Hoshy's rebuild and s/c conversion - dyno chart on page 5

[Dan318-is]

that looks impresive Ash

are you still planning on keeping up with us 6 pot boys in Scotland then

From what i have heard he kicked all their arses last time with a standard four pot but just got accused of driving "dangerously" ?

[billgatese30]

no doubt it was Ash who was spreading that vile, detestable, rumor

[hoshy]

It's all 100% stock atm. Fuel reg is still the tweaked one. Perhaps a little rich. I should have stuck the lambda on it this evening but hey.

I think there are two main factors for the power now. A good thrash, but defo cam timing. Today and yesterday I took the rocker cover off to do the upper front timing case oil leak and noticed we'd lost a nut from the cam carriers. Ended up fixing three of them with some proper engineering Sorted the oil and reset the cams (which didn't look out). She idled really badly after resting the cams but a quick tweak on the idle CO pot and she was lovely again. Did about three or four runs that all came in around 140odd. I think the power above stock is due to a little upped fuel pressure and perhaps slightly higher comp form the skim. Either way, the numbers are right on paper and she drives well.

Track day tomorrow should be good

I do need a diff rebuild and new rear wheel bearing though

Oh well. Next few weeks the s/c will be back on and mapped. Can't wait now!!

[Dan318-is]

What oil is in it now? Any nastiness in it ash? Pretty happy its all worked out

Is the SC stuff still at my house? I need to ring guy by the way he has found a bloke in guildford who is a differential hero!

[hoshy]

Sweet! Kepp me posted about that diff guy. Somebody local would be very useful.

I was down at your place last Thursday. Picked up all my bits except the e36 and the jack (they can go at the same time). Need to make a plan for getting the 36 home and selling it. Needs to come to Shrewsbury really for a spot of welding.

Changed the oil today too. It was on 1000 miles when I did it.

I'm so pleased that it seems sorted now. Seems apart from a few stupid things we did a pretty good job mate

[Jon_Bmw]

Yep that graph looks normal, the torque drops right off at 5600rpm which is perfectly normal. So all you changed was the cam timing! Power looks inline with most 318is I have seen on the rollers which is all good.

Dan I'm final 'yearing' atm as well To make matters worse, I am currently commuting 3 or 4 days a week to Bristol from Salisbury. Despite it being closish(60 miles) the roads are non direct Lpg is saving me a fortune mind. Gotta get a house so I can get pissed with the brizzle council crew.

Ash, sorry I won't be able to pop in tomorrow as I have tomorrow off uni and the 40 mile trip is a little bit too much just to spectate. Sorry fella. Enjoy it and grab 20 mins with an instructor, get Ed moore if you can, he will show you the good lines around there. Worth 2 seconds I reckon.

[lionsze]

Hoshy - have you mentioned to anyone that you are looking for a shell....and then you saw the link?

*click

"Hope it's not red"

*webpage loaded

Sh** ---- (it's red)

[Dan318-is]

Jon, all i can say to that is B****cs! I live a ten minute walk from campus and thats bad enough! My lpg ideas and car i general are on hold at the moment, in fact i have only driven to tesco and back twice since the end of september!

What track is it Hosh?

[Jon_Bmw]

To make matters worse I have to be in for 8.30 in the morning, twice a week Thats a 6am start, and 6am doesn't really go hand in hand with a student.

Mrs Hoshy, have you been on the wine?

[hoshy]

Cheers jon. Shame you can't make it but there's always next time

Dan - it's Colern, an airfield track somewhere Bristol or whiltshire way.. Who knows exactly - Sat nav will sort it :0

[Jon_Bmw]

Bath! Near Wiltshire

[hoshy]

To make matters worse I have to be in for 8.30 in the morning, twice a week Thats a 6am start, and 6am doesn't really go hand in hand with a student.

Mrs Hoshy, have you been on the wine?

Lol. Dunno who changed it to Mrs Hoshy - I reckon Neil had some hand in it though

She's talking about when i opened up a page to look at a potential iS shell - Ask I click I said I hope it's not red... Just as I finished the last word.... the page loaded and it was indeed red. Funny at the time

[hoshy]

Bath! Near Wiltshire

Whatever.. I'm in the pub

[d6dph]

To make matters worse I have to be in for 8.30 in the morning, twice a week Thats a 6am start, and 6am doesn't really go hand in hand with a student.

Mrs Hoshy, have you been on the wine?

Lol. Dunno who changed it to Mrs Hoshy - I reckon Neil had some hand in it though

[daimlerman]

Hummmm,by the look of that graph without the 'charger,my M50 project touring needs to be a bit special to stay in front... mind,the 2.7 with it's improved suspension will make you work a bit harder

[BadDave]

I have got a braking system to design

Drop me a PM or email if you need a hand

[Jon_Bmw]

How did the day go then Ash? Enjoyable? Weather was good for you, although not quite as good as the weekend.

[hoshy]

Hummmm,by the look of that graph without the 'charger,my M50 project touring needs to be a bit special to stay in front... mind,the 2.7 with it's improved suspension will make you work a bit harder

Will be fun.

[hoshy]

How did the day go then Ash? Enjoyable? Weather was good for you, although not quite as good as the weekend.

To sum it up in two points.

1. Lots of fun.
2. Time for new rear tyres.

lol. It was really good actually. Smashed the near new come-whores on the first one or two goes out!

Met a coulpe of cool people. A guy in an e90 chipped 320d still on factory run flats was funny as. Initially he pasted me but as soon as I nailed my lines he stood no chance. Both him and my colleagues (chipped Ibiza and well sorted s14) have some video that'll be on youtube and linked here soon enough.

Pasted a very nicely track prepped 325i with a claimed 188bhp too

Can't wait for next time. Will post up but dunno where it'll be. Maybe Olton park.

How's the pug coming on??

[georgen]

Oh great,

So even with my chip, cold air induction kit, BBTB and LSD, I'm still gonna get owned by a 4 pot on the zone roam ?

Can't wait to see the car in action Ash. Nice one fella

[hoshy]

Oh great,

So even with my chip, cold air induction kit, BBTB and LSD, I'm still gonna get owned by a 4 pot on the zone roam ?

Can't wait to see the car in action Ash. Nice one fella

hehehehe

I'm looking forward it mate. Be nice to see you and hopefully Miriam too. Hope all is well on that front mate!

[Jon_Bmw]

How did the day go then Ash? Enjoyable? Weather was good for you, although not quite as good as the weekend.

To sum it up in two points.

1. Lots of fun.
2. Time for new rear tyres.

lol. It was really good actually. Smashed the near new come-whores on the first one or two goes out!

Met a coulpe of cool people. A guy in an e90 chipped 320d still on factory run flats was funny as. Initially he pasted me but as soon as I nailed my lines he stood no chance. Both him and my colleagues (chipped Ibiza and well sorted s14) have some video that'll be on youtube and linked here soon enough.

Pasted a very nicely track prepped 325i with a claimed 188bhp too

Can't wait for next time. Will post up but dunno where it'll be. Maybe Olton park.

How's the pug coming on??

Still waiting on some clown to remove the gearbox so I can pick it up! I'm getting seriously tempted to go remove the fucking thing myself when he is at 'work.' Bad sellers are as bad as bad buyers.

Glad you had fun. What colour was the 325, bronze?

[hoshy]

Glad you had fun. What colour was the 325, bronze?

Red, Brilliant. I think.

[hoshy]

Ahh finally got around to putting the megasquirt in a motronic box today. Had wanted to do it like this from day one but impatience took over. Need to find out what wrong with the fucking wide-band next. Then sort out some pipework and finally... maybe... hopefully... It's be ready for a proper mapping session with the charger on.

Made a few improvements too:

1. Added the idle control circuit
2. Replaced a blown cap (I think that's what caused me grief some months back - it was in backwards!!!)
3. Tidied and significantly shortened the wiring for the tach and ignition.
4. Replaced the giant Automotive relay with a little PCB mount job (it provides an ignition switched ground that powers up the DME relay)
5. Used a new motronic connector with longer pins on the back for more durable connections


Original loom adapter:



Trial fit:



Complete:


The lid will fit fine as soon as I find the hacksaw to cut out the LED and DB9 ports.

[hoshy]

Well, I've done some good miles (100+) on the reworked MS. Even though I've got no wideband to know for sure, the old map that was in it from the old engine is pretty close. Power is there but there's a bit of a stutter at light cruise - Made some improvements on the way to work.. Will hopefully crack it on the way home

Would love to know what values people are using for their idle valve too. I've for a pwm freq of 156, warmup only mode, crank 70%dc, cold 67%dc and 36%dc warm. That's good enough to use everyday but not quite perfect. I guess I can't get it right until I can get a wideband on there and make sure the fuel and spark is right before adjusting the idle air. Want to switch to closed loop as well some time.

All in all I'm very happy with MS now. It's much better than its ever been. It almost feels as smooth as motronic and it's not even been properly refined yet.

[rix313]

I can't tell you how sexy I think that looks! Once this project is out the way I wouldn't mind doing an engine rebuild (will prob end up doing it on mine at some point any way lol)

Got any more pics of how the charger is mounted? How have you conntected the hose to the outlet?

[hoshy]

Some s/c pics on their way.

Added a little serial port pigtail and got the motronic lid fitted. Now all I have to do is convince the insurance company that it really *IS* an aftermarket ECU

[hoshy]

A few s/c pics:


Round pipe on to the s/c inlet - a rhino boot - basically a universal CV boot cut down. this is subject to change because where the back of the s/c sits near the fuel filter and brake m/c there is not much room for bringing a pipe out to the front of the car.


Main s/c bracket as made by Alex - with some kind of S50 eccentric tensioner.


rear bracket - this needed some modification because it wouldn't clear the starter motor. I ended up chopping out one corner so the s/c only has one bolt in the back now.


A random piece of merc exhaust was used for the exit pipe:


A plate made up with some pretty horrendous stitch drilling:





The final output pipe assembly - the pipe/plate welding was the first ever real welding I'd done. No training and i must have ground and welded it a million times. I really need to take a welding course and remake it



A rough first draft assembly. This actually worked but I never got it mapped because of the previous MS problems. Over Christmas and the coming weeks I'll change it to use two dump valves and add an intercooler - notice where I had to chop off a rear s/c lug to make it fit


First draft in situ - before engine rebuild - seems ages ago now.


Hope they're of some use.

[d6dph]

Impressive stuff Ash

[hoshy]

Cheers Dave. I can feel that after lots of apathy and a healthy amount of setbacks it's getting close now.

Barring anything major I should be hooning about in the new year.

Can't remember if I mentioned it above of not but I've also had my diff fully rebuilt. It's waiting up north to be fitted over christmas

4.1 medium case slipper upgraded to "motorsport spec", all new bearings and 4 plate clutch upgrade. No whines and lots of sideways.. perfect

[Jhonno]

Kevo rebuild on the diff?

[hoshy]

Kevo rebuild on the diff?

No but I spoke to Kevo first and he gave me some good advice. I think his services would have been good if I just wanted a minor refresh, plates tightening, case swap etc. But I wanted the full works so I decided to send it to a place my dad uses - they only really do OEM spec rebuild though and that would have been 500. So I opted for gearboxman.co.uk who specialise in motorsport sutff and did the job for 600.

It's a ridiculous amount to spend really but they reckon the 4 plate upgrade makes them very durable so it should hold good value and certainly need no work for the time I'll own it.

I did think that for that sort of money I'm getting in to Quaife territory but I still think it would have worked out quite a bit more than 600 by the time I've had the bearings and fitting done as well.

[rix313]

Gawd ya gone stuck it where I wanted to put mine lol!

Wheres you alternator?

[hoshy]

Gawd ya gone stuck it where I wanted to put mine lol!

Wheres you alternator?

it's on the ofter side. aircon bolt holes on the block were used with a little step bracket, a flat metal plate with 8 holes, 4 for the upside down alternator bracket and 4 bolted to the block with about 5cm of so of spacers. Unfortunately the belt rubs a tiny tiny bit on the crank sensor - just enough to leave a slight rubber trail.. Matt did exactly the same thing but I don't think he had that problem. I thought I had some pics of it but can't find it.

Matt put a thread up with pics but I don't have the link - it took me bloody ages to find it using the search last time too.

[appletree]

There you go hoshy, had to do the "view your posts" and then go through about 6 pages of stuff i'd posted, i cant get the search to work even with the correct title typed in LOL must be doing somthing wrong.

http://www.e30zone.net/modules.php?name ... highlight=

Mine also does just to say touch the sensor but nothing dangerous or to worry about