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Old 15-03-2011, 11:35 PM   #1
drmo
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S1 Race Car

Hy everyone! My name is Luka and i'm from Slovenia (A little country near Italy and Croatia)

I own a rallye a few years and at first it served me as my daily driver. Since I bought it, it has gone thru a lot of changes. the story is really long but i will make it a lot shorter.

This is how it looked when I bought it:


First wash:


Resprayed:


Then, after a while I decided I want a litle more from this little thing, so I bought gsx-r 600 throttle bodies, catcams 645, I noched the pistons, raised compression, and a few other things.
On the dyno it pulled 120hp and 130Nm of torque. I was quite happy...for a while, but then I wanted more.
The first evolution:


I allways want to invent and try things that are not so easy or not so common, so I build a 1490cc baby. The engine block is from 1.4 xsi (75mm bore) rebored to 78,5mm, pistons are from 1.6 tu5 90bhp, crank from 1.4xsi (77mm stroke), 1.3 rallye reworked head from previous engine with itb's and catcams 645 cam.
Second evolution:

The engine made 140bhp and 160Nm of torque on the same dyno.
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Old 15-03-2011, 11:35 PM   #2
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Then I fell in love with C5 alloy steelies (who wouldn't)


I also bought some cheap coilovers and just used the sleeves and lover and upper spring pan. The inserts are bilstein b8 and springs are from GAZ (325lbs)


Then the third engine evolution came (omg)

The plenum is made by me and it is made out of poliester.

I was driving for about a year like that, just making some minor adjustments like suspension setup changes, throttle bodies thrumpets and other things. Then I decided that I want a car made primarily for the track. With all the mods it was quite hard for every day driving and the cops in our country are not very fond of the mods that I made, so decision was made.
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Old 15-03-2011, 11:36 PM   #3
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There was another evolution off the engine..."omg, not again" you would say, but yes. We had a catcam 671 laying in the garage for a long time. It was for my brothers 205 project car, but he (thank god) change his mind and will be fitting ew10 into 205 instead of tu5. We fitted the cam, diesel rad and some other things in searching for more power.




custom made upper and lower strut brace:


And inside:


The mapping session is on friday so fingers crossed

I probably didn't tell the whole story ore the whole list of mods, but some can be seen from the photos, other will be shown in the future.

And If you don't mind me telling, next year there is going to be new engine inside and this one for sale. I'm building a tu5jp4 screamer

And, sorry for three posts, but couldn't stick all those photos in one post.
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Old 15-03-2011, 11:40 PM   #4
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Looks like a great project, I love the plenum you've done, looks the business!
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Old 16-03-2011, 01:30 AM   #5
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very interested in the results of the 671 cam over the 645 - an overlay of the 2 graphs would be good
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Old 16-03-2011, 02:40 AM   #6
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i really look forward to seeing the results from the new cam. its what i am looking at for my 8v.
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Old 16-03-2011, 08:41 AM   #7
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will do an overlay, so we can compare the two different cams.

This is the old one (without the plenum and slightly different design of thrumpets currently on):



Setup was:
tu4j2 engine :P
gsx-r 600 itb's
catcams 645
raceland manifold
2" piping from manifold to backbox

My calculations tell me that the raceland exhaust manifold is not perfect for my setup, but I don't know any other that has bigger dimensions. We wanted to do a custom one, but since I decided that next year the tu5jp4 is going in, there is no point doing it for this engine.
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Old 16-03-2011, 04:20 PM   #8
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When i had a raceland manifold on mine the power went completely flat from 6000rpm all the way to almost 8000rpm. i swapped for a Janspeed 4-2-1 manifold and i gained around 11bhp and 11ft/lb (around that) with some tweeking to the map.
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Old 20-03-2011, 10:08 PM   #9
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I remember your findings but mine still climbs at 6k rpm. Probably becose of less capacity (1490cc).

Well, the findings with this cam are quite interesting. Definitely not what I was expecting, regarding the revs. We managed to squize 7hp and 10Nm of torque out of this little baby. That is ok, but I hoped that it would rev more freely. I will post the overlay graph as soon as I get it, but here is how it goes:
Under 5k rpm there is some loss in power and torque and after that the power shoots up. The torque is also climbing. It is really interesting becose the graph is just shifted at one point. The maximum horsepower is still at the same revs and then droping as before, so is torque. This leads me to think that the problem is probably in the manifold.
The final power is (before/after):
138bhp/145bhp
158Nm/168Nm (116lbft/124lbft) torque
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Old 21-03-2011, 08:42 AM   #10
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that still impressive for that capacity.

Mine makes brilliant power all the way to 8000rpm then to the limiter at 8300rpm it is still good.

Go for a custom manifold and head work would most likely help your figures too.
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Old 21-03-2011, 12:10 PM   #11
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Can you measure your janspeed manifold primaries? I need outer diameter.

Here is the graph:


I'm using quaife sincromesh gearkit and lsd with 4,28 fd, so when shifting up the revs drop less than with an regular gears. The car is really rapid.
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Old 22-03-2011, 04:03 PM   #12
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A few of my friend's photos of the car:







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Old 29-03-2011, 09:38 PM   #13
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youve done an awesome job on the air box.... how did you make it??
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Old 30-03-2011, 10:00 AM   #14
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It's made of poliester. It's off at the moment, becose I was loosing 10hp with it. I belive that it's got to do with the piping and inlet port shape.
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Old 30-03-2011, 10:32 AM   #15
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Great car with some interesting mods. Lots of respect for people who make their own stuff
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Old 30-03-2011, 03:43 PM   #16
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Thanks Cris, really apreciate it
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Old 08-04-2011, 10:39 AM   #17
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Love this thread! Great work!
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Old 03-06-2011, 02:16 PM   #18
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A video of last friday

http://youtu.be/3dbNsVcYHUw

Had a problem with 5th gear coming loose (damn quaife gears) so had to finish after 15 laps. Still finished second in my category.

This is who is in front of me every time:



200bhp b18c engined eg6
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Old 12-06-2011, 09:35 AM   #19
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What a great read,great project,and an interesting engine build,just what we need ????.....a section for 'Frankenstein' engines like this one so we can all enjoy and if so desire EXPERIMENT..
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Old 28-06-2011, 11:58 AM   #20
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Some new things!

I finally got to do a custom manifold and the rest of the exhaust. It was a joy making one, even without the machinery required. The real shocker was when I opened the backbox. The pipe inside was only 38mm(1 1/2") ID !!!It should be about 2" OD (1 7/8" ID)

I decided to go with 2,25" piping, which should be enough for the next engine I will be building next year. It is a little to big for now but I don't want to build another next year so this has to be ok.

Some pictures of the manifold:









We started TIG welding it but then we ran out of wolfram needle so the rest of the mani is made with MIG/MAG. The inside is really clean which matters the most.

Comparison between before and after piping in the backbox:






regards,

Luka
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Old 08-07-2011, 06:36 PM   #21
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That's very very cool mate - any more pics of the backbox?
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Old 09-07-2011, 08:11 AM   #22
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That's the only one I got at the moment. I will get some more when I get back from Norway in a week.

Here is the sounfd of the exhaust:

http://youtu.be/5X4oDLeVoUk

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Old 02-08-2011, 09:11 AM   #23
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I did't have time lately to update the progress on the engine.

After installing a wideband lambda and a gauge we saw that AFR was all over the place, so the mapping was a necessity. We went to a different rollers this time.

The first pull showed only 130 bhp atf. Mapping showed that the engine was low on fuel in the upper rev range. The final figure was 140 bhp and 141Nm (104 ft lbs) of torque.

The big difference is the torque and power curve. The max power is now at 7750 rpm, before it was at 7000 rpm, and the torque is at the same revs. Torque curve is broader and doesn't fall off so quick. So now i have more than 500 rpm more useable powerband. It revs freally to 8000 rpm.

The numbers really are strange, becose it looks like it is a "downgrade" to before figures, but the lap times show that it isnt. The figures really are low compared to what people get from simillar mods on here, but I think this just proves how different rollers show different numbers.

I managed a win in my class on friday. The best time before was 53.236s and the new best is 52.921s.

here are the best lap times:



the EVO X that is before me has a personal best of 50.3xx s

I have to lighten the car till next time, so the next mods are policarbonate windows at the back, roof lining has to come out, back wiper motor out, drill some holes , camber/caster adjustable top mounts, and some tweeking of the suspension settings.

Oh, and Im searching for a used tranX or gripper plated diff. The Quaife is shit!
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Old 28-08-2011, 10:43 PM   #24
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I managed to improve my time again. The new personal best is 52.350s

The only new stuff is camber/caster adjustable top mounts which are set for 2.5 camber and 4 caster. Turn in is sharper and out of corner grip is also improved, which is what I wanted. Il post some photos when I get a chance.

Here is a video of this fridays Time Attack:

Peugeot 1.3 Rallye @ Time Attack Chapter 7: Pray for Rain
"> Peugeot 1.3 Rallye @ Time Attack Chapter 7: Pray for Rain
" type="application/x-shockwave-flash" width="425" height="350">


And promised dyno graph:

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Old 29-08-2011, 07:52 PM   #25
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Looks like fun

What top mounts are you running?
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Old 29-08-2011, 11:37 PM   #26
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I'm running BakerBM 205 top mounts, modified to fit.
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Old 06-09-2011, 08:13 PM   #27
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Interesting, any pictures?
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Old 07-09-2011, 08:34 PM   #28
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finally a photo:

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Old 27-11-2012, 10:42 AM   #29
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Some new stuff with the car:









Preping for fitting the cage and welding the chassis.

Bought some sweets for it




Unfortunately the drivers side has to stay glass.

OMP CrMo cage


And new arches


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Old 27-11-2012, 10:52 AM   #30
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Nice work, some neat work to come!
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Old 27-11-2012, 01:47 PM   #31
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good work
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Old 30-11-2012, 11:13 AM   #32
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Suspension has finally arrived. Haven't seen it in flesh yet, but it looks awesome













And weighted one rear damper



Still waiting on the engine internals to come.
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Old 30-11-2012, 12:01 PM   #33
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^ looks awesome!
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Old 30-11-2012, 12:02 PM   #34
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Sweet, must have set you back a bit?
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Old 30-11-2012, 01:26 PM   #35
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Yes, quite a bit...full price is arround 3200gbp for 5200 series (club sport). I wanted something that can be fully adjustable and in the end decided to go for AST. Can't wait to fit them, but unfortunatelly that is not going to happen soon.
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Old 21-12-2012, 07:17 AM   #36
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Looks like a very nice setup!
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Old 26-03-2013, 12:51 PM   #37
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Finally some stuff arrived. I was beginning to give up to the fact that the car won't be finished this year, and now I regained some hope and joy to speed it up a little bit.

Catcams 1322826 cams, solid lifters, valve springs/retainers, sinus valves


12mm lift

specs: http://www.catcams.co.uk/acatalog/1322826.pdf

lifters:


valves:


Colin Satchel engine mount kit:


Steering quickner:


Throttle bodies:




That's it for now.
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Old 26-03-2013, 01:25 PM   #38
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Some nice items there mate, for a serious engine!

I'm particularly keen to find out more on that "steering quickner!" How does it work?
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Old 26-03-2013, 03:16 PM   #39
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It will be serious No more of that pussy 10mm lift and 250 duration cams I'm still waiting for pistons and rods to come. The problems that I had with the seller and time it took already, I hope they are worth it. Otherwise I'm gona go there and shove it in their ass!! Literally!

The steering quickner does the same job as a quaife quick rack, with it there is less turns left to right. It goes between steering rack and steering wheel. It involves some cuting and welding. This was my only option as we LHD guys can't fit quaife RHD steering rack and pinion.
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Old 26-03-2013, 03:26 PM   #40
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Looking awesome mate! How much were the rear dampers if you don't mind me asking? Thanks.
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Old 26-03-2013, 04:03 PM   #41
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Thanks mate!

Sorry, don't know a separate price just for the rear dampers. There not cheap probably.
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Old 26-03-2013, 07:54 PM   #42
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What gearbox /ratios are you using?
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Old 26-03-2013, 10:50 PM   #43
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What kind of power / powerband are you expecting with the 826's? Build looks great man, looking foreward to seeing what's to come
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Old 27-03-2013, 12:52 AM   #44
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@Garry.M: I'll be using BE4R gearbox with a nice combo of gears from 405 Mi16 and 205 1.6 gti. I hope I can bodge something nice out of these two boxes, combined with 4.92 FD. I know that there are some differences between the gearboxes and something can and something can't be used. I'll see when I get to that. If that doesn't work out I'll probably find out something else that will suit my needs. I'll also go for gripper diff.

@Cornally13990: I hope for a nice powerband from 4k-8.5k. I'll be using JP4 engine, and these cams will probably work quite nice with the specs I had in mind. The exhaust manifold will be custom made, to spec of the engine. I'll be using 139mm rods with pistons to suit. The compression ratio will be around 12.5:1. The throttle bodies that I'll be using are from kawasaki zx12r, a little bigger than gsxr 1000. They're not ideally spaced, but not miles away, and can still be spaced a little closer than they are originaly.
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Old 27-03-2013, 09:07 AM   #45
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Hmmm,,, think your usable power band is going to start nearer 5k than 4k. There is other box ratios that cam be used/fitted if you can get some machining done ;-)
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Old 27-03-2013, 12:38 PM   #46
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Can you divulge which ratios?

We'll see what the final spec will be, but I think it is possible.
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Old 19-09-2013, 11:50 AM   #47
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Finally a little update. The previous piston and rod combo that I received was not for my liking and there is nothing available off the shelf that I would like, so I decided to go with custom pistons and rods. I received the pistons:



compared to oem JP4 piston:


weight:


My design and will not suit any engine.

Waiting for Robson to make me a custom set of rods now.
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Old 19-09-2013, 05:13 PM   #48
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Looking very good pal! When are you hoping to have it all done? I take it your making your own manifold & trumpets for the bodies?

What power are you after with it? Should be a good machine when done! Are you going to cap the power a 9k rpm or push it further? Them cams peak very high but should have a lot of power at the top end, as Garry said your power will come at 5k-9k. My new engine will be very similar to yours so i'm very intrigued to see the results!

Good luck & hurry up so we can see the results!

Chris
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Old 20-09-2013, 08:00 AM   #49
drmo
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Thanks mate! Uff, a long way to get there. Prep the block, a lot of headwork, custom inlet, custom exhaust, and then I'm left with only the whole shell to be made :S Unfortunatelly I don't have any spare time to work on my project as I work on a few customers engines, but I hope I'll have time over the Winter.

The main thing is to have great torque spread. I still think I can make good torque under 5k rpm. I know I only made a couple of engines but I believe that it is doable as I managed that before with agressive cams. I won't divulge what has to be done to get to that, but you can look at Sandy's engines and see.
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Old 20-09-2013, 03:03 PM   #50
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Pistons look great man, where did u get them made? Keep us updated anyway man, it's going to be a great build
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