Club G40 Forum

Club G40 => General Car Chat => Topic started by: Robin on November 24, 2008, 09:02:17 am

Title: Project 180!
Post by: Robin on November 24, 2008, 09:02:17 am
Spent all weekend in my garage ripping the G to bits to start the mission to get 180bhp.

Its currently running 147bhp and has the following mods.

1341cc
GT Inlet
250cc Injectors
Full Blend
Toothies
Tweaked ECU Map
DeCat Pipe
Jetex Exhaust

Rest of the spec is:

PPP subframe
13'' ATS Classics
Rear Disc Conversion
Fog lights
Badgeless grill
60mm Spax RSX Damper Adj Suspension

The plans for the car are as follows:

Front Mounted Intercooler
High Lift Cam - 1341cc Spec- Yoof get that group buy sorted!!!
4 Branch Manifold - Yoof get that group buy sorted!!!
Stainless Exhaust System - Yoof get that group buy sorted!!!
Aquamist
Oil Cooler

So the first thing to get off that list is the FMIC.

So after 2 days in the garage the intercooler is fitted, radiator moved slightly and a new fan has been fitted as i hate the look of the standard heap of crap.

It did look like this
(http://i19.photobucket.com/albums/b155/robinyau/PICT5404.jpg)

and now.......................

My garage has now turned into a workshop, Audi has to sit outside now :-(
(http://i19.photobucket.com/albums/b155/robinyau/G5.jpg)

Front end Stripped
(http://i19.photobucket.com/albums/b155/robinyau/G1.jpg)

Bigger Intercooler sat in place
(http://i19.photobucket.com/albums/b155/robinyau/G2.jpg)

Intercooler mounted into place
(http://i19.photobucket.com/albums/b155/robinyau/G4.jpg)

New fan fitted with the rad moved.
(http://i19.photobucket.com/albums/b155/robinyau/G3.jpg)

Next task is to get all the hoses sorted out so thats not going to be cheap!

I'll post pics up as i go along with the 180 mission!
Title: Re: Project 180!
Post by: samg40 on November 24, 2008, 03:09:10 pm
Nice one Robin, sounds like theres going to be some money spent on this car! What changed your mind about floggin it then?
Title: Re: Project 180!
Post by: giorgio on November 24, 2008, 03:25:07 pm
http://www.polog40.co.uk/forum/index.php/topic,878.0.html

easy as pie......... ;D
Title: Re: Project 180!
Post by: Max on November 24, 2008, 03:27:18 pm
Sweet, love this car cant wait for more updates  ;D
Title: Re: Project 180!
Post by: Robin on November 24, 2008, 04:39:08 pm
http://www.polog40.co.uk/forum/index.php/topic,878.0.html

easy as pie......... ;D

nah thats cheating..............G lader to the max!
Title: Re: Project 180!
Post by: lance on November 24, 2008, 08:00:33 pm
lookin good so far mate!
Title: Re: Project 180!
Post by: Robin on December 06, 2008, 06:24:13 pm
Bit of an update.

Made a new cross beam to hold the IC and Rad.
(http://i19.photobucket.com/albums/b155/robinyau/G21.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G22.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G17.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G16.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G15.jpg)

Got it sitting right on the car and then chopped the ends off to suit the chassis legs to make it neater.
(http://i19.photobucket.com/albums/b155/robinyau/G19.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G20.jpg)

Removed old exhaust manifold...........
(http://i19.photobucket.com/albums/b155/robinyau/G12.jpg)

.............and then fitted the new 4 branch as access was easy without the charger on!
(http://i19.photobucket.com/albums/b155/robinyau/G14.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G13.jpg)

Fitted the Supercharger back on and a new blanking plate as the old one was bloody leaking which didn't help das powers!
(http://i19.photobucket.com/albums/b155/robinyau/G8.jpg)

Got hold of a 49mm TB which turns out to be a 50mm one when i measured it! Wicked! So that got fitted with a new gasket blah blah

(http://i19.photobucket.com/albums/b155/robinyau/G5-1.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G10.jpg)

Fitted the new slim line fan.
(http://i19.photobucket.com/albums/b155/robinyau/G24.jpg)

Fitted the boost hoses and pipes which was a bit of a bitch but got there in the end. Ignore the blue hose, still waiting for the black stuff to come in the correct size.
(http://i19.photobucket.com/albums/b155/robinyau/G7.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G6.jpg)

Everything else back on now.
(http://i19.photobucket.com/albums/b155/robinyau/G9.jpg)

Just waiting to get an exhaust reducer from 64mm to 51mm to hook the new manifold to the shitty old Jetex one and to get some coolant in the bad boy!

Then its off to Aldon to see how many ponies she puts out!

Pre Project mods are:

1341cc
Green Injectors
SNS Chip
Toothies
Decat Pipe
GT Inlet
Full Blend
Jetex Exhaust

147bhp..............

Current Spec:

1341cc
Green Injectors
SNS Chip
Toothies
Decat Pipe
GT Inlet
Full Blend
Jetex Exhaust

Front Mounted Intercooler
50mm Throttle Body
Dewedged Throttle Body
4 Branch Manifold

155bhp???

Next Phase...........

1341cc
Green Injectors
SNS Chip
Toothies
Decat Pipe
GT Inlet
Full Blend
Jetex Exhaust
Front Mounted Intercooler
50mm Throttle Body
Dewedged Throttle Body
4 Branch Manifold

Oil Cooler
1341cc High Lift Cam
Proper exhaust system - hopefully the PPP one, if not i'll get a custom one made at JP Exhausts (shit hot!)
Stand Alone Oil System
Aquamist
Big Valve Head

180bhp???
Title: Re: Project 180!
Post by: giorgio on December 06, 2008, 06:47:00 pm
Looking pretty swish there. Nice bit of fabwork on the IC bracket etc.

Title: Re: Project 180!
Post by: breadman on December 06, 2008, 07:26:48 pm
Nice work Robin.
Sort out the front bumper iron though, it's covering nearly half of the intercooler core up. A quick go with the angle grinder and a few speed holes in the plastic outer bumper and you'll make the most of the intercoolers large frontal area.
What's the intercooler off, something GM?
Title: Re: Project 180!
Post by: hayesey on December 06, 2008, 08:39:16 pm
nice work rocket  ;D I got a fair bit done to mine today too.  Now ready for it's new engine.  Did some more strengthening in the engine bay too.
Title: Re: Project 180!
Post by: Robin on December 06, 2008, 08:46:38 pm
Nice work Robin.
Sort out the front bumper iron though, it's covering nearly half of the intercooler core up.

I have taken as much as i can off the bumper iron, if i took any more out there would be nothing left, its only covering 4 inches off it so its fine in my eyes.
Title: Re: Project 180!
Post by: Max on December 06, 2008, 10:08:22 pm
Top work mate, looking good!
Title: Re: Project 180!
Post by: supercharged spaniel on December 06, 2008, 11:12:32 pm
liking this robin...as mentioned the bracket for the ic looks great!!
Title: Re: Project 180!
Post by: breadman on December 07, 2008, 10:07:04 am
Nice work Robin.
Sort out the front bumper iron though, it's covering nearly half of the intercooler core up.

I have taken as much as i can off the bumper iron, if i took any more out there would be nothing left, its only covering 4 inches off it so its fine in my eyes.

 :-\ Can you not use a holesaw and pepper the bumper iron? This way you get a better airflow to the I.C. rather than covering so much of it up and still be able to fit the outer plastic part. Alternatively, you could lower the intercooler a couple of inches (refab new mounting bracket! :o)?
Multiply the core width (25"?) x the 4" currently covered and you'll see what I mean by the amount of effective area covered.
Airflow is King for intercoolers. 8)
Hope this helps?
Keep us posted with this project. I have to say, although I'm not keen on the looks of G40's/mk3 Coupes in general, your one looks bloody cool on the ATS wheels and half CC bumpers. 8)
Title: Re: Project 180!
Post by: Robin on December 07, 2008, 10:12:46 am
Nice work Robin.
Sort out the front bumper iron though, it's covering nearly half of the intercooler core up.

I have taken as much as i can off the bumper iron, if i took any more out there would be nothing left, its only covering 4 inches off it so its fine in my eyes.

Airflow is King for intercoolers. 8)
Hope this helps?



wow really? didn't know that....................

as i said there is no point taking more out especially when the front bumper will cover that area anyway even if i do put holes in the bumper iron.
Title: Re: Project 180!
Post by: breadman on December 07, 2008, 10:24:13 am
Fine Robin, no need to be sarky. ::)
I did suggest in my first post that speed holes in the outer bumper would be required if you cut the steel inner.
Just seems pointless fitting a big I.C. then covering half of it up?
Group hug, it's a Sunday!
Title: Re: Project 180!
Post by: Robin on December 07, 2008, 10:27:42 am
Fine Robin, no need to be sarky. ::)

lol

nah mate i am all for getting more air into the IC but i always like to keep my car as stock looking as possible to frighten the odd chav trying it on with me.

plus drill bits are expensive nowadays....................
Title: Re: Project 180!
Post by: breadman on December 07, 2008, 10:45:12 am
quote" i always like to keep my car as stock looking as possible to frighten the odd chav trying it on with me".

Ah now that IS where its at! ;D
Better still, you can frighten a few modern day performance cars too! Watch out BMW M3's driven by suited bully boys who think they own the road.
Sleepers are where its at, EVERYTIME!
Title: Re: Project 180!
Post by: Robin on December 07, 2008, 05:16:52 pm
Pretty much done now, moved the car outside to tidy the garage and to flush the coolant out.

(http://i19.photobucket.com/albums/b155/robinyau/G27.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G25.jpg)

All that is needed now is the exhaust reducer from 64mm to 51mm which i have ordered from ebay, £20 for a custom joiner out of stainless which aint too bad!

Started the car up and idles fine so fingers crossed when the exhaust gets sorted then its time for the rolling road!

Had to chop some parts of the bumper away to get more air flow but didn't want to go too far as i wanna keep it stock looking.

(http://i19.photobucket.com/albums/b155/robinyau/G28.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/G26.jpg)
Title: Re: Project 180!
Post by: breadman on December 07, 2008, 06:15:22 pm
'Tis looking good now it's all back together, the front bumper is very subtle.
How jealous am I of all you G40 boys that have (relatively) so much room in front of the engine? Damn you all! ???
I'm trying to get everything all neatly installed into my mk2 and it's impossible to put anything in a decent position without lots of cutting. Put it this way there ain't much left of my front valance and the new slam panel I'm fitting is somewhat heavily cut about! My front bumper iron's lost plenty of weight too!
Function over form for me. I'm still working to try and keep it a subtle looking as possible though.
Title: Re: Project 180!
Post by: Max on December 07, 2008, 06:38:21 pm
When we going to see some progress pics Breadman  ;D
Title: Re: Project 180!
Post by: breadman on December 07, 2008, 07:37:52 pm
If I knew how to put pics in a post I gladly would. Whenever I've tried in the past it always says the pics are too big for loading etc. Help me out here and I'll start my own thread if you want?
Unfortunately I'm a bit of a numpety when it comes to computors. :-[
Imagine a red mk2 breadvan, with lots of bits taken off. That's how it pretty much sits right now! :D
Title: Re: Project 180!
Post by: Max on December 07, 2008, 08:01:58 pm
www.photobucket.com

or

www.imageshack.us

 8)
Title: Re: Project 180!
Post by: fluxco on December 09, 2008, 07:27:54 pm
wow, i like your front cross member for the rad and intercooler

do the mk3 front cross member just unbolts?  or did you have to cut it out?
Title: Re: Project 180!
Post by: Robin on December 09, 2008, 08:28:37 pm
Kam the front bumper iron bolts on, i have trimmed it to give more air flow!
Title: Re: Project 180!
Post by: Dan on December 09, 2008, 10:13:47 pm
Both mk 3 crossmembers bolt on. Looks nice in ali, must admit !
Title: Re: Project 180!
Post by: Robin on December 10, 2008, 10:13:34 pm
These 2 items arrived in the post when i got home from work.

(http://i19.photobucket.com/albums/b155/robinyau/stack1.jpg)

so straight away after having tea i was in the garage replacing my old boost gauge and fitting the AFR meter.

(http://i19.photobucket.com/albums/b155/robinyau/stack2.jpg)

I'll wire it all up tomorrow.

Pretty much all spent out now till next year so the extra ponies will have to wait!
Title: Re: Project 180!
Post by: breadman on December 10, 2008, 11:23:18 pm
Stack instruments are very nice indeed. 8)
There's a few quids worth sitting just there I bet?
Title: Re: Project 180!
Post by: Robin on December 11, 2008, 11:01:48 pm
oh yes, a few pennies thats for sure!

(http://i19.photobucket.com/albums/b155/robinyau/stack3.jpg)
Title: Re: Project 180!
Post by: giorgio on December 12, 2008, 12:40:47 am
flocked dash? more pics please.


stack stuff looks well trick
Title: Re: Project 180!
Post by: Robin on December 21, 2008, 08:40:24 pm
The previous owner flocked the whole dash, a really good job but does come off if you rub it by accident a few times.

Not done much for the pass couple of weeks, fitted a new thermostat housing as the old one was cracked, fitted an oil pressure gauge to complete whole stack gauge combo, they look good in the dark, really do get what you pay for most of the time.

Got a schrick 1341cc High Lift cam coming from Germany over xmas so that will be fitted before the clubpolo RR day at the end of Jan, bring on the ponies!

(http://i19.photobucket.com/albums/b155/robinyau/dash.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/gauges.jpg)
Title: Re: Project 180!
Post by: hayesey on December 21, 2008, 09:06:05 pm
those be some pimp gauges right there  ;D

Random question, your IC, did it come with any rubber bushes on the pins on it to mount it?  If so did you use them?
Title: Re: Project 180!
Post by: Robin on December 21, 2008, 09:52:25 pm
I used the bungs mate
Title: Re: Project 180!
Post by: Dan on December 21, 2008, 10:44:29 pm
Certainly finishes it off with an oil pressure gauge, really like them !
Title: Re: Project 180!
Post by: PeteG40 on December 22, 2008, 08:31:49 am
yeah, those gauges do look quality!
Title: Re: Project 180!
Post by: sohailG40 on December 29, 2008, 12:46:16 am
car looks good  ;D

gauges look fab  ;D

and projects look good  ;D

its all your hard work paying off mate well done  ;D
Title: Re: Project 180!
Post by: Robin on December 29, 2008, 07:45:48 pm
thanks for the comments chaps!

bit of a set back today after a plug melted on cylinder one but the car will be back to together for the RR day at the end of Jan to give more ponies!
Title: Re: Project 180!
Post by: sohailG40 on December 29, 2008, 10:48:51 pm
yeh good man thats wot us guyz like to hear  ;D
Title: Re: Project 180!
Post by: Robin on January 10, 2009, 05:15:03 pm
Bit of an update on the old project 180!

As most you will know i killed the engine a couple of weeks ago due to a dodgy valve and valve seat combo.

instead of sorting out the problem in the car i decided to take the whole lot out and do a proper job with seals, gaskets etc, currently costing ALOT of wedge!

Spent another fortune at VW and eurocarparts getting new seals and gaskets etc. Got a new clutch from a place in Yorkshire which is going on seeing as the engine and gearbox is out.

Got hayes old head which i have cleaned and lapped the valves in and also put new stem seals in, got a new wtaer pump which is actually the correct one this time and cambelt.

Got a metal headgasket this time so it will give a higher compression ratio which should help towards hitting that 180bhp.

The engine is currently on an engine stand, did a few odds and ends but can't really do much more as i am expecting a new camshaft next week so the head will go on when that comes (the dreaded headbolt tightening process) and new tappets will also be fitted too.

So the plan is get the whole engine back to one piece next weekend and hopefully into the car ready for the weekend after for the clubpolo RR day but its going to be tight!

Here are some pics anyway.
(http://i19.photobucket.com/albums/b155/robinyau/engine1.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine2.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine3.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine7.jpg)

Parts waiting to be mated to the engine
(http://i19.photobucket.com/albums/b155/robinyau/engine8.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine6.jpg)

Couple of pics for Dan of the new clutch.
(http://i19.photobucket.com/albums/b155/robinyau/engine5.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine4.jpg)
Title: Re: Project 180!
Post by: cheddarcheese on January 11, 2009, 06:41:29 pm
Nice little project! the flocked dash looks good!  That custom cross beam looks good but dont you think its abit weak would flex very easy why not get some box section there help stiffen the front end up?
Title: Re: Project 180!
Post by: Dan on January 11, 2009, 07:26:53 pm
Thanks for the Pics Robin  :) Does it look well make and up to the task ?

Project looks to be going well, I'm a bit behind you but doing the same sort of thing.
Title: Re: Project 180!
Post by: Robin on January 11, 2009, 07:56:05 pm
Yeah the clutch seems good quality, alot lighter than the original one so i don't know if it will last as long but time will tell, the materials seem to be nice quality.

Got all my stuff now to complete the 180 project, ordered the Aquamist last night so thats the last and final major mod i have got to shell out for.

Title: Re: Project 180!
Post by: sohailG40 on January 12, 2009, 11:14:12 pm
that looks like a nice clean block and pistons
Title: Re: Project 180!
Post by: Robin on January 13, 2009, 10:37:27 pm
Bit of an update now.

Got my 1341cc camshaft so rebuilt the head last night and bolted it to the block, put a bit of oil onto the bolts and washers so they tightened up nice and smoothly, no squeeking!

Tonight the engine is all back together along with gearbox etc, all i need to do now is to borrow an engine crane and its ready to go into the car, gotta remember to top up the gearbox oil though!

Also got my aquamist kit through the post today so that'll be going on this weekend.

I'll get some pics up tomrrow.
Title: Re: Project 180!
Post by: breadman on January 13, 2009, 10:42:18 pm
Ah some good news at last Robin.
Lets hope that's it for nasty (expensive) surprises and everything comes together nicely now.
Keep us posted and plenty of pics to gawp at too.
Cheers,
Richard.
Title: Re: Project 180!
Post by: sohailG40 on January 13, 2009, 11:45:27 pm
yeh it nice to see al these pic its all looking flash ( looks like the credit crunch hasent hit you then ) lol  ;D
Title: Re: Project 180!
Post by: Yoof on January 14, 2009, 07:40:26 am
The credit crunch hasn't hit him, but his credit card bill has  ;) ;D
Title: Re: Project 180!
Post by: sohailG40 on January 14, 2009, 10:47:42 pm
lol nice one yoof i like that  ;D
Title: Re: Project 180!
Post by: Robin on January 14, 2009, 11:02:16 pm
Right another update.

Finished my tea at 8pm and was in the garage for 8.15pm, engine in the car by 10.15pm. The missus had to give me a hand lowering the lift whilst i tried to ge tthe gearbox end down first - thanks Tracey!

Borrowed me mates engine lift - thanks Yoof for your help!

I'll let the pics do the talking.

(http://i19.photobucket.com/albums/b155/robinyau/engine20.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine21.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine23.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine24.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine28.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine25.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine26.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/engine27.jpg)


Mist
(http://i19.photobucket.com/albums/b155/robinyau/engine22.jpg)

Another couple of nights in the garage will hopefully get the car running.
Title: Re: Project 180!
Post by: breadman on January 14, 2009, 11:14:18 pm
Blimey Robin, you could of swept the leaves up whilst you were out there! ;D
What size/capacity water (methanol?) tank are you gonna use with the Aquamist? Which Aquamist system is it?
 
Title: Re: Project 180!
Post by: Robin on January 14, 2009, 11:39:18 pm
I'll be using the washer bottle for the methanol/water mix and i have ordered a 2litre new bottle for the screenwash supply.

The kit is ERL Aquamist 1S.

i'll be running a 0.3mm jet just after the intercooler and might put a 2nd jet in nearer the TB but its going to be all experimental for the time being.
Title: Re: Project 180!
Post by: Max on January 14, 2009, 11:50:18 pm
You don't hang about do you! Look forward to the next updates  8)
Title: Re: Project 180!
Post by: hayesey on January 15, 2009, 09:18:35 am
good work my friend.

glad to see my g40's old head is living on  ;D

yoof has an engine crane now?
Title: Re: Project 180!
Post by: Robin on January 15, 2009, 10:14:50 am
Nah the engine crane is my mate from work, Yoof gave me a hand getting it over to my place in his trustworthly SDI!
Title: Re: Project 180!
Post by: hayesey on January 15, 2009, 10:28:18 am
ahh trusty diesel barges always come in handy. 

Will look forward to seeing this at the RR then, still on for 180bhp you reckon?
Title: Re: Project 180!
Post by: Robin on January 15, 2009, 10:57:58 am
nah i don't reckon i'll get 180bhp, 170bhp maybe.
Title: Re: Project 180!
Post by: giorgio on January 15, 2009, 10:49:53 pm
nah i don't reckon i'll get 180bhp, 170bhp maybe.

ye of little faith  ::)


Title: Re: Project 180!
Post by: Robin on January 18, 2009, 03:56:41 pm
Engine started 1st time but there is a whining noise coming from the water pump area, took the cambelt cover off and it sounds like the noise is coming from the water pump but hard to tell.

Very high pitched whining, i am thinking it could be the water pump but its new so surely it can't be faulty, anyone else had the same problem or know what is could be?

The cambelt tension is ok so its not too tight.
Title: Re: Project 180!
Post by: Dan on January 18, 2009, 05:58:40 pm
Hmm, I haven't known water pumps new doing that. But it's not to say it's not faulty just because it's new. Was it a good brand or genuine one ?
Title: Re: Project 180!
Post by: Robin on January 20, 2009, 10:47:27 pm
brand new one mate :-(
Title: Re: Project 180!
Post by: Robin on January 23, 2009, 10:19:06 pm
Project 180 is now up and running!

Found out that the noise was the timing mark pointer thing catching the toothed belt crank pulley.

Been spending a couple of hours before with Yoof trying out different PPP maps to suit the car and have seem to got a good one.

Off to the RR day tomorrow to see what ponies she is putting out, not had chance to get the mist onto the car yet so it'll have to run tomorrow with the following extra mods:

FMIC
1341cc Cam
New Map
4 Branch
PPP Exhaust (cheers to Yoof for lending it me)
Metal Headgasket

I am guessing 167bhp, Yoof is guessing 169bhp.

Title: Re: Project 180!
Post by: Max on January 23, 2009, 11:04:53 pm
I guess 168bhp  :D
Title: Re: Project 180!
Post by: Robin on January 24, 2009, 03:41:28 pm
Just got back from the RR day.

Interesting day thats for sure as the car went on the rollers and came out with 155bhp which was pretty damn shit seeing as it got 147bhp in October without all above modifications.

So with the help of Yoof and Andy we timed the engine up as it was retarded due to pinking on the way down and Andy then created a new map for the car in the carpark in his girly Audi TT, an hour later we put the car back on the rollers and created 166bhp.

Well pleased with it, the moto is 'what a difference an hour makes'!!!!

Many thanks to Polo Performance Parts Andy and Yoof for sorting the maps out for the car. There is still alot more to get out of the car via the mapping so 180bhp should be easily achieved along with Aquamist.

On the way back the car feels VERY rampant, rampant enough to give a brand new S3 a good spanking!

(http://i19.photobucket.com/albums/b155/robinyau/RR.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/155bhp.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/166bhp.jpg)
Title: Re: Project 180!
Post by: Andy on January 24, 2009, 07:37:59 pm
You can see from the torque curve that it needs some tweaking around 3250rpm, and we know it needs a tweak at 2000rpm too - but I was pleased with the result.

I suspect even without Aquamist there's more in the car - I'd have said 170-175bhp with a proper custom map. Still, +11bhp from a first-guess development of the base map the car came with wasn't bad!  ;D

Get the 'mist fitted and when my emulator arrives we'll sort it properly.
Title: Re: Project 180!
Post by: Alex on January 24, 2009, 09:25:06 pm
Good result that, what map did you have before?
Title: Re: Project 180!
Post by: sohailG40 on January 25, 2009, 01:09:15 am
looking good robin the powers is getting closer to the 180bhp mark keep going my son  ;D
Title: Re: Project 180!
Post by: hayesey on January 25, 2009, 04:59:43 pm
it was amazing how sorting the ignition timing out & tweaking the ignition map got so much more power.
Title: Re: Project 180!
Post by: Robin on January 25, 2009, 08:50:52 pm
Bit of an update.

The mist is almost ready to rock!

Spent this afternoon dicking around in the garage fitting the mist kit and also a new screenwasher bottle.

I will be using the standard screenwasher bottle as a feed for the mist kit so i got a smaller one for the windscreen from ebay.

Put a level switch in the bottle so i know when i have run out of mist supply, put the 2 led's in the dash next to the gauges, one on the right goes blue when the mist pump is running and the one on the left goes yellow when the level of water reaches a minimum.

Some piccies.

(http://i19.photobucket.com/albums/b155/robinyau/mist8.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/mist4.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/mist2.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/mist6.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/mist7.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/mist1.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/mist5.jpg)
(http://i19.photobucket.com/albums/b155/robinyau/mist.jpg)

Bit worried about the vibrations the pump will be subjected to so i might need to mount it on some rubber or something.

Hopefully by this weekend i'll have it running although i need some methanol.............
Title: Re: Project 180!
Post by: breadman on January 25, 2009, 09:44:10 pm
Nice, tidy installation there Robin.
For the pump, how about using some of the rubber mounts that are used to mount the electric fuel pump bracket under the car? That'll keep things a fair bit quieter.
A nice result at the R.R. too after Andy sorted out the mapping.  8)
Title: Re: Project 180!
Post by: Robin on January 25, 2009, 09:46:33 pm
Yeah i think some rubber mountings would be a good idea, i'll see what is about at work ;-)
Title: Re: Project 180!
Post by: Ä‘uro on January 26, 2009, 07:30:09 am
Just one question: I know this is mixture of water nd metanol nd it will decrease temperature in cilindar but how will effect on lader work? - some bad influance ???
Title: Re: Project 180!
Post by: hayesey on January 26, 2009, 09:09:40 am
well the methanol wont go into the glader because it'll get injected after that and robin has no boost return pipe connected.

Check out ebay for methanol, lots of people buying it to make bio-diesel.
Title: Re: Project 180!
Post by: Ä‘uro on January 26, 2009, 10:10:23 am
Ok but if return pipe in on ? than metanol can go into glader! it can wash glader inside?
Title: Re: Project 180!
Post by: samg40 on January 26, 2009, 11:05:11 am
Is that your boost gauge plumbed into your ecu vacumn feed?
Title: Re: Project 180!
Post by: hayesey on January 26, 2009, 12:55:16 pm
Ok but if return pipe in on ? than metanol can go into glader! it can wash glader inside?


it's possible yes, although the methanol injection should only be on at full throttle, it's certainly possible that some could do.  I wouldn't run the boost return hose if you have aquamist.
Title: Re: Project 180!
Post by: Ä‘uro on January 26, 2009, 05:55:47 pm
Ok but if return pipe in on ? than metanol can go into glader! it can wash glader inside?


it's possible yes, although the methanol injection should only be on at full throttle, it's certainly possible that some could do.  I wouldn't run the boost return hose if you have aquamist.

But if I move boost return hose than I will hv "boost hole" or not? nd lot of compresed air will go directly out! Only on full throttle all air fm glader will go in engine! can I put blow off walve instaid let air to go out? Do y. hv maybe some sheme how can i connect this walve?

Title: Re: Project 180!
Post by: hayesey on January 26, 2009, 08:29:51 pm
air that goes through the boost return doesn't go into the engine anyway, it just goes round and round.  The whole point of the boost return valve is to stop all the air going into the engine unless you are on full throttle.
Title: Re: Project 180!
Post by: Robin on January 26, 2009, 09:44:13 pm
Is that your boost gauge plumbed into your ecu vacumn feed?

it is sam, i know alot of people have said its a bad idea but i haven't had any problems so far but whilst i am messing with the boost etc i will be replumbing it into the mist boost feed.
Title: Re: Project 180!
Post by: Robin on January 30, 2009, 04:31:36 pm
All engine mods now completed! At last!

Just been out setting up the aquamist, engine seems to pulls more smoothly now, got the mist coming on at around 3psi as the boost change from 0 to 12psi is pretty much nothing on the throttle pedal so i got it coming in action pretty early.

Currently running 50:50 water and methanol mix. Got the jet after the intercooler on the 45degree aluminum elbow, did a bit of a pikey job on the fixing of the jet as the alu tubing is too thin to tap so the old chemical metal has come into action!

I'll be getting a new pipe to do a proper job when i have decided that this is the best place for the jet. Has anyone run 2 jets before? I currently running 1 0.3mm jet but i have a spare one so i am tempted on running 2 jets but don't really know if it will give a benefit.

I think the mods are done for the engine until i end up with something like 175bhp and thats when i'll be hunting for a big valve head!

The next thing on the shopping list is a Grippa LSD as i simply can't get any power down with dinky 175/50/13 conti tyres! Even in the dry i struggle to get traction until 3rd gear!
Title: Re: Project 180!
Post by: hayesey on January 30, 2009, 04:33:55 pm
yoof had two in his initially, one in the turbo outlet and one in the back of the inlet manifold pointing down the runners. 

where did you get the jets from in the end?  I still need to order some bits for mine.
Title: Re: Project 180!
Post by: Robin on January 30, 2009, 04:41:36 pm
i got them from aquamist directly, i was going to get a list together and order loads of stuff as Yoof wanted some stuff but was unsure of what he needed so i just bought 2 jets direct from them, very helpful and friendly, stuff arrived next day as well.

Title: Re: Project 180!
Post by: hayesey on January 30, 2009, 04:54:49 pm
ah right, I didn't know they would supply direct.
Title: Re: Project 180!
Post by: Robin on January 30, 2009, 04:59:03 pm
yeah just ring the main number on their website.
Title: Re: Project 180!
Post by: Yoof on January 30, 2009, 05:33:16 pm
Put the boost pressure up a little, you'll use a shed load at only 3psi!!!

Probably set it to 80% of your total pressure around 9/10psi.

Title: Re: Project 180!
Post by: Robin on February 06, 2009, 09:17:34 pm
Got the mist set up properly today, using the washer bottle pump as a priming pump when the boost kicks in, currently the mist is coming into action at 8psi boost, max boost i get is 11psi at 6500rpm.

Still pinking at low revs and high load but its bloody rampant, its loving the freezing cold air tonight.

The next stage of stuff to be done on the car are maintenance things, got the following stuff to do on it.

Front Top mounts - OEM VW
Rear Top Mounts - OEM VW
CV joint is pretty damn noisy so gotta find out which one is it which is fucked
Brakelines are corroded really baldy - i'll pay a garage to do this as its a right bitch of a job
Rebuild the charger with new seals etc - PeteG40!!!!!!!

Car will be going to JP exhausts next month to be used as a jig to get some PPP exhausts made up, after that the car will be used to test a few more PPP ECU maps.

Said to Yoof the other day that if i blew the engine up or something went really wrong i would strip it for parts and sell it off, after giving it death tonight i wouldn't be able to strip it for bits and sell it off, i'd have to rebuild it as there is no substute for G smilies!
Title: Re: Project 180!
Post by: Yoof on February 16, 2009, 08:15:39 pm
Man up and get some proper boost  ::)

(http://www.stormdevelopments.co.uk/images/g60.jpg)

Anything under 14.7psi is n/a  :P

Title: Re: Project 180!
Post by: polo dan on March 04, 2009, 11:56:38 am
ha if the above goes on it will be more like project 220 haha
Title: Re: Project 180!
Post by: hayesey on March 04, 2009, 12:37:16 pm
Man up and get some proper boost  ::)

(http://www.stormdevelopments.co.uk/images/g60.jpg)

Anything under 14.7psi is n/a  :P



naaah, man up and get some PROPER boost

(http://derby.polog40.co.uk/photos/big_turbo.jpg)

project 1800 (or project kill yourself)
Title: Re: Project 180!
Post by: Yoof on March 05, 2009, 06:42:46 pm
Project 220- Dan knows  ;D Same colour as the anger car too, all the quickest cars are the red ones  ;D

Rocket Robin is now fitting his 'uprated' fuel pump....looks dead similar to the ones we use at work...  ;)
Title: Re: Project 180!
Post by: Max on March 05, 2009, 07:49:11 pm
Perks of the job! Jammy git  ;D
Title: Re: Project 180!
Post by: Robin on March 05, 2009, 11:27:13 pm
Project 220- Dan knows  ;D Same colour as the anger car too, all the quickest cars are the red ones  ;D

Rocket Robin is now fitting his 'uprated' fuel pump....looks dead similar to the ones we use at work...  ;)

yeaaaaaaaaaaaaaaaaah boooooooooooooooy!
Title: Re: Project 180!
Post by: Dan on March 06, 2009, 09:05:10 am
Be sure to get pics of the new exhaust !  :)
Title: Re: Project 180!
Post by: Robin on March 06, 2009, 03:53:48 pm
car has just been dropped off at JP exhausts so Yoof will be selling a load of them in a couple of weeks time!
Title: Re: Project 180!
Post by: Robin on March 14, 2009, 07:23:28 pm
Project 180 has come to an end - its now Project Grey 180

Pics will follow tomorrow
Title: Re: Project 180!
Post by: Dan on March 14, 2009, 07:26:11 pm
Grey ?  ???
Title: Re: Project 180!
Post by: Max on March 14, 2009, 09:08:47 pm
Must have bought that Grey shell that was for sale, looked clean!

What was up with the Red shell mate?
Title: Re: Project 180!
Post by: Robin on March 14, 2009, 09:28:17 pm
Yeah i have bought Kustoms Grey shell along with the stage 3 subframe.

The current red shell is not great, basically the bodywork is pretty grim up close

the Grey shell is pretty damn mint so looks like another original Red G will be scrapped!
Title: Re: Project 180!
Post by: Dan on March 15, 2009, 10:20:12 am
Is the chassis ok ? Is it just cosmetic bodywork that needs doing ?
Title: Re: Project 180!
Post by: Robin on March 15, 2009, 12:08:27 pm
yeah chassis is ok, passed the mot last year no problems, just the bodywork which is shabby, i will put it up for sale to try and avoid an orginal G being crushed.
Title: Re: Project 180!
Post by: Fred on March 16, 2009, 01:14:49 pm
Where are you based Robin?
I have Toms/Juans old Red G shell and that is proper Shabby
so may be interested in yours fella.
Regards, Fred.
Title: Re: Project 180!
Post by: Robin on March 16, 2009, 01:20:42 pm
hi fred

i am in cheshire

the car still has MOT till the ned of October.