Turbo Raceco Exhaust

Fitted a 3 inch Raceco titanium exhaust silencer. Used a Caterham exhaust bracket that I bought online and fixed to the body tub with a large repair washer on the inside. This fits perfectly with the angled Caterham style bracket on the end can.

The silencer is incredibly light and the quality is superb, the silencers finish really goes well with the brushed stainless down pipe. 

Lock Up Multi Stage Clutch

Managed to get a good deal on a MTC multi stage lock up clutch kit from a drag racer. The kit was fitted to a 620hp turbo hayabusa and used for full bore launches at 10,000 rpm. So should be more than capable to stop my clutch slipping with the higher power engine.

The clutch kit comes with a MTC billet inner hub that completely replaces the stock clutch centre and back torque limiter, a billet clutch basket, a modified clutch pressure plate, updated springs, and an updated clutch centre that has spring loaded arms that sequentially push the pressure plate down above 5,000 rpm and locking the clutch in place. There is also a larger billet clutch cover with a removable access lid for easy clutch adjustments. 

I decided to keep the Extreme Engines billet basket and to put the MTC item on eBay, which I'll list at a later date. In a drag application where the clutch is designed to slip before it locks, the racers often run more steel plates than fibre. For the time being I am going to run the standard clutch set up with the half plate at the back swapped for a full plate.

Turbo Rebuild #11 - Downpipe Welded

Some pictures if the down pipe that's been TIG welded by G19 Engineering. Hopefully the plenum will follow shortly.

MBE 9A9 ECU Upgrade

The MBE 9A4 ECU has reached its limits for my set up and whilst it is fine for a normally aspirated engine, to achieve boost control I needed to fit an external boost controller, also for wide band lambda yet another controller and I had to monitor fuel pressure and oil temp on my Dash 2.

The software for the MBE 9A9 has been significantly developed over the last 6 months and now has many more features than before. Previously I was advised to use a boost controller for adjustable boost, however it only provided different boost settings but did not tie in to rpm and gear limits.

With the MBE 9A9, the boost control software now provides switchable boost with waste gate maps for the first three boost levels and also has the ability to limit boost in gear for all maps, 

In addition to boost control the ecu also has traction control, launch, inbuilt 4.9 Wideband lambda controllers, anti lag and much more:

Control Strategies · 2 Fly-by-wire/EGAS · Sequential Fuel Injection & Semi Sequential fuelling up to 8 cylinders · Sequential Ignition & batch ignition up to 8 cylinders · Programmable Dwell Control · Multiple Crank Trigger Wheels · Acceleration Fuel  · Overrun fuel cut-off  · Wide Band Closed Loop Lambda (2 inputs)  · Fuel Pump Relay · Gearshift Light · Radiator Fan Control · Powershift · Full Gearbox Control · Launch Control · Boost Control · Water Pump control (PWM) · Traction Control · Variable Cam Control up to 4 camshafts · VTEC Control · VANOS Control · Anti Lag · Starter Motor Control · Pit Lane Speed Limiter · Low Oil pressure warning · Nitrous oxide control · CAN Data Stream · NEW functions added all the time*

As I did not want to spend £1k on another loom, I decided to re use the 9A4 loom and to make an adapter harness to connect to the new ecu, then to wire in the additional functionality over time. I started by making up the adapter and wired in new cables for the Amil valve, 4.9 Wideband, boost selection switch, wheel speed sensors and control for the additional water pump on the charge cooler. 

The ecu fired up ok and the sensors read fine, all the outputs I checked worked. Will check the ecu fully when the engine is fully back together.

When it is up and running I'll put the 9A4 ECU, eboost 2 boost controller and AEM Wideband lambda on eBay.

Turbo Rebuild #10 - Exhaust Downpipe

Made up a Downpipe to connect the v band on the turbo to my silencer. Made the pipe from mandrel bent 3 inch stainless steel sections, taped in to place and sent it away for mig welding. Will also get a lambda fitting welded in.

Turbo Rebuild #9 - Fitted the Manifold and Turbo

Fitted the new turbo engine and installed the manifold. Bolted the turbo in to place to check for alignment.

Fitted the 102mm K&N filter directly on to the turbo to look at options. I can either leave the filter exposed or fit a 90 degree elbow in to the engine bay and fit the filter inside. Will leave the filter externally to start with, however there may be excessive induction noise that would be quitened down by relocating the filter.

Need to fit the internall waste gate actuator and adjust for the best fit. The turbo is also fitted with a 3 inch exhaust connection with a v band and clamp, this will provide a tidy connection to the link pipe and easily swappable for cat or decat options.

Turbo Rebuild #8 - Cam Timimg

Finished off the assembly of the top end. Fitted a new APE cam chain and added spacers from Extreme Engines to position the cam chain tensioner. As the engine is fitted with a spacer, the cylinder and head are lifted slightly which makes the cam chain tighter. To rectify this, the cam chain tensioner is moved outwards by the spacers which means that it can operate normally with the barrel spacer in place.

Fitted the Extreme regrind cams and dialled them to 105 inlet 108 exhaust. May need to be adjusted later on the dyno. Engine is now back together and ready to go back in.