Tutuur's Big turbo Clio R27

Discussion in 'Other Projects' started by tutuur, May 2, 2015.

  1. Don't forget the golden rules of robust tuning. Keep It Stupid Simple and Don't Fix it if Ain't Broken.

    My experience showed me that the best project were the simple ones.

    My 2cents,
    S.

    Sent from my E6653 using Tapatalk
     
    ianplymouth likes this.
  2. okay, yes i see your point
     
    Roop48 likes this.
  3. Well nothing too complicated here, where just fitting a higher rated fpr, what's not simple about that?

    I've told you the advantage, you'd be able to make use of the rising rate fpr on the rail. For the power you'll be running with std turbo it should be possible with 630's on std pressure, but if you ever want an upgrade in the future you'd still need to upgrade the pump....

    Also if you do use the std pump/fpr DISCONNECT the rising rate fpr on the rail!!!!!!
     
  4. Pics weren't working, see next post
     
    Last edited: Mar 26, 2017
  5. Exterior hasn't changed much apart from the obligatory cup splitter:
    IMG_2060_zpsj5prvepv.jpg

    I have been busy with the engine though!

    New additions:
    Megane 3RS turbo
    630CC Siemens deka injectors

    After alot of time recalibrating the ecu to cater for the bigger injectors and turbo i finally got a chance to finetune it on the dyno:
    D76D042E-DF80-4B31-A31C-E8B364B015A7_zpsgfllkevy.jpg

    Ecu was pulling back timing on the dyno due to insufficient cooling so did another run building up power slowly to see what it would do on top rpm's:
    C5B7EEA3-3B75-47C0-998D-6619132773B0_zpsvidiv97k.jpg

    309PS will equal about 305bhp so by far the strongest Clio in the Netherlands atm. This was before winter.....

    Decided to skip the hybrid turbo and go big instead!
    DF9D390E-CE67-4C27-82CB-0D530A4C3559_zpsyvidltjh.jpg

    Fuel pump hole modified so i can swap out the pump in car, also cleaned the whole fuel tank as 10 years of debris does make it look filthy!
    4D7F89C3-2204-449D-A2F0-C0F82879C08F_zpsy6hx7cvg.jpg

    Standard fuel pump housing with 255lph pump and M3RS 550kpa pressure regulator.

    Had a manifold made by Tim Hicks for my new turbo setup:
    6E35B5B8-20B9-42DE-8DD5-4EFF8C6F74D9_zps5h7pt4or.jpg
    B391034A-9D11-4166-94C1-3D6A1A789BA5_zps3qqciw7d.jpg
    CF9F5423-A809-4BE6-AD52-0652B9400047_zpsqb6xsy9k.jpg

    It is going to be powered by a Borg Warner EFR 6758 turbocharger, should be good to a realistic 450bhp and awesome spool, boost treshold and transient respone!

    Also opted for a big brake setup based on the M3RS cup brakes, accompinied by DS2500 pads alround:
    BA623667-5033-42A8-A59D-98A29E4333EA_zpspc9i5noi.jpg

    Bought myself a TIG welder and started practicing/welding:
    1BCA01A0-1A11-409D-BA09-FC9BF877DB2A_zpssoqn8n5a.jpg

    7E9F817F-3F3E-4ADF-8315-3AF01FB6ADFE_zpstgxpgi8e.jpg
    490FC972-1C80-44CA-BF71-0E93B47E371A_zpslpyvcscd.jpg

    F2F3AC49-F130-43E4-9468-0085638E9F2A_zpscpfmzdrp.jpg
    B9EA7F91-4B2A-4352-9804-1733F39C0790_zpsvtbe6ioy.jpg
    4CAD3191-EA89-473C-BB6D-D1C021EF08F7_zps5rozav1z.jpg

    Now awaiting a few more bends so i can finish the silencer section.....

    For the people wondering, the engine will be a M3RS item aswell, will stay standard internally as i'm convinced they can take way more beating than anyone has the balls for. Next winter i'll put my rod-jobbed 25K M3RS engine in just for peace of mind :smile:
     
    Last edited: Mar 26, 2017
    Nigelo, ewant81 and ianplymouth like this.
  6. Ohhhhh yeah! It is going to be absolutely MENTAL! Love it even more now :smiley:
     
  7. That's proper that is :grinning:

    Good plans and good skills.
     
  8. That's going to be bonkers. Wheels don't do much for me personally, but it's going to surprise a few people with that kind of power.
     
  9. Did you have to machine down the 5.5 bar fpr to fit the pump or was it a direct swap?

    Also, how easy was it to fit the M3RS callipers and discs?
     
    LTMR26 likes this.
  10. Hi Mate
    Looking awesome didn't expect anything else with your attention to detail :sunglasses:
     
  11. With the Non sport Clio pump housing it's a direct fit, for yours you need to put in the lathe.

    Cheers mate, tbh if i'd go balls out just like Stephen Venning everything would've looked even better, although that's not my priority atm, enough to fab while i'm at it and progress is slower than i would like already!

    Still waiting for the mandrel bends unfortunatly...
     
    ianplymouth and ewant81 like this.
  12. Brakes same idea as Ian, just a little bit different. The ones i have for myself are mulit-pcd because of my 5x112 wheels.

    These are the ones i have for sale:
    [​IMG]

    I have 2 sets atm, including spacers for the calipers and longer bolts
     
  13. Yeah, definitely interested. Would happily buy them as long as you can stick them in the post
     
  14. Np mate, might be a bit expensive because of the weight though. Let me PM you regarding price
     
    ewant81 likes this.
  15. -Jamie-

    -Jamie- RSM Moderator

    Oh wow I this has moved on a bit, interested to see how you get on with EFR and stock internals.

    I had planned in a tubular mani from Tim to suit hybrid but I may scrap that and just get one to suit a larger turbo. If they can take ~400 then that's definitely my next winter upgrades sorted
     
  16. Tbh if the engine is out anyway a rod job isn't that much work, however this one will be used to prove these engines can handle a bit of abuse!
     
    Nigelo likes this.
  17. -Jamie-

    -Jamie- RSM Moderator

    If they can take that power I'm all in for the same kind of setup. I had planned forged and big turbo anyway but if I can get away for a while with stock internals it's a no brainer. A
    400 would be nice but I'd eventually like the option of 450 plus on a boost controller
     
  18. You use the car as intended by Renault so my engine might hold out a bit longer being a DD.

    However the pistons are male hypereutectic cast items so just dropping in rods will make the bottom end 500bhp+ capable.

    Sadly no one makes rods that fit the standard pistons but that's where i come in :smile:
     
  19. -Jamie-

    -Jamie- RSM Moderator

    Yeah I know Paul had reckoned the stock pistons would take 500, the guy that bought my old engine was in the process of sticking some forged rods in it but was needing to get them machined as they wern't tapered or something along those lines
     
  20. -Jamie-

    -Jamie- RSM Moderator

    Actually, I wonder if the rods are torque limited again like the MK2s. I'm sure if you keep the torque sensible and the boost linear and smooth it may help. Properly interested to see how you get on with it thiugh nice to see someone actually pushing the stock engine to see what it can actually take
     
  21. Exactly:
    [​IMG]
    [​IMG]
     
  22. -Jamie-

    -Jamie- RSM Moderator

    You got plans to get rods machined or similar?
     
  23. Yeah getting them machined.
     
  24. -Jamie-

    -Jamie- RSM Moderator

    What rods have you chosen to go for? I assume there won't be any strength issues with them machined?
     
  25. Ebay special!

    With a turbocharged engine the reciprocal forces on exhaust stroke are way lower than with an N/A engine so i guess it should be fine.

    Tfsi's have the same style rod and plenty of people take them over 8000rpm...
     
    -Jamie- likes this.
  26. Haven't had much time to work on the Clio but managed to do a bit today:


    F275440B-26DB-490A-9759-3B1F48C06A5D_zpsx3o5sm6g.jpg
     
  27. A bit more progress today:

    D517AEA5-B015-483C-BD13-3A97FE82BF16_zpspwiqy3e4.jpg
    E382EC8D-A788-421C-B14B-36F83F7ED478_zps69blvao4.jpg
     
  28. Wow that looks great
     
  29. Cheers mate, the diffuser needs some agressive looking tips so i thought slash cut 3" pipe would do the job!
     
  30. It's done the job, i'd think twice if i was following that and cause i know what's under the bonnet :laughing:
     
  31. Finally managed to free up some time to work on the Clio again.


    Exhaust system nearly finished now, just need to have the v-bands welded by someone who knows what he's doing as they warp like crazy when not doing it properly.


    7FA01FAD-9C29-4B94-BC33-D5EFE68CB00B_zpsge8fhyt2.jpg

    EF1B1959-8246-4723-AEED-C35EB858BD8C_zpsuu1jpgfx.jpg

    4AA46658-6C41-4868-8A66-122DAEB8805F_zpsyonjclgw.jpg


    I also bought new alloys (same as i had) so i could treat them with some gtechnic stuff, the products might seem expensive but they don't lie about how little you need for full coverage, got this left after doing all four wheels:


    5383031D-2207-4B9A-BB27-2924BA67ED6F_zpskvgczrrf.jpg


    And this is how they are curing atm:


    D832441B-C9DA-48F1-9029-F0AAF0B3BC3D_zpsftl5eotg.jpg


    Still loads to do but i'm getting there eventually :smile:
     
    Nigelo, MartijnGizmo, StephRS and 3 others like this.
  32. Last weekends progress:


    New, genuine, rear discs drilled to accomodate for 5x112 again aswell as new pair of front hubs

    129D975E-C888-4854-B65D-3804892F3FA1_zpse0zwgagw.jpg


    Oil feed and water feeds sorted, now just have to do the oil return and fab a bracket for the wastegate actuator

    030E4105-3051-491C-8DCA-31990FA30AA9_zpslsu64uxs.jpg


    Calipers stripped, cleaned and treated with some Gtechniq aswell

    046FBE77-5093-468A-B021-DDDDE647B0C0_zpsmowiiuad.jpg


    Alloy v-band made as heatsink for welding the v-band couplings

    D6B8F622-D4CF-49BF-81AA-D8A36225B487_zpsmmxnmmt4.jpg
     
    Korky and MartijnGizmo like this.
  33. Just spotted this thread ....

    Clicks like......

    like......

    like......

    like........

    like... .. . ..


    :laughing:
     
    Xanda73 likes this.
  34. Top stuff - coming on great.
     
  35. Yesterdays progress:


    Fuel pump cover finished

    B14A9249-2465-4663-98D0-E8F996054FCC_zpse3eunequ.jpg

    D727A7CD-F9DD-40B3-89DD-B4334AA8465A_zpsj0lho1af.jpg


    New brakes and hubs fitted

    C6A96491-0430-4AD2-BB7F-A8526F31FB37_zpscgla53z5.jpg


    Nice fit

    0D819CFF-A96E-4E00-9ECD-0FB2FCF98A68_zpswuw881ti.jpg


    Turbo oil return mocked up using 2 original return pipes and an aftermarket pipe

    FBA632E3-0913-4710-91CC-2C0B10D72CB4_zps8a315lwz.jpg
     
  36. Wheels ready :smile:

    6B12D5AF-96E7-48D6-BE76-8B13B8B64746_zpsoqvffheg.jpg
     
    Nigelo likes this.
  37. Feirny

    Feirny RSM Admin

    Not sure on the wheels as they are off the car, but I'm sure they'll be better once fitted and my qualms will be sorted.
     
    tof73 likes this.
  38. Check page one mate, already had them on before.

    A bit of progress again, my friend who was going to weld my v-bands didn't have any spare time so i decided to do it myself. With a few hints his side and using the alloy heatsink they turned out pretty well.

    E98BCC70-034C-41DB-B23B-850AFAD08A98_zpsqgx2wzld.jpg

    Exhaust is nearly finished now, just have to make two lambda bungs in the downpipe and redo the rear section mounts as i want to make them adjustable so i can level both tailpipes perfectly.
     
  39. yet some more progress, pressure side of compressor housing custom made to suit standard boost pipes:
    031EFD86-E2FE-4918-B404-21F63131A0D2_zpse7p8uszr.jpg

    took a while to get everything lined up as the silicone hose only just fits between the coils!
    8EBCACA8-C437-4EE3-B53E-6393754A1C61_zpsorlaasfx.jpg

    lambda bungs added to downpipe aswell:
    739F37FE-2709-4081-AC01-601505136865_zpsu3wcaqb0.jpg
     

  • Share This Page