Club G40 Forum

Club G40 => Photos and videos => Ongoing Projects => Topic started by: lance on July 25, 2010, 04:30:32 pm

Title: Lance's G40 turbo with ITB's
Post by: lance on July 25, 2010, 04:30:32 pm
I bought the car a good few year ago now from a lad called cliffden it was still funning the G charger R1 spec, looked like this,

(http://img.photobucket.com/albums/v204/Hilferty/lances%20G40/DSC00041.jpg)


I then got bored so sold the standard charger and fitted a eaton charger with a front mount i/c

(http://img.photobucket.com/albums/v204/Hilferty/lances%20G40/DSC00021.jpg)


I ran it like that for a year or so and then melted a piston

(http://i305.photobucket.com/albums/nn210/lance_m45/400.jpg)
(http://i305.photobucket.com/albums/nn210/lance_m45/404.jpg)

So i then went onto going 1341cc rebore with forged pistons and rebuilt the whole engine with all vag parts.


it then looked like this,
(http://i305.photobucket.com/albums/nn210/lance_m45/polog40.jpg)
fitted 280mm brake conversion, compomotive 15" wheels and afew other bits and pieces.


i ran it like that till around 15 month ago to wich my newman camshaft snapped! too a few valves with it so was a goood excuse to start buying parts to make it better again, so i sold all my eaton charger and kit with other bits to fund my new parts,
(http://i305.photobucket.com/albums/nn210/lance_m45/387.jpg)
k03 turbo
(http://i305.photobucket.com/albums/nn210/lance_m45/407.jpg)
turbo manifold
(http://i305.photobucket.com/albums/nn210/lance_m45/389.jpg)
DTA standalone management
(http://i305.photobucket.com/albums/nn210/lance_m45/395.jpg[IMG]
helix paddle clutch
[IMG]http://i305.photobucket.com/albums/nn210/lance_m45/396.jpg)
oil cooler
(http://i305.photobucket.com/albums/nn210/lance_m45/398.jpg)
rear axle bushes
(http://i305.photobucket.com/albums/nn210/lance_m45/406.jpg)
jabba heat shield and cotten green air filter
(http://i305.photobucket.com/albums/nn210/lance_m45/driveshaft.jpg)
my mate sleaved my drive shaft
(http://i305.photobucket.com/albums/nn210/lance_m45/385.jpg)
some 300mm 4pot brakes
(http://i305.photobucket.com/albums/nn210/lance_m45/topmounts.jpg)
top mounts
(http://i305.photobucket.com/albums/nn210/lance_m45/383.jpg)
vernier cam pulley from cat cams
(http://i305.photobucket.com/albums/nn210/lance_m45/382.jpg)
cat cams turbo spec cam shaft
(http://i305.photobucket.com/albums/nn210/lance_m45/379.jpg)
water injection
(http://i305.photobucket.com/albums/nn210/lance_m45/384.jpg)
slim line fan

so i got to start on the car.
stripped the engine down and rebuilt it again
(http://i305.photobucket.com/albums/nn210/lance_m45/Image059.jpg)

bought a PPP subframe/wishbone conversion and fitted it
(http://i305.photobucket.com/albums/nn210/lance_m45/Image034.jpg)

fitted brakes and also had some coilovers made up
(http://i305.photobucket.com/albums/nn210/lance_m45/Image036.jpg)

got another head and sorted it
(http://i305.photobucket.com/albums/nn210/lance_m45/Image059-1.jpg)

built the head up with new tappets and the cam plus pulley fitted it to the block along with the turbo
(http://i305.photobucket.com/albums/nn210/lance_m45/Image062.jpg)

i then fitted the engine plumbed in the intercooler to the turbo and oil cooler also a seperate rad for the turbo water cooling
(http://i305.photobucket.com/albums/nn210/lance_m45/Image045-1.jpg)


got my comps refurbed
(http://i305.photobucket.com/albums/nn210/lance_m45/Image002.jpg)


got some track wheels with some slicks fitted
(http://i305.photobucket.com/albums/nn210/lance_m45/ozracingwheels.jpg)



then got some motorbike throttle boddies to modify and fit to my inlet
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/inletbefore.jpg)

cut my standard inlet up
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/cutupinlet2.jpg)

tig welded to my inlet flange so the inlet rubbers could be fitted
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/inletfittedone.jpg)
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/inletmade.jpg)

couldnt use the standard fuel rail
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/standardfuelrail2.jpg)

so made another
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/bespokefuelrail2.jpg)

started to modify the plenium
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/beforeholeonplenium.jpg)
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/inletpipewelded2.jpg)
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/inletpipeweldedcloseuo.jpg)

sizing up
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/sizingup.jpg)
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/sizingup2.jpg)

fitted and fitted the dump valve
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/dumpvalvefitted.jpg)

modified the angle of the boost pipe
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/modifyangleofpipe.jpg)

made a blank to fit where the dizzy went
(http://i305.photobucket.com/albums/nn210/lance_m45/02042010056.jpg)
then fitted coil pack just a mock up really
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/coilpack.jpg)


(http://i305.photobucket.com/albums/nn210/lance_m45/G40/fullengineshot.jpg)

thats as many pic's as i have on my phone, i have more on my camera of fitting other things.

what are peoples thoughts?

it might not make a big performance difference but i just wanted to do something different and interesting.

will be mapping it soon and should be all sorted to take to leeds vw festival for a run out.

cheers

Title: Re: Lance's G40 turbo with ITB's
Post by: wierdo on July 25, 2010, 04:37:29 pm
Sweeeeet  :) :)
Title: Re: Lance's G40 turbo with ITB's
Post by: Nick_S on July 25, 2010, 05:54:53 pm
Thats top notch effort Lance, look forward to having a butchers at Harewood House in a few weeks ;D
Title: Re: Lance's G40 turbo with ITB's
Post by: Etches on July 25, 2010, 06:36:49 pm
Insane dude, was thinking about the possibilities of this before but actually seeing it done is a treat! nice work
Title: Re: Lance's G40 turbo with ITB's
Post by: cheys03 on July 25, 2010, 07:28:23 pm
Very nice indeed! Great photos and comment. Please keep it updated, looking forward to the next instalment!
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 25, 2010, 07:32:21 pm
try my best to take photos but i mostly forget!

fingers crossed ill get it to leeds nick
Title: Re: Lance's G40 turbo with ITB's
Post by: cheddarcheese on July 25, 2010, 09:07:27 pm
Very nice more pictures if possible?
Title: Re: Lance's G40 turbo with ITB's
Post by: Alex on July 25, 2010, 11:16:43 pm
Awesome! :-)
Title: Re: Lance's G40 turbo with ITB's
Post by: Etches on July 26, 2010, 02:04:56 pm
the fabrication is well impressive, is it your own work?
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 27, 2010, 04:24:23 pm
mostly a fella i know does the tig welding. he's a very good person to know!
he built a mk1 escort space framed with a cossie v6 in it. the rear suspension setup is artwork!


anyway trigger wheel and crack position sensor are on now and throttle boddies have the right throttle position sensor fitted, ill add pics once my camera stops being gay
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 27, 2010, 10:33:45 pm
(http://i305.photobucket.com/albums/nn210/lance_m45/G40/26072010206.jpg)
trigger wheel fitted

(http://i305.photobucket.com/albums/nn210/lance_m45/G40/26072010208.jpg)
throttle pot fitted to throttle boddies

(http://i305.photobucket.com/albums/nn210/lance_m45/G40/26072010207.jpg)
crank position sensor fitted
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on August 23, 2010, 10:59:17 pm
mapped it on 14 psi to run it in and it made 164bhp with s bit of a rich map. gonna wait till i get a box and lsd for it then map it on 21 psi and see what it makes with the water injection wired up too. got a pic of the computer screen somewhere. ill look now
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on August 23, 2010, 11:05:12 pm
167bhp even, not had much mapping yet so far from finished.

(http://i305.photobucket.com/albums/nn210/lance_m45/G40/g40dynoresult1.jpg)
Title: Re: Lance's G40 turbo with ITB's
Post by: Ä‘uro on August 25, 2010, 11:27:47 am
what is the capacity of the plenum ?
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on August 25, 2010, 08:45:02 pm
god knows, never got that into it
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on August 29, 2010, 10:25:51 pm
Very nice  :)

You got a plot against RPM instead of time base?

If you are making 167bhp @ 4347rpm then you're making 199lbft there too, not 214lbft. but my interpretation of this graph could be wrong  ???

Impressive work, when are you winding the boost up?
Title: Re: Lance's G40 turbo with ITB's
Post by: cheys03 on August 29, 2010, 11:49:01 pm
It looks like torque is 202lbft at that frame in the graph, 214lbft looks like a comment (manually?) added for the earlier torque peak..? Maybe..? :?
 
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on August 30, 2010, 03:23:56 pm
it didnt make 214lbft it is just the dyno cos it started to wheelspin. was just a quick power run really as i wasnt too fussed with just running it in. i donno if they'll be a plot agaisnt RPM yoof ill have to ask the fella that does the dyno stuff for me. i havent got a clue lol.

my gearbox is on its way out so am getting another box and lsd then ill be turning the boost up as well as finishing the rest of the jobs off.
was hoping to take it to action all mapped up but with the box on its way out looks like ill have to go in my mates van.

anyway once its fully mapped ill put i graph up and maybe make it to a rr day see what it does on a trusted dyno.

cheers.
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on August 31, 2010, 08:36:34 pm
Fair enough- time base is a very strange way of plotting data, wheelspin is always an issue with the Polos- if you can find a dyno with a 'torque bar' the more the car rises up out the dyno, the more force is exerted onto the tyres, stopping wheelspin. Also as you've got a subframe a cheeky rachet strap can be used to pull the chassis down without damaging any suspension components  ;)

Looking good, not sure if you'll see a massive benefit of the ITB with only a K03, but should give big number with a larger blower.

All mapped an ready for Club G40 rr day?  :)
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on August 31, 2010, 08:48:32 pm
yea mate i ratchet strapped it down over the subframe! without that id of been fucked! yea ill hope its all sorted and ill come to the club G40 rr day and see what it makes, ill be happy with 200bhp as i dont have a bvh.

am just gonna run it for a bit on the ko3 but to be honest there is no lag at all really so a bigger turbo is needed! think ill go gt2554r next but just make my own manifold and downpipe up. all my roth stuff will close to pay for it.
Title: Re: Lance's G40 turbo with ITB's
Post by: hardchargin40 on September 12, 2010, 10:42:01 am
Great fab work and ingenuity for going iTBs, like yoof said get better results out of a larger turbo and better flow.  I had 45mm Jenvey iTB's sat waiting to go on my old one, defo the way forward.

Any reason or advantage why you opted to put the inlet to the airbox on top in the middle as opposed to the routine norm way of inlet through the side?

Cheers

paul
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on September 12, 2010, 09:36:08 pm
was just easiest place to put it in, all the throttle boddies have ram pipes inside the plenium,

cheers.
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on June 30, 2012, 03:02:37 pm
long time since a update,


well i decided to keep the G40 and do what i planned on doing, thats going with a bigger turbo.
i found a gt2560r turbo an went about fitting it.

(http://i305.photobucket.com/albums/nn210/lance_m45/20120407_142745.jpg)

(http://i305.photobucket.com/albums/nn210/lance_m45/20120407_142931.jpg)

(http://i305.photobucket.com/albums/nn210/lance_m45/20120421_152936.jpg)

sold my comps as i fancied something a little different,
went with OZ route's

(http://i305.photobucket.com/albums/nn210/lance_m45/20120503_182227.jpg)
refurbed

(http://i305.photobucket.com/albums/nn210/lance_m45/20120505_160016.jpg)
stickers on and fitted to my very dusty G40


after that it went to my mates workshop,

made up the 3" down pipe v-banded on both ends fully tig welded,
(http://i305.photobucket.com/albums/nn210/lance_m45/20120627_181311.jpg)


fitting was rather tight,
(http://i305.photobucket.com/albums/nn210/lance_m45/20120627_153510.jpg)

(http://i305.photobucket.com/albums/nn210/lance_m45/20120627_213959.jpg)
fitted a few more bits relocated the actuator and wired the fans into the ecu.
also tig welded a cam cover breather fitting and hose to a catch tank.

on the dyno for mapping
(http://i305.photobucket.com/albums/nn210/lance_m45/20120629_194628.jpg)

and the result,

(http://i305.photobucket.com/albums/nn210/lance_m45/dyno2.jpg)

am happy with that. the turbo is a little big on the hot side so little laggy but not bad really.
it was also wheel spinning so johnny that was mapping it worked out its around 258bhp so all good.
bodyshop next for fresh paint.

cheers.
Title: Re: Lance's G40 turbo with ITB's
Post by: cheys03 on June 30, 2012, 04:06:28 pm
*gulp* impressive power!!
Title: Re: Lance's G40 turbo with ITB's
Post by: Alex on June 30, 2012, 05:28:48 pm
Holy crap that's gotta be a bit hairy on the road! :o
Title: Re: Lance's G40 turbo with ITB's
Post by: djtez on June 30, 2012, 07:17:53 pm
very nice.!
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on June 30, 2012, 09:33:35 pm
What cam you got in this Lance, makes power very low down for such a large turbo. Nice power figure too!
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 01, 2012, 01:34:10 am
its a cat cams, cam. turbo spec one. cant remember the spec's on it.(by the way am loving how yours looks now!!!) its a bit laggy but drives nice off boost with being fairly high compression. it made nearly standard g40 power at 0.3 bar of boost lol. have not even touched the vernier cam pulley yet. fitting a wheel speed sensor on the back left wheel for launch control next. maybe have to cnc the rear disk brake so it has trigger marks for the speed sensor

thanks for the comments.  ;D
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on July 01, 2012, 10:39:59 pm
Be interested to know, mine makes peak power about 1200rpm higher with a smaller trim turbo!

Loks like it's coming along well, going to the Pod anytime soon?
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 02, 2012, 12:40:33 am
269 261, took a bit of finding online. 7606139 i think is the part number for the catcams cam.
hard to find time mate but id really like to get to the pod. id be more that happy if it got into the 12's!
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on July 02, 2012, 10:45:57 am
Proof is in the podding!

Should be low 12s if you can launch well and the dyno tells the truth  ;D

Will compare the cams tonight, I'm genuinely shocked it makes peak power below 6k, what's it like on the road?

Pete
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 02, 2012, 08:44:12 pm
haha shockingly you're the first person to say the dyno could be wrong. i expected a lot more.
should launch well with launch control. I'll prob run toyo 888's. can get them cheap enough with working at camskill now.

havent driven it much but i am driving it on friday to take it for mot. so i'll find out what its like on the road. from how much i have drove it, it feels good. could be the bodies helping me make power below 6k. it just has a flowed head with slight valve work but not enlarged. what cam do you run?
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on July 02, 2012, 09:06:31 pm
Don't take it the wrong way- I don't really trust rolling roads, what did it make at the wheels?

1/4mile terminal speed is a good indication of power, even if you're traction limited in 1st/2nd the terminal speeds will only vary a couple of mph. I'd expect to see this at 115mph+  ;D

My cam is a 268/268 Schrick copy, I'll compare them tomorrow at work, I guess mine at (crank) 220bhp (rolling road figure) so I'm trying to see the 30bhp gain yours makes with a slightly larger trim turbo and throttle bodie, and also why the power is much lower rpm...  ???
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 02, 2012, 10:50:00 pm
Don't worry mate i wont. even if it was 220 bhp id of been very happy! i was aiming for anything over 200 anyway. johnny that does the mapping for me is very very good. he maps nick barnes corsa which has around 600 bhp. the bodies will help me flow as much air as my boost pipes allow my charge temps are very cool. and timing is just about perfect. other than the larger turbo mine i cant see why mine should make so much more than yours, mine is on dta management but that shouldn't make a difference if you can map yours. I'll see what i get on the strip then mate. last time i run on a local 1/4 mile strip day (shit surface) i reached a terminal speed of i think 99 mph. I'll have to dig the cards out. next drag day is September.
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on July 03, 2012, 08:52:20 am
I'm 100% convinced this will make more power than mine (I'd hope so!) I'm interested to see the benefits of throttle bodies, it's more when it makes power that's got me baffled, possibly smaller valves, different cam timing, and less boost (but more flow). I need to get my engine simulation working!

Sounds like he’s done a good job on the mapping, I think several people get too hung up on peak power figures, especially at rolling roads days- the car is still as quick as before going on the rollers  :)

Andy worked out a way to implement ‘launch control’ with digifant but it’s quite a crude system, has DTA got sequential injection and ignition? I.E you can pull spark/fuel from individual cylinders not as a batch?

What are you doing for front wheel speed? There’s some electronic speedo drives on early Ford Fiestas you could use, if you can calibrate the input on DTA, then use golf rear wheel sensor and job done – that’s quite a nice feature to have.

Have you got DTA doing boost control too? Again nice feature to have, as you can limit boost in 1st/2nd (saving gearbox/driveline) then in 3rd give it full boost, presume DTA can do that aswell- again it’s just time to calibrate it.

99mph is ~180bhp (+/- 10bhp!) I'd expect 115mph+ (helmet required!) I think my fastest terminal is 112mph, be good to see it, are you coming to VW Action?
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 03, 2012, 07:49:53 pm
honestly mate you wont meet anyone who cares less for bhp and all the bragging rights. as long as it feels good to drive am happy. i have built the car for me nobody else.

yea the dta runs the boost through a n75 valve. havent done in gear boost yet but that is interesting about the fiesta speed drive. cheers. i am fitting a speed sensor the the rear left wheel and make trigger marks on the rear disk. all thats needed for the launch control.

i am trying to get time to come to action. think i am gonna have a run to cumbria vag in it on sunday see what its like on a run. then its booked in the bodyshop next week and am away to Greece after that. but i'll try to get to action. id expect something to break on that sticky strip!!! maybe take spare cv's and a shaft. gearbox too and maybe clutch.....
Title: Re: Lance's G40 turbo with ITB's
Post by: Andy on July 08, 2012, 09:23:05 pm
Quick heads-up - Yoof might've just found the limit of stock G40 rods.  :(
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 08, 2012, 10:59:21 pm
ouch! has it let go?
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on July 09, 2012, 07:11:19 am
Yup! Strangely I thought of your car after it had gone, not sure if its taken the head with it yet (I'm guessing yes)

Title: Re: Lance's G40 turbo with ITB's
Post by: hayesey on July 09, 2012, 09:23:19 am
only just seen the updates from july in this thread.  Great to see it together and making such good power lance.  You said it was wheel spinning, is that what happened at just under 6k rpm when it makes it's peak power, drops off and then starts going up again?  get some fat people sat on the wings :D

heard about yoofs too, not good!
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 09, 2012, 07:32:26 pm
yea well on one dyno run boost dropped for a second and i didnt know why but now i do.......... new turbo required as the blades touch the wall on the cold side on full boost so bearings are shot!

new turbo time but im undecided whether to go same size turbo put uprated rods in and get 260bhp or gt2554r and run 220bhp maybe a little less. my car is just a road car really with living so far away from tracks and having such little free time. plus i'll be selling it next year for money towards a house...

worst part being my car is worth more in bits but it will hurt to break it.
Title: Re: Lance's G40 turbo with ITB's
Post by: djtez on July 09, 2012, 07:59:52 pm
i fully understand your view here as im similar, it would be really great for you to go ahead with the bigger turbo and make some top power!
cant say i've ever heard or seen a 260bhp t40.

i think it could possibly been down to bad luck or long periods of running major power in yoof's car thats done his rods in, your could well be fine but it is a large risk!

Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on July 10, 2012, 10:38:39 pm
Just get your current turbo rebuilt? Try turbo dynamics: http://www.turbodynamics.co.uk/services/turbo-repairs/cost-of-repair/

They're fairly good and hopefully you'll not need a new compressor housing.

I'd go with a set of new rods, I think there may be a few people getting them!
Title: Re: Lance's G40 turbo with ITB's
Post by: djtez on July 10, 2012, 11:45:56 pm
hm got me worried..

its about £ 870 for rods and piston kit..

but i am at the stage of building my engine ... :-/
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 11, 2012, 07:51:05 pm
its about £500 pound for a new cartridge for my turbo with it being ball bearing, and have found a company that will sell the turbo to me for a little over £700 and i'll get about £100 pound for my turbo id say as the wastegate always cracks on them so people always want spares.

i'll look into rods then, maybe build another motor up.
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on August 24, 2012, 09:32:29 pm
got a new turbo

(http://i305.photobucket.com/albums/nn210/lance_m45/20120822_112930.jpg)

fitted it
(http://i305.photobucket.com/albums/nn210/lance_m45/20120824_185130.jpg)


now needs to go for a final mapping session and then bodyshop for a few bits sorted.
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on August 24, 2012, 09:36:51 pm
28RS?  :o
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on August 28, 2012, 09:22:41 pm
28r mate well gt2560r. runs really well now. very happy with it. any news on your turbo then? them gt2554r from turbo dynamics are not bad money. i was tempted but went with the .60 in the end.

out of interest what oil do you run in yours yoof?
am going to buy a petrol tank for mine soon. anyone know where is best to buy one?
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on August 29, 2012, 04:55:54 pm
Yup, I've just bought a new one from them, was tempted by the 2560R but I'm happy enough with the 2554R currently, already breaks enough drivetrain/engine components!

Oil is good quality 10W-40 Semi-Synth, change it every 3k or so as the filter is small and it gets to ~130'C on trackdays.

Title: Re: Lance's G40 turbo with ITB's
Post by: jez1272gt on August 29, 2012, 06:56:39 pm
Jesus that 2560 looks ridiculous... which is a good thing!
Title: Re: Lance's G40 turbo with ITB's
Post by: Nick_S on August 31, 2012, 02:47:05 pm
WOW! only just updated myself with this thread. Nice one on achieving that power, good to know there is still progress to be made with fresh ventures in polo engines :) When i was first looking into 1.5's with turbos thats the sort of power I was looking towards, but hats off to get there with a 1.3 If I still had a mk3 then it would have a turbo'd 1.5 in there by now, but i'm sticking with mk2, so no room for turbo and huge intercooler :P
Title: Re: Lance's G40 turbo with ITB's
Post by: dub-disaster on September 01, 2012, 07:33:10 pm
just looking back over your thread lance and one thing I've wondered is, where do you get a common vacuum source for things such as brake servo MAP sensor etc...etc.. i can see that yohve may be able to get a source just under one of the throttle plates but surely that's only the vacuum of one cylinder and would give poor signals/not enough vacuum to run ancillarys..Or have you removed these things and got around them by running un assisted brakes/supermarket management.
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on September 03, 2012, 06:23:24 pm
i have taken a vac from each cylinder mate. works fine. it stops so so so well. does not lock the back brakes at all.

going for mapping session number 2 soon so i'll update with a RR printout.
Title: Re: Lance's G40 turbo with ITB's
Post by: Karlos the jackyl on September 05, 2012, 06:46:49 am
That dyno printout looks weird , you have max torque before full boost ? Almost 250 hp @ 5800 is crazy ? And still 1.3 on standard head?

Please correct me if I've miss understood this!
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on September 06, 2012, 11:04:01 pm
not a standard head but not a big valve head and 1341cc

more mapping last night. couldnt stop it wheel spinning on the dyno during the power run though. here is the graph, it'll be a little over 260 bhp if it wasnt loosing it through wheel slip.

(http://i305.photobucket.com/albums/nn210/lance_m45/Image1.jpg)
Title: Re: Lance's G40 turbo with ITB's
Post by: Karlos the jackyl on September 07, 2012, 06:35:29 am
I see , that graph looks much better   , very good output , you could easily squeeze 300 hp and a good wedge of torque with bigger blower and careful headwork.

Title: Re: Lance's G40 turbo with ITB's
Post by: dub-disaster on September 07, 2012, 06:49:18 am
that realy is impressive power. what's it like to drive on the road with regard to traction and torque steer are you still running an open diff? Also what is the throttle response like is it very sensitive and quick to respond without making it difficult to do road car duties like parking and traffic ?
Title: Re: Lance's G40 turbo with ITB's
Post by: Andy on September 07, 2012, 09:58:17 am
Nice numbers! ;D Peak power is at such low rpm for a big turbo - most of the K03'd units with same engine spec are peaking at circa 5,900rpm with the same cam, and bigger turbos are closer to 7,000rpm. The power band seems to be narrower than usual too.

Would be really interesting to see whether it's the ITBs that are making the difference, or whether your cam is timed differently.
Title: Re: Lance's G40 turbo with ITB's
Post by: Justin14100 on September 07, 2012, 03:57:00 pm
Incredible!
Title: Re: Lance's G40 turbo with ITB's
Post by: Etches on September 07, 2012, 04:17:34 pm
Shit man awesome power figure, good torque curve too!
Title: Re: Lance's G40 turbo with ITB's
Post by: Alex on September 08, 2012, 10:15:43 pm
Holy shit! :o
Title: Re: Lance's G40 turbo with ITB's
Post by: z3i on October 13, 2012, 04:22:16 pm
Wow! Thats insane!! also enjoyed reading your thread :)
are these sort of figures only possible with turbos?
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on November 13, 2012, 09:00:08 pm
couple of drag racing vids,

vs M3
http://smg.beta.photobucket.com/user/Hilferty/media/20120929_131225.mp4.html

solo,
http://smg.beta.photobucket.com/user/Hilferty/media/20120929_140001.mp4.html

up against my mates mental sierra 3 door. red top turbo massive spec BIG power,
http://smg.beta.photobucket.com/user/Hilferty/media/20120929_150705.mp4.html

another of his mad sierra,
http://smg.beta.photobucket.com/user/Hilfe...135903.mp4.html

another mates mk2 escort cossie v6 with a charger,
http://smg.beta.photobucket.com/user/Hilferty/media/20120929_150851.mp4.html
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on November 13, 2012, 09:19:22 pm
Links don't work mate- what times did you get?
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on November 13, 2012, 09:40:08 pm
hate photobucket, on my mates account, try that now?

i got in the mid 13's mate. traction was a problem and a head wind of i think it was around 21mph i heard. so that didnt help. well that plus my terrible driving haha, not easy to drive though. was getting used to it at the time too. launch control is good once you get the hang of it...

couple on youtube

vs m3 http://www.youtube.com/watch?v=BPeqdd_Tp3o&feature=youtu.be

solo run http://www.youtube.com/watch?v=mT19fOKyyF0&feature=youtu.be

i'll maybe run it at the pod next year, id love to get in the 12's. something may snap though if i get too much grip!
Title: Re: Lance's G40 turbo with ITB's
Post by: djtez on November 14, 2012, 05:48:43 pm
wow! ...

bloody cool mate :)!

Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on November 14, 2012, 06:19:12 pm
Yeah quick difficult to drive, what kinda trap speeds you getting?
Title: Re: Lance's G40 turbo with ITB's
Post by: djtez on November 14, 2012, 06:32:36 pm
for shits n giggles im willing to take a stab in the dark and guess..

105.2mph ... .
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on November 15, 2012, 12:43:42 am
only card i can find, 13.96 and terminal of 102mph with a 60ft 2.300 i did do better that that though by a little. i'll put it on once i find it.
Title: Re: Lance's G40 turbo with ITB's
Post by: Karlos the jackyl on November 18, 2012, 09:54:05 am
The time seems odd , as I'd expect you to be passing alot faster than that with 260hp on tap , even with a hefty headwind and roadies  ?
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on November 18, 2012, 12:49:46 pm
yea i expected better, i did do a better run than that but not loads better. i got faster as the day went on but then the welds holding my trigger wheel to my bottom pulley give way. car was still running just top end it felt like the clutch was slipping. took me a while to figure out what was wrong. sorted now though and it wont happen again.
Title: Re: Lance's G40 turbo with ITB's
Post by: djtez on November 18, 2012, 02:08:46 pm
i dont understand how the little polo's do not get a great quarter time ? ..

My best mates civic was 181bhp in a stripped out eg (still heavier than a polo) and it was 14.1's all day :/


do the polos have that much traction issues at these power figures?
Title: Re: Lance's G40 turbo with ITB's
Post by: Karlos the jackyl on November 18, 2012, 04:59:54 pm
Yeah it doesn't help when the wheel flaps about in the arch on a standard polo setup although I think Lance has a subframe? Not sure if he has an LSD though ?



About 10 years ago I stuck a camcorder to the outside of car  pointing at the front wheel and the amount of movement was crazy while driving.

 

These Polos are so badly made!!




i dont understand how the little polo's do not get a great quarter time ? ..

My best mates civic was 181bhp in a stripped out eg (still heavier than a polo) and it was 14.1's all day :/


do the polos have that much traction issues at these power figures?
Title: Re: Lance's G40 turbo with ITB's
Post by: Karlos the jackyl on November 18, 2012, 05:06:38 pm
yea i expected better, i did do a better run than that but not loads better. i got faster as the day went on but then the welds holding my trigger wheel to my bottom pulley give way. car was still running just top end it felt like the clutch was slipping. took me a while to figure out what was wrong. sorted now though and it wont happen again.

Yes it did seem strange , 1/4 mile terminal speed are usually a good indication of how well the engine is working.

It doesn't matter so much  if you fluff the start or have no launch grip either . as you'll find on a really good run ( low ET ) your terminal wont differ much at all.
Title: Re: Lance's G40 turbo with ITB's
Post by: djtez on November 18, 2012, 09:13:00 pm
thanks karl, it just shows the chassis is such an old design, modern cars just handle this so much better.


Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on November 19, 2012, 12:55:03 pm
i dont understand how the little polo's do not get a great quarter time ? ..

My best mates civic was 181bhp in a stripped out eg (still heavier than a polo) and it was 14.1's all day :/


do the polos have that much traction issues at these power figures?

Correct slicks help, alot! Although as Karl correctly states, the actual start has little impact on terminal speed as a fairly general link to trap speed and power with G40 turbos I'd expect:

185-200bhp ~ 100-105mph (Andy and Robin are both in this section)
200-225bhp ~ 105-110mph (Mine trap speed with K03 was 110mph, 108mph with a strong headwind)
225bhp+ 110mph+

Standard G40 traps around 85-90mph, and a modified circa 150bhp one about 95mph.

Slicks and a diff help alot, I found my car was much harder to launch with a bigger turbo, couldn't get within 0.5s of my best time.

Polos generally aren't built for drag racing! But it's fun making them try  ;D
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on November 19, 2012, 09:56:00 pm
next time am gonna do it without launch control. with the turbo being the size it is i have to launch at about 4k revs. i'll see what my terminals are next time. early next year it will be.
Title: Re: Lance's G40 turbo with ITB's
Post by: Karlos the jackyl on December 12, 2012, 05:33:41 pm
Keep us posted  ....  You should be trapping between  115 - 120mph
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on April 29, 2013, 09:44:42 pm
powder coated my rocker cover and made a better catch tank with baffles in to catch oil vapor.

(http://i305.photobucket.com/albums/nn210/lance_m45/g40bay_zpsd3c55115.jpg) (http://s305.photobucket.com/user/lance_m45/media/g40bay_zpsd3c55115.jpg.html)

few more bits in the engine bay to sort an try to make it look tidy.
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on June 17, 2013, 10:31:39 pm
Few photos from bodyshop, should be back on the road in the next couple of week.

(http://i305.photobucket.com/albums/nn210/lance_m45/poloprep3_zps1e14ce81.jpg) (http://s305.photobucket.com/user/lance_m45/media/poloprep3_zps1e14ce81.jpg.html)

(http://i305.photobucket.com/albums/nn210/lance_m45/poloprep2_zps1e825b0a.jpg) (http://s305.photobucket.com/user/lance_m45/media/poloprep2_zps1e825b0a.jpg.html)

(http://i305.photobucket.com/albums/nn210/lance_m45/poloprep_zps83f706ae.jpg) (http://s305.photobucket.com/user/lance_m45/media/poloprep_zps83f706ae.jpg.html)

(http://i305.photobucket.com/albums/nn210/lance_m45/polopaint1_zps458df633.jpg) (http://s305.photobucket.com/user/lance_m45/media/polopaint1_zps458df633.jpg.html)

(http://i305.photobucket.com/albums/nn210/lance_m45/polopaint2_zpsfb59f89e.jpg) (http://s305.photobucket.com/user/lance_m45/media/polopaint2_zpsfb59f89e.jpg.html)

(http://i305.photobucket.com/albums/nn210/lance_m45/polopaint3_zpscc161e88.jpg) (http://s305.photobucket.com/user/lance_m45/media/polopaint3_zpscc161e88.jpg.html)

(http://i305.photobucket.com/albums/nn210/lance_m45/polopaint5_zps02f2c4ca.jpg) (http://s305.photobucket.com/user/lance_m45/media/polopaint5_zps02f2c4ca.jpg.html)
Title: Re: Lance's G40 turbo with ITB's
Post by: dub-disaster on June 18, 2013, 10:34:57 am
Looking good :)
Title: Re: Lance's G40 turbo with ITB's
Post by: Yoof on June 23, 2013, 07:28:23 pm
Hmmmm red G40 Turbo  ;D

Bring it out to play: http://www.polog40.co.uk/forum/index.php?topic=9940.0

 8)
Title: Re: Lance's G40 turbo with ITB's
Post by: lance on June 24, 2013, 08:28:54 pm
(http://i305.photobucket.com/albums/nn210/lance_m45/polopolished1_zps40cbfd51.jpg) (http://s305.photobucket.com/user/lance_m45/media/polopolished1_zps40cbfd51.jpg.html)


coming together now, started to put trim back on after a good polish. windscreen to go in bumpers to paint then fitted and should be on the road.
happy with it so far!


I think thats the weekend of my mates wedding an im best man so cant miss it haha. if it isnt and i can make it though id be well up for it. make sure i have recovery though........

Title: Re: Lance's G40 turbo with ITB's
Post by: lance on July 30, 2013, 08:15:50 pm
After a good clean,

(http://i305.photobucket.com/albums/nn210/lance_m45/DSC_0608_zpsea56d8bd.jpg) (http://s305.photobucket.com/user/lance_m45/media/DSC_0608_zpsea56d8bd.jpg.html)

(http://i305.photobucket.com/albums/nn210/lance_m45/DSC_0600_zpsd44917e5.jpg) (http://s305.photobucket.com/user/lance_m45/media/DSC_0600_zpsd44917e5.jpg.html)

still a lot of metal polishing to do in the engine bay

(http://i305.photobucket.com/albums/nn210/lance_m45/DSC_0587_zps8db53aeb.jpg) (http://s305.photobucket.com/user/lance_m45/media/DSC_0587_zps8db53aeb.jpg.html)
Title: Re: Lance's G40 turbo with ITB's
Post by: z3i on July 30, 2013, 10:03:40 pm
looks smart mate! liking the wheels :) proper motorsport look :D