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Madmac Motorsport's Twincharged Evo 5

598098 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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Very impressive Donald, looks very neat as well :smthumbup:coolsm:
Thanks, yea apart from the mould flaws the finished part has come out looking nice.

I'm still thinking of selling this one at cost and making another :lol:
I could be interested in the "flawed" one depending on costs and postage, I'm not collecting again! :lol:
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Got the turbo off, checked cleaned up and ready to sell on. No damage found on compressor or turbine wheels, seals and bearings all good. It had better designed seals and bearings fitted a few years back and hasn't been above 1.5bar since. Nothing of concern showed up on the dyno which was its last outing.

I'll start a for sale thread. ;)

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Change of subject again..

I picked these 3 air jacks up in the summer with intentions to so something with them over the Christmas break. They're too big to be installed within the car so i'm thinking about making something up so 2 could lift the car at the sills around the cars balance point so once the front is up the rear can be lifted onto a stand by hand. I don't need them inside the shell as there's not really time constraints so if it takes a couple of minutes to set them up then there's no problem with that. They're also 1.5kg each so I'd rather have an external system.

Perhaps make them slot into tubes in the sills from outside? Obviously they will need to be fixed securely to the car so the car cant roll back or forward but also need to be simple and light to carry in the toolkit. The car is low with the underfloor so manual jacking in the paddock is a pita.

They have a lift of 410mm so they will give a better lift than any trolley jack can do. I placed an mlr mag so you can see the size of these jacks.

Feel free to make suggestions :smthumbup

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Look at the SVA car as they did a side mount that fits into the holes made for the rally style stands .


http://www.timeattack.co.uk/sva-attacking-evolution/#sthash.q9HIoHaW.dpbs
Yea I saw that one. Problem is I only have 3 jacks and the idea is to be able to lift the front at both sides then the rear can be lifted by hand while an axle stand is put under.

I've found a balance point across the sills so the rear shows 30kg on the scales when the front is lifted at those points. I can lift the rear easily by hand then. I need to look at simple methods of fixing the jack to the sills without it being able to pivot.
Buy another jack saves messing around with three, sure someone on here will have one
Buy another jack saves messing around with three, sure someone on here will have one
I can do this with only 2 jacks and keep one spare :smthumbup

I've started installing the sill anchor holes already ;)
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Are you putting them in the middle of the sill?
Hi mate,
What's the price on the turbo kit ?
Have a friend interested in the turbo in particular.
Are you putting them in the middle of the sill?
Not in the middle but just forward of the balance point so the back becomes light enough to lift without a jack :D

Ls2, hope to get £2k for the lot but if he's interested then he can make an offer and i'll give a quick answer.
With the two jack method around the balance point you could use a single seater type quicklift jack to lift the rear, they are easy to fabricate, carry and can double as a stand for changing wheels.
obviously if your working under the car you will be using axle stands or something to make it safe so that's easy (your back to sill axle stands like rally cars), but I think you've answered your own questions Donald, if your only using it for the purpose of changing wheels then make the balance point say 10kgs heavier to the rear so when you have one wheel off it then favours the front and will then pivot to the front. I presume your jacking point is made of 2 holes rather than 1 as this will stop the tight twisting effect you would have by say only using a tight box section fit (if you follow), you could then offset the brackets on the jacks so you could insert them one way and that would lift the front then swap them side for side and it would then favour the rear.
4 jacks would make it proper easy like the SVA car.

good luck
obviously if your working under the car you will be using axle stands or something to make it safe so that's easy (your back to sill axle stands like rally cars), but I think you've answered your own questions Donald, if your only using it for the purpose of changing wheels then make the balance point say 10kgs heavier to the rear so when you have one wheel off it then favours the front and will then pivot to the front. I presume your jacking point is made of 2 holes rather than 1 as this will stop the tight twisting effect you would have by say only using a tight box section fit (if you follow), you could then offset the brackets on the jacks so you could insert them one way and that would lift the front then swap them side for side and it would then favour the rear.
4 jacks would make it proper easy like the SVA car.

good luck
Yep, I've started to fit 2 tubes through the sill which will keep the jack perpendicular to the sill. Rather than axle stands i'll make horseshoe stands that fit around the extended jack stanchions then I can release the air pressure and work under the car from there.

Where the jacks are positioned I could lift only one side or the front using both jacks. No need for a quick lift jack as steve suggested (thanks) because the back of the car then weighs only 30kg which I can lift easily enough then drop it onto a single axle stand under the rear subframe. The problem I always have up until now is there are only the 2 wooden blocks built into the side pods which I need to jack the car up. I then can't put axle stands in because the only exposed structure that could take axle stands usually needs to come apart to do the work which is more often than not a transfer box replace :lol: by having the car able to sit on the propped jacks I have full access to all areas to work on ;)

The problem I'm having now is the sills are weak at the outer skin and flex when the force is applied upwards. A simple outrigger will cure this but add weight. I should have the one side welded up today. Pics to follow ;)
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Happy New Year to you all. Let's hope 2015 is the best yet.

A couple items up for sale soon. 4" intake K&N filter good clean condition

A pair of front Polycarb windows, driver side slider, pass side no slider. £60 delivered and i'll throw in a pair of rear one piece windows with vent holes which are new but have been lying around the garage for a year so there may be slight marks on them.

More random bits to follow in due course. Photos to follow
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Happy New Year to you too mate. Looking forward to this years update reports.
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Santa arrived late :D

Am still waiting on the manifold and a few other parts though. It's likely going to be into February before I have it fully plumbed in.

The sill anchors for the jacks are finished now

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Just to give an idea of the size of the GTX42, here's it next to the T04z :eek:

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