V6 Ka - Remote turbo project

[Twellsie]

a very interesting build, will you be going with an aftermarket ecu/injectors, or will the standard one cope with the incresed fuel requirement

If you were logged in, you wouldn't be seeing this ad! Register your free account today, or log in if you already have an account.

[Shonky]

Originally Posted by Jonzy

updates?

Aye, the engine is back in and running with a big missfire with the MAF on or off and won't idle with the MAF on at all, compression is 11bar on all cylinders and it's not using water, I've put a new dispack on which didn't really make much difference so it's probably the timing.

Next week the decomp plate is coming out and it'll be put back to a standard 3.0 to ensure the base engine is fine then I'll take it from there

[Shonky]

Originally Posted by Twellsie

a very interesting build, will you be going with an aftermarket ecu/injectors, or will the standard one cope with the incresed fuel requirement

I've got some aftermarket to go on but need to put some cash together for mapping and an electric water pump etc so it won't happen this side of christmas

The standard injectors will be fine on the standard ECU, after that I have no idea!

[Chip]

What management are you going to be using?

I can probably map it for you FOC.

Ive also got an audi waterpump that works well enough to cool my GT35R that you are welcome to borrow for a few months?

[saph4be]

interesting project

[Shonky]

Originally Posted by Chip

What management are you going to be using?

I can probably map it for you FOC.

Ive also got an audi waterpump that works well enough to cool my GT35R that you are welcome to borrow for a few months?

I've got Autronic SMC with a virgin loom so needs wiring, I have 3 ignition amplifiers ready too

I need the EWP to replace the engine's water pump but to keep costs down I could get just the pump and leave the thermostat in instead of getting the EWP kit and get the controller at a later date, I was going to put a 2.6 clutch in as they take more power which I can also do when the engine comes out next week

I'll get this engine to a point I know it's running/timed properly and the turbo installed then I'll give you a shout, I know you help out a load of people but I don't expect anything FOC, I'll at least get you a mcdonalds, some beer and a go on my sister lol

[Chip]

Cover my bridge and my fuel and will call it quits.

Although a go on your younger sister would be a bonus, LOL

SMC = Nice one, can definately map that for you!

[Shonky]

Originally Posted by Chip

Cover my bridge and my fuel and will call it quits.

Although a go on your younger sister would be a bonus, LOL

SMC = Nice one, can definately map that for you!

Awesome, I assume you're still around Western then?

I'll PM you in a couple of weeks when I'm ready to wire in the management, I'll need to know which sensors you want!

[Chip]

I'm in taunton mate, but its no drama to pop up one weekend.

Sensor wise you will need:


Autronic intake temp sensor (from what I recall you have to use the correct one on SMC you can recalibrate like on my SM4)

Any TPS you happen to have, the standard one is fine

Ideally a 3 tooth trigger wheel with one tooth being located at 60 degrees before TDC on number 1, but depending on your chip version you may be able to run the standard 60-2, what chip are you on?

A sync sensor input (I would imagine the standard one is fine but you may need a reluctor interface)

Internal MAP sensor will be fine, so you just need a pipe to it from the inlet

Coolant temp the standard one should be fine


That should be all we need to get it up and mapped fairly well, obviously up to you if you want to start adding in wheel sensors etc later on.

[Shonky]

It says v1.92 Hi Speed on the ECU, do I need to get a trigger wheel?

I assume the black box towards the left is the reluctor interface and the wire in the middle next to the water temp sender is the is the air temp?

[Chip]

Sorted!

1.92 does flat shift and antilag

Yes thats the reluctor, water temp, air temp.

You can run a 60-2 disk, just set mode flag 14 to be 20 to represent 60 teeth on a 3 cylinder engine, the problem you will have is that I believe that your missing teeth are about 115 degrees or so and it expects them at 60, but I think if we play around with mode 15 we can probably get it to adjust that correctly.

[Jonzy]

updates, updates, updates

[M4RTY]

Thats one crazy Ka! I cant wait to see the finished product

[Shonky]

Engine's back in and misfiring a bit

clicky

Im going to try plugging a spare water temp sensor into the loom and leave it in the engine bay so it'll be reading the air temperature, thinking it's cold and advancing the timing to try getting it to run better

Chip, I'm pretty sure there's a 36-1 trigger wheel on there as standard, would SMC work with this?

[Chip]

I think it depends on the chip revision again mate, check in the manual.

There is one on the MRM site to download IIRC

[lanfire]

haha gota love that antilag

[Little_Hoss]

any updates?

[CarbonRick]

Mad as fookin toast! Need updates!

[ghigo]

hows it going fella? we need updates lol

[dois]

boa noite, curioso pra ver como fica. parabens pela ousadia e arrojo

[Rides]

WTF! how the hell did that engine even fit in that little KA.. insane or what and turbo also fuck me...1 totally insane KA..you're going to have some bloody good fun with that little pocket rocket pmfsl... just the look on some peoples face when you leave them standing still lmfao.. keep it up i love it.. something totally crazy..

[Spammage]

Jesus titty fucking christ read the feature thought this was mental but it's getting so mental your gonna need locking up soon!! Absolutely awesome project mate defying the laws of physics by squeezing 3ltrs of engine in a KA that turbo cradle's pretty sweet as well. Good luck with it mate will be following this one!

[Chip]

you still alive shonky?

[Jackass1983]

hello what EWP is your choice?
Im thinking about the davies craig 110L pump!
But i dont know anybody fitted it?, can you give me some informations about it?

Cheers Mark ( www.ST2000.de )

[craigybaby]

awesome matey your insane

[DNA Tuner]

i just love it when people think outside the box, i remember seeing in a mag a current M5 with twin rear mounted turbo's and i thort that was bonkers, this takes bonkers to another level and drops it off at insane, really wana see this ka work

[hillzy2k]

[quote=Shonky;4039121]With the turbo being in the boot what's the difference between boosting it with a supercharger or a turbocharger? both produce no heat (in this case). I'm also already ducting air from the bonnet over the rear manifold to help as I know it's a weakness

thats what i was thinking. doesnt make any odds whats creating the boost be it turbo or supercharger. if its gonna get hot and go bang i think it would have already done it in that space!!!! now with the turbo miles away from the engine theres no more heat getting in there than a supercharger would cause. good luck with the build fella, looks interesting!!!

[chaffe]

Ace project mate, as said previously good to see someone think outside the box, or in the boot more to the point! good luck with the final stages of the build

[Karlos G]

I have only just seen this!! What a fucking awsome project!!! Love it!!
Makes me want to build something crazy myself!!

[Ken_ZS]

ok so i havent been on this for ages due partly to having driven american fords for the past 2 years and now am back in a fiesta but not modifying it. anyways i start gettin ideas of fitting my 2 litre zetec into a Ka so look them up, find this one and remember it from the original build thread of the engine going in, anyways im thinking of doin a rear mount turbo on the zetec and here one is, top work mate, i read through real quickly and noticed some people puttin ur idea down, they are wrong!

having read about the vettes in the US running rear turbos and that 205 that appeared in PPC (which i need to fish out and read again now im interested) rear turbos make sense, they run cooler due to being away from the engine, im gonna run a independent oil system for it meaning it has clean oil with no shite from the engine plus means i can run a different grade oil for the engine and turbo which surely must be great as i bet turbos and engines benifit from different oils, also i was thinkin of getting a american incar charge cooler, the yanks love them in their drag cars and they make sense for this sort of project, look them up if its something u think could be useful to your project

il keep a eye on this thread and hopefully once i sell my fiestas il be buying a Ka and fitting the 2 litre and start saving for turbo and engine internals

[Shonky]

I haven't done much in the last few months, just fannied up bits and pieces generally and....

I've changed the Vectra plenum/inlet for an Omega one which is supposed to be better (but at least it's smaller), I've added a 3/8" (9.5mm) fuel line which is massively over spec but hey ho, the stand alone management wiring is pretty much done, got to make a bracket for the ignition drivers, boost pipe in the bay is done bar a final leak test, I've now have a boost pressure feed for the ECU (map sensor is built into the ECU)




This lot will be mounted on a plate to the rear bench, it's two generic external fuel pumps fed from a swirl pot into their own filter then into one 3/8" PTFE lined stainless hose to the engine


Got to mount the swirl pot too...


Turbo setup as it has been for a while except the oil scavenge pump I had was far too powerful so I've fitted a facet fuel pump




I bought a Wideband lambda kit that is plumbed into my ECU so we can use the management's Autotune feature to get the car going, at least this way I'll know there are no major issues then it can be mapped


This is how she looks at the moment


I'm currently waiting to get some fittings braised onto the exhaust for an EGT probe and I've got to make an adapter for the fuel rail to plumb in a fuel pressure gauge, being able to see EGTs, Lambda, fuel and boost pressure should give us a good idea of what's happening during mapping

The ECU is reading the RPM while cranking so it's a step closer to being ready!


I sprayed the bonnet green a while back too but I don't know if I like it!

[jamie rigby]

insane, remember this featured in PF about 18months ago, changed some what since then

[wattie]

i love the thinking involved in this car, awsome keep it up cant wait to see it finished!

[COCHYN]

This is awsome and ridiculous at the same time! How long till its running and we can see some times?

[1980blakey]

Did this get finished?

[24vcossiemat]

Originally Posted by Jonzy

there is something missing up stairs with you lol

lol... yeah it will be a bit loooony.. plenty of torque.

[Hobomassiv]

ITs in this months FF in a mini feature of FITP, im int he picture hiding.

He has recently upgraded the turbo since and is expecting over 400bhp!

[Glenn.]

I seen that little feature.Its a mad project lol.

[Shonky]

It's hard to believe the one on the left is a t34! The new one is a 35R type turbo, it's massive compared to the old one!




I'm waiting for some rocker covers to turn up so I can make some breather modifications, drove it a few miles last week, without any mapping over what had been done on the t34 it wanted to hook up and go so I can't wait to drive it properly

[Maxwell]

holy good fuck!!! what a project!!!!!!!!