Ford Escort RS Turbo This forum is for discussion of all things pertaining to the Ford Escort Rs Turbo Series 1 and 2.

Caterham RS Turbo overhaul

Old 26-11-2018, 09:50 AM
  #1  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Smile Caterham RS Turbo overhaul

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
ostpol76 is offline  
Old 26-11-2018, 10:40 AM
  #2  
Caddyshack
PassionFord Post Whore!!
 
Join Date: Mar 2013
Location: Guildford
Posts: 9,769
Received 827 Likes on 772 Posts
Default

Welcome Stefan, this should be a good project....keep the updates coming
Caddyshack is offline  
Old 26-11-2018, 12:55 PM
  #3  
big_wasa
Too many posts.. I need a life!!
 
Join Date: Jan 2012
Location: Linc's
Posts: 816
Received 84 Likes on 82 Posts
Default

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.
big_wasa is offline  
Old 26-11-2018, 01:29 PM
  #4  
Caddyshack
PassionFord Post Whore!!
 
Join Date: Mar 2013
Location: Guildford
Posts: 9,769
Received 827 Likes on 772 Posts
Default

Originally Posted by big_wasa View Post
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.
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?
Caddyshack is offline  
Old 26-11-2018, 04:15 PM
  #5  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Default

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.
So once again I am aware that it is not the best way with the CVH, but I would like to make the best of it with the CVH.
Or do you think it's absolutely worng and money thrown out to get on with this engine?
ostpol76 is offline  
Old 21-02-2019, 08:49 AM
  #6  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Question

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
ostpol76 is offline  
Old 21-02-2019, 11:56 AM
  #7  
Lee read
Rs turbo
 
Lee read's Avatar
 
Join Date: Dec 2018
Location: Kidderminster
Posts: 152
Received 16 Likes on 15 Posts
Default

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!
Lee read is offline  
Old 28-02-2019, 01:39 PM
  #8  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Arrow

Originally Posted by ostpol76 View Post
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
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 is offline  
Old 05-04-2019, 03:15 PM
  #9  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Talking

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 is offline  
Old 05-04-2019, 03:20 PM
  #10  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Talking

Light Flywheel from Turbosport TSFF03:


ostpol76 is offline  
Old 05-04-2019, 03:29 PM
  #11  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Talking

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



ostpol76 is offline  
Old 07-04-2019, 03:27 PM
  #12  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Default



The weight of the four forged connecting rods is between 566,3g and 567,8g.
ostpol76 is offline  
Old 07-04-2019, 03:31 PM
  #13  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Default



The weight of the four Accralite forged pistons is between 346,8g and 347,2g.
ostpol76 is offline  
Old 13-04-2019, 08:46 PM
  #14  
ostpol76
Virgin
Thread Starter
 
Join Date: Nov 2018
Location: St. Gallen
Posts: 13
Likes: 0
Received 0 Likes on 0 Posts
Default

New Pictures






ostpol76 is offline  
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
AustenW
Pictures, video & Photoshop Forum
7
28-09-2006 02:48 PM
Tim_H
General Car Related Discussion.
47
19-01-2005 07:23 PM
TIFF
General Car Related Discussion.
7
19-10-2004 04:38 PM
SteveT
General Car Related Discussion.
6
07-10-2004 03:57 PM


Thread Tools
Search this Thread
Quick Reply: Caterham RS Turbo overhaul


Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.