Dj Wilmas T Series 111S S2 400Bhp Ish

[DJWilma]

14 hours ago, Dr H said:

Nice progress. I could do with a man to leave mine with

Ive been trying to find someone who can do it all locally, but they are few and far between, but Ian was recommended by a well known engine builder and turns out he is an old school friend of a friend. Have someone local thats Ex Omex and is good with looms so its off to him soon.

But if you had yours finished what would you do and talk about ?

Got the inlet and the turbo on today

Looks like it was meant to be in there, lot of room for the turbo and inlet was fitted in 30 mins as it went through the inspection hole

Wiring is now being sorted and I'll plumb in the water and oil hoses when home

[DJWilma]

The new fuel pump turned up today, big thanks to Gaz at Spitfire Engineering. This (small) pump should provide enough fuel for 500bhp at 3.5bar and Gaz kindly sent me a complete unit, i have to send my old unit back. I went for the Deutschewerks pump

This will save me a swirl pot, lots of fuel pipes and i dont need the Bosch Motorsport pump i had on the T series.

Hoping to have the car wired up to the ECU and Ford Loom next week

[DJWilma]

Got the Elise out today and did some work at home

Put the engine cover on and it will be tight but the HPFP pressure sensor and the wastegate both it (when level) but need to get the rear clam on to check

I have the Duratec Silicone Hoses from Essex Autosport and tried to get them to fit. I got very confused until i realised the Ecoboost water inlet and outlet are on the opposite side to the Elise so after doing some searches (yes i know) of the Duratec builds i saw the swap of water pipes. With some pipework from the rover i managed to get it all set up

This makes it a little congested under the inlet, as the water pipes Swap over, the oil cooler water pipes, the remote filter pipes and the throttle body inlet. 

Fitted the starter and it fouls the bell housing adaptor, bit strange but an easy fix

Also looked at fitting the fuel pump, and the hole is too small, i think i will go for the easy option of cutting the top rather than dropping to the tank (as no ramp)

[DJWilma]

I think it's best to say my motivation with the car is waning, work, travel, family and work on the house have ground me down. 

I cant even be bothered to fit some water hoses and sort out the vacuum......its got that bad. 

So tomorrow the car is off to HPE Automotive in Bromsgrove for Dan to finish

Monday the engine is then with Specialist Components to map and see what she's got (if the turbo can give it enough air)...... 

Pick a power figure if your bored, I'm going with 400bhp at 11psi and 8000rpm for a giggle and 480bhp at 23psi and 7250rpm.

But today I suddenly realised I hadnt fitted the rear clam with the new engine in, and I was off to Germany at lunchtime

First fit didn't look too bad at the back

But terrible at the front 

So I found the sabre saw and made it fit. 

But it hit the wastegate(built when the engine wasn't with the car so can't complain) 

I gave accepted I will be losing the boot so will fabricate, sorry asked Dan to fabricate something to lock the hatch too. 

Boot will be exhaust as it was way too loud before

[DJWilma]

Engine lasted 10 minutes on the dyno last week, then started to have a bad misfire at 2500rpm and load. So the head have to come for a re-check

Spoke to the Engine builder today and its pretty clear whats happened

The head was coked up, one of the down sides of direct injection, so the valves were sticking. 

An expensive lesson, yet again, but asked them to strip the engine, check and rebuild. They found a few minor issues and have mentioned that it may be worthwhile porting the head..........it never ends

Should be a couple of weeks to get it put back together

[DJWilma]

Damico have kindly sent some shiney clean photos...........getting closer....again...again

[DJWilma]

OK results are in and dont know whether to be happy or sad.......i should be happy looking at the curve, i really really should be

Anyway.......

It’s a mixed bag of news

The engine wanted to boost, way above the 11psi set in the actuator. So the dyno removed one of the two springs and got this down to 20psi. The spring should set actuator pressure to 4psi so need to find out why this is happening. 

It may be connected to the vacuum pump, this was disconnected and open to atmosphere and caused the crankcase to pressurise. Once disconnected, or sealed up, the engine was fine. Took a while to find out why but hey ho its not been done before.

Weirdly the std gdi injection was ok at 410bhp, auxillary wasnt needed (was tested and wasnt great when injects as the injector opens to much for the need) but does work if needed. Theory is 350wbhp so 400bhp is the limit, which its not as they still had some headroom. 
 
But the major issue was detonation, at 20psi (1.4bar) the sensors were detecting knock, so the ignition was retarded to a point where the egt's got too high......This though should not happen, inlet temps were 30C so even if the compressor was blowing hot air (which its not according to the comp curve) this shouldnt effect detonation.

A theory, which i need to confirm, is that the pistons are higher than the 9.3:1 they should be. This is because i used the 2.3 crank and rods, and the 2.0 pistons. The std 2.0 and 2.3 have the same comp ration, so longer stroke and short rod should ,ake the same as they share (i hope i am right) the same piston diameter. However, the 2.3 and the 2.0 use different heads so i dont know if the volumes change to compensate. 

As is normal here Dyno session finished late, so i will get more information tomorrow. 

So it may 410bhp, 300lbft at 3000rpm and 350lbft of torque with a flat chunky curve with lots of room under the curve.

So i should be happy, right

[Dr H]