My MK1 runs again

[Joshstix]

Hi Guys

I did a Gen 3 3S swap into my AW11 early last year however a lazy second hand fuel pump lead to a failed number three piston. Since then I've been biding my time saving some money and picking up gear to rebuild it a bit tougher than it was last time.

Here's some pics.
http://users.tpg.com.au/joshaw11/sw11/DSCF0786.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0787.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0788.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0789.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0790.JPG

Nice and stock looking with only wheels and exhaust to tell it's not stock.

[Joshstix]

This is what's under the engine cover.

http://users.tpg.com.au/joshaw11/sw11/DSCF0791.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0792.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0793.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0794.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0795.JPG

http://users.tpg.com.au/joshaw11/sw11/DSCF0796.JPG

It's a fully built bottom end with forged rods and pistons etc. There's a set of 1mm oversize valves, some tidying of the ports and 266 degree 10mm lift cams. It's controlled by a power FC running 800cc injectors fed by a walbro 255lph fuel pump. The cooler is a ST205 water to air setup and that massive turbo stashed up the front there is a HKS TO4S kit with tuned length stainless manifold and 50mm wastegate.

It is an angry angry car. I love it.

Just need to get it run in and then tune it and take it to the track for some legal fun.

[djdna2000]

Wow, looks great. What power are you hoping to achieve with that setup? What size tyres etc are you planning to run for decent traction?

[Shugsta]

Nice Job :D . Just one thing though..... That monster turbo looks real close to the firewall. Is there enough heat sheilding to prevent a melt down? Better safe than sorry.

[Driftin_AW]

mmm lovely...
I would quite like to hear how it goes when all run in and tuned. I have a Blitz turbo kit here that noone seems to want to buy off me that I might oneday put onto the sw11, but I wondered if it might just be a bit too crazy in such a light, short wheelbase car

[Joshstix]

To answer the questions, the aim is 300KW at the rear wheels. The turbo is rated for 550HP and all of the supporting mods are good enough to do the job so we'll have to wait and see how it goes. I plan on running 245-35 17's on the back.

As to the firewall clearance there is 17mm more clearance around the turbine housing of this turbo than there was with the CT20B. The compressor housing on the other hand is a whole other kettle of fish, it's got about 10mm of clearance total, but the mount system I've got setup means it'll never hit.

Driftin you certainly aren't the only one who'd like to know how it goes once it's tuned. It is possible that it might be a bit crazy but hell that's the idea as far as I'm concerned. I actually got it running at 3AM on Saturday night to get it to a show I was running on Sunday. I took it for a shake down and a bit of a wash once it was running, on the way to the car wash I figured I better make sure it is making some boost so I gave it a bit of full throttle run in third gear. Once it cam on boost it was nice and sideways up a straight stretch of road.

A word of advice though, getting up at 8AM on Saturday then working on your car until 6:30AM Sunday and then running a car show at 7AM Sunday where you have to judge is not a good plan. But then maybe I'm just getting old.

[Paul Woods]

that 1.5 is insane,cant believe the size of that turbo....that thing will suck up small children and pets if you arent careful.

The car itself looks very street sleeperish...lovely.

I was running 280bhp in my 1.5 and that was on the edge of useable traction on 215/40/17 rear tyres....that thing is going to be one twitchy mo-fo....i love it!

[Paul Woods]

oh if you get a chance please post some video of it running for our media section,i have a feeling it will be mostly tyre smoke but we'd love to see it in action.

[Joshstix]

I'll definately try and get some video when I take it to the track.

[MegatronUK]

Nutter!

Love it :D

[Joshstix]

A bit of an update.

The car has been spending a bit of time on the dyno. All the off boost area has been setup and it runs as smooth as a stocker even with the big valves and big cams.

The turbo kit I have came off an imported SW20 rear cut. It had a heap of corrosion on the outside from road salt so the car had obviously spent a fair amount of time driving in snow. Now the really strange thing about this is, I had no idea what spring was in the 50mm wastegate. The tuner did a part throttle run to try and find out how much boost it was going to make but stopped before the wastegate opened because it was getting up there. Turns out the spring is a 20 pound spring. Some nutter in Japan has been driving around on snow in a SW20 with a 550hp turbo running 20 pounds of boost minimum.

I've got a 1.1 Bar spring for the gate so that will make the low boost setting a little bit less ironic.

On the down side the right hand shifter cable melted from being too close to the dump pipe when it was on the dyno. I'm getting a new shorter one custom made today to get the tuning finished ASAP.

On the up side during the part throttle run at part revs without the wastegate even opening and without the boost part of the map being tuned the car was making 177KW at the wheels on a dyno dynamics. It should make a fair wack of power once it's done.

[nik]

thats 237bhp at half chat..im liking your swap so far mate..
could you shrink your pics down from 1280 x 960 pixels to around 800 x ???

[Joshstix]

No worries on the shrinking. I didn't do it origonally because I started this thread on the old forum and it scaled the pics automatically.

[adamh]

angry :lol:.. understatement of the year. nice mods... 800cc injectors.. jeez!. 10mm lift 266's.. is that 26 to zero litres in under 4 seconds =P~ ?

what do yo have cooling all that? just the wta ic?

[Joshstix]

Yep just using the ST205 water to air intercooler. it also has a nice 600x200x39mm PWR aluminium radiator out front to keep the intercooler cool though. The intake temps when I have had a chance to look at the display have been quite low.

We'll see about fuel consumption, but the tuner is doing some good work. It sounds like a stocker at idle now, there's no lope from the cams or anything. I think I need to put the stock wheels back on and get a subtle exhaust then go and scare some people at stop lights ;)

[nik]

I think I need to put the stock wheels back on and get a subtle exhaust then go and scare some people at stop lights ;)
now you're speaking my language..:twisted:

[Joshstix]

I just picked up the car from the dyno shop. We managed to get it down to 10lb of boost for the running in period since the engine has only done about 100km.

It made 203.8KW at the wheels on a dynodynamics. I'll get the graph hosted later.

On the way back from the dyno I never saw more than 5lb but it was a real eye opener. This is a scary fast car. I can't wait to get it run in nicely and then see what it can really do.

[Joshstix]

As promised here are the dyno graphs, the first one shows power and AFR the second power and boost.

http://users.tpg.com.au/joshaw11/sw11/dyno%20AFR.JPG

http://users.tpg.com.au/joshaw11/sw11/dyno%20boost.JPG

[Shugsta]

273 BHP atw at 10lb!:shock: thats mental!:twisted:

[adamh]

how are the cams set? in/exh.. on tdc?, steely hg?

[Joshstix]

Yeah it is fairly mental. Luckily it is also fairly linear so it is quite controllable, in a straight line at least. I haven't got the courage up to give it a big boot full in the corners yet.

The head gasket is a stock Gen3 1mm metal gasket. The cams are set to manufacturer specs, which I can't remember off the top of my head. The cams were a custom grind that the grinder made for Group A rally cars. They're 266 degrees advertised but they have more duration at 50thou than the HKS 272's. I'll get the specs for the timing when I find the cam sheet.

[Joshstix]

Things have progressed a little since I last updated this thread. The block cracked in cylinder number 2 on the number 3 side of the bore. This happened at the 10 psi 203KW configuratin listed above, actually only a couple of weeks after I posted that. I got both 2 and 3 sleeved with nodular iron sleeves, which have been standing up nicely.

Once the engine was solid I got the car retuned for 19psi and it made 247rwkw. This was really nice and very enjoyable to drive. Unfortunately the thin wall turbo manifold and welded in turbine flange were not very durable, I had to have each of them repaired/rewelded and when the turbine flange came off the second time I snapped and decided to build the turbo setup I really wanted.

The manifold went of to a local fabricator to have a jig created off it as I did like the layout. We made a replacement the same design as the HKS one except we put a T3 turbine flange on it 12 mm lower than the original flange and tweaked the tube angles to get a better collector. This was built in cast steam pipe for durabillity. I bought a nice little Garret GT3582R with 0.82A/R turbine to replace the HKS TO4S with 0.58 A/R. I was concerned that the fact the new turbo is rated at ~700hp while the TO4 was rated at ~550hp I would end up with a top end screamer but I wanted to try it out.

This is what the engine bay looks like
http://members.iinet.net.au/~warrenh/toyota_fest/images/DSC02752.jpg

And this is what the dyno graph looks like comparing the new setup to the old one
http://img201.imageshack.us/img201/108/dynojosh3sgtekl1.jpg

As you can probably guess I'm fairly impressed with the turbo selection. The car is a different animal to drive only requiring quite small throttle openings to make serious amounts of boost.

Now it's time to enjoy it for a while and then buy a 3bar map sensor to get it tuned for some real boost and turn some serious numbers.

[Paul Woods]

bloody hell mate....thats seriously impressive! how does this car rank with other US 1.5's? got to be the fastest one surely? i know deno's is putting down some good figures at the moment.

Hats off to you,superb work!

[Murf]

Lovely car too, a real sleeper :)

[Sponge Bob]

Damn, that is one seriously awesome mk1... looks like it'd take a lot to tame that!! lol

Paul: Australia = not the USA ;)

[Joshstix]

Thanks for the kind words guys.

As far as I know Deno's car is the most powerful SW11 in the US. According to the records page it makes 341rwhp. Mine is making 385 or so, ignoring the fact that the kind of dyno I use reads considerably lower than the dynojet. I really need to get a run on a dynojet so I can directly compare it to the US guys. Unfortunately there is only one dynojet on the east coast of Australia and the guys that own it are clowns.

[adamh]

holy smokes ! that's a lovely engine. i'm aiming up there eventually as i'd guess we all dream :-). what tyre size are you using and how do they hold up?

[Joshstix]

Still running 215/45 16 Azenis. They really don't hold up.

I have a set of 8 and 9 inch wide rims on order and am looking for some Datsun ZG flares so I can get some 265/275's under the back.

[adamh]

had a look at them zg flares, not bad at-all for a bolt on!. are they expensive?

[Joshstix]

I'm not too sure about the price of the flares. I'm sure if you tried to get genuine ones they'ed be stupidly expensive so I'll be getting replica's. I have seen replica's go for anything between $150 and $600 Australian per set.

[superchargedsam]

ouch !