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Madmac Motorsport's Twincharged Evo 5

598542 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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58.36, 0.04s away.

One run to go ;)
just seen the times, i hope you didn't lift early again ;)
amazing time to say it was boost cutting all the time. only 95 up the hill on the last run.
Well done Donald,, get back soon.. :)
Thanks, Not bad times from yourself too ;). I'll be back next year hopefully.

Kenny, I had a quick look at the data logs and i'm only using 80% throttle most of the time to keep the boost sensible and away from the cut threshold.

To explain the situation, the engine was overboosting all weekend with no obvious reasons why the boost aim would have changed. We were seeing 3.5bar :eek:.

She needs to go back onto the dyno to be setup again as I've applied an overall trim of 70% and she's still making 3.1bar :wallbang:

Frustrating as i've had a few boost issues this year and it's affected the performance at every event so far. Most of the time it's been too low boost.

I'll get some vids up later in the day :)
Well done Donald, especially given the boost issues.
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Email me the logs if you like. Rick is on holiday but i can take a look through it this afternoon and give you a call.

Thanks, Not bad times from yourself too ;). I'll be back next year hopefully.

Kenny, I had a quick look at the data logs and i'm only using 80% throttle most of the time to keep the boost sensible and away from the cut threshold.

To explain the situation, the engine was overboosting all weekend with no obvious reasons why the boost aim would have changed. We were seeing 3.5bar :eek:.

She needs to go back onto the dyno to be setup again as I've applied an overall trim of 70% and she's still making 3.1bar :wallbang:

Frustrating as i've had a few boost issues this year and it's affected the performance at every event so far. Most of the time it's been too low boost.

I'll get some vids up later in the day :)
Email me the logs if you like. Rick is on holiday but i can take a look through it this afternoon and give you a call.
Will do. Am going to check wastegate diaphragms tonight too as that's about the only reason I can think of for the changes we're seeing
Well done Donald, if you can bottle any of that extra boost up I'll buy it no problem :smthumbup

Tony
I think you would have been in the 57s had it not been for your problems Donald.
I think you would have been in the 57s had it not been for your problems Donald.
Possibly. That 58.32s record of the Banana is a quick time, I had to drive Tiddles hard to get into the 58's let alone a low 58
Well done Donald, if you can bottle any of that extra boost up I'll buy it no problem :smthumbup

Tony
If only :lol:

Made me wonder how much boost the system is capable of if it went without any control at all

I reckon over 4bar :eek: :naughty:
Great time Donald, good effort!

Looking at your sector times on the 58.36 run, you went quicker then me off the line, and then through the esses section to the blind left, although i suspect that may well be due to the zero lag response of your car coming out of the essess.

3C 124 Donald McCaskil 2.02 7.93 12.62 12.48 13.82 9.49 58.36

3C 147 Steven Darley 2.03 7.89 12.78 12.46 13.80 9.36 58.32

Couldnt be any closer! I will have to try find some Avons, and see if i can push it into the 57's like my sectors suggest is possible!

Look forward to the videos.
Possibly. That 58.32s record of the Banana is a quick time, I had to drive Tiddles hard to get into the 58's let alone a low 58
I watched your run and heard the boost multiple boost cuts. I'm surprised you even got a 61 with it running like that.

I saw you do a 95 terminal, but I've seen mr Darley do at least 103 up there. I'm sure he said he was doing over 110 at the top. Steven?
Great time Donald, good effort!

Looking at your sector times on the 58.36 run, you went quicker then me off the line, and then through the esses section to the blind left, although i suspect that may well be due to the zero lag response of your car coming out of the essess.

3C 124 Donald McCaskil 2.02 7.93 12.62 12.48 13.82 9.49 58.36

3C 147 Steven Darley 2.03 7.89 12.78 12.46 13.80 9.36 58.32

Couldnt be any closer! I will have to try find some Avons, and see if i can push it into the 57's like my sectors suggest is possible!

Look forward to the videos.
That's pretty close on sectors. My logs ECU show I hardly used full throttle as I didn't want to be damaging my engine and most of the time i never went above 80% throttle. I still had boost cut.

Here's the in-car video of my T2 run from Sunday. I forgot to press 'record' on the line of my 58.36s run :eek:

I can be seen turning the boost down just before the entry to the Esses. Didn't make much difference though

I watched your run and heard the boost multiple boost cuts. I'm surprised you even got a 61 with it running like that.

I saw you do a 95 terminal, but I've seen mr Darley do at least 103 up there. I'm sure he said he was doing over 110 at the top. Steven?
Yes, the speed trap is part way up the hill, and you can hit higher, having hit 112 before lifting for quarry. I have done 108 through speed trap and only just made the corner.

Perhaps the acceleration whilst overboosting was making up for the boost cut! ;) We run 2.5 bar up there, although i think i tried a bit more when i ran the 42.
That's pretty close on sectors. My logs ECU show I hardly used full throttle as I didn't want to be damaging my engine and most of the time i never went above 80% throttle. I still had boost cut.

Here's the in-car video of my T2 run from Sunday. I forgot to press 'record' on the line of my 58.36s run :eek:

I can be seen turning the boost down just before the entry to the Esses. Didn't make much difference though

Looked a handful on boost :smthumbup
Yes, the speed trap is part way up the hill, and you can hit higher, having hit 112 before lifting for quarry. I have done 108 through speed trap and only just made the corner.

Perhaps the acceleration whilst overboosting was making up for the boost cut! ;) We run 2.5 bar up there, although i think i tried a bit more when i ran the 42.
Boost cut is set at 2.8bar in the ECU but the system still makes boost during the boost-cut itself as it builds boost so quickly. After 2.8bar there is no more power, just a tell-tale in the logs of the system reaching 3.5bar
Trackside video of the 58.36s run here:
Yes, the speed trap is part way up the hill, and you can hit higher, having hit 112 before lifting for quarry. I have done 108 through speed trap and only just made the corner.

Perhaps the acceleration whilst overboosting was making up for the boost cut! ;) We run 2.5 bar up there, although i think i tried a bit more when i ran the 42.
112 is mental. that's 17mph quicker than Donald's car looking at the video he poster. crackers. how did you make the corner? :lol:
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