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#1
16-02-2010, 02:28 PM
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2.15 Stroker P1 Project
Thought i might start up a project thread on here so people have a vague idea who i am when i finally make it to some meets once this is finished!
You guys made me very welcome and I have some interesting shot of the build process so thought it might be nice to share. Car started smoking one morning on cold start so it got taken to Chris Palmer Auto's in Bristol for Spencer to take a look at. They found masses of petrol in the sump. 600 hydro carbons to be precise! Told this would normally be below 100. The cause it still unknown until my engine is stripped down but look like piston 4 has an issue – Compression Test Results: Pistons 1-3 = 155-160psi, but number 4 down to 135psi. Leak Down Test Results: 1-3 = 10-15% but number 4 = 22%. Spark plugs: 1-3 were black where it had been running lean and number 4 had a fine glaze of oil over it. There was a small amount of tiny swarf particles found in the sump. Bores and top of pistons and valves etc look of with the camera (although he can’t seen them too well with the camera) but it’s feared the side of the piston might be where the issue lies, and the small bits of swarf could have blocked but the oil pump cause the loss in pressure. So anywho I had to make a decision and after about a month of research bugging the hell out of other specialists, mappers, and Techy gurus I opted to go for a 2.1 Stroker Kit, capable of 550bhp. I only wanted to rebuild once and didn’t want to be restricted by the build spec, this is what we decided on: Actual build outsourced to Advance Automotives, build by Nick Johnson. Closed Deck Block with under piston oil squirters Striped, cleaned, honed and bored Rear thrust converted 14mm head stud converted Machined block faces and modified oil ways 2150cc Stroker kit New 2.5 STi nitride crank cross drilled Manley steel H section rods and ARP2000 bolts Mahle 2618 race material lower deck stroker pistons, rings and pins ACL full RACE bearing set Full gasket/seal set 0.6mm 3 layer Cometic head gaskets ARP 14x12mm head bolt set Skim and clean cylinder heads 12mm RCM modified high flow oil pump New cam belt, rollers, and tensioner New modine oil cooler New sump pan and pick-up New water pump Fuel lab 3 port adjustable FPR with braided lines and pressure gauge Reversed fuel rails Cossie sump baffle plate RCM light-weight pulleys nickel plated Cool running thermostat. Then for uber-blingness I am getting parts painted or powder coated in 74F / Red / Black and replacing bolts with shiny stainless options: Painted block Rocker covers Header tank PS pump reservoir Timing belt cover Pulley cover Fan shroud Rad brackets Fuse box cover Ancillary brackets holding alternator / air-con / PS pump etc I already have: Engine External: HKS 3” Hi-Power Strait through Centre pipe HKS 3” Hi-Power back box H&S 3” Decat downpipe GT spec Gen II Tubular unequal length headers, Harvey Smith Custom up-pipe, Headers DEI Titanium heat-wrapped Up-pipe DEI Titanium heat-wrapped Downpipe DEI Titanium heat-wrapped RCM Hi Flow Induction, Lateral Performance MD321T Turbo, Power Enterprise 550cc flow matched injectors, Bob Rawle Remap, Walbro 255 Fuel Pump, NGK PFR7B spark plugs gapped to 0.6, 3 port boost control solenoid, Ported throttle body, Insulating manifold spacers, Header tank spacers, GT spec Gen II FMIC, J Performance High capacity Aluminium Radiator, Exedy Single Plate Organic Clutch, Fidanza 4.4kg Lightweight Flywheel, Prodrive Slam Panel, Full Samco setup. Heavy Duty Battery, Hot coolant throttle body mod. HKS SSQV DV, SETRAB 26 row Oil Cooler with custom made stainless braided lines Group N Engine mounts PowerFlex Polyurethane Exhaust Hangers Handling: Prodrive Alcon 330mm Brake Upgrade, 330mm Godspeed Rotors 316mm rear Brembo 2pot conversion, Whiteline 22mm adjustable ARB, Whiteline rear Droplinks, Whiteline front sway bar bushes Whiteline steering rack bushes Whiteline front anti-lift kit, PowerFlex Wishbone Bushes Prodrive geometry Stage 1 fast road setup, Anodised blue split bells, F+R Braided Hoses, Ferodo DS2500 Pads, Goodyear Eagle F1 tyres 
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#2
16-02-2010, 02:30 PM
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Here’s the build so far…
Sourced myself a Closed Deck Block pair with under piston oil squirters –   Worried by this at first, but once taken to 92.5mm it wouldn’t be an issue as it would machine out.  Block cases @ Advanced after inspection  UV crack testing  Pressure testing  Measuring bearing parent bores  14mm head-stud conversion  Rear thrust conversion  Bore alignment template before rebore  Bore to 92.5mm    Cleaning the cases      Crankshaft assembly          And that’s where were at at the moment! My engine and heads are all coming out the car next week so should have some more pictures then! Cheers! Spooky
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#3
16-02-2010, 02:42 PM
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I'm liking this thread matey.
 Can't wait to see the progression of this one 
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#5
16-02-2010, 03:52 PM
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Crikey.....13 posts then this....you know how to make an entrance!
Good luck with it!
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#7
16-02-2010, 04:16 PM
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__________________
Eat, Sleep, Race , Repeat
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#9
16-02-2010, 04:21 PM
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Actually, ignor the later, i just saw your post on my 22b thread! How does it sound!?
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#10
16-02-2010, 04:23 PM
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I can guarantee it sounds the dogs, been for a blast in CJ's and it sounds fookin great!
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#14
16-02-2010, 05:28 PM
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Quote:
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#17
17-02-2010, 09:56 AM
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Out of interest. Who is doing your mapping?
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#18
17-02-2010, 10:05 AM
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Next choice would have been Paul Blamire or Pat Herborne.
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#19
17-02-2010, 11:28 AM
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I used Bob for my mapping before the engine change. He is spot on. Used to enjoy the drive home from Swindon
I am now using Simon JGM, the legend in the making. Got a sesh with him on Friday at Surrey RR, along with a few others from here.
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#20
17-02-2010, 11:48 AM
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So what have you changed since you last map Mr.Wozel sir ? Can I come and spectate?
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#21
17-02-2010, 12:20 PM
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RCM Induction Kit fitted yesterday, new simtek map being fitted by JGM on Friday at SRR.
CJ, Nick (Blue Bugeye), Simon and I will be there from about 10.30am I expect. Plus others I expect. More than welcome to come and watch if you want to.
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#22
17-02-2010, 01:23 PM
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looking very good, whos doing your maching work?
__________________
all over it jaffa style!!!
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#23
17-02-2010, 01:55 PM
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Thanks Tone. All the machining and building is being done by Nick Johnson @ Advanced Automotives. He is closely affiliated with RCM and does some work for them when they are too busy...
The engine removal, head removal, redress and refit plus all my toys are being done by Spencer Chard @ Chris Palmer Autos...
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#24
17-02-2010, 02:43 PM
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So............ a cheap rebuild then
 Yet another cracking project to watch on here.
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#26
17-02-2010, 03:25 PM
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Quote:
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#27
17-02-2010, 03:31 PM
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Cool, the more the merrier.
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#28
17-02-2010, 03:34 PM
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Lets stop Hijacking this thread and move our session conversation to a suitable home. I'll get something in General going.
 Sorry Spooky, you can get your thread back on track now 
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#29
17-02-2010, 03:38 PM
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Cheers Worzel 
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#30
18-02-2010, 12:24 PM
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Love it, doing a rebuild myself but i dont think i have the sort of money you have....
 Looking forward to the end result, keep up the posts flowing.....
__________________
1.6 Terzo........ Non turbo.............http://www.surreyscoobies.co.uk/foru..._vehicle&id=87
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#31
23-02-2010, 11:06 AM
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Latest update, bottom end is now complete
Just waiting for Spencer to whip out my old engine and get the cylinder heads off and over to Nick for long build to be completed.                Also got this pic sent to my phone late last night… Rocker covers, PS tank, Header tank, various front end bolt on block brackets all tarted up! Just need to paint my timing belt cover, and a few other things and I’m done. 
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#32
23-02-2010, 11:39 AM
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excuse me
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#36
25-02-2010, 11:33 AM
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Just a wee update.
Ordered an RCM billet timing belt guide HKS LTD Edition Rad Cap (1.1) HKS Oil Filler Cap Tuesday night I took a road trip to pick up my powder coated bits. Got some nice new shiny bolts for them today! Not sure how the Allen key style will go down on the rocker covers, but no biggie to change them back over. PS Pump Reservoir and Header Tank    Rocker Covers    And just another shot of the Aircon / alternator / PS brackets / Slam panel brackets   Also got a few bits sand blasted for me to spray myself in 74F blue, will post picks when they are done. Will be picking up the MD321T Saturday morning and most likely adding a few more things to the list while I’m at the garage. Really really looking forward to Saturday! I get to see my car again, I haven’t seen it since 01/10/09 
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#37
25-02-2010, 01:22 PM
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Mate, that is a lovely pile of BLING!
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#39
27-02-2010, 06:13 PM
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Took an early morning road trip with my mate dan to Bristol this morning to see the crazy west country folke and drop off my blinged up goodies!
took a stop off on my way to collect my new tubby too. Wasn't a great start me on the phone to Matt both saying were in Costa coffee before realising we were at different services, but a burger king and 10 miles later i picked up this baby, Lateral MD321T    Got to CPA and after a cuppa when to have a butch at my baby, she looked so lonely tucked away in the back, cold, with the lights off   Fitted a new headunit while i was there and done some shiny nut and bolt replacements under the bonnet   Before leaving tucking her back in for the weekend...  Estimated time of completion is about 3 weeks, so long as i don't ad anything else to the list. Although i did add a few more things to the list already today, DOH!
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#40
15-03-2010, 03:43 PM
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Small update, not much interesting to post until the engine comes out tomorrow and gets stripped. Hopefully this will happen to make sure i'm ready for the 26th!
Lateral Performance Custom 76mm Hybrid Inlet pipe with breathers blocked off. Lateral Performance MD321 series fitting kit. 
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#41
15-03-2010, 04:07 PM
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Very Very nice mate...
__________________
1.6 Terzo........ Non turbo.............http://www.surreyscoobies.co.uk/foru..._vehicle&id=87
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#43
15-03-2010, 04:24 PM
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This really is going to be another stunner
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#46
15-03-2010, 04:42 PM
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Ridding Your System of Impulse Buys!
I wish we all had a pound for every time we had said that.
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#48
15-03-2010, 05:58 PM
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Nice to see someone doing it right Spook. That will be a lovely pice of kit when finished mate, good on yer......... and it's a P1
Only 700 left world wide now and I know of 3 that have gone from a nice road car to a stripped track car. Are you coming to the 10th Anniversary at Prodrive ? I have not checked the list by 80 P1's have confirmed and I have booked the Holiday Inn at Banbury (Nr Prodrive) on Sat 8th of May. P1's all meeting up in lay by then all 80 are driving in convoy to Prodrive to meet up with other clubs. Holiday Inn - Banbury (Reception 01295 234567)
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#49
15-03-2010, 06:03 PM
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Cheers Fudge! I can't wait to drive it again, it feels like i have butterflies in my stomach 24/7 for the last month or so, the wait is agonising! Maybe i'll pop down to Tonbridge one night and meet up in an effort to clock up some running in miles?
I think that will be a plan Clive, what time are you heading up there on Saturday roughly? could get a convoy together and tie it in with a bit of grub and a few beers? Will speak to me mates who are along for the ride and sort out sleeping arrangements!
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#50
16-03-2010, 01:51 PM
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Yeah that would be good Spook.
Regarding Sat 8th I can arrange the time around you and your convoy. I reckon if we get to Banbury for early evening, then have a meal and a few gallons at the hotel Feel free to use some milage driving to Tonbridge. I can take you for a spin to give you an idea of what 560 is like in a P1.
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#51
16-03-2010, 02:47 PM
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I think i may just do that! See if i can get something booked hotel wise in the next week or so, so its all confrimed and i can begin to look forward to it 
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#52
17-03-2010, 02:09 PM
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Just got off the phone to Spen and the car won't be picked up till the 9th April now
 There has been a delay with mine and FatBoy's P1's due to some extra work required on some inconsiderate git's car... *cough* Coalville *cough*  But on the plus side, i have just declared everything with the rebuild and turbo and exhaust and suspension etc etc etc to my Insurance companu and guess how much it went up? £59.00 Good old Greenlight, they are just Brilliant! I have however, just bought me some BC Racing Coilovers to give them something to do with all this extra time they now have on their hands 
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#53
17-03-2010, 02:21 PM
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Thats a bugger about the delay mate.
But blinding news with the insurance. And also cracking stuff with the coil overs.
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#54
17-03-2010, 03:39 PM
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What's John having done? (Fatboy) Spook you are local to us SES guys right ?
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#55
17-03-2010, 03:44 PM
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Yes mate, I'm an Orpington boy... init!
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#56
17-03-2010, 04:29 PM
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Huh Orpington, that's right I remember now
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#58
17-03-2010, 05:35 PM
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#59
18-03-2010, 10:32 AM
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Latest pics from Spenbot himself… FMIC pipes etc all removed and engine is now out and heads will be with Nick @ Advanced Automotive later this morning.
I feel quite traumatised seeing my poor baby being ripped apart  But progress is being made           
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#60
20-03-2010, 05:17 PM
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Went up to CPA again today to fit a stereo and some harnesses and see how things are going...
Ended up adding more things on my list! Dam spen and his smooth talking Got to meet Nick properly today as well as he popped down which was great had a good chat about my build and other bits and bobs. Just a few random snaps i took through the day...     Quick lunch time snack...  And looms as though Spence has had to up his security... 
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#62
24-03-2010, 11:22 PM
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Just purchased:
1 x Syvecs ECU 1 x Wideband Sensor 1 x Cal switch 1 x Harness support bar 1 x Magnecor HT leads 1 x RCM catch tank kit Ok thats my lot no more fricking spending!!! Well maybe coilovers... but then thats it no more!! Harness Support Bar:  
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#63
27-03-2010, 08:33 PM
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Back to CPA today, this time with FatBoy along for the ride to pick his car up in the morning
Job for today was to get the harnesses and harness bar in. spencer was off to scrutineering for tomorrows rally so off he went and i got cracking      Also fitted some extra ghey bling in true spooky fasion! 
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#65
05-04-2010, 03:20 AM
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 looking very nice, whens the big day?
__________________
all over it jaffa style!!!
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#70
12-04-2010, 04:57 PM
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The car is awesome!!! loads of attention to detail taken on the engine bay that you wouldn't get elsewhere. As a bonus, spencer suprised me with parallel fuel rails and system fuel filter with all the braided fixings
i'm still noticing little touches now... CPA really do know how to build an engine And oh my god the sound... the sound is AWESOME!!! The flutter you get coming boost gives me a constant semi and i'm only taking it to 0.5bar so far  god know what its going to sound like at almost 2bar! the next two weeks really can't go quick enough.So i got to CPA at about 10.30, and checked out the work they'd done, after much drooling i had to go get some tax for it so i was off into town with a fresh MOT certificate. returned and gave it a wash ready for bob's arrival. bo arrived about 3pm and get strait to work settig up his kit, and off we went. got onto the ring road and checked the fuelling etc and all was fine and dandy. Had a scary moment though when my actuator pressure hit 1.4bar before bob yell'd STOP!!  Someone has wound up the actuator i believe as i should have only got about 1.0bar! Mapping went very well though and Bob really did seem impressed with the overall standard of their work.Then off i went home on the motorway getting funny looks as i was crawling at 50, then accerating up to 70 then back to 50 again for almost 140 miles on boost off boost on boost off boost change gear change gear, it was hard work! Here's some pics of the engine, i will get some better ones when i have the sun on my side. ROLL on 23rd with LC, ALS, and 450bhp!            
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#71
12-04-2010, 05:35 PM
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VERY VERY NICE....after sampling 405 horses recently you will absolutely adore 450 in a classic I am sure....very jealous.
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#72
12-04-2010, 06:16 PM
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Very nice mate you must be over the moon
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#76
20-04-2010, 11:58 AM
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Cheers Guys, i am very chuffed with the end result! Still on standard box but for how ling is yet to be confrimed lol!
Final purchases now made ready for Friday! RCM 80mm induction trumpet as I will now be MAF-less, and all the rest Lateral Performance Supplied – Walbro 290 High Flow fuel pump Nismo 740cc Injectors plus flow matching 3 bar MAP sensor 74 hours and counting! lol
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#77
20-04-2010, 12:24 PM
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Looked an absolute gem in the flesh. Was great to see you and the car yesterday at Brands.
So, you have Bob Rawle doing your mapping then? He's a good lad our Bob. You'll have a good safe map with Bob
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#78
27-04-2010, 02:28 PM
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Went back to CPA on Friday for the Grand Finale!
Last minute purchase with the Systec 290ltr Motorsport pump just to be sure. I feel a Bosch044 but hey ho you lives and you learns! Didn’t go quite as planned, the pump and injectors were delivered to my home address instead of work so no one was there to sign for them. Meant to leave at 05.30 for Bristol to avoid rush hour and get some breakfast on the way but the parcel ended up back at the PO Depot. So I had to drive over there and wait till 7am to pick the parcel up and then got stuck in the morning rush hour, got to CPA about 2 hours later than planned (and still hungry) and they got cracking right away. Trumpet would not fit do had to use the MAF tube and block off the MAF port and remove the gauze for now. Injectors in and fuel pump in and after a quick road test I was on my way to Bob’s an hour later than planned. Then got pulled over by undercover police and warned about my number plates and given a producer! Then got to Bob’s about an hour and a half late, therefore didn’t have time to set up the LC or the ALS and the loom for the Wideband sensor had not arrived so no wideband just yet either! But got the Cal switch in and got the main map done which was priority number 1. The car pulls really hard right into the red! Loads or torque and definitely feels mid 400bhp-ish. Boost is 1.85bar dropping slightly top end to 1.7bar and sounds AWESOME coming off boost!!! I was going to take a vid but I wanted to do one with the ALS and LC on really… The clutch slipped a smidge on one of the final in 4th runs but hasn’t slipped since so I’m hoping it will be OK to get a readout on the rollers in 3rd. Bob confirmed the engine was running beautifully and performing very well indeed. Rolling road is on Saturday so time will tell! Will be going back to Bob ASAP to the ALS and LC set up and finish the wideband control.      
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#79
27-04-2010, 02:33 PM
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Great stuff mate. Sounds like you had a day of it though!
 Roll on the final result.
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#80
27-04-2010, 02:35 PM
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Cheers Worzel! you're not wrong, i didn't get in till half 11 and still had not eaten all day! We ended up mapping until about 20.30, Bob was meant to be going out that evening too... 
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#82
27-04-2010, 05:28 PM
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Sounds like you had a day of it!
I'm sure it will be worth it thou! What probs did you have fitting the trumpet as I have got the same one! I'm not copying you just seems that we have got a lot of the same parts
__________________
Turbo 2000 and tommy kayira track day beasty
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#83
27-04-2010, 05:37 PM
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Quote:
I needed the 76mm - 80mm airbox hose to ensure a good fit on the trumpet!
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#84
01-05-2010, 05:07 PM
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Today wasn't a great day to bring closure to the project.
For some reason i wasn't holding boost properly and only achieved just under 1.7bar peak and dropped off to 1.6 post 5k. It pulls really hard but the power tails right off when the boost drops which is probably why it feels mid 400's when it comes on boost and its pulling but the figures were not showing at the top end as it lost boost. Charlie said he can feel it pulling hard on the rollers when the boost comes in and the first run it started jumping the rollers so we had to strap it down harder! Only made 408.6bhp and 390ft/lb, and we know it can do alot more than that. Possibly BCS, possibly MAP sensor, possibly Actuator? Will be investigating to see what can be done. Fueling seemed a bit rich but the Wideband control is on the way so will worry about fuelling after that. Anyway a few pics and a vid of the day as it was...       
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Last edited by Spooky; 01-05-2010 at 05:17 PM.
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#85
01-05-2010, 05:41 PM
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Mate 400bhp atw isnt to be sniffed at. In a classic it will be bolistic.
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#86
01-05-2010, 05:52 PM
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sounds like actuator or a small boost leak.
__________________
all over it jaffa style!!!
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#88
01-05-2010, 07:23 PM
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Boost control drops slightly yes, but it's quite stable so it may be that the duty it set fine for the road but under-achieves on the rollers. if it was a BCS issue I would expect to see more oscillation on the graph.
Does it read the same boost out on the road. If the boost control on the road only just achieves the mapped desidered boost, then on the rollers, where the induced load is slightly less it will under-achieve. Not sure how good the syvecs is on boost control, but the OE ECU has a level of learning i.e if it doesn't achieve target boost it will add or take away a % (within the mapped limits) in order to achieve target. The fuelling also looks OK, you don't want it reading much leaner then that on Charlies rollers, most on his RR read under 11 AFR but read leaner i.e 11.2/11.3 out on the road. TBH looks like a Bob map...nice and safe.... FYI Mine reads bang on 11.2AFR on the road but on charlies the plot was similar to yours.
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#89
01-05-2010, 07:53 PM
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Agree with above.
400 in a classic is an achievement and I believe is a great balance for a P1. Chin up you
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#90
02-05-2010, 09:21 AM
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Would not agree on looks like bob mapp as his normally a boost junky
__________________
Eat, Sleep, Race , Repeat
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#91
02-05-2010, 09:40 AM
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#92
02-05-2010, 09:51 AM
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As I say, just my thoughts an I'm more than happy to be proved wrong but hey...
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#93
04-05-2010, 09:20 AM
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Sorry to hear things didn't go as you quite wanted them mate.
I'm sure it'll all step into line with a little tinkering. Keep the faith mate, you'll get there
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#94
04-05-2010, 10:08 AM
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At least your cars on road Spooks...
Im sure you will get to the bottom of it..
__________________
1.6 Terzo........ Non turbo.............http://www.surreyscoobies.co.uk/foru..._vehicle&id=87
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#95
05-06-2010, 09:59 PM
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Just got back from Bob's with another successful mapping session
Plan was to play with the wastegate duties and up to boost to nearer 2.0bar and hit 450-460bhp, finish with wideband fuel control install and setup and finish the ALS and LC. But i told bob to leave the WG duties alone as the car is fast enough as it is, and i needed to preserve my gearbox! very hard for me to say as i've very greedy with the figures lol but definately the right choice. The ALS and LC is awesome, i've set them up as below: CAL 1: Normal CAL 2: Normal + ALS CAL 3: Normal + LC CAL 4: Normal + LC + ALS CAL 5: Normal + LC + ALS + 330rpm CAL 6: Normal + LC + ALS + 660rpm CAL 7: Normal + LC + ALS + 990rpm CAL 8: Valet mode 3k rpm limit The ALS really does make a difference to the pulling force through the gears, its very impressive. I umm'd and arr's about whether to launch on the standard box but i soon found myself engaging 1st with the Lc and ALS on and went for it. It was like a rocket! i'm very used to my car and it doesn't give me many suprises but it was really shocked how fast it took off! The LC is so loud too, it sounds like an airstrike! Will got some vids up as soon as i get some more petrol LOL
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#96
15-09-2010, 12:00 PM
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I miss updating this so I was trying to find an update… lol
Ah yes! Clutch line split! Decided to go just as I was queuing up to the exhibitors gate at Modified Live this year! Wasn’t impressed  But having seen a recent Bear Grylls documentary I was inspired to fix the problem with what ever I could find… I managed to conjure up 2 zip ties, some double sided tape, some gaffa tape, some insulation tape, a jubilee clip and some sticks and wild berries which I used to make a screwdriver. First double sided tape, then insulation, then gaffa, then jubilee then the zip ties… then a quick pressure adjustment on the jubilee clip to get the pedal feel just right and the job was a good’un!  Felt good as new and got me from Brands Hatch to home a few junctions away and then from home to Bristol with no dramas! It made me feel real manly like Got to Bristol to see Spencer and the gang and had a trick braided version fitted in replacement   Still saving for gearbox and clutch 
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