[engine_work] 2.2 Gti6 Engine Build

[welshpug 1,622]

Probably because Paul's a handier driver and he can take more risks of binning a £10k 205 over a £??(?)k Porsche!

 

 

you haven't seen the Belgians drive then!

[Mad Scientist 106]

First event is the Jack Neal memorial at Blyton, 10th march.

 

Looking forward to it.

 

Driveshaft sorted today. The bearing and sleeve pushed back by hand! Shocking. All welded up now, so should be ok.

 

 

[welshpug 1,622]

Colin had the very same issue first time out too, guess shafts aren't made as well as they once were!

[brumster 135 1 Cars]

I think you've hit the nail on the head there, Mei. I know it's always been a bit of a problem but I'm amazed how many times I've heard of the issue in the past few months - I think clearly the quality of driveshafts on the market now is rapidly diminishing

[Batfink 201]

Well the Porsche is faster at the moment. I see a race coming on...

[Mad Scientist 106]

Not getting into that again! Lol!

 

The Porsche is actually for sale now too! New house and baby on the way!

[kyepan 291]

how much?

[Mad Scientist 106]

http://www.autotrader.co.uk/classified/advert/201302235470683/sort/default/usedcars/make/porsche/onesearchad/used/onesearchad/nearlynew/onesearchad/new/radius/1/page/1/postcode/st86tn?logcode=p

[Mad Scientist 106]

Entry for the Jack Neal has been confirmed. Looking forward to it.

 

[Mad Scientist 106]

Taxed, tested and on the road.

 

Two words:

 

Noisy

Scary

 

 

It really is unbelievably quick.

[kyepan 291]

some vids please

[Mad Scientist 106]

We will get plenty next Sunday.

 

It's weird that all the noise comes from the front! It's a real deep rasp in the car, god knows what it sounds like outside!

[Mad Scientist 106]

Was just writing down the full engine spec. for my records and thought it would be nice to put on here. Hopefully this will give people an idea of how extensive a build needs to be to get this kind of power. Yes, with some minor tweeks (including a better ring pack: don't EVER use Total Seal rings people) it would make more power, and perhaps with a slightly different exhasut manifold might make a little more torque, BUT that would mean revving it more (peak power currently at only 7500rpm) and more frequent rebuilds, not to mention another £600 manifold. What you have to remember is that this engine, with the gearing I am using, makes it the perfect tractable tool for the stage rallying I am doing. It's not always about headline numbers, even if they are real, but something I have learned is you are not going to be able to buy some off the shelf cams and bodies, and stick them in a standard engine, and make 220bhp! Nowhere NEAR in fact.

 

Engine Specification: 2186cc

Power/torque (engine DYNO): 240bhp / 190lbft

Power/torque (rollng road): whatever you want it to be!

 

Base engine:

XU10J4RS GTI6 Head

XU10J4RS GTI6 Block

Bottom end:

XUD11 92mm stroke diesel crank (forged)

JE 87mm forged pistons (custom made)

Total Seal piston rings

Robson’s conrods (custom made)

Carillo rod bolts

Race main and big end bearings, Pug thrust bearings

Standard GTI6 oil spray jets

Bottom of cylinders chamfered for pistons

Top end:

Piper cams (custom spec, circa. 300 degree)

Piper double valve springs

Piper solid lifters

Piper vernier pulleys

Oversize 1 piece stainless inlet valves, wasted stems

Oversize 1 piece stainless exhaust valves

Ported initially by SRD race engines, final port/combustion chamber and valve seat work by Sandy Brown Engines (including recessed valves to accommodate cams on overlap)

One way oil valve replaced by reducer and oil spray bars removed and blocked

Cam covers machined flat to allow sealing with minimal silicone, breathers welded up etc.

Inlet:

Custom ported inlet manifold by Colin Satchell/Sandy Brown, using standard GTI6 inlet as base

48mm Jenvey DCOE throttle bodies (118mm)

Custome Colin Satchell/Sandy Brown trumpets

ITG air filter/back plate

Inner injectors on standard GTI6 fuel rail (GM Omega V6 Bosch)

Outer injectors on Jenvey rail (Clio 182 Pico)

Exhaust:

Custom 4:2:1 stainless manifold

Custom 2.5” system with 2 x silencers

Oil system:

Pace drysump

AH fabrications oil tank located in engine bay

AH fabrications breather tank located in engine bay

Electronics:

DTA S40 ECU

Custom loom

Mapped by Sandy Brown Engines on engine dyno, fuel tweaked on rolling road

 

Ancilliaries/Other:

Standard GTI6 timing belt/rollers/tensioner

Cometic head gasket

Standard spec GTI6 headbolts (same bolts used by Millington engines!)

Custom solid bottom pulley (alloy)

TRE billet flywheel

Radtec/BBM alloy radiator

Custom cooling pipework to fit around exhaust manifold

Standard spec Valeo push clutch (BX 16v)

Alternator tensioner is a tail rotor adjuster from an RAF Lynx helicopter!

[Mad Scientist 106]

Crappy phone picture of engine bay:

 

Uploaded with ImageShack.us

Edited March 2, 2013 by Mad Scientist

[Mad Scientist 106]

Just uploading a little video of "smokey Joe" on the rollers. The rings are starting to settle in now, but it smells lovely! Just like a rally car should!

 

One last point on the build. Even with careful consideration, calculation, advice, and lots of custom engineering, you can't just throw all these parts together and get the best result from the off. I know to many, that is obvious, but too many people think that's all there is too it.

 

It takes lots of trial and error and years of testing to get to where Sandy's full engine's are now. Take Colin's hill climb car as a case in point. Sandy did 4 heads for it before he was happy, and even then there are still things he would do differently next time.

 

Building engines really is an art form people!

[Mad Scientist 106]

 

TURN IT UP!

Edited March 2, 2013 by Mad Scientist

[allye 530 3 Cars]

I've been waiting for pictures and videos for ages.

 

This is absolute filth! There needs to be a warning on this thread now!

[clen666 2]

Beast!

 

Sounds lovely, good to see it all worked out in the end mate

[stu8v 68 1 Cars]

Sweet......

[Sandy 189]

Smashing

[dcc 855]

I do hope mine sounds half as good as that when sandy does his magic!

[Mad Scientist 106]

100 road miles in it today. Half motorway. Just got a bit of a starting issue when cold. New starter needed. Other than that, pretty trouble free. Stretched its legs a bit and it's very nice to drive when you push on and get the revs up.

 

Got the scruitineers to have a look over it at the Roskirk stages. They think it's spot on and very well screwed together. Got a lot of compliments which expanded my head slightly

 

Roll on next weekend!

[BlueBolt 156]

Had to open up the laptop to view the video...

 

​

 

God dam that was worth the wait!!!

 

​ ​ ​

[Dj_mini 7]

Nice to see it up and running! Quick question how many litres is your dry sump tank as iv got no chance of getting the pace one in my engine bay so may go custom like you yours or just stick in the boot again.

Cheers Dan

[Mad Scientist 106]

Dan,

 

Tank holds just over 7 litres to the top baffle. Full system has just under 10 litres in it with the cooler.

 

Question for you: what starter were you running on the last engine? Brise?

 

Pete