Lancer Register Forum banner

Madmac Motorsport's Twincharged Evo 5

598109 Views 2421 Replies 217 Participants Last post by  Madmac
2
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:D) 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:D. 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:D

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:D:D Should be fun!

Keep watching....;)

Attachments

See less See more
1161 - 1180 of 2422 Posts
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.
I'm pretty confident the air ducting will be enough, air being pushed through from the front and pulled through from the top. I may fit a fan if it's needed for around the paddock but only if it's needed. The motec is logging 4 induction temps so we'll wait and see what the data says.

One day maybe I'll be in the sports libre class and build a spaceframe, lightweight silhouette body etc but for the moment I'm keeping her as a saloon bodied car and see how far I can go with the development. I have rough plans drawn up for the spaceframe, only to assess if it would be worth doing in the future. No firm plans to build it in the next few years though
Looking great Donald. Any news on the side plastic windows buddy?

Jon.
Looking great Donald. Any news on the side plastic windows buddy?

Jon.
I need to get a set made for Tiddles within 3 weeks so i'm working on it :lol:

The rear glass needs to be scanned and setup as a CNC file. The fronts are ready, just playing around with slider opening sizes/positions just now :smthumbup. The CNC files should be ready within the week, the moulds could be another 2 weeks yet.

I think we're cutting it fine to have the car ready in 4 weeks though :blah:
It'll no be the first time you've beaten the clock mate.
  • Like
Reactions: 1
It'll no be the first time you've beaten the clock mate.
This is a bit different than the odd mechanical failure :lol:

Managed to get a new pair of carbon wings and a set of arches made this weekend as i'd sold the set earmarked for Tiddles a few weeks back. The wings are fitted but i can't fit the rear arches until the doors are back on which won't be until the wiring and dash are fitted :blah:

The wiring is coming along as well, the loom is ready to join everything up to the dashboard plugs and then the Motec. All the power distribution and connecting the isolator switch still has to be done as well

Other than that, lots of small jobs still to do then the dashboard and console can be finally fitted and the interior finished. The new intercooler vents/ducts and connections are all finished at last.

It looks like it'll be a last-minute build then off to the dyno :smthumbup

Still cutting it very close!
Wiring 90% complete so we're hoping it will be finished at the weekend. The engine is out for tidying up the engine bay and to do some work to the blower. A valve supplied with the blower has been the only part of the system that has been problematic, not for operation but for strength as it can't take the boost for long. I finally found an alloy one that i modified to fit. That's been needing done since the start of the twincharger project!

While in there I found a plastic drive cushion inside the rotor pack that had come apart - the reason the belt had come loose a few times last year. Luckily I have a spare from a dead blower.

Also waiting on a set of clutch plates. This set has done 14 events and is just on the lower limit. False economy to not fit new ones while it's apart. The gearbox has had a quick look inside and all looks great. This is the first time the Samsonas box has been out since July 2011 as its given no problems since.

She's getting there. She might be a bit rough around the edges at doune but I'm determined to be there! Could be interesting in the snow...

Also big thanks to DBA and Performance HQ for supplying a set of new disks for tiddles. Awesome guys, these combined with the Carbotech XP8 pads are again our weapon of choice in the stopping department :D
See less See more
  • Like
Reactions: 2
Got to agree on the DBA and Carbotech combo. An excellent setup.:smthumbup
  • Like
Reactions: 1
Bloody good progess Donald:smthumbup Good to see the car up close at the weekend. Sure you will make Doune now the spagetti is nearly done.

Edd:smthumbup
Bloody good progess Donald:smthumbup Good to see the car up close at the weekend. Sure you will make Doune now the spagetti is nearly done.

Edd:smthumbup
Wiring - Arrrggghhhhhhh! :wallbang:

I'm glad i have an expert doing the wiring. Another full day should see it mostly finished but it's dragging on. There are 40 wires to be connected to the dash alone and moving the main distribution box has been a lot more work than we first thought. So far every wire in the loom has a place to go, it's just a case of hooking them all up.

Clutch plates arrived so the engine is going back in tonight. By Monday we should be ready to start setting up the Motec sensors, then another couple of hours to have her ready for the dyno. This assumes all the wiring is okay :lol:
Wiring - Arrrggghhhhhhh! :wallbang:

This assumes all the wiring is okay :lol:
:eek:

A Motec PDM, or equal, would have made life easier but the £££ ;)

Call me with any last minute issues :)

Grant
:eek:

A Motec PDM, or equal, would have made life easier but the £££ ;)

Call me with any last minute issues :)

Grant
Yea it would have been nice but simply out of budget. The distribution box is now on the tunnel below the dash where it's easy to reach. No wires across the front of the car now.

Thanks for your offer of help. Hopefully it's all going to be okay but I have your number :D
I couldn't help but chuckle looking at that boost button :D great topic, I remember reading this from the start. Glad you kept the thing :)
I need to keep a sense if humour owning tiddles. Boost control is that simple now, like a volume control. I was going to label it 'full yosh' but may keep that for the rev counter:lol:
I need to keep a sense if humour owning tiddles. Boost control is that simple now, like a volume control. I was going to label it 'full yosh' but may keep that for the rev counter:lol:
DO IT

Full Yosh :D then have a picture of Yoshi from Super Mario lol
A 17 hour stint on the wiring yesterday saw it 99% complete, just the ecu connections to do. Engine back in ready to go. Once the ecu is finished I can get the dash and console finally fitted and test everything. Still a load of small jobs to do but most can wait until after the dyno work.

It's starting to come together at last but we're cutting it fine for doune!
  • Like
Reactions: 4
Hope to see her finished when im back from my hols mac...
Nae slackin now.

Sent from my GT-I9300 using Tapatalk 2
Nae slackin now.
Says he who is sunning it on the beach in an exotic location! Just cos your car's ready :lol:
Update

We've had a few all-nighters to break the back of the 'to do' list which has paid off so far.

We had her running briefly on Thursday all all seems good with the new ignition system. Nice clean spark :smthumbup

There's a few gremlins to deal with in the wiring but nothing too big to fix so far. All the ABS sensors are working again and the motec is taking over the traction control. The heater is in, plumbed and connected now. I had to move the engine radiator so brackets are made and it's ready to fit.

I got a new carbon boot floor made, carbon centre section of the floor too so more weight off .:D. So far we have 103kg out and expect to see 1100kg on the scales next Friday

I should have some photos to post up in the next few days. Dash and console is looking great now that it's in.

Dyno booked for midweek. If everything goes okay then we should be good for next weekend.

Thanks to Russs for advice and help with the motec wiring. Top man :smthumbup
See less See more
1161 - 1180 of 2422 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top