Tutuur's Big turbo Clio R27

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

  1. [​IMG]

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    Korky and matt e like this.
  2. pure exhaust porn, look so good, is it a sport cat you have on this after the flexi
     
  3. You must be getting near the end by now. We are getting impatient and want to see the finished car! [emoji23]
     
  4. Me aswell! Hopefully be bringing it to FCS if i don't get too much setbacks!
     
  5. Daz

    Daz

    I want one of those cats fitted to my exhaust!
     
  6. The cats are cheap as chips mate, check ebay.

    Changed the design of the silincer hangers a bit to make them adjustable:
    [​IMG]

    Now just need to source 2 m8 bolts and corresponding bushes which will fit snug into the rubbers

    Decided to redo the oil return, way more futureproof now:
    [​IMG]

    This is where i'm at atm:
    [​IMG]

    Biggest challenge now is fabricating a bracket for the wastegate actuator....
     
    Feirny likes this.
  7. Daz

    Daz

    Cats are cheap - getting someone with welding skillz costs!
     
  8. Finally some progress again, had to make an egt probe into the exhaust manifold, fabricate a bracket and rod for the wastegate actuator, together with some more smaller stuff.

    However that has been finished now after which the engine looked like this:

    [​IMG]


    Put it in straight after:

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    Now waiting for me to proceed next week:

    [​IMG]


    And a bit of porn:

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    Still alot on the to-do list but i'm getting closer!
     
  9. Two steps forward, one step back.... fired up the engine today which was great, however after fitting new outer cv's, bolting subframe, wishbone's etc back together i noticed the wheels where stuck, guess what, brand new gkn outer cv's don't fit.....

    Going to put the old driveshafts back on now as the car has to be back on the road before FCS, a day worth of work in the bin though!

    Now on to the happy bit:
     
  10. -Jamie-

    -Jamie- RSM Moderator

    Thats annoying, Still looking forward to seeing the results of that turbo setup!


    I have said i wont bother with more but if you can get around 390/400 and do it safely it might be an option for me still LOL!
     
    tutuur likes this.
  11. Pav

    Pav

    nothing better than firing her up for the first time!!well done mate..
     
    tutuur likes this.
  12. That sounds quite meaty! Apparently you need to top up the oil though [emoji6]
     
  13. It sound the nuts, nothing attached to downpipe though so doesn't surprise me!

    Oil is fine, halfway :smile: this was the first 5l, guess it needs one more
     
  14. Really curious how the 6758 will do, should be awesome! If you're only after little over 400 i'd pick the 6258 though
     
    -Jamie- likes this.
  15. First update without pictures as i haven't found an alternative for Photobucket yet.

    Managed to finish the car off yesterday, only to find out i've made a mistake with the tank breather so the fuel tank had to come off again....

    So that's what i did today, after that bled the brakes another time as it wasn't perfect yet. Some cleaning of the 6 month dust eating in the garage and took it for a testdrive after.

    The turbo already made a few woosh and phie sounds which sounds so addictive! Sadly i came to the conclusions the cooling fan wasn't working properly, after some continuity tests i came to the conclusion it has a short somewhere, doh!

    Managed to get a day off work tomorrow so that'll be my last chance to fix it before heading over to FCS next weekend, fingers crossed!
     
  16. Try Flickr or Imgur for pictures bud.
     
  17. Will look into it in the future, just way to busy atm.....

    Fixed the car today and had a proper testdrive, seems all issues are sorted now so hopefully she will get me to and from FCS without problems :smile:
     
  18. Bit of a long due update but been kinda busy with the car last week! Also decided to make a flickr account to be able to post some pictures again after the photobucket debacle.....

    I had some annoying teething issues which showed up on the last moment. Had to remove the fuel tank again and also the fan didn't seem to be working properly. After having those sorted i took it for a 200km round trip to and from work. During this she performed faultless so i was confident it should do the 1000mile round trip to FCS aswell.

    A few pictures shot at the event:

    35638717210_c65ace17d2_c.jpg

    35986650896_46f628e99d_c.jpg

    Tbh i found FCS pretty dissapointing, been there a few times in the past but this time round the organisation was horrible! better be doing an other event next year!

    On a positive note though, i got invited to do a photoshoot for the PFC magazine, sadly it won't be a cover feature as their policy is not too cover foreign cars.....

    35986651346_720a92043b_c.jpg

    So what is the current, technical, setup of the car:
    Megane 250 engine which covered 80kkm, incl megane 250 throttle body (+ boost hose adaptor made by Ste_R26)
    Borg Warner EFR 6758 turbocharger on a T25 tubular manifold + all connections custom made by me
    R26 gearbox with R26.R clutch and SMF
    Fully handmade 3" turbo back with loudvalve
    Megane 250 intank 550kpa fpr and megane 225 pump (temporarily), std injectors for now.
    Airtec 95mm FMIC, modified because of bad fitting on Clio
    Forge hardpipekit also modified because of bad fitting on Clio
    Handmade 2,5" stainless inlet tube with Ramair filter
    Oil catchcan
    upfront new Megane 250 cup brakes and at the rear new Original brakes, fitted with DS2500 pads alround
    Motul RBF600 brake fluid

    In the ecu i've changed the fuel injection so it accounts for the rising rate fpr at the rail, knocked up base map for fuel injection itself to get me to and from FCS in a short notice.
    Ignition map loaded with a meg 250 one, slightly altered to make up for the missing vvt.
    Boost duty set to zero so i could drive it around without having too much risk of overboosting considering i haven't properly mapped it yet.

    Hopefully i'll be able to put it on the dyno next saturday to properly dial in the part throttle maps, maybe, just maybe i'd have enough time to do some boost mapping aswell :smiley:
     
    Last edited: Jul 19, 2017
    Muxa, Paul21, Korky and 1 other person like this.
  19. Well done Tutuur, so you have managed to get the 250 throttle body to work, great news, i have kept mine just for this occasion :laughing:
    Car is looking great, was hoping to get to FCS to meet you but things got in the way, will meet up one day :sunglasses:
     
  20. We will certainly have to mate :smile:

    Had a spare few hours yesterday so put the car on the dyno. I haven't had any time to play with ignition yet so this is running on my quickly bodged basemap. All i did was dial in fuel for .5, .7, .9 and 1.1 bar, also on a quickly set up open loop boost control just to get the values i wanted.

    It was nearly 30* in the dyno room so a pretty big correction made, however on a turbo car i don't think the difference would be that massive so let's say it 340bhp atm, not bad i'd say :smile:

    35710866620_ef70d3c2b5_c.jpg
     
    Juk3sy and ianplymouth like this.
  21. 36272891875_4141668cf4_c.jpg

    Got boost threshold a bit better in the meantime, still plenty of work to do though. Spent most of the time perfecting fuelling and finding out i maxxed the fuel pump/injector combo. With a few more degrees of ignition it could probably make some more power but nothing shocking probably.

    Next up is 875cc injectors and DW200 fuel pump. After perfecting ignition on .6 and 1 bar i can then proceed upping the boost :smiley:
     
  22. Impressive results. When you talk about the correction factor, is this to correct for the temperature?
     
  23. -Jamie-

    -Jamie- RSM Moderator

    Like where this is going, is that wheel figures?

    Torque isn't that high either but looks like it holds it well
     
  24. Calculated value of crank bhp. 252bhp on wheels, so pretty exact a 20% loss.
     
  25. Temperature, relative humidity and atmospheric pressure

    Torque should get a bit higher with some more finetuning of ignition, especially when i get the boost threshold down. In the end of the day it's only on 15psi though so not like it's going to be massively more vs now.

    You can't compare a maha to any other dyno available tbh. These do a coastdown run to calculate power that is absorbed by drivetrain, rolling friction, windage etc.

    Mind you this is a double roller setup which suffers from more rolling friction vs a large single roller. However if this test was to be done on a newer msr500 single roller dyno the wheel figures would've been higher but the crank figures should be similar. That's the beauty of it!
     
  26. Maxxed out the 225 fuel pump so fitted the DW200 pump, no more fuel pressure dropping from 6000rpm on so i could finetune fuelling and ignition.

    Next result is on 0,55bar (actuator pressure):

    36670156942_a6da734702_c.jpg

    And on 1,1bar peak, 1 bar constant:

    36444290110_031582c14a_c.jpg

    Still on open loop boost control so boost curve leaves a bit on the table to improve!

    Next step is fitting 875cc injectors and trying out the max of the BW medium actuator!
     
  27. -Jamie-

    -Jamie- RSM Moderator

    Oh nice!

    Promising!
     
  28. Finally got it running the way i want, it's running 1,6 bar from 4000rpm till redline now. Heatsoak was a bit of a problem on the dyno which caused it to pull a few degrees of timing on topend, which it doesn't do on the street. So probably has a few more ponies in real life but this will do for now. Dare i say i have the highest horsepower standard Megane 250 engine in the world right now?

    36878035816_9ea8d37b20_c.jpg
     
    evlution, Juk3sy, ianplymouth and 2 others like this.
  29. -Jamie-

    -Jamie- RSM Moderator

    That is fucking awesome! I really hope it can withstand it reliably
     
  30. wow nice one mate, can't wait till Nurburgring to see it go :sunglasses:
     
  31. Well, i don't really track it so can't comment in that respect but have been giving it death from the day i've built it.......

    Yeah, would be great to meet up mate!
     
  32. You do some sweet maps Tutuur, the power curves are so smooth.
     
  33. clutch even more so than the engine.
     
  34. -Jamie-

    -Jamie- RSM Moderator

    Torque isn't particularly high and the curve is nice and progressive so I wouldn't be too concerned about clutch tbh
     
  35. It's an R26R clutch which should hold this fine, even with prolonged use!
     
  36. My clutch (r26.r) with ap racing drive plate nothing fancy just a litle more havy duty organic lining, start to slip at about 1.8 bar on gtx3071 gen 2 turbo (probable around 530 Nm). Which in my eyes is preaty inpresive for stock preassure plate.

    Nice project and car you have. I thought that 6758 will spool a litlle faster but non the less nice results!
    Is this with cloose loop boost control?
     
  37. This is still on open loop control, low timing around peak torque and low load on the dyno to prevent heatsoak. In reality it's at 1,6bar at 4000rpm.

    Closed loop boost and more timing midrange will make it even better :smile:
     
  38. Just a little video showing how driveable this sort of power actually is, mind you this is on maccieD wheels and just H&R street coilovers:

     
  39. -Jamie-

    -Jamie- RSM Moderator

    Fancy swapping engines and turbos next weekend?
    [emoji23][emoji51]
     
  40. This is excellent work... does look driveable.

    I'm looking at turbo options for my 250, with an increase in rev range too... looking at going to 8k, but running lower boost (say 1-1.2 bar max)

    Would the setup you have keep pulling do you think or do you hit other limitations (ignoring the fact you'd need built engine etc)?
     

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