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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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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:
That's per the gps unit on the Car, peak speed is reached after the speed trap ;)

You sure the wastegate solenoids arent plumbed the wrong way round?
One of the solenoids on the Banana had a wire sheer flush with the solenoid which i only just spotted, we also stripped it down and it had seized interally too.
You sure the wastegate solenoids arent plumbed the wrong way round?
Absolutely sure
That's per the gps unit on the Car, peak speed is reached after the speed trap ;)
not in Donald's case.
Here's my times from 2011 when I had standard doors on and 600 ish bhp. I need to get back to harewood to get a PB.

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Stripped both wastegates tonight. One has a small area of latex peeling away from the woven diaphragm material so im hopeful this is the cause of the ever worsening overboost. I've ordered two new diaphragms so I'll know if this is the cause in a few days. Also have another solenoid ready to swap over if needed. Obviously I want to change only one thing at a time so we can be sure of the cause.
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Well done Donald considering the boost problems.

Jon.
Well done Donald considering the boost problems.

Jon.
Thanks Jon, 2 class wins as a bonus too :)
That's the 2 wastegate diaphragms replaced now. I haven't been able to give it a proper test drive yet as it's been chucking it down with rain since I got her back together again and she's wheelspinning rather a lot :rolleyes:

Also been looking at a suitable turbo for next year. Bigger of course ;) :naughty: It will be a hybrid to take advantage of the Twincharger's characteristics. A GTX42 shouldn't be laggy at all :eek:
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Its hardly laggy on the Banana, so shouldnt be on a 2.4 twin charger setup
Update, only had a quick test drive to see how the boost is holding out and it looks like the boost issue is sorted finally. We have a double header at Fintray hill climb this weekend so I'll find out for sure on Saturday.

Spent a bit of time making a headlight blank for the drivers side as having one headlight looked odd, especially at a distance. Also removes 1.6kg from the front of the car as the blank is 120g. I opted to hold it on with velcro so it can be removed quickly as it makes fitting the bumper difficult.

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Just back from Fintray. Damp/wet but got a clean run on the first timed run to take my first ever FTD at an MSA hill climb :D

Got it all to do again tomorrow ;)

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In Car video of the FTD run on YT now. Damp from the hairpin entry to the finish line and positively dangerous over the line :blah:

The rattle you can hear while warming the tyres is stones trapped in the sidepod :lol: as the RH mic is fixed just inside the rear door above the exhaust

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Well done Sir awesome result, great performance.

Jon.
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Thanks guys, she went well all weekend and survived intact again. Finished today with a 28.38 run to take fastest modified award. Track remained damp and greasy from the hairpin to the finish line all day although it improved every run. Good news is the boost problem is fixed at last.

I'll post up the video later tonight.
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