Chips engine build
03-11-2005, 08:41 PM
#1
Chips engine build
Copy of a post i made in repsonse to a question about my engine spec in general section, thought it might interest a few people here too so have copied and pasted it:
Steel motorsport crank
Steel rods
Forged low comp pistons (8.2:1)
Hotter (than calibra turbo std) cams, on vernier pulleys
Double valve springs
Solid valve caps
Garrett GT35R
Autronic SM2 management
Tubular manifold
Block has been destressed by hand by me with files and die grinder
Line bored, then the bottom skimmed referenced to the bearing tunnel then the block top skimmed relative to that, so that when it was bored i could guarentee it was exactly perpendicular to the crank
Head has:
21-4n steel waisted stem inlets (+1mm oversive)
21-4n steel exhausts (+1mm oversive)
ported to my specs with nitrous use in mind
Wizards of nos nitrous kit with maximiser controller
I'll be making 500bhp ish, and attempting to put it to the road by a 6 speed gearbox in FWD format.
Silly keeping it FWD really, as would be a 9 (or certainly 10) second car too probably if i went mid engined, but to me its kind of not really a mini any more then, and i wanted to built the ultimate (for me, obviously everyone likes different things) mini without it stopping it driving like a normal mini.
Still very much a work in progress, but here's a few shots of it so far:
head and valves:
approx how it will look assembled (i just put it together to check clearance between the manifold turbo flange and the block, its not bolted up yet here as i'm still working on the head at the moment)
The oil squirters ive installed in the block, as unlike a cossie it doesnt have a spray bar as standard so ive had to invent my own method for doing that (with some advice from Stu@MSD
and ACDodd from ML motorsport)
Random picture of the block:
Some of the destressing work:
Before:
After:
Piston and rod:
Steel motorsport crank
Steel rods
Forged low comp pistons (8.2:1)
Hotter (than calibra turbo std) cams, on vernier pulleys
Double valve springs
Solid valve caps
Garrett GT35R
Autronic SM2 management
Tubular manifold
Block has been destressed by hand by me with files and die grinder
Line bored, then the bottom skimmed referenced to the bearing tunnel then the block top skimmed relative to that, so that when it was bored i could guarentee it was exactly perpendicular to the crank
Head has:
21-4n steel waisted stem inlets (+1mm oversive)
21-4n steel exhausts (+1mm oversive)
ported to my specs with nitrous use in mind
Wizards of nos nitrous kit with maximiser controller
I'll be making 500bhp ish, and attempting to put it to the road by a 6 speed gearbox in FWD format.
Silly keeping it FWD really, as would be a 9 (or certainly 10) second car too probably if i went mid engined, but to me its kind of not really a mini any more then, and i wanted to built the ultimate (for me, obviously everyone likes different things) mini without it stopping it driving like a normal mini.
Still very much a work in progress, but here's a few shots of it so far:
head and valves:
approx how it will look assembled (i just put it together to check clearance between the manifold turbo flange and the block, its not bolted up yet here as i'm still working on the head at the moment)
The oil squirters ive installed in the block, as unlike a cossie it doesnt have a spray bar as standard so ive had to invent my own method for doing that (with some advice from Stu@MSD
and ACDodd from ML motorsport)Random picture of the block:
Some of the destressing work:
Before:
After:
Piston and rod:
03-11-2005, 08:57 PM
#3
Yes mate it is going in a mini.
A stripped one, as light as i can get it while still be road and track useable.
Hopefully be around 600kgs dry, 800 with me in it and full tank of fuel etc, and should be making around 400bhp@wheels.
Giving it a power to weight ratio fully laden of 500bhp per tonne @ wheels.
Thats approx the same power to weight at the wheels as a normal road weight escos would be with 850-900bhp or so, just to put into perspective what it should be like from 60-120 etc where grip and aerodynamics arent so important as they are during a launch or top speed run.
A stripped one, as light as i can get it while still be road and track useable.
Hopefully be around 600kgs dry, 800 with me in it and full tank of fuel etc, and should be making around 400bhp@wheels.
Giving it a power to weight ratio fully laden of 500bhp per tonne @ wheels.
Thats approx the same power to weight at the wheels as a normal road weight escos would be with 850-900bhp or so, just to put into perspective what it should be like from 60-120 etc where grip and aerodynamics arent so important as they are during a launch or top speed run.
03-11-2005, 09:32 PM
#7
Originally Posted by PJ ENGINEERING (PROX)
Chip how does grinding the block the way you have done destress it and why do you feel the need to do this ?
The more important bits are the bits you dont really notice in the pics, like around where the bearing tunnel was line bored radiusing off the machined edges, some of the other stuff like taking the casting lines out the block isnt really needed, but its nice to have a smoother surface, easier to keep clean (and more pleasing to the eye
)
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03-11-2005, 09:38 PM
#8
Too many posts.. I need a life!!
Originally Posted by chip-3door
some of the other stuff like taking the casting lines out the block isnt really needed, but its nice to have a smoother surface, easier to keep clean (and more pleasing to the eye )
) all for show, I have never seen a engine stress crack in the lower part on the block. Nice job though, i fitted a T3 to a let on DTA in 1997 it was one of allans 1st Euc.
Good luck with it all
03-11-2005, 09:41 PM
#9
Originally Posted by PJ ENGINEERING (PROX)
Originally Posted by chip-3door
some of the other stuff like taking the casting lines out the block isnt really needed, but its nice to have a smoother surface, easier to keep clean (and more pleasing to the eye )
) all for show, I have never seen a engine stress crack in the lower part on the block. Nice job though, i fitted a T3 to a let on DTA in 1997 it was one of allans 1st Euc.
Good luck with it all
Im a tart at heart
Cant beat a nice bit of engine porn
As i said though, around the bearings it actually IS important, they do fail at that point sometimes on the bigger power motors.
If i was putting it in a heavier car where it would see more strain i would have fitted a girdle to it as well to be honest, but it will never see full throttle for long enough in a mini for it to be an issue with fatiguing it hopefully!
03-11-2005, 10:00 PM
#13
Too many posts.. I need a life!!
Yes i have a lot to do with the car back in the day 1998 ? it is a kas space frame with a 2ltr 297 bhp XE motor in it.
Bill solis took it ou on it 1st run a mallory park for Car and Car convershions. It was built to run the fastes mini in the world race wich it won 1 but the next time aound BMW brought a new mini with a M3 Engine in it and sort of won
Very quick and light car around 500 kg if i rember.
Got some photos of my old engine, give me your Email Address and i will send them to you.
Yes it was back in the day when lost of pepole where claming 300 brake from a KKK Let with a Std ECU and std fuel pump
Bill solis took it ou on it 1st run a mallory park for Car and Car convershions. It was built to run the fastes mini in the world race wich it won 1 but the next time aound BMW brought a new mini with a M3 Engine in it and sort of won
Very quick and light car around 500 kg if i rember.
Got some photos of my old engine, give me your Email Address and i will send them to you.
Yes it was back in the day when lost of pepole where claming 300 brake from a KKK Let with a Std ECU and std fuel pump
03-11-2005, 10:10 PM
#14
Originally Posted by PJ ENGINEERING (PROX)
Yes i have a lot to do with the car back in the day 1998 ? it is a kas space frame with a 2ltr 297 bhp XE motor in it.
Bill solis took it ou on it 1st run a mallory park for Car and Car convershions. It was built to run the fastes mini in the world race wich it won 1 but the next time aound BMW brought a new mini with a M3 Engine in it and sort of won
Very quick and light car around 500 kg if i rember.
Got some photos of my old engine, give me your Email Address and i will send them to you.
Yes it was back in the day when lost of pepole where claming 300 brake from a KKK Let with a Std ECU and std fuel pump
Bill solis took it ou on it 1st run a mallory park for Car and Car convershions. It was built to run the fastes mini in the world race wich it won 1 but the next time aound BMW brought a new mini with a M3 Engine in it and sort of won
Very quick and light car around 500 kg if i rember.
Got some photos of my old engine, give me your Email Address and i will send them to you.
Yes it was back in the day when lost of pepole where claming 300 brake from a KKK Let with a Std ECU and std fuel pump
Wow, very interesting stuff indeed mate, 500kgs is incredible too, especially with a fairly heavy engine in it, i take it that was on an F20 but a quaiffe gearset or similar then as a stnadard box wouldnt last 5 mins at that level of abuse IME!
chip@miniracing.co.uk
03-11-2005, 10:17 PM
#15
Too many posts.. I need a life!!
Strate cut F20 with a Harry Hocklay Groupe A gear kit and ZF plated diff.
Space frame carbon fibre body, KAd alloy rear arms Very Very light
Always remembr it had Yam RD discs on the rear and 2 pot calipers that is how light it was. It also ran on a DTA
Space frame carbon fibre body, KAd alloy rear arms Very Very light
Always remembr it had Yam RD discs on the rear and 2 pot calipers that is how light it was. It also ran on a DTA
03-11-2005, 10:23 PM
#16
Yeah ive noticed quite a few of the REALLY light mini lads using motorcycle rear disks on their cars.
Ill probaby just go for a set of alloy radius arms and KAD rear disks for mine, i want it light, but not obsessively so, its mainly a road car at the end of the day and its a full steel body not a space frame too, so subtley different class of vehicle, its never going to be a competition weight wise against something like that!
Ill probaby just go for a set of alloy radius arms and KAD rear disks for mine, i want it light, but not obsessively so, its mainly a road car at the end of the day and its a full steel body not a space frame too, so subtley different class of vehicle, its never going to be a competition weight wise against something like that!
19-11-2005, 08:42 AM
#25
Originally Posted by Mr C
impressed
What tools and bits did you use to do your oil ways, block etc, what heads did they have on
What tools and bits did you use to do your oil ways, block etc, what heads did they have on
Then a die grinder to slot the block behind the bearing to feed the squirter.
22-11-2005, 04:53 PM
#28
Originally Posted by Red16
loooking good chip
did you grind the bearing surface for the feed to the spray jets before the block was line bored ?
did you grind the bearing surface for the feed to the spray jets before the block was line bored ?
We have checked its still round though and it is, so no harm done
22-11-2005, 04:55 PM
#29
Originally Posted by jhw
Fookin fair play any pics of the car its going in.
27-11-2005, 12:00 AM
#32
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As said on MIG, nice work mate, should be one of the finest LET's built and the fact its going in a mini really says you are a nutter but fair play
but fair play
01-12-2005, 06:04 PM
#35
Originally Posted by Cliff S1
More updates 
And im probably getting a different manifold made for it as im not confident the one i have can flow enough gas for 500bhp+
Radders, will be an extended clubman front, it doesnt even fit under a normal clubman and ive no chance of a roundnose.
Going to have to make the front about 4" longer i guestimate.
12-12-2005, 02:15 PM
#37
Originally Posted by Cliff S1
GT35 that's a bit serious 
Although TBH im not bother if it falls a bit short of that, as ive still got the nitrous on top anyway if i need it.
13-12-2005, 09:08 AM
#39
Originally Posted by Freddy_mercury_magic
I understand now seeing the size of the turbo 
Shame you cant have it the old retro look...
Oh well
Shame you cant have it the old retro look...
Oh well
All seems a bit more obvious when you've seen my GT35 up close and personal.
You go and pop your bonnet and see how little clearance there is for stuff like the distributor on the little tiny 998cc engine and it starts becoming obvious that a 2 litre engine with a fapping huge turbo hung off it just isnt going in there and it all still looking factory