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Madmac Motorsport's Twincharged Evo 5

598553 Views 2421 Replies 217 Participants Last post by  Madmac
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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....;)

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:smthumbup for the spark ;)

Now you have some little terminals to crimp you might like to invest in one of these :eek:

G
:smthumbup for the spark ;)

Now you have some little terminals to crimp you might like to invest in one of these :eek:

G
Got one already and giving it a workout :lol:

Thanks for your help grant. Almost there...
Just finished bolting in the dash and interior, doors etc. Had her up to temp and all seems good. Off to the dyno tomorrow eve for mapping.

Weighed her as well tonight. Under 1100kg, result! :D
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Just finished bolting in the dash and interior, doors etc. Had her up to temp and all seems good. Off to the dyno tomorrow eve for mapping.

Weighed her as well tonight. Under 1100kg, result! :D
1100 kg with the power and response should make for a serious tool donald.

You are the mlr's answer to doc emmet brown, :smthumbup
You are the mlr's answer to doc emmet brown, :smthumbup
No flux capacitor in tiddles. Different time travel technique :crackup:
Yea this season could get interesting :lol:

She was already pretty serious but i just can't leave it alone :D. The diet was long overdue and theres still a good bit more to remove from the underfloor when I get round to making it all in prepreg. On target for sub 1050kg which is pretty good with floor and twincharger system.

1000Hp per ton is the goal. I've made some changes to the twincharger setup which should balance the system and improve spool, mid-range torque and top end power. We'll see once it's been on the dyno.
1000bhp per tonne? WTF? :lol:

Donald, I didn't know you were going to that much power?

Get that harewood hill weekend booked! You have a record to break!

http://www.harewoodhill.com/events/
Sounds great Donald, another late night, some stock of time going into this build :smthumbup
1000Hp per ton is the goal. [/QUOTE said:
:eek: You'd better down to NASA Donald for some launch and take-off training :D
I think 1000hp per ton is achievable given time - she's almost 800hp per ton at the moment, with no turbo lag :D

Tonight's dyno work is to make it safe to drive after the new intercooler has been installed and not an all-out quest for power. I know i can see over 1000hp from this system quite easily (on pump fuel) but don't want to go there just yet. That will follow as a natural evolutionary process when the time is right :lol:

Kenny, Harewood is on the hitlist this year but not sure when, it depends on how Tiddles behaves and whether or not she needs expensive bits to keep her going. With 130kg removed and a wee bit more experience of the track i don't see why the record isn't achievable. Lets hope the weather is good on the day :naughty:

The new pre-preg floor will take another 20-25kg off later in the year - another bag of cement :lol:

Doune is certainly going to be interesting if it stays dry :naughty:

I'll update after the dyno work. There's still a LOT to do to her before she's fit for the track
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any plans to enter ten of the best?
any plans to enter ten of the best?
Probably not. I spend too much doing the Scottish Championship as it is, any southern events depend on sponsors and available funds. It's also not very fast believe it or not - but it gets there insanely quickly :lol:
Probably not. I spend too much doing the Scottish Championship as it is, any southern events depend on sponsors and available funds. It's also not very fast believe it or not - but it gets there insanely quickly :lol:
Shame, would love to see her south of the border, as you say maybe Harewood later this season, good, its 10 mins from my house:smthumbup
I'll be keeping the thread updated with the events as and when they happen :smthumbup
Doune is certainly going to be interesting if it stays dry :naughty:
Are you running at Doune this weekend Donald? Might take a run up for a nosey on the Saturday.
Superb work Donald, your car is one of the reasons I have ventured into the world of Evo Hillclimbing from little rwd Escorts!
I'm gathering lots of information reading through the wealth of knowledge here on MLR and I'm really looking forward to stripping the car out over the winter to get some weight out of it (currently running Roadgoing series production)
How light do you think I could get an Evo 5 but still run in category S12 (Modified series production)? 1150kg?
Are you running at Doune this weekend Donald? Might take a run up for a nosey on the Saturday.
Unsure, we had some issues on the dyno so i don't know if they can be resolved in time. I'll be there either with Tiddles or driving an Integra DC2 as i've been offered a double-drive. I may also just be there as a p155-head and go for the party! All unknowns :lol:

Good news is the new IC is awesome, really awesome and the figures seen were beyond our expectations so once we iron out the issues we should see a much larger area under the graph than before. Not sure about top -end but on the lowest boost setting 1.8bar there's silly amounts of torque :naughty: It looks like we should be able to match last years figures on a much lower boost setting :smthumbup

It's going to be lively, that's for sure :lol:

Thanks to Russ and Performance HQ for all the time, patience and effort so far. Much appreciated guys ;)

She's shaping up to be quite a machine. It even feels lighter to tow on the trailer, instantly noticeable! Cannae wait to drive her in anger!

Mr G racer; I'm glad this has inspired you to tackle your own project. Advice is at the other end of the phone ;). I don't see why you can't reach 1150kg but it may take some select lightweight carbon parts to get that low :lol:
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The new pre-preg floor will take another 20-25kg off later in the year - another bag of cement :lol:
Weight removal is so easy these days.........When I was a lad the bags of cement were 50kg (well 112lbs if I'm honest) :lol:
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Well she's just about there. A last push tonight got the floor back on, harness fitted, the voltage regulator in the alternator went faulty so it's replaced. One of the dyno issues was the bodge on the power steering pump pulley from last year finally failed so a new one was made yesterday and sent up. Many thanks to Alan young engineering for superb turnaround and quality again. He certainly knows his pulleys!

The interior is almost finished and although the bodywork isn't wrapped, the carbon comes up great with a wax. There's no time to wrap it so this event she'll be bare except for a few sponsor logos. Still a few jobs to do and the first test drive tomorrow to make sure everything is as it should be. We had a misfire on the dyno that we believe is being caused by interference in the loom so I stripped the loom again and stripped some coaxial cable to pull the copper shield then covered some of the sensor wires and grounded them to the ecu. Until I drive her tomorrow I don't know if that has been sorted. Fingers crossed! If it's not cured I'll use the weekend to data log some channels at high frequency and analyse to see if I can find what's causing it.

Photos to follow. She's scrubbed up well again! A sea of carbon inside and out:D

Doune this weekend, forecast is good for Saturday but rain Sunday. Come over and say hi if you're coming to spectate
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Nice one Donald, sounds like you're that on top of it you may be able to slip in a couple of hours kip before the event too! :lol:
All the best for the weekend :smthumbup
well she's just about there. A last push tonight got the floor back on, harness fitted, the voltage regulator in the alternator went faulty so it's replaced. One of the dyno issues was the bodge on the power steering pump pulley from last year finally failed so a new one was made yesterday and sent up. Many thanks to alan young engineering for superb turnaround and quality again. He certainly knows his pulleys!

The interior is almost finished and although the bodywork isn't wrapped, the carbon comes up great with a wax. There's no time to wrap it so this event she'll be bare except for a few sponsor logos. Still a few jobs to do and the first test drive tomorrow to make sure everything is as it should be. We had a misfire on the dyno that we believe is being caused by interference in the loom so i stripped the loom again and stripped some coaxial cable to pull the copper shield then covered some of the sensor wires and grounded them to the ecu. Until i drive her tomorrow i don't know if that has been sorted. Fingers crossed! If it's not cured i'll use the weekend to data log some channels at high frequency and analyse to see if i can find what's causing it.

Photos to follow. She's scrubbed up well again! A sea of carbon inside and out:d

doune this weekend, forecast is good for saturday but rain sunday. Come over and say hi if you're coming to spectate
pics!!! :D
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