Well it’s complete, receiving new engine tomorrow morning and it can live and breathe. It has taken a little longer than expected due to delay’s in the fabricating of the new flywheels.
I am super happy with the new emerald K3, have added a boost control valve and Haltech wide band controller. The biggest difficulty was trying to source a trigger wheel for the wasted spark system, there is precious little room on the crank pulley side so a camshaft mounted setup had to be used.
Going to try and do a bit of a photo log of the assembly process, there are so many little details that just get lost when all the panels are in place.
The modification process was made far simpler by having 1 customer who is in the electronics business and another who has an amazing engineering shop. This meant that the only limitation to my mounts was my imagination and cad skills. The left and right side mounts are cnc milled. And on the other side I had a delivery of more good quality wire and a selction of mil spec heatshrink and connectors than I knew what to do with.
Every single fluid transfer hose and connector have been replaced with goodridge items and their flame proof heat shield, surprised I can even sit after that invoice
flowed and cams re ground to better suit turbo
Solid lifters
Uprated valve springs
Exhaust -
Custom made manifold
76mm outlet pipe with small resonator
TurboNetics Wastegate
Inlet-
Turbonetics T3/T4 combo (so many specs and permeatations I will have to consult my reference work for A/R sizing etc)
Turbonetics Blow off valve
Charge cooling system with large front radiator
Management-
Emerald K3
wasted spark
haltech wide band lambda controller
Solenoid operated boost control
Haltech 3 Bar map sensor just in case
Gearbox
5 spd Mazda unit
Quaife ATB
Custom Shafts
300 HP is the number asked for, and is virtually guaranteed. For that HP there is probably no need to go to the level we have with comp and head but it is nice to have a motor capable of running on pump gas and revving to 8400rpm if you need to.
It’s going to be a little a little monster on 1 BAR of boost and maybe a huge monster on 1.2
Excluding the pipework, it holds 7l. The pipework adds up in the lengths so more than likely another litre in the pipes.
Running the 2 cooling fans at 1/2 speed permanenlty and swicthing to full if needed for engine or charge air temp. Pretty sure I could get away without the half speed option but best to have to much cool air and avaoid major temp fluctuation.
the weight of the charge cooler was chosen over an engine mounted air to air, because of the ratio of cool air in the nose at virtually any speed over the higher heat soak temps in the engine bay at low speed, around town.
The large cap is for those moments when you want a little bit of ice and alot of boost.
The pump runs permanently again to avoid major fluctuations.
Looks very neat.
But are you not going to roast your back with no firewall insulation, or is that an alu cover over an insulation sandwich?
And where is th air filter - sticking out of the body vent?
It is always interesting reading you posts
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