CasperGTI Posted December 24, 2008 Author Report Share Posted December 24, 2008 Thats good, pauls car has been going for a good while now hasnt it, think the only problem he has was his clutch in that area?I bought a car cover yesterday... machine mart for £22 and its fleece lined! that will stop the ****e landing on the car!John Quote Link to comment Share on other sites More sharing options...
Mike_M Posted December 24, 2008 Report Share Posted December 24, 2008 Great progress on this and cant wait to see more...........keep it up mate! Quote Link to comment Share on other sites More sharing options...
Tigz™ Posted December 24, 2008 Report Share Posted December 24, 2008 Can I move the thread into the projects section of the tuning forum? Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 24, 2008 Author Report Share Posted December 24, 2008 (edited) But i like it at the top of the readers ride, it was a readers ride thread when i started it!Ill make a deal, once its finished.. it can go in the projects bit??And ill start a new readers ride thread.John Edited December 24, 2008 by CasperGTI Quote Link to comment Share on other sites More sharing options...
Tigz™ Posted December 24, 2008 Report Share Posted December 24, 2008 Coolio You thinking about producing a kit? Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 24, 2008 Author Report Share Posted December 24, 2008 I am yes, But once ive finished the car. Because a few things that i have obviously had made will need drawings modifed slightly for a better fit. Plus i now know that some parts from the TT can be used.Its just trying to get a balance of quality and value for money. I couldnt really put a set of £1000 con rods in it as id have no one interested, but i suppose it could be an optional extra.John Quote Link to comment Share on other sites More sharing options...
scrappy doo Posted December 24, 2008 Report Share Posted December 24, 2008 wouldnt happen to know how big the pulley is to run 4psi would you as ive bein having the some trouble finding this out thanks in advance Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 24, 2008 Author Report Share Posted December 24, 2008 (edited) wouldnt happen to know how big the pulley is to run 4psi would you as ive bein having the some trouble finding this out thanks in advanceIts the standard pulley, what is used is some type of pressure regulator that opens the blow off valve and dumps pressure so it maintains 4 psi boost and dosent go any higher.Ask andyp, he will know more as i dont really know much about it, plus im not going to run it anyway.You cant adjust the pulley size to acheive that ammount of boost, the pulley would be huge compared to standard.you have to work it out from the M45 performance map:Pressure ratio is the difference between atomspheric pressure and the pressure out of the charger. So 4 psi is about 1.25 PR..John Edited December 24, 2008 by CasperGTI Quote Link to comment Share on other sites More sharing options...
scrappy doo Posted December 25, 2008 Report Share Posted December 25, 2008 tar very much Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 25, 2008 Author Report Share Posted December 25, 2008 (edited) Ive just done an email answering a load of questions, So i thought id put some of the answers to the questions up on here as there is alot of info in it.1.) pistons Prices for the pistons change as the dollar moves about and the cost of the billet that it is forged from, what i did is delt with a company called performance unlimited, i gave them the piston and told them the application, power, boost, rpm, compression bore and stroke etc. Then they mapped it and sent it to CP/JE pistons (whoever offered the best deal as there so competitive) My pistons are as the original ones are, but have a reinforced gudgeon pin, and through pin oiling. I think i payed about £465 for them, and then bought total seal piston rings (gapless) which are extreemly good, and good for a few more horsies. They are about £70 a set from what i can remember. 2.) conrods Again down to the dollar and the price of the billet. I am possibly being supplied new coated bearings, but dave at performance unlimited thinks i dont need them, so i may not go for it as there quite dear. The oil channel beterrn the big end bearing and the little end bearing costs an extra £90 per rod. The base price of the con rods was about £243 per rod i think. That was a copy of the original rod, without the oil channel through the rod (stronger) and oil channels drilled in to the top of the rod for gudgeon pin oiling. and carrillion specialits CARR bolt (£32 per bolt X8). Again these were all designed to the specifications of my engine.. power etc etc, its what you pay specialists for! I think my rods have cost about £930+vat, my total for both pistons and rods came to £1645. 3.) machine work inc. head/bottom end rebuild I will either have stangard bearings or coated bearings, the way it looks, i will have standard ones as there more than adequate for the job. I have had my head ported and gas flowed, with multi angle valve seats, new valve stems (more of a precaution than anything), inlarged inlet valves (exhaust cant get much bigger for the ammount of gain), and the ports have been matched to gasket size, and then the inlet/exhaust mainfolds adjusted accordingly. I have been taught to do so i got it at a very cheap rate through a friend of the family for £330 including parts. you can expect to pay normally £450+ for that sort of work. My sudgestion is to try and find a small local machine shop that can do it, avoid the mainstream stuff as your pay through the nose. 4.) strenthened bolts. Im thinking about ARP head bolts, but havent decided, dont think theres any need as your blow a head gasket before doing a head bolt to be honest. The con rod bolts are the weak point of any engine so make sure you get strong ones of those, Id sudgest the carillio CARR bolt, but that means you will need to use a carrillio con rod. 5.) work on crank, I am having the crank balanced and knife edged, you should really re-balance your crank when changing the pistions and rods, ideally you need to balance it with the pistons, rods, flywheel and clutch to make it 100%. Again im being taught to do it myself so i dont know how much it will cost. Also if you are to use total seal rings, then you either need the cylinder bore honed or de glazed, id say deglazing as it dont change the bore size and you get the factory surface finish back for the new rings to bed in propperly. 6.) decompression gasket, Mike at ferriday engineering did mine. Send them a new OE head gasket and they will make one, they also provide the sealant, think i paid £163 in total for the plate and sealant. 7.) uprated clutch Helix clutch, you will need to see if theres one made for your engine/box I havent decided between a paddle clutch or heavy duty one, but you will need an uprated clutch if you want to go 180bhp+. They are about £350 8.) lightened flywheel? I dont know about the flywheel, i might aswell get it lightened and balanced aswell. Havent asked yet, as ill do it myself again so no cost incured there. 9.) valves/springs in head, Larger inlet valves and multi angle seats, think the valves were about £12-£16 each on the inlet size so X8. 10.) pulley for charger, The standard mini one comes on it, so thats normally good for the job. Gives you a ratio on the lupo engine that allows it to spin up to 13600rpm at 7000rpm with approx 10psi boost. You can get 15% and 19% reduction pulleys wiich will see you approx 4psi boost increast, but will change your peak power, and will make the charger get alot hotter, there about £100 for the 15%. 11.) custom inlet/outlet on charger I made mine myself, havent made the inlet yet as im not too sure what it needs to look like yet untill ive put the engine back in. I have made a plate that covers the outlet, and has a 76mm outlet hole on it. this reduces to 63mm in the pipework for the whole system, as thats the size of my throttle body. 12.) AUX belt Again i need the engine in one peice to map the belt propperly, you can get a custom made belt, or a belt to the size you want for about £30. Put a peice of string around the pulleys to measure it up and then go about 5mm shorter and order accordingly. 13.) ECU mapping, Ive allowed £1000 for the std ecu to be mapped. It proabbly wont be that expensive though, dont know too much on this atm as its still in development. 14.) pipework for charger , I worked it out where i wanted to route it then went on to silicone hoses web site and ordered it accordingly. I havent had any custom bits made. my pipework cost about £250, but i have spare bits left at the moment. 15.) the most important part- THE CHARGER- which generation? Eaton M45, off a mini cooper S, Is ample fo the job of 180bhp. yi can pick them up for up for under £200 with just delivery miles on it. If you can find one off the S works cooper then that will have a smaller pulley on it and a better coating on the blades allovwing it to get hotter. But there like rocking horse **** and very expensive as thats the charger the minis upgrade to when using the GP package. I dont think its necessary.16.) Total Cost.Its hard to say what the total cost will be for this specification if you did it as i had alot of things done on the cheap because i was taught to do them. If you got a company to do it, i wouldnt expect to see you much change from £8000-8500 to be honest. Labour on some parts is very intensive i have found out. I now have everything ordered and paid for, there is nothing i need to spend really any more to have it running. I have spent £5600 on the conversion. Budgeted for £5500 so im not too far off. I want to buy a few other bits though (tarox 6 Pots and a sparco milano 2 seat) but those two alone come to about £1400! so probably over this year i will do them.Merry ChristmasJohn Edited December 25, 2008 by CasperGTI Quote Link to comment Share on other sites More sharing options...
nfbr Posted December 25, 2008 Report Share Posted December 25, 2008 I've kept quiet on this thread so far... But I gotta say...F¨ck Yeah! Way to do it properly ! Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 25, 2008 Author Report Share Posted December 25, 2008 MMM shiney presents.Forge Single piston high flow atomspheric blow off valve, With upgrade spring if i start to go over 12psi boost, shame the pipework is blue though.And raceland manifold. Note the port matching on the exhaust, its not finished, but nearly there.John Quote Link to comment Share on other sites More sharing options...
Lee_ Posted December 25, 2008 Report Share Posted December 25, 2008 Nice Is that matched to the exhaust port on the head or are you going as far as the gasket?Did you do the porting yourself? Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 25, 2008 Author Report Share Posted December 25, 2008 On the gti, the original exhaust port on the head is way smaller than the gasket (about 3mm all round each port)The head has been ported both sides to gasket size, then the manifolds ported to the head size. It didnt need too much, just a bit of cleaning up.I have done it myself, im being taught by the guy at the machine shop doing it all. Its pretty cool, easy once you know how. Still have to gas flow it, but i doubt ill do that as im back at work when it will be done.John Quote Link to comment Share on other sites More sharing options...
Lee_ Posted December 25, 2008 Report Share Posted December 25, 2008 I saw tttada's thread showing the difference in size between the gasket and actual port,seemed a fair difference between the two.Nice one for having a go at it yourself. Quote Link to comment Share on other sites More sharing options...
Dubbprince Posted December 26, 2008 Report Share Posted December 26, 2008 John..cheers for the pms dude...i'm now working on a way to finance this as quickly as possible LOL. Take a look at this thread on CP, what i want you to see is the PSD (G40 conversion) cnc machined piece that creates the room for extra stabilisor pulleys and a tensioner.What do you make of this:http://www.clubpolo.co.uk/forum/lofiversio...hp/t129790.htmlAlso, that raceland is a poor fit...it may touch the side of the sump like it does on mine, so you might need to either machine the sump a couple mm, put up with it or try to bend the straight on the downpipe.Lovin that forge item mate! Am i guessing that these dont need to be divertor type then like they do on a 20vt. Quote Link to comment Share on other sites More sharing options...
Dubbprince Posted December 26, 2008 Report Share Posted December 26, 2008 the other reason for the above is because you would run a toothed belt instead of a ribbed...thus meaning less belt slip and more power Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 26, 2008 Author Report Share Posted December 26, 2008 John..cheers for the pms dude...i'm now working on a way to finance this as quickly as possible LOL. Take a look at this thread on CP, what i want you to see is the PSD (G40 conversion) cnc machined piece that creates the room for extra stabilisor pulleys and a tensioner.What do you make of this:http://www.clubpolo.co.uk/forum/lofiversio...hp/t129790.htmlAlso, that raceland is a poor fit...it may touch the side of the sump like it does on mine, so you might need to either machine the sump a couple mm, put up with it or try to bend the straight on the downpipe.Lovin that forge item mate! Am i guessing that these dont need to be divertor type then like they do on a 20vt. Dont you worry, the raceland will fit no problems.... i have my ways!I like the PSD kit, But not at £740! That makes the eaton too wide and it wouldnt fit at the front of the lupo. Plus if you wanted to use a toothed belt system on the lupo you would need to change every pulley and have every pulley for the aux belt system remade custom, as there a different fit to the toothed belt applicaitons in other cars, theres not enough room even to run two belts side by side either in the lupo. Less room than the eaton in that PSD thread.My pulley arrangement is using the same sort of parts seen in those pictures. Once ive finished it ill have the pictures up... But at the moment its standing still as i dont have the head to make the plate the right length.You can use whatever valve you like aslong as it has a high flow. Remember superchargers are different to turbos in the way that when you take your foot off the accelerator, a turbo spools down. Where a charger is still at the same speed as the engine.. much more air to get rid of, Think about that when you get round to getting yours.John Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 28, 2008 Author Report Share Posted December 28, 2008 (edited) Been working on this over the christmas period.Its nearly finished, just needs a final polish up when its all back together.John Edited December 28, 2008 by CasperGTI Quote Link to comment Share on other sites More sharing options...
nfbr Posted December 28, 2008 Report Share Posted December 28, 2008 Ace work ! Fantastic choice in colour scheme for the engine! Orange is for Winners. Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 28, 2008 Author Report Share Posted December 28, 2008 Al, it was our conversation that made me go for orange....I really cant wait to start putting it back together now. Quote Link to comment Share on other sites More sharing options...
darth vader Posted December 28, 2008 Report Share Posted December 28, 2008 (edited) I've kept quiet on this thread so far... But I gotta say...F¨ck Yeah! Way to do it properly !Those would be my words!! Everything so perfect Top work Edited December 28, 2008 by darth vader Quote Link to comment Share on other sites More sharing options...
Lupo D Posted December 28, 2008 Report Share Posted December 28, 2008 Outstanding work John...! D. Quote Link to comment Share on other sites More sharing options...
CasperGTI Posted December 28, 2008 Author Report Share Posted December 28, 2008 (edited) Polished bolts FTW.And to celebrate, i dripped a bolt on the rocker.... Chipped 2nd picJohn Edited December 29, 2008 by CasperGTI Quote Link to comment Share on other sites More sharing options...
dubsy Posted December 28, 2008 Report Share Posted December 28, 2008 i to have kept quiet following this thread but fair play john i think all your hard work will be worth it and will be all the more because its been built not bought. the attention to detail is what has caught my eye and that should be appreciated just as much as the conversion. im waiting in atticipation to see what the final bhp figure will be 200+ easy, could this be the most powerful charged lupo in the country? pottentially yes in my opinion! i never follow trends or other peoples comments when it comes to my car i do whats right for me but you have given me the insperation to finally start my own conversion after talking myself into and out of the idea of a 20v conversion for the last 12 months, that has now been ditched in favour of the charged conversion, i know there have been alot of people stating that this is what they intend to do also but i dont think they realise both the work and money involved to get the end result, good luck with the rest of the conversion john and i hope to see the car on the show circuit next season ps. a pic of my rocker cover just to give you an idea of what yours will look like when finished Quote Link to comment Share on other sites More sharing options...
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