

wicked coversion! very bling engine bay! how much d u think the engine has set u back cost wise? great sleaper, looks like it'll take some people by suprise 170bhp! good job!

[rc]

and the 4x4 astra sound intresting!

[Green16v]

JUst dropped car off for alarm, then mot tomorow then run some miles into the engine (1000). Got engine running correct in the end with FSE fitted going for a basic tune monday to make sure its alright to run in, wont try and boost it until run engine in to be on the safe side but might have omex fitted when engine run in. Still waiting on grill and boot handle from painters!!! then carbon fibre bonnet in jan. My mates trying to get a stand at the TV show next year with chrome and polished bits for sale and he can fab anything you want like my mainfold, his just doing all the pipe work on the 4x4 astra as we speak willl take some pics this afternoon of it.


how much d u think the engine has set u back cost wise?

About ?1600-?1800 but ?800 of that was mainifold and turbo, car prob owes me in the reg of 6K+ but i dont want to think about that still got ?400 bonnet to get then omex + setup ?1000-?1500. The underneath of the car is concours standard and every bit ive tryed to use gen vauxhall parts. still got a lots of bits to chrome like door latches wing bolts etc....

cheers for the commets.

[rc]

stunnin :thumb:

[craig green]

Dont be scared to run any boost on running in. You can ruin a new engine running it in like a pussy.

Just dont rev the nutts off it or make it labour at low revs, You can actually fully run in an engine in a couple hours if you know how.

Its all about cylinder pressures & vacuum. Taking it to 3000rpm & closing the throttle & letting it overun is the way. Then take it to 3500, then 4000rpm & so on. Best to do it down a gradual hill.

dont use synthetic oil to start off with either.

[Stuart]

a nice chewy x/50 oil from hellfrauds for the first 50-100 miles then a normal 10/40 mineral for the next stint and finally the semi/fully synth you want to run.

as craig said, run it in keenly as for a start i dont envisage many of these conversions to last much more than say 5-10K miles so do you really wnat to be running it in for a 1/5th of its life? lol

[craig green]

You can always fit a manual boost controller to limit the boost anyway.

I used one & it decreased the spool up time of the turbo, nice little mod.

Dont get a bleed valve but a MBC.

try; http://www.gb-ent.com/turbo.shtml

I used a mk1 controller & was very impressed. This is a mate of mines site.
tell him I sent you.
CG

[Green16v]

cheers for the advice.

Got a phone call last night from the alarm place telling me his having probs with the door popper on the drivers door, i was ment to be picking the car up this morning to take for an MOT then tax and start running it in. but now there keeping it till monday lunch so im sitting here bored when i could have been out in the car!!!!!! DOING MY HEAD IN!!!!!

[Green16v]

YEAH!!!! got car back from alarm place last night at 5pm so to late for mot, sorted last little jobs for the mot out and took it for a drive round the yard, it runs pretty well i must say we run i bit of boost to make sure everything works. got mot this morning so should be on the road this afternoon running it in and trying to get back my grill and boot handle from the painters.

[rc]

top job mate!

[Matt2107]

More pics needed :D

[Mazz]

Cracking thread Chris, and loverlee car :) Nice meeting you (briefly) on Sunday..

[s14a]

nearly have craigs old engine fully fitted in my nova,should be out for a blast in it iver the weeknd,lookin at this thread just makes me even more impatient to get a blast in it lol
is it just the bigger turbo you have to get the expected 175??
stunning job mate fair play

[Green16v]

Right cars up and running and will hold a bit of boost havent tryed reving all the way up yet. Problem is that took for an mot yesterday and the car didnt smoke at all, then on way home about 4 miles later when the car sat in traffic for more than 10 seconds it started to smoke badly, but when i drove off it cleared again, we where thinking it cant be the turbo seals because it should smoke all the time. but at the moment the car is running rough so were thinking its either over fueling so im off this morning to get the fuel and air setup. apart from that the car runs sweet its a bit hard with the poly bushes in but i bet it will handle a treat. any thoughts on the smoking???? or is it thats its a fresh build and just needs running in?


it just the bigger turbo you have to get the expected 175??

Bigger turbo and some more mods we have done, full engine spec when up and running right. rolling road jan to see how much im pushing then standalone getting put on.

cheers for the commets will take some more pics today.

[craig green]

No ideas on the smoking. Hope for your sake its nothing major. Maybe have a smell & see if its unburnt fuel or keep an eye on the water & oil levels.
You should get pretty good economy from it off boost so if it consumes a lot of fuel then it could be overfuelling.

[scott.parker]

Nice car mate,still find that manifold strange though.

I would say your over fueling etc,as the cars not set or running right on the "tricked" ecu set up,my mate has a e16 turbo and its not set up/mapped on his dta yet and it burns fuel on over run and also staves it at times when he plats his foot so it stuters then it compensates and russhes fuel in and bang it back fires lol he needs it sorting,sounds like you might have the sme thing - the pop bangs.

Scott

[Adam]

What colour is the smoke?

[Green16v]

its blue smoke we have put it down to the inlet seals on the turbo because it only smokes on tick over, so turbos going for repair on the 3rd jan. will be looing for my standalone man system soon everyone keeps telling me mega squirt has anyone heard of this?

got my grill and boot handle back yesterday about time!!

pics are from the other day.
http://i102.photobucket.com/albums/m89/Makwal/STP60456.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60457.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60455.jpg

lost camera at the moment will try get some pics up with grill later
http://i102.photobucket.com/albums/m89/Makwal/STP60454.jpg

[Green16v]

Right then found camera after i lost it for a day, heres some pics with the grill and boot handle in and some engine bay photos, its looks loads better in person. i found the turbo doctors phone number last night on an old thread hoping it still works after new years because i hear he has done 1.6 turbos before and might be worth the drive up to see what he can help me with anyone know if his still around? or any good? i need to get the standalone man on because the cars not ticking over correctly. i was also looking at people are running a 5th injector do you have to run this because at the moment the car boosts alright and doesnt feel like its lacking fuel. parking car up for xmas until the turbo has been sorted on the 3rd so back after the new year, and ive got loads of ideas still to come.
cheers for the comments and help have a good xmas.

http://i102.photobucket.com/albums/m89/Makwal/STP60463.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60462.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60461.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60460.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60459.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60458.jpg

[Adam]

Car is looking great mate, bay looks sweet, needs a blue top rad hose tho ;) Lol
Liking the manifold now its turned same colour as motorbike cans do..


Megasquirt can do exactly what you need.

But you will need a mapper who can use it....
You will also need a MAP sensor etc so it knows how much boost is going in.
4 injectors should be fine with megasquirt, as it will just add more fuel depending on how much boost is entering the inlet. Might be worth fitting 20xe injectors to make sure the 1600 ones dont reach max duty cycle.

Also, a wideband lambda and controller would be handy.



Yeah, sounds like turbo seals.. Was the turbo a re-con? Or just bought off ebay or something?

[Lee]

Looks lovely that pal. Novas always look nice in black IMO.

[Green16v]

Top hose is not that simple in samco both ends are different size's and ive moved the rad, but will sort something out in time, only started on engine bay theres loads to be done yet. yes turbo is re-con from a turbo centre in derby, so takin it back on the 3rd for them to sort out. my mate had same problem with his turbo from there so it makes me think there no good. got a set of xe injectors lieing around so bonus.

[Green16v]

Xmas prezzi off the girlfriend.

http://i102.photobucket.com/albums/m89/Makwal/STP60474.jpg

[craig green]

Looks stunning (front on pic) with the grille on.

Glad its running semi-OK aside from the turbo seals (hopefully). You shouldnt need a 5th injector as the Bosch management can squirt enough fuel for upto 10psi approx of boost. 5th injectors are used on SRi's & GSi's with a cat as the Rochester management on them cant dump in that much fuel, but megasquirt running 20XE beige injectors would be much better.

Can I ask what handbrake cables you have used wityh the rear disc conv & any part nos?

[Green16v]

Cheers craig, i was out of the country when my mate fitted the rear disks and cables but i'll ask him tonight mate, the car runs brill apart from when on tick over then the smoke appears but will be sorted on the 3rd, running 5psi at the moment and it goes alright done 500 miles now not thrashed it yet waiting for turbo to be done and the 1000 mile point. so where can i get this mega squirt from and who knows how to set it up best anybody recommend anyone in the midlands who has worked with the man system and this ind of engine before?

Heres a header tank my mate did for me yesterday!!!

http://i102.photobucket.com/albums/m89/Makwal/STP60475.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60476.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60477.jpg

[craig green]

Tank looks nice & shiney.

You can get MS on ebay etc etc. The prices vary massively but I would advise you get it from a respected MS seller & get it prebuilt & soak tested.

Chip on Vauxsport is a good man with contacts.

Search Google & find the MS forums, lots of talk & info aswell as WIP projects of all manner of stuff on there. Should give you a better understanding of it & baffle you. LOL

[Green16v]

Right then sorted the smokin out the other day and it was the return into the sump cheers guys moved it right upto the lip of the sump.

heres a pic of before.
http://i102.photobucket.com/albums/m89/Makwal/STP60483.jpg
http://i102.photobucket.com/albums/m89/Makwal/STP60482.jpg

Heres after
http://i102.photobucket.com/albums/m89/Makwal/STP60488.jpg
http://i102.photobucket.com/albums/m89/Makwal/STP60489.jpg
http://i102.photobucket.com/albums/m89/Makwal/STP60490.jpg

couple of the under side after a couple of drives in the rain

http://i102.photobucket.com/albums/m89/Makwal/STP60485.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60484.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60492.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60494.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60495.jpg

Car run in now, the actuator will only let me run 7psi so havent been able to turn boost up that much but goes alright for now. just had a oil breather pot made and fitted will post pics up as soon as. just looking around at differnet managment systems at the moment then will have one put on in feb. going to santa pod on the 21st to run it on standard managment to see what time it does the see how much differnce it will make when i change.

[draper]

looks good, should see you at pod on the 21st aswell, ill be the 1 drooling on your engine lol

[Adam]

Looks excellent, liking the chrome bits.

Fooook me, no silencers(apart from backbox)! It must be loud as fook on boost,Lol.

Most of the sensors already on the engine will work with MS fine.
Ring a mapper/rolling road place first tho, no point buying and fitting it all if they turn round and say they can't map it.

[craig green]

All good. Glad the smoking/sump issue was easily sorted.

You ought to move the oil filter, looks a bit cramped & hot if left there. You could use a Mocal relocation kit to do that & have run an oil cooler which it will benefit from.

The straight through exhaust probably isnt loud, mine wasnt.

Tempted to come to POD on 21st to take a look.

[NOV4_SPORT]

love it, love it, love it.

[Green16v]

Got this oil breather tank made up the other day looks alright what do you think.

http://i102.photobucket.com/albums/m89/Makwal/STP60512.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60513.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60514.jpg

Put a bleed valve on earlyier until i get a bigger actuator, it boosts up to 10 psi but only still holds 6 psi.
Got the paint work mopped at last aswell. looks alot better.

http://i102.photobucket.com/albums/m89/Makwal/STP60511.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60510.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60509.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60508.jpg

Cheers for the coments, hope it doesnt rain next weekend for Santa Pod.

[rc]

ive said it once and i'll say it again...... stunning!!

[bigbened]

i bet that things loud as **** lol

[craig green]

i bet that things loud as **** lol

NO! I said before I doubt it.

I'll explain why, with a turbo the exhaust propeller absorbs & uses the energy in the gases to to drive it. When the gases exit the turbo through the wastegate & off into the rest of the system, the gas has lost a lot of its energy & it doesnt exit with so much force to use a word. Wheras with N/A the gases shoot out the xhaust ports at a much higher speed & make more noise & pressure in the exhaust system.

Thats why turbo cars can have a single silencer/straight through system.

http://i30.photobucket.com/albums/c323/turbocraig/bits4sale/Novabits4sale033.jpg

I had my centre box removed & a new straight through section made & although it sounded different & deeper it wasnt loud like you may expect.

Looks awesome mopped btw :thumb:

[draper]

loving it, i think im gonna get a oil catch tank like that i think !!

[Green16v]

Quick little update- i snapped the cam today while out on the motorway, luckly a friend has a cam spare and will be changing it in the morning so will be putting some pics up in the morning. also brought another CR F13 box so will be stripping and polishing that for the PV2007 show. apart from the cam the car was running alright. was out the other night and only just beat a 2L 8v nova, but it was pissing it down and i was spinning up to fouth then got past him but after that he could'nt keep up with the pace, LOL its like a little toy im so glad i built this and didnt go back to the XE. i would recommend this any person.

[c'2.0lrt]

do you know somebody that makes tanks? ie header or what im after washer bottle? cars looking nice mate sounds good

[rc]

snapped a cam :eek:

[General Baxter]

you got that blokes phone number that made your manifold, as i need one making the clear the steering rack!

[carnoisseurcraig]

These megasquirt things are handy. I wish they were about when i turbo charged my Corsa 1400 16v.

I used the pressure switch with a 5th injector. Was a cold start injector from an audi. I screwed it into the inlet manifold so it condensed and gave me the extra fuel i needed. This was also controlled my an aquamist MF2 injector driver. I also upped the pressure using an fse boost valve.

Mine was roaded at 152bhp and sounded very throaty on full boost.

Nice work mate, keep it up.

[Green16v]

This is his number and he does anything and i mean anything, in his work shop at he moment his got a twin engine festia nearly done, and just started a twin engine series one. he makes any tanks and mainifolds. his name is SEV.

http://i102.photobucket.com/albums/m89/Makwal/STP60405.jpg

[Green16v]

Changed cam in it yesterday and its running mint again so looks like i didnt damage any valves luckly. i think this week were going to try and put another breather port out of the rocker cover because it doesnt seam to be breathing well enough. hoping the weather holds off this weekend and i'll run it POD to see what it does on standard managment, then in later feb put some omex on with a cam and run it again.
heres some pics-

cam snapped where nail points too.
http://i102.photobucket.com/albums/m89/Makwal/STP60515.jpg



http://i102.photobucket.com/albums/m89/Makwal/STP60517.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60518.jpg

here one of the F13 CR box i brought on the engine stand ready to be stripped.
http://i102.photobucket.com/albums/m89/Makwal/STP60519.jpg

Anyone else snapped a cam before?

[Adam]

What revs were you doing when it snapped?

If the cam housing/top of the head isn't perfectly flat exactly the same may happen to the new cam.
Or maybe the headbolts in the centre weren't torqued/angle tightened to the same as the others, i'd say that may cause it too.

Have you changed head gasket and bolts swap the cam? Or used a removal tool?

[craig green]

Ive heard of snapped cams in the past & I'm sure a mate snapped one in a 1300 Astra. You wont see much gain from an aftermarket cam, the lower compression means the gains arent what you'd expect & tbh the characteristics & spec of an off the shelf fast road cam wont suit the turbo setup.

I had a Piper on mine, it spooled up quicker with it IMO but the std GM cam seemed to rev harder at top end. So I sold the Piper & put a std one on again.

Route the breather on the back of the rocker cover to the filter/AFM pre turbo.

[Adam]

A custom grind cam is best for a turbo application, so you can get a suitable cam duration/overlap etc.

Seeing as all kent/piper jobbies are designed with NA in mind.

[craig green]

exactly. Minimal overlap is what you want, so you dont blow the inlet charge down the exhaust ports.

[Green16v]

I was sitting at 90mph on the M6 so about 3000-3500rpm i think when i snapped.

I used the removal tool to get the cam out i didnt want to be undoing the headbolts just in case something leaked into the chambers.

Craig its breathing heavy i dont really want to put the pipe back into the AFM beacause of all the crap coming out of the pipe.

Really i dont want to mess with different cams till i get the omex on it in feb.

Craig are you going to SANTA POD sunday if its dry???

[Adam]

Put the pipe into a catch tank(drinks bottle for now,Lol)

[Green16v]

Im running a catch tank at the moment

[craig green]

Craig are you going to SANTA POD sunday if its dry???

I wish I was. Its too far really esp to stand in the cold & watch other feckers have a good time. Get someone with a steady hand to get some vids of your car.

There must be a reason why its breathing heavily. Run the rocker cover breather pipe to a catch bottle then tap into the AFM (flat surface b4 the filter) & use that as a vacuum source for the bottle.

[craig green]

Did you get any times at the POD?

[Mazz]

iirc he was doing low 17's, but he also said the car isn't set up yet - waiting on management atm..

[Adam]

17s?
He must have really be struggling with traction.

[Mazz]

tbh, quite a few people said it was really really bad. A friends AStra GTE 16v was doing 16.8's at the start of the day! They should do mid-low 15's..

[Green16v]

I ended up with my best time of 16.4 but sayying that most people were doing crap times even the evos were slow, its off on the rollers tomoz to get this standard managment set up until i get the omex on. The bloke at the rolling road said he gets 160bhp on this managment ive got on at the moment, i think ive done something wrong along the way it needs setting up anyway because it doesnt tick over right and, i mean its quick but not rapid i got licked the other night by a standard RS turbo!!!!! not happy. hopefully things will be better tomoz night fingers crossed.

[craig green]

You should reap a std RS turbo. I nailed a highly modded one in my 1600T.

[Green16v]

Thats why im thinking theres something wrong

[draper]

car does look stunning in the flesh tho, and as said everyone was complaining about traction, the 4wd boys were sideways on launch !!!

and maybe your last run would of been better if you hadnt of panicked when the car in the next lane didnt backfire ;) lol

[Green16v]

I know i thought my engine had gone tits up LOL that skyline was making some right noise's

[Adam]

Tbh, theres not really much that can be setup on the std management.
Can't change the map or anything.

Only fuel pressure, and idle co.

[Green16v]

Just got back from hi-tech motorsport where ive had my car on the rollers, i'm buzzin now its come off with 157BHP!!! its a total different car now it pulls really well im well happy. he changed the plugs because they were the wrong ones (too deep) messed with the timing and fuel/air and bobs your uncle. he said i could do with bigger thottle body maybe one off a cav sri 130, does anyone know if they bolt straight on if not which ones do?? and a vernier pulley so he can set it up even better. his quoting me up for the omex where he said possible another 30-40bhp incress. i'll put a pic of the print out up tomoz when i get time.

[draper]

good one, now go find that RST lol

[Green16v]

Too right and his going to have a shock this time, because bets are he'll think not this idoit again then it will be bye bye ford boy!!!!

[craig green]

It was running in! LOL

Thats awesome news Chris, I knew something was amiss.

Either have the std throttle body enlarged (Ive got a contact) about ?150 or the official Irmscher one for the E16 engine is available still from GM. It does however have the same part no as one from a mk1 Carlton 2.4. So look out for 2 of those (one for me).

Ive seen 2.0 8v throttles fitted, but people complain about jerkiness, the breather pipes are different too & I'm sure the bolts dont line up so you need an adaptor plate etc. Your mate Sevs could enlarge your std one I bet?

[c20xesleeper]

nice car mate .

[Green16v]

heres the print out from yesterday. i've been out in it today again and im going to end up killing myself in it LOL!!!!!!

This read out is 157bhp at the wheels!!!!!!!


http://i102.photobucket.com/albums/m89/Makwal/STP60549.jpg

[craig green]

Whats the torque output?

I'll scan mine in when I get a chance.

[Mazz]

Bargain dude :) Bet your well pleased!
Have t back to Pod now and try again, and i got some special tyres which i might let you borrow aswell ;)

[craig green]

Just looking at the printout, peak power at 6008rpm is good going IMO. Mine was lower than that & I dont think a 2.0 LET peaks as high as that, typically.

Cant find my printout, Ive got 2 copies but I think one is with my GSi glovebox..... (shed).

[s14a]

if my 1.6t puts out 157 il be delighted fair play lad id say its a animal to go lol

[Green16v]

Right then havent updated this for a while. Car has been running mint with no problems until last week when it started smoking one day so did a compression test and number 4 was low so stripped engine that day to find a hot spot on the bore and piston which was letting the oil past. So ive done a rebuild with a different piston new rings, new mains, head skimmed, new head bolts. did all this in about 3 days because i need the car for work. so i had to run the engine in again so did this in 2 nights on the M6 and it was booked in at high tech again for a tune. Night before the rolling road i got this toy-
http://i102.photobucket.com/albums/m89/Makwal/STP60569.jpg

So fitted this about midnight and changed the oil. then off to rolling road in the morning.
http://i102.photobucket.com/albums/m89/Makwal/STP60579-1.jpg
My mate in his corsa 2L 16v
http://i102.photobucket.com/albums/m89/Makwal/STP60570.jpg
this corsa only ended pushing 153BHP at the wheels.
then mine went on and to start with he was only getting 147bhp out of it then a bit more messing we got this-!!!!
http://i102.photobucket.com/albums/m89/Makwal/STP60580.jpg

175bhp at the wheels so thats got to be 200bhp at the flywheel?? or am i wrong? before it only pulled upto 4000rpm now it pulls al the way 7200rpm, went out last night and i sat on a Mk2 astra LET and he was only just pulling away from me!!!! its rapid. and best of all im of to the RING fri night so i cant wait!!!! will update with some pics after germany!!!!

Link here to rolling road vid-

http://s102.photobucket.com/albums/m89/Makwal/?action=view&current=STP60577.flv

[Mike]

fook me go on! thats some impressive power from a 1.6!

[craig green]

I'm a bit miffed how the std management is allowing it to rev to 7200rpm

I would imagine 175 is flywheel power, which is still V impressive.

[Mazz]

Awesome result Chris, i know why you weren't at the meet now!

[Adam]

I really dont see those results at the wheels tbh.
Is that XE'd corsa std? 153bhp at the fly is about right for a xe. 170ish aint.
Is your ecu superchipped? As CG said, that RR printout, max power is way above the e16se's rev limit.

What Psi is the turbo running, i was having a discussion with a mate, and he recons 200bhp(at the fly) is easily gettable with proper management....
Not sure how the fuel pressure mod compares to that.
So i reckon your 175bhp is at the fly, still, fookin awesome result. :thumb::cool:

Abit worrying about having to rebuild the engine tho...

Makes me want to get some parts together and build a turbo 1.6 myself. As usual for me, a proper pikey build lol, but spending out on decent management to look after it all.


s14a (http://www.novaload.net/forum/member.php?u=15088)-157 should be easily achievable, you can get 150bhp from a 1.6 8v NA.

[Green16v]

Im not joking lads its 175bhp at the wheels phone Hi-Tech and ask Mick 01384561777. I would only have to take you out in it and you would belive me its f**king rapid and handles brillant. Im running 10psi because i dont think the managment can take anymore. I am getting omex soon its just that things have come up so have'nt enough money at the moment. its running a standard ecu!!! Im not happy about the re-build aswell but we still dont really know the cause, so were carrying on are testing of different mods but things seam to be going well, there arent many people who have messed with this conversion loads. Still looking for en-larged thottle body for it. im on the rollers again on the 14th at hi-tech for a power run with migweb and hopefully TV will be there so come on over lads.

The corsa is'nt standard i dont know alot about whats been done but it came out of my mates astra and it was running 180bhp(flywheel) then so his lost a bit of power in the swop.

[Adam]

Not trying to have a dig or anything, but how has it revved to over the e16se's rev limit?

Also, im interested in how you lowered the comp ratio? Did you change pistons or use a spacer plate or something.
May be doing something similar myself v. soon.

[Green16v]

I dont know how it revs that high but it does, ive got the courtney spacer plate. you lads are never going to belive me are you!!!!! i have no need to lie to you lot im not some kid who lives in a dream world.

[Adam]

Im not saying your lying, i can see the RR print out, 175@7266rpm :)
Its just hard to explain how a engine management system limited to 6600rpm or there abouts, is still running at 7266rpm. Even yourself can't explain it. Unless its a chipped ecu, with a raised limit.

Where did you get the spacer? From courtney themselves?

I might get my ass down to hi-tech on the 14th, will be very interested in seeing it run :)

[Green16v]

I brought the turbo kit with bits missing out of the bargain pages about two years ago. Tbh i didnt even know that was the rev limit of a 1.6i so ive learnt somethink there. were going to try bigger injectors before the 14th and see what happens if it blows up we know not to do that again LOL!!! come down before the 14th if you want and i'll take you out cause im only at J10 M6

[Mike]

Im not saying your lying, i can see the RR print out, 175@7266rpm :)
Its just hard to explain how a engine management system limited to 6600rpm or there abouts, is still running at 7266rpm. Even yourself can't explain it. Unless its a chipped ecu, with a raised limit.

Where did you get the spacer? From courtney themselves?

I might get my ass down to hi-tech on the 14th, will be very interested in seeing it run :)

my old black E16 engined GSi used to rev over 6600rpm easily :thumb:

[Adam]

Perhaps the limits 6800rpm then?
Ive not owned a e16 engine, but they must have a limiter.

Green-Might pop down sometime, dont blow it up before i get there tho,Lol.
If the RR operator checked the fueling, and said it was ok i'd leave the injectors, fit 20xe injectors when the Omex goes on.

[Mike]

ive got one ready to go in next weekend lol

Tbh though, id go with what Hi-Tech say, as they've got a really good rep round here and we take our rally car's theres for tunning an dyno work on a regular basis and have never had any problems

[craig green]

My GSi (E16) used to limit out at 6600 or there abouts.

Certainly wouldnt pull hard to anywhere near 7000+. I beleive you so fair play I guess. I'd still love to see it for myself though.

Hope its coming to PVS Green16v (whats your name?) I havent received a ticket payment yet.

I'd leave the other injectors off until the OMEX goes on too. Could be a whole different can of worms tbh.

[Green16v]

What a brill time over there heres some pics and i'll tell you all about it tomoz.
http://i6.photobucket.com/albums/y214/kfrankham/chris2.jpg
http://i6.photobucket.com/albums/y214/kfrankham/chris1.jpg

[Rob77]

Really smart mate!

[vaughanmc]

looks mint that :)

[NovaLad]

Wish mine looked that good :(

[Driver]

looks good looks like the one in the recent TV

[craig green]

Quality pics!

[Mazz]

I'm not jealous at all.....

[SRimon]

Stunning, good project too! Love the difference of a turbo'd 1.6 instead of just wacking in a LET

[TonySR]

I've been pondering over the thought of building a 1.6T for the last few days, what exactly would I need to build one from scratch?

Awesome build by the way, love the pics at the nurburgring :thumb:

[Green16v]

It does say in the thread what ive used but here are the basics-
1.turbo
2.ex mainifold to fit turbo an engine (courtney do one)
3.Spacer plate or low com pistions
4.Intercooler
5.Trick switch or different management
6.Boost pipes
7.Strong engine

there the basics but i have done alot more, what ever you think its going to cost you x2 it, i would say its prob cheaper and easyier to put a LET in but i went for the different option, i mean how many 1.6i turbos do you see now?? not many. and ive still got alot of power from such a small engine 175bhp at the wheels. hope this helps.
chris.

[Green16v]

http://i102.photobucket.com/albums/m89/Makwal/STP60773-1.jpg
http://i102.photobucket.com/albums/m89/Makwal/STP60767.jpg
http://i102.photobucket.com/albums/m89/Makwal/STP60760.jpg
http://i102.photobucket.com/albums/m89/Makwal/STP60762.jpg
http://i102.photobucket.com/albums/m89/Makwal/STP60776.jpg
http://i102.photobucket.com/albums/m89/Makwal/STP60780.jpg

[Rob77]

Beautiful!

[Driver]

looks ace mate ;)

i want one of those nurburg stickers :(

[krobinson]

looks ace mate ;)

i want one of those nurburg stickers :(

You have to go to the ring first, otherwise its just gay!

[Driver]

You have to go to the ring first, otherwise its just gay!

be reyt lol

i just like the look of the sticker TBH

[vaughanmc]

looks mint!

one of the only novas that i'd say suits the clear rear lights :)

[meach86]

hiya mate thats a mint nova iv got a nova van im restoring and i am thinking about turboing a 1.6 hoe much do you reckon its goona cost me

[Ash]

be reyt lol

i just like the look of the sticker TBH

get an M25 'ring one - way cooler :thumb:

[Mazz]

Looking as stunning as ever Chris :)

[kevster]

love the nova dude looks so nice !!

[Adam]

Looking awesome.

Will it be at pv?

[Green16v]

yes will be going to PV07 just have to send my money to craig in the morning. the car is still running good at the moment have turned the boost up a bit which im pushing my luck with because i dont think the managment will cope with it, but it goes like a rocket. it coming off the road middle of may so i can get the engine bay re-polished and clean the car in all over.

cheers for the comments
chris

[craig green]

Pushing your luck with the management wont help the piston crowns or head gaskets much....

Looking forward to seeing it in the flesh however. Any plans for running up the strip @ PV?

[Green16v]

Craig i know im pushing it but its fun!!! as you already know

im trying to go to POD on the 7th of may then def run it at PV just got to sort out how to get it to stop spinning.

[Rob77]

Craig i know im pushing it but its fun!!! as you already know

im trying to go to POD on the 7th of may then def run it at PV just got to sort out how to get it to stop spinning.

Decent front tyres, and an LSD always help.

If your running coilovers at the rear, raise the rear end and set the damping to rock solid, so that the weight stays over the front wheels.

:thumb:

[SRlew]

that looks nuts! good work there fella!

the work that guy does seems bloody good! i like fiestas aswell, anychance you could chuck some picture in muppet corner of it if you have any?

i need to get to pv to see this lol

[Green16v]

Update- ive got my new reg plates on now which look good. ive spent all day re-polishing all my boost pipes and tanks and cleaned the gearbox again hope its not raining the weekend or all that work for nothing. still going to PV will be there on sat if anyone wants to come over and have a look.

see you all the weekend.

(oh and its smoking on tickover now and again so you wont miss me)

[Dave.]

this going pv? its stunning

[Green16v]

Sure is and i'll be running up the strip sat and sunday if its dry

[s14a]

lookin good dude,tryin to build 1 of these myself,have the courtenay conversion...

how you findin realiability??

[Green16v]

done 5000mile and only 1 rebuild due to piston rings, went to germany and back and use it as a daily runner to go to work and back and have no probs mate

[chris-gsi]

get an M25 'ring one - way cooler :thumb:

been there done that as much as people thinks its sad.i had a right laughf.

[walker-nova]

very tidy

[saloonwoody]

i like it hows it goin now ??

[DIB]

just read this through and looks a very good build:thumb: .

one thing i will say though is Hi techs rolling road figures are flywheel HP not wheel HP;) .I`ve had a fair few of my past cars run there and they are flywheel figures.

[Green16v]

http://i102.photobucket.com/albums/m89/Makwal/STP60823.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60822.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60821.jpg

http://i102.photobucket.com/albums/m89/Makwal/STP60819.jpg

heres some pics i forgot to post up from PV07. car is in dry storage at the moment until i get back into the country. then going back to the bodyshop for new wings, because when i first put the speedlines on the tyres were the wrong size and rubbed the arches. and front bumper and bonnet sparyed due to stone chips from the ring, the new windscreen again due to the trip to germany. and trying to get my speedlines polished or buy some. then back to the rollers before PV08. also fitted chrome strut brace to front and got a chrome strut brace for rear that needs fitting. In the process of buying another car so after the PV show this car will go into storage. ive got the car upto the standard i like it at, so a bit more chroming in the engine bay and will leave it like that. nearly sold it at the start of the year but glad i didnt.
will update with more pics of the respray as it takes place.

[Mike]

Chris, been looking thourgh the pics of your engine build/bay, where are you getting the oil feed for the turbo from?

[Geordie-Chris]

Looks excellent, have I seen this on JOV??

[Green16v]

Geordie-Chris can you put a link upto where you have seen this on JOV please.

Mike, i have put in like a T joint in where the oil pressure sensor is on the oil pump hope this helps. the big problem i had was where to send the oil once it had left the turbo. how far are you into the project any pics?

[Geordie-Chris]

Geordie-Chris can you put a link upto where you have seen this on JOV please.
Seems I may be confusing this with another Nova. I'm sure I've seen it somewhere before tho?? Probably on here lol :roll:

[Mike]

Nice one for clearing that up for me Chris.

TBH ive not got to far into the build at all due to lack of time. The engine is nearly totally rebuilt in N/A form, ive got a pair of T2's which are both in bits pre-rebuild. The shell is mid chassis plating and awaiting paint etc.

Ive had to start from scrath tho as the car itself was stolen and stripped so its more then just engine work im doing. Complete new interior, all new electrics, panels, paint, wheels, suspension etc etc the list is endless.