Donald Im sure there is a guy in the northwest that will make any core to any size.
If you need to know, ill speak to my guy and get his details. :smthumbup
If you need to know, ill speak to my guy and get his details. :smthumbup
Madmac Motorsport's Twincharged Evo 5
During the winter build of the old Evo 5 hillclimb slag I decided to look at ways of reducing the turbo lag which was becoming an issue and costing precious hundredths of seconds on the hills last year. It never lacked top end power but the lag really started to get to me and i knew i could make it quicker point to point by reducing the lag - but keeping top end power.
I looked at many possible ways to do this but in the end settled for adding a supercharger to run in conjunction with the turbo.
Designed and built by myself with input from friends and members on MLR, most parts have been fabricated in my garage from whatever was lying around, the end result has been worth the blood, Sweat and tears I've put into this.
We've had her on the dyno at Wallace Performance in Aberdeen and had surprisingly few teething problems considering the unknowns and the huge amount of bespoke parts that needed to be designed, fabricated and made. Initial mapping is done now and the whole package is showing some serious potential! We've decided to keep the system at it's minimum until i do reliability tests and learn how to drive it properly :angel:
I've also designed and built a tubular front subframe and arms (total 9Kg
) to reduce front weight and while i was at it, it seemed rude not to play with the suspension geometry!
I want to thank a few people for their input and help:
Russ and the guys at Wallace Performance who did the mapping and supplied parts/tea/banter etc. Top guys and never ones to shy from a challenge! Can't thank you enough:smthumbup. http://www.wallaceperformance.co.uk/
My mate Steve Marr who is the main technical guru, and who i regularly bugged to ask lots of questions on a daily basis:smthumbup.
My mate Graeme Wight Jnr for his help with the front subframe and major suspension geometry changes, Exhaust and general setting up
Alan Young Engineering Ltd for the quality machined bespoke pulleys and parts, Spot-on parts and great prices http://www.timingbeltpulleys.co.uk/pages/home.php
And everyone else who suffered because of my constant lust for knowledge during the build:smthumbup
As yet i've to do some miles and get her setup for the start of the 2010 Scottish Sprint & Hillclimb Championship, so for the moment i'm being realistic about expectations & screwing the nut until i check everything over and get used to driving it. Hoping to do some track testing soon though. I've had her out for a short drive and so far the whole package is working impressively. Instant delivery at anything above 2500rpm with absolutely awesome accelleration in every gear! This is on it's lowest boost setting too....
Over the next few months The guys at Wallace Performance & I are going to refine some of the setup and see what she's really capable of! We know we can find a lot more power & torque with some simple changes.
Meantime i'm happy with the initial results and looking forward to Doune Hillclimb in 2 weeks Should be fun!
Keep watching....
I looked at many possible ways to do this but in the end settled for adding a supercharger to run in conjunction with the turbo.
Designed and built by myself with input from friends and members on MLR, most parts have been fabricated in my garage from whatever was lying around, the end result has been worth the blood, Sweat and tears I've put into this.
We've had her on the dyno at Wallace Performance in Aberdeen and had surprisingly few teething problems considering the unknowns and the huge amount of bespoke parts that needed to be designed, fabricated and made. Initial mapping is done now and the whole package is showing some serious potential! We've decided to keep the system at it's minimum until i do reliability tests and learn how to drive it properly :angel:
I've also designed and built a tubular front subframe and arms (total 9Kg
) to reduce front weight and while i was at it, it seemed rude not to play with the suspension geometry!I want to thank a few people for their input and help:
Russ and the guys at Wallace Performance who did the mapping and supplied parts/tea/banter etc. Top guys and never ones to shy from a challenge! Can't thank you enough:smthumbup
. http://www.wallaceperformance.co.uk/My mate Steve Marr who is the main technical guru, and who i regularly bugged to ask lots of questions on a daily basis:smthumbup.
My mate Graeme Wight Jnr for his help with the front subframe and major suspension geometry changes, Exhaust and general setting up
Alan Young Engineering Ltd for the quality machined bespoke pulleys and parts, Spot-on parts and great prices http://www.timingbeltpulleys.co.uk/pages/home.php
And everyone else who suffered because of my constant lust for knowledge during the build:smthumbup
As yet i've to do some miles and get her setup for the start of the 2010 Scottish Sprint & Hillclimb Championship, so for the moment i'm being realistic about expectations & screwing the nut until i check everything over and get used to driving it. Hoping to do some track testing soon though. I've had her out for a short drive and so far the whole package is working impressively. Instant delivery at anything above 2500rpm with absolutely awesome accelleration in every gear! This is on it's lowest boost setting too....
Over the next few months The guys at Wallace Performance & I are going to refine some of the setup and see what she's really capable of! We know we can find a lot more power & torque with some simple changes.
Meantime i'm happy with the initial results and looking forward to Doune Hillclimb in 2 weeks
Should be fun!Keep watching....
Attachments
1141 - 1160 of 2422 Posts
Update
That's the Intercooler just about finished. I still have to fabricate brackets to hold it in place and make the remaining pipework. I made the end tanks from some alloy tube i had lying around :lol:
Pressure tests ok at 40psi so the next stage is to mount it securely and make all the air ducting in carbon
The dash is finished and we've started the wiring. Another stint tomorrow should see the dash wired and the IC mounted.
That's the Intercooler just about finished. I still have to fabricate brackets to hold it in place and make the remaining pipework. I made the end tanks from some alloy tube i had lying around :lol:
Pressure tests ok at 40psi so the next stage is to mount it securely and make all the air ducting in carbon
The dash is finished and we've started the wiring. Another stint tomorrow should see the dash wired and the IC mounted.
Attachments
Been a busy week. We have our new CNC router installed so I'm getting to grips with its operation. I'll be using this mainly for the sign manufacture (day job) but I've found many uses outwit signmaking for it so far....:lol:. It can scan points on a template so I can copy large shapes and use the data to cut any material to shape. Watch this space!
Work on tiddles is slow. The dash is wired, still a lot more wiring to do
I made a pattern in alloy for the intercooler ducting which also supports the cooler. This is being used to take a carbon copy so the final ductwork will be light. I have it in the oven now. All going to plan, the ducts should be finished tonight. I have the cooling air come in from 3 places at the front and I'm happy this will feed a substantial amount of cold air to the core.
Photos later tonight hopefully.
Work on tiddles is slow. The dash is wired, still a lot more wiring to do
I made a pattern in alloy for the intercooler ducting which also supports the cooler. This is being used to take a carbon copy so the final ductwork will be light. I have it in the oven now. All going to plan, the ducts should be finished tonight. I have the cooling air come in from 3 places at the front and I'm happy this will feed a substantial amount of cold air to the core.
Photos later tonight hopefully.
This is the duct straight off the pattern, untrimmed and literally just placed into the car. I still need to make brackets to support it so it can hold the weight of the intercooler as well as channel the air through - why make something that only does one job...!
The top section over the slam panel and inner wing rail seals the air and will fix with Dzus fasteners to the lower duct. I need this to be easily removed to access below. There's a lot still to squeeze in there :lol:
Another full day should see this mounted, sealed and plumbed, then the engine can be removed for rebuild
The top section over the slam panel and inner wing rail seals the air and will fix with Dzus fasteners to the lower duct. I need this to be easily removed to access below. There's a lot still to squeeze in there :lol:
Another full day should see this mounted, sealed and plumbed, then the engine can be removed for rebuild
Attachments
Almost there with the Intercooler
There's still a few brackets to be made, neoprene seals for the ducting to add in, and connect up the pipework. Probably still a full days work before I can say it's finished enough to get the engine out.
More wiring getting done tonight and hopefully i can make the battery box in the new router tonight and get it fitted. I seem to be jumping about between different jobs just now as time permits.
Other news is my tubular front subframe design is almost completed as a 3D CAD model with the bottom arms etc so I hope within a few months I will have a cutting list for tube profiles and other parts i need water-jet cut then I can assess the viability of this going into limited production next winter. A jig will need made before any subframes can be produced and I will need to look carefully at the costs of the jig, product build time and final costs spread out over 10 units
Here's the Intercooler so far
There's still a few brackets to be made, neoprene seals for the ducting to add in, and connect up the pipework. Probably still a full days work before I can say it's finished enough to get the engine out.
More wiring getting done tonight and hopefully i can make the battery box in the new router tonight and get it fitted. I seem to be jumping about between different jobs just now as time permits.
Other news is my tubular front subframe design is almost completed as a 3D CAD model with the bottom arms etc so I hope within a few months I will have a cutting list for tube profiles and other parts i need water-jet cut then I can assess the viability of this going into limited production next winter. A jig will need made before any subframes can be produced and I will need to look carefully at the costs of the jig, product build time and final costs spread out over 10 units
Here's the Intercooler so far
Attachments
Thanks Jon, it's a labour of love at the end of the day and all the parts have to be made bespoke, so it takes time to build it up. This IC has been a lot of work to make, fit and get the air through it to give it the best chance of cooling the charge. The core is 120mm so i have no doubt this will be as good, if not better than the water-air cooler I had. It's certainly lighter by 30Kg
I needed to get this finished before the engine comes out which doesn't leave much time to rebuild the engine and get her mapped again. It looks like it will be very last-minute again. This bonnet vent will take a full week to make the mould :blah:
Through the headlight area and inner wing with some coming in through the fog light hole in the bumper. I'm sure it will get plenty cold air as the inner arches are sealed to the floor so all the air coming in through the left OE air duct is reaching the engine (under similar pressure as at the bumper) and the core. It should work as a ram effect at high speed, well that's the theory
.The air exit is more tricky as I'd need something big that will probably look ugly on top of the bonnet to create a substantial low pressure area above the vent to pull the air through the core. This bit is going to be a compromise as the air is going to have to exit in a higher pressure area of the car and i don't want a massive lip on the outside. Happy enough with the shape i'm working on at the moment tho
I'll post pics up when it's done :smthumbup.
Not had a chance to get photos up so there's a few bits been worked on lately that are coming along slowly...
After the new IC was installed with the ductwork I decided the main distribution fusebox had to be moved as there was no space for it under the bonnet. This is now mounted under the dash but still needs connected up to the loom again. The good thing is there are now no wires going across the front of the car, two looms now run to each side from the bulkhead for lights etc as i'm still keeping her MOT'able for the moment.
The bonnet air exit duct was a headache, and still isn't finished :wallbang: I tried to make a single shape that could be cast in one piece of carbon but shelved that idea after spending a few night on it. I ended up making the outer shroud and another part separately that joins the bonnet to the core. This is as far as I've got as i've needed to make moulds for making each part in carbon. I still have to make louvres for the inside of the vent and bond it all together on the bonnet, so another few nights still to do on this. The design turns the airflow up sharply which creates a low pressure zone directly behind it to draw the air through the core. We tested two designs with a high pressure airline and wool, then concluded this upturn would be the best compromise of drag V's effectiveness of drawing the air out. I may yet cut it down a bit to make it slightly less ugly :lol:. Cooling the charge air is more important overall than adding a few square inches of frontal area. It's all about compromise!
The dash is ready to be fitted as soon as the wiring is complete :smthumbup
I also played with the CNC router and made this basic battery box in aluminium by routing into it for the folds and then cutting it around the outside. This isn't the finished one, only seeing how easy it was to make from scraps of aluminium. This one was too heavy :lol:
Still a long way to go. The engine rebuild may have to take a back seat as the season starts on 20th April and we still have a LOT to do before we can start building the car back up. I have to do some work on the supercharger though so I may have to take the engine out to do that properly...
After the new IC was installed with the ductwork I decided the main distribution fusebox had to be moved as there was no space for it under the bonnet. This is now mounted under the dash but still needs connected up to the loom again. The good thing is there are now no wires going across the front of the car, two looms now run to each side from the bulkhead for lights etc as i'm still keeping her MOT'able for the moment.
The bonnet air exit duct was a headache, and still isn't finished :wallbang: I tried to make a single shape that could be cast in one piece of carbon but shelved that idea after spending a few night on it. I ended up making the outer shroud and another part separately that joins the bonnet to the core. This is as far as I've got as i've needed to make moulds for making each part in carbon. I still have to make louvres for the inside of the vent and bond it all together on the bonnet, so another few nights still to do on this. The design turns the airflow up sharply which creates a low pressure zone directly behind it to draw the air through the core. We tested two designs with a high pressure airline and wool, then concluded this upturn would be the best compromise of drag V's effectiveness of drawing the air out. I may yet cut it down a bit to make it slightly less ugly :lol:. Cooling the charge air is more important overall than adding a few square inches of frontal area. It's all about compromise!
The dash is ready to be fitted as soon as the wiring is complete :smthumbup
I also played with the CNC router and made this basic battery box in aluminium by routing into it for the folds and then cutting it around the outside. This isn't the finished one, only seeing how easy it was to make from scraps of aluminium. This one was too heavy :lol:
Still a long way to go. The engine rebuild may have to take a back seat as the season starts on 20th April and we still have a LOT to do before we can start building the car back up. I have to do some work on the supercharger though so I may have to take the engine out to do that properly...
Attachments
Bonnet vent lookms really good mac! I say keep it tall and then stick a pulled fan on there!
Are you still in the same class as last session? Just wondering if there is any plans to go into the ultimate class (think that's right) which will allow you to mod the chassis also. Would be nice to see some carbon wishbones or subframes!
Chris.
Are you still in the same class as last session? Just wondering if there is any plans to go into the ultimate class (think that's right) which will allow you to mod the chassis also. Would be nice to see some carbon wishbones or subframes!
Chris.
1141 - 1160 of 2422 Posts
