Nova GTE - turbo

[Fester]

What's the basic outline for the parts?

Are the pistons up to being machined down or replacements available rather than big head gasket?
Will a Dastek Unichip be able to control a 5th injector?
Any place in particular make custom manifolds to suit?
Reconditioned Escort T3 turbo with -31 actuator suitable?
Would an F15 gearbox be able to handle the power one of these would produce?
Whats the deal with getting all the pipework make up?
Any specific intercoolers anyone got in mind suitable for all of this?

Cheers, just an idea got going

[mikeoxford]

chris ward has a 1.6 turbs, have a look in the turbo section in the features to see what he is running or Pm him i guess

[Chris_W]

Fest,
As I said last night, I'd go with spacer plate to check everything works before you waste money on pistons, as if the project don't work it's something like ?100 loss as opposed to ?400ish loss if you go with pistons.

5th Injector not really needed as we discussed last night, though would be a nice addition if you got a proper mapable ECU in there.

As for manifolds, if you run a T2 (I'd reccommend it) you can buy a manifold off the shelf from Courtenay for something like ?250, as I said this is prefered to the arrangement on my car, but then again I have a T3 so didn't have that option.

I'n running the standard gearbox on mine, so F15 should have no worries with it, but remember to uprate the clutch, I've got one of those Black Diamond ones on mine, and it seems surprisingly effective, but then I don't drive like a nutter to often.

Pipework - Well, let's go with the basics, you'll need some Samco or similar bends and some metal pipe work, this will get the intercooler in no problem. The turbo needs an oil feed and an oil return, on mine I've got the oil feed taken from the oil pressure sender, and the oil return goes straight into the sump via a connector welded into it. Then you also have all the vaccum hoses, but once you know where they go it's just a case or again getting silicon hoses and connecting it all up.

Intercooler - I've got some unknown Jap one in my car, but looking at the size I'd guess a Renault 5 one or RST one would do the same job, but remember, the bigger the intercooler the better, I think the Universal ones sold by Forge would be a good bet, or if your really flush, or good at finding stuff in breakers a charge cooler would be good.

As I said, I didn't do the conversion on my car, but I have had a fair bit of it apart and this is what I've found from it. Anymore questions just ask, and if I can't answer it, I'll try to get the guy who did the conversion to.

Hope that helps

Chris

[mikeoxford]

found him then 8)

[Fester]

thanks chris


how much can the rods and crank take before nasty things happen?

[Chris_W]

Well, working on the theory that the 8V and 16V use similar bottom ends, the breaking point on the 1.6 16V seems to be up around the 200bhp range, but obviously if your gonna be rev happy put in some ARP bolts. At about 200bhp on the 16v I'm sure they say you should switch to steel crank and rods, but don't quote me as I'm not 100% on that.
So how's the project looking? :D

Chris

[Fester]

quite an interesting idea

yep youre right on the bottom end sharing, if, and this is is a big if, i would be looking for around the 180bhp mark

still looking into stuff

[Chris_W]

Well, I was thinking something similar. My engine is 'supposedly' making 150bhp at 12psi, so in theory if I dumped the adapter plate and got proper low compression pistons, and fitted a bigger intercooler, or maybe even a chargecooler 180-200 bhp should be possible quite easily with just a little increase in boost. All depends if I can be bothered spending the money, and chances are I won't as I'm looking to chop the car in for something else next year.

Chris

[neiloakley]

where does the fifth injector go? At work, on cosworths we use air injectors to control the wastegate. We take a presurised air feed from the fresh air side of the turbo, feed it thru four injectors and back to the wastegate acctuator. The injectors are controlled by a Pectel T6 ecu and means the boost can be electronically controlled (and can even be mapped).

[Chris_W]

where does the fifth injector go?

There is no 5th injector, extra fueling is controlled via what I believe is a courtenay developed system, and personally I think it's a bit of a bodge, when the turbo spins up and boost is created there is a microswitch that sets the injectors to full, so basically the injectors flow loads of fuel in, as they think the car is at full chat. Obviously it would be better to get a mapable engine management system in place so that the fueling could be accurately controlled on boost, and if you get a fancy one you can get it to control Nitrous, or water/methanol injection as well for you real speed freaks :D
This really is an underdeveloped form of tuning on the 8V and I think that someon could make a really good engine out of it.

Chris