We might still have some of the pipe left for the riser if you need it Graham. Ask Gary It's nice and thick but cos of the extra height we are still gonna fit Bailey style dampers to my turbos
We might still have some of the pipe left for the riser if you need it Graham. Ask Gary It's nice and thick but cos of the extra height we are still gonna fit Bailey style dampers to my turbos
Sierra cosworth turbo race car
QMN saloon car championship
RETRO Motorsport
cheers david
re dampers yes you will need them and i know i will, it looks like my riser might need to be 6+ inch long, the trick will be to get both enough movement and support
Graham pop in and grab that tube if you want
cheers gary,
but your excellent delivery service dropped it off, thanks andy/david/jim
done a bit off and on over that last coupke of days, made a start on one of the adapter plates obviously i still need to cut out the ports which wont be easy espeically as that bit of steel is 5/8 thick and the ports will need to be tapered to give a gentle transistion doen to the smaller Yb ports, also what the pic doesnt show is i've redrilled and tapped all the manifold stud holes in teh heads to take beefier m8 bolts as opposed to the std m6 ones
Dont supose you race at Castle Combe do you???
once a year trig
great to see a properly built racer.
built in a shed.by the driver for the driver.
pure stealth!!!
progress is real slow at the moment, probably something to do with having a women around and remembering that mr private parts are for more than just peeing
anyway,
i've just finished the Yb side of the adapter plate, rather than use studs to attach the adapter to the manifold which tend to come out i used countersunk allen screws, so they will never unscrew because the heads will be sandwiched between the two adapter plates, a big 19mm drill and my die grinder made short work of cutting out the ports even though the steel is 16mm thick, still some work to do as the ports in the adapter plates have to taper in two different directions as the yb ports are wider and shorter than the beemer ones, the plan is to to beld the two adapters together once they both fit what they are bolted two.
i've also been porting the manifold, my theory being that by opening up the runners from cylinders 1,3,4 and giving them a gentler upward turn and some more room the manifold wil flow better, obviously i have cyut into the materail where the turbo normally sits, but thats not going to matter as i need to make a riser to lift the turbo anyway
i've now cut the ports in the head adapter, as with the yb half, the shapes are a bit rough, but the adapter is nicely matched to the bit it bolts to, i now need to offer the two halfs together and blend them into one, so i will probably end up with really iffy shape ports!
been back in the garage again and have now blended the two adapter plates together
Last edited by Graham; 03-08-2007 at 02:05.
got a suprise today! i bolted the manifold adapters on, dropped the head on the block which is still in the car, and the turbo fitted lovely on the manifold which wasnt supposed to happen as i knew it didnt have room without a riser to lift it up off the manifold a fair way.
calling my self a i then fitted the cam carrier thinking that was why the turbo fitted somewhere i knew it didnt have room,
still the turbo fitted
then i remember the water rail which i'd unbolted from teh head and had forgotten all about, unlike most engines the water take off doesnt come off the end of the head but out 4 outlets spaced out allong the head like a BDA, the water rail was why i had to lift the turbo, so at that point i had a change of plan, rather than lift the turbo and add weight and complication to the turbo instalation i've decided to re engineer the water rail.
Last edited by Graham; 12-01-2007 at 01:18.
Looks like a nice fit there Graham. As you say better to modify the water rail than lift the heavy turbo higher.
Is there a lot else to do to the car?
Sierra cosworth turbo race car
QMN saloon car championship
RETRO Motorsport
yeah the turbo looks quite at home, its not obvious its bolted to a ford manifold,
apart from replumbing the water, i've got to unmodify the intercooler! its an rs500 one which i altered to suit the turbo location last year, so i've now got to put it back to sierra mode to suit the new turbo location, the exhaust needs to be remade, i think this time i might be able to get it to run past the steering colume which will save sereral feet of pipe, i'm also going to make the exhaust 0.5 inch bigger upto where it splits in two,
not least of all is to rebuild the engine, and get the engine runing on mr walkers latest ecu software with EGT correction.
no plans for any modifications to the car itself apart from the 9x17 front wheels and necasary arch mods to cover them
But is it gonna be done in time?
never yet missed the start of the season..................
although i've found having a girl friend is severely slowing some things down...................
other things are definatly speeding up though............
Of all the handicap rules I've seen, they have never included a woman. Strange as they certainly slow you down.
Nice work Graham, look forward to seeing you racing somewhere this year.
cheers dave,
i've been busy again and done a bit of porting on the exhaust manifold, and made up a 10mm spacer plate to lift the turbo a bit, and modifing bits 2wd sierra down pipe and some exhaust tube to make a new down pipe fitting for the turbo, as i had to weld up the old one several times last year, sorry no pics at the moment my computers died, so i've blagged a few mins on someone elses
using the old hot rodders trick of using a blow lamp to see which bits of the ports trip flow up, i've done more porting on the exhaust manifold and appear to of vastly reduced the amount of gasses from nos 3,4 cylinders trying to back flow into the other cylinders
it turned out i'd warped the cylinder head by a fairly massive 0.014" so it was refaced, i also had to have the top sde where the cam carrier bolts to refaced so as not to snap the cams in half
the vlave seats were all cut and the shortened to get the valves cleances back in the correct tappet range, here the head ready for reassembly after a trail check on valve clearances
as the head gasket gave out big time last year despite an o ringed block i looked for something uprated,
apparently you can get uprated "std" type gaskets, butthey cost a fortune and according to mosley motorsport who prepare and race beemers they are no better than teh std ones
aparently cometic do a multi shim steel gasket, but i got nowhere with them, the guys in the USA werent overly headfull and their Uk distributor didnt want to know
so i went to mike at ferriday engineering who do know through teh work he's done with my mates race car and he has made me a special aluminium/copper gasket, on an experimental basis, in that it might or might not work! but at the moment it seems the best option, its that or std ones, and its such a bitch to get the head off this engine no way do i want to risk using std gaskets again.
mikes special gasket is much thinner than a std gasket that along with machining so much off the head caused an unexpected problem, i when i worked out the compression ratio on the engine it had lept from 7.8:1 upto 9.2:1
sticking the pistons in the lathe i machined them down, as far as i dare, compression is now 8.5:1 a bit higher than i would of liked, but seeing as the engine only runs modest boost it will probably be ok pray: pray: pray:
rest of the engine is fine, merely requiring a hone and a new set of rings, the crank was perfect and even the old bearings went back in, clutch was practically unworn too,
the water rail has now been modified, the water now exits from the other end of the rail, which means i've got to plumb it right round the engine bay, but it does much simplify the turbo installation.
the intercooler has been modified too, its a sierra RS500 one which had the intake pipe cut off and moved to the side so it would work with last years turbo instalation, the trouble is this years one meant the pipe had to go back to where it started out , we've also added some straps to locate the intercooler and radiator better, last years quick fix of big fat cable ties ended up permant!!!
due to tyre supply issues i decide to run the same 17x9 wheels all the way round this year, so ordered a couple more wheels, compomotive are obviously doing good deals at the moment because when my 9 inch wheels turned up and we fitted them they turned out to be 9.5 wide with the extra width on the outside so they fit the rear a treat, but will be way too wide for the front, although they will come in handy if i end up going up a size ofn rear tyres from the current 235 to 265, although that isnt very likely to happen as you cant get cheap 265's
these wheels do look the dogs on the rear though
finally for now, one of last years rear wheels in its new front position, as you can see the wheel arch is going to need a few mods!!!
Last edited by Graham; 07-03-2007 at 16:09.
nice looking rims graham, lets hope your home brew beast of an engine holds together this year scares the pants of mr birley when all he see's is your blue beemer in his mirrors
yeah i used to love seeing this blue thing tear past everything but then it would usually end in retirement if it holds together this year it could be a force to be reckoned with
tommy 2000
i hope so alex, despite fitting a hotter exhaust cam ( actually a group N inlet!!) and the raised compression and bigger bore exhaust which will be 0.5 inch bigger at 3.5 inch, i doubt i will have as much power as i did last year as im sure the 4x4 cossy exhaust manifold i'm now going to use will hurt power, i could be as much as 50bhp down judging by the fact few cossys seem to exeede 400 bhp on that manifold, but as tom said i had reliability issues last year, far too many races i started with near 500bhp and finished either with none or only 150bhp, either way i'm looking to better my best ever result against a class field which was first race last year when blew all away my class B competition and all but two of the class A cars way when i got on the bottom step of the podium.
Last edited by Graham; 08-03-2007 at 10:37.
Good to see you out in the shed again Graham,
And good luck
Glad to see you have stopped playing with your new toy and got on with the old one .... wonder which one costs more ???
Good luck with the prepping Graham and see you in the paddock
cheers chaps in the words of arnie i'll be back.....
theres a cheeky young upstart with a flashy looking v6 escort that needs a few on track lessons
oh i do love it when the class A cars cant keep up
women was marginally cheaper in £££££
but even more expensive in heart ache
Err David here, my computers offline still so I've hyjacked Garys. Bring it on class 'B' boy, I'll see you later in the season
Oh and good luck with your car, let us know if you need any help
(especially as you have to come and help get mine running!)
David (not Gary)
got a bit of time on my car today, i lapped the valves in, then stood back and admired just how good the the m3 head is, lovely straight inlet ports with a nice steep approach and huge exhaust ports, which probably accounts for why my engine makes excellent power on very little boost, so heres a couple of head pics
most of you wont know, but i have a large double garage, unfortunatly i have so much in it in the way of tools and machinery, that it now only holds one car, sound familiar?
trouble is that one car it holds isnt mine but gregs alfa i'm rebuilding, the beemer lives outside , it wont once my builder finishes the big extension that i'm adding to the garage.
anyway it was so nice this afternoon i thought it would be rude not to go and work on it in the sun,
i pondered what to do with the front wings which wont cover the 17x9 wheels, i thought of fitting M3 wings, but they are expensive and still might not cover the wheels anyway, fibreglass replicas are a lot cheaper, but still might not fit, and dont save much weight anyway, and came up with allsorts of clever ideas on making box arches but then settled on the cheap easy option, a simple steel extension on the existing wings,
after trimming a bit off the arches i welded on some steel strips, and zinc primed them, the extensions are wider than they need be, because i might convert the front wheels to the same wider spec of the rears by changing the outer rim sections.
its not the prettest welding, the welder was having a bad day, not helped by it being a bit windy and rather blowing the gas away which i was getting low on anyway, but as its non structual will do fine
Last edited by Graham; 03-08-2007 at 02:03.
Graham... what about Gp2 Zakspeed arches ?????
Cheap and replacable
maybe, but not as cheap as free, and i've kind of got to the stage where anysort of price is too dear!!!!!!
on balence i prefer steel anyway, it doesnt just shatter it it gets hit and can usually be hammered back into some sort of usable shape
Last edited by Graham; 12-03-2007 at 11:10.
a little more progress,
i've installed the valves, rechecked the valve clearances, and fitted the head using the ferriday gasket, the fire rings are one big single piece of copper, inset into an aluminium gasket that comes precoated with a silicon type sealant.
finally for today i fitted the cam carrier which is no 2 min job, having several o rings between it and the head and is held down almost 40 bolts!
Thats one pretty engine your building there!
When do you need this finished by for the series you are racing in?
need it finisjhed 1st week in april, the car races in the dunlop track and race championship (dtrc)
which does brands, snet, silverstone, castle coombe and lydden.
where your also find some other TS members in the shape of alex ribbins, andy pipe and hopefully david white
Bookmarks