Badman38

iTrader: (2)

Finally had our first mapping session Paul @ rs tuning strapped her down then tried an initial run the first pull on the rollers started out promising until the kevlar clutch started to slip at 3200rpm he had another attempt but by now the clutch was hot and just would not hold so he had to abort the mapping session, power wise the screen showed 197bhp 275fbt on a dyno dynamic rollers which is a great start.
I was going to order a twin plate clutch but helix they advised against this on a diesel due to the Vibrating nature of a compression engine running unsprung plates there is nothing to dampen the shock which could cause damage to my gearbox,shafts etc so I have ordered a single plate 215mm sprung race clutch rated to 446fbt so easily handle 500+fbt not a straight fit flywheel has to be machined and there also an adapter for my slave cylinder........

Farndon engineering are in the process of building me a set of H-beam steel rods all this low down torque is going to bend standard rods

RoscoST

iTrader: (1)

Lot of work going into this mate - be intresting to see the finished results !

jghs83

Flipping awsome mate. Would live to see it in the flesh.

Whens the next your going diwn to RST? Might have to pop down fir a sneak peek

clarke5700

what a cool project will be keeping an eye on this top work

B19 JUB

total fair play to you fella for going the derv tuning route

PumaJay

you sir are an idiot... the best kind of idiot that is!!

love it, will be keeping an eye on this and looking forward to seeing how it turns out.

good luck with the rest of the build.

Rsturbo james

wow this is gonna be metal..............

Badman38

iTrader: (2)

Sometime in june I will let you know when its booked

rallycross

Good luck to you but seems like a hell of a lot of money sunk into something where you won't see any of that money back and it will be a pig to drive with a narrow power band and no traction.

Badman38

iTrader: (2)

215mm clutch cost an arm and a leg, the cover was crazy expensive but its a must in the search for power rated to 446fbt flywheel needs machining to fit

helix six paddle plate




modified heavy duty cover to work with the standard slave cylinder

Badman38

iTrader: (2)

station motorsport designed modified bottom sway mount, standard item broken

Badman38

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machined flywheel plated with en24t steel

Badman38

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robson engineering custom dv6 steel rods

Badman38

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most projects there is no return which i accept, made just under 10k when breaking my rs turbo but thats after pouring 40k over the years i dont think any builds a car thinking what could i make once finished or bored...
the power band yes narrow but i've bought the gearing down to suit, traction wise i cant say but the fabricator stated in its unmapped state the torque makes the car frightening to drive but we will have to see when the car complete

tekno

awsome build you've got here, i really hope you can reach your power targets.

any chance you could shed some light on the vnt enabling? hardware wise, did you just connected the pug 110hp hdi vnt solenoid to the designated pins in the wiring loom connector or did you have to open up the ecu and connect the pins to the pcb?

Badman38

iTrader: (2)

Did none of the above the boost control on the dv6 90hp wastegated engine is the same as the 110hp vnt engine plus the mk6 fiesta 1.6tdci comes with te excellent edc16 ecu used on loads of diesels comes with vnt firmware, it was only a case of software flash 110hp map then enable the vnt control.
Failed to work instantaneously but eventually the ecu self learnt now it works well,

Glenn_

iTrader: (1)

As it been back on the rollers yet.

DanW@FastFord

iTrader: (1)

Loving the car, and the approach. If you want a feature when it's 'done', drop me an email and I'll sort it! dan.white@futurenet.co.uk

2wdsaph ben

Very different mate, good luck in reaching 300

botters

iTrader: (2)

well 10 out of 10 for being different to the norm! keep it up

Zetecfiesta

Awsome project, fancy getting a mk6 zetec s tdci.

Badman38

iTrader: (2)

will keep you in mind dan still undecided weather to go rebore, big valve head etc or keep 1.6 and compound charge with a rotrex sc, no room under the bonnet for two turbos and the sc is a dam site easier to do

Badman38

iTrader: (2)

back on the rollers wednesday 10th

Glenn_

iTrader: (1)

Cool keep us updated.

Badman38

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After taking an age to setup the vnt which was causing boost fluctuations final power figure ended up ss 230hp & 310fbt, but car is off the road due to fuel return pipe bursting
Due to the high pressure fuel pump fuel can get quite hot most diesels 110hp upwards come with a fuel cooler standard but not a fiesta diesel because they are only 90hp 150fbt standard .... I have to invest in a fuel cooler of sorts.

JamesG89

This looks awesome!

tutuur

Any updates yet mate?

Badman38

iTrader: (2)

Haven’t posted on here for a few months car been off the road due to a oem part failing, only had the car back two days I had broke down on the motorway turns out the bracket holding the fuel pump fractured slackening the timing belt which in turn took out all my rocker arms, I feared I might of bent my valves but I don’t think this is the case all the valves spring and valve stem retainers are in place I put the cam carrier back together everything seems to be working as it should, I am going to have a few teething problems on the way which I expected but I did not foresee something like a fuel pump bracket to fail, station Motorsport made me a custom bracket I am just in the process of putting the car back together, I had lost a bit of interest the car ought to be back on the road a long time ago..

Badman38

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destroyed all 16 rocker arms

Badman38

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good old egr doing its best to kill an engine

Badman38

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The engine made 230hp and 310fbt the torque is relatively low because for a 1.6 gtb1756 vk turbo is way too big just doesn’t come on boost early enough, I will have to bring the engine build forward I had always planned to increase the engine capacity to a 1.85cc, fitting a turbo from a 2.7L onto a 1.6 is asking too much of the turbo.

tutuur

Looks nasty mate! However luckily enough the valves and pistons aren't damaged!

Always the same thing, you think you build everything bulletproof and than slmething you haven't thought about breaking breaks.

Why didn't go for a smaller gtb turbocharger? Afaik there are 49 and 52 gtb's around too.

Or is your only goal 300bhp+?

CrOwSoN15

Love this, proper "because fuck you" build!

Shame about the failure, hell of a teething problem

Badman38

iTrader: (2)

I didn't expect the third generation vnt to be so laggy, the turbo is the smallest in the gtb range which come standard on the audi 2.7tdi which is the same externally as its bigger brothers gtb2056 and gtb2260 just a matter of swapping turbos this turbo will only do 240hp at full boost 32psi I am running 27psi ... the engine standard as was the oem aluminium bracket for the fuel pump which failed.. made a custom bracket out of steel.
Eventually I have to go for a gtb2260 hopefully increasing the engine bore will rectify the spool if not may have to look at going compound but I should think compounding wont be nessasary plus there is a serious lack of room, there is space for a rotrex sc but never heard of compounding with a turbo & supercharger

Sean

tutuur

Well looking at the graph it doesn't look that bad. You get a bit distracted by the difference but tbh 200lb/ft around 2200rpm isn't that bad!

I'm more curious what it does below that, does it drive like a sluggish old diesel car under 2000rpm?

Badman38

iTrader: (2)

after repalcing the rockers i attempted to fire her up engine didnt sound right i thought i bent the valves in the first place was just praying for a bit of luck putting the engine back together so off with the head, i dont like replacing with standard parts if i can help it on goes a ported head.

Badman38

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Badman38

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attempt number two again total failure but this time the engine was turning over very slow, seeing as the car been standing for so long and taking an age to start i thought maybe the battery has died and maybe the starter motor past its sell by date..............but still nothing by this time i was getting quite annoyed and frustrated could not understand why the
bloody thing turned over so slow ended up sending the car back to station motorsport.
who conducted a compression test, number four cylinder pressure was low the top half of the engine is tight and there is a tight spot on the bottomend possibly bent rod which i doubted at the time due to the strong design of the standard rod, turns out the cams are both dead ( an area i failed to check):smt101 slightly bent with with deep grooves,the bottomend tightness wasnt enough to slow the starter motor down but still a concern, jonathan removed the head and checked the piston height no problem there but one of the pistons had no side to side movement caused by major carbon build up, sprayed some loosening agent which freed up the piston ,but i thought if we gone this far number four pressure was low number two piston problematic better to replace the rings. only saving grace at lease the engine doesnt have to come out to remove the pistons.

scored bearings

jghs83

Bad times buddy.

Sadly trial & error stuff can always be costly & time consuming.

The outcome though will be great.

Fez boy

U no u changed the injectors mate and got a remap and exhaust system will that be ok to change without anything else ??