ostpol76

Hello

my name is Stefan, I come from Switzeland and this is my first thread. This winter I would like to overhaul my engine. I would like to present my project here and I am thankfull for any advice.

I own a Caterham Super Seven with an CVH 1.6L RS Turbo Motor:
https://drive.google.com/open?id=1Yj...tskzs5kanjhJ7a
https://drive.google.com/open?id=16L...qOeaB2UcWmgftD
https://drive.google.com/open?id=1nv...JJZGfPQL6RH31E
https://drive.google.com/open?id=13D...Cuzcl9VmSAezh8
https://drive.google.com/open?id=12C...bt3BGmGOJ8L-xu


Here some information. The car is built 91 and has now 86000 km. I drive with the Caterham approx. 12000 km per year on public roads and partake in about 3 mountain races. Therefore what I do should be durable.
The boost pressure is 0.7 bar and the Caterham should have about 150hp. The Turbo is a Custom Garret turbocharger with an A/R of 0.48 and a max boost pressure of 1.2bar.

My wish (it will be Christmas soon) would be around 220 stable hp. Because it is a very light car (550kg), an constant power delivery is important (as far as this is possible with a turbo). Rather more power in the lower rev range than much maximum power.

Now I just write how my procedure is, what I want to do and which components I want to use. But I'm sure you have better tips and suggestions.

1. Honing cylinders to oversize for forged piston.
(Which piston would you prefer? Mahle, Accralite, Wössner, Wiseco or something else)

2. Fine-balance the crankshaft together with the flywheel. Possibly lighter flywheel.
(Is a weight loss on the crankshaft worth it or is it at the expense of longevity? Is the light flywheel form Burton Power recommendable?)

3. H-con rod from Farndon EN24V.
(These are very expensive. I think a little overdone for 220 hp. Are there good alternatives?)

4. Cylinder head Stage 3 from Burtonpower.

5. ARP stud bolt.

6. Head gasket for 8.0:1 compression (or am I wrong with the compression?)

7. adjustable camshaft sprocket

8. What kind of camshaft can you recommend which is good for everyday use? (https://www.burtonpower.com/kent-cam...-kccvh31k.html)

9. Roller Rocker Arms (Harland Sharp).

I hope I'm not completely wrong here. It is my first project at the engine and I am aware that I have to pay dearly

A colleague of mine develops and sells control units and is an expert in this field, I will "convert" it completely to electronic fuel injection and ignition.

I'm not sure what to do with the turbo yet. But here I have to change something, because the turbo lag bothers me the most. Under 3000 rpm nothing works at all. Cause there is very little space in this area (in the millimeter range) it is very difficult to find something off the rack that fits.
That's probably why I have to continue using the "old" one. I have read that Turbo-Berlin, Turbos can revise. They use ball bearings and mill an aluminum compressor wheel to get it up to speed faster.
That'll be done later. First you want a solid "basis" engine.

I hope I didn't ask too many questions.

Best regards
Stefan

Caddyshack

Welcome Stefan, this should be a good project....keep the updates coming

big_wasa

My recommendation would be start with a better base engine.

2.0 zetec with a Cr of some where between 8:1 and 9:1 and a small turbo like the Gt25 or TD04 will give 220 at very low boost and can be very reliable. Example a copy of the focus Rs mk1 engine.

it still bolts on to a T9 but you will be pushing its limits.

even better would be an eco boost engine.

Caddyshack

Good point, you can get 300 bhp from a Duratec, non turbo on throttle bodies.

The only reason I did not mention it was that I have an inkling that it may be harder to do an engine swap where the OP lives?

ostpol76

Hi guys

thanks for the first answers. I am aware that there are better engines than the CVH. Caterham uses the Duratec engine in the new cars, even some with a compressor (310 hp). https://westermann-motorsport.com/pr...ec-he-cosworth

Nevertheless I want to stay with the CVH. The reasons for this are as follows:
- If I change the engine type it can be that I don't get the approval from the licensing office anymore (Is that the correct word in English? In German Motorfahrzeugkontrolle). And this is an show-stopper in switzerland
- There is very little space in the engine compartment. If I take another engine it can be that I have to rebuild many other things.
- I am a "beginner" and I think this engine is very simple and good for the 1 project.

ostpol76

Hello together

the engine and the gearbox are now removed. The engine is currently honed for the new 81mm pistons.

The T9 gearbox gets a new gear ratio (semi helical):
2.482
1.610
1.225
1:1
0.82

Many parts I ordered from Burton Power and have already arrived.
I will post some photos next week.

I have one more question.
What kind of oil pump would you recommend? The standard one:

https://www.burtonpower.com/oil-pump...-86-cv401.html

or the high pressure variant:

https://www.burtonpower.com/high-pre...6-cv401hp.html


Best regards
Stefan

Lee read

Welcome sounds like a fun build. The cr will be dependent on the pistons you choose id go wossner or wiesco and also on the thickness of head gasket. With the cam iv heard and seen bad with Kent cams as the lobs haven't lasted long. I'd personally go piper or Newman cam!

ostpol76

About the oil pump I received the following answer from Burton:

We only recommend the high pressure if you are going round lots of corners very quickly as it helps avoid oil surge - if its a road / fast road car then a standard oil pump is fine.

ostpol76

Now, I got my reworked cylinder block back:


Cylinder Block 1.6l CVH

• Honed cylinders to 81mm
• plane grinding the top
• Oil channels washed

ostpol76

Light Flywheel from Turbosport TSFF03:

ostpol76

Fine-balanced crankshaft together with the flywheel and Helix clutch cover and v-belt wheel:

ostpol76

The weight of the four forged connecting rods is between 566,3g and 567,8g.

ostpol76

The weight of the four Accralite forged pistons is between 346,8g and 347,2g.

ostpol76

New Pictures

ostpol76

Finally new pictures from the project:


Helix Clutch

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CVH Engine

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Cylinder Head Burton Power Stage 3

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Harland Sharp

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ARP Bolts

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Trigger Wheel with Sensor

ostpol76

"Self-made" inlet

ostpol76

"Self-made" inlet

ostpol76

MSD Ignition