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Madmac Motorsport's Twincharged Evo 5

598096 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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On another note, if you sync this video using each screen's play button using pause when the car starts to move, you can use the pause and play button below which controls both videos at the same time. This way you can see how far you were in front or behind at certain points. It's pretty accurate if you sync the videos.

http://www.youtubemultiplier.com/5534f827ef129-madmac-2015-vs-2014-doune.php

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Not too far behind your record to say it's the first sprint of the season. :smthumbup

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That's much further into the comparisons than I've had time to do since the weekend. The GPS is unreliable IMO at areas due to the trees there's no doubt when you look at speeds up through tunnel. Some videos show 95mph, some only 70mph at the same point. For unknown reasons the Motec hasn't logged GPS speed so I can't compare the 2 GPS signals. The Motec has a faster GPS frequency so i'd be more inclined to believe that log.

Doune isn't the place to be going nuts early in the season. To do a 44s run needs full commitment. The 45s run on Sunday felt 'easy' so I was fired up to do a fully committed run when I broke the front shafts :wallbang:

Car is back in bits. I'm installing a block breather so to get access with the engine in situ the turbo has to come off. I'm also moving the alternator and getting stronger shafts made before the next round at Fintray.
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That's the alternator brackets made. There's 2 belts at 90 degrees to each other so I needed to keep the alternator adjustable in 2 directions. I just used 12mm aluminium plate and cut it on our CNC router.

Also block breather -12 fitted and a -10 drain from the catch can back to the sump.

Fintray Hillclimb this weekend ;)

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That must be about mk4 on the bracket!


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That must be about mk4 on the bracket!
This was the Mk3 version, Mk1 and Mk2 versions were too heavy. Mk3 was a whole 550g lighter, and moved the alternator back 24mm which keeps weight back in towards the centre of the car and help balance - less overhang forward of the front wheel axle line. ;) :D
Any updates Donald? Have you made tiddles fast yet? :lol:
Any updates Donald? Have you made tiddles fast yet? :lol:
I'll tell you once I've had a chance to drive her :lol:

Was back at the dyno for the last stage of the mapping - delayed as I've been too busy with my day job for months so last week was the first chance to get back to Simon Norris dyno.

Happy with it now. There's 140hp more than last dyno session and a massive spread of torque from 3600rpm to the redline at 8500rpm. If I were to rev it to 9k it would make anther 50hp but I doubt i'll need any more.

New front driveshafts are fitted, am still waiting for the rears to arrive, exhaust completely rebuilt as the boxes literally split apart on the dyno :eek:

New carbon front bumper and floor section needed to be made after running out of talent at Doune :blah:. I was 0.2s up from last years record split time during the accident so it's fair to say I was pushing on :blush:

Alford Sprint this Sunday. Will be the first time i've driven her with the new map :D

I'll update with more when I get a chance as there's a lot gone on since I last updated.
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As already said last Saturday, respect Sir, figures are just crazy.

All the best for the sprint.

Keep us posted.

Jon.
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I'll tell you once I've had a chance to drive her :lol:

Was back at the dyno for the last stage of the mapping - delayed as I've been too busy with my day job for months so last week was the first chance to get back to Simon Norris dyno.

Happy with it now. There's 140hp more than last dyno session and a massive spread of torque from 3600rpm to the redline at 8500rpm. If I were to rev it to 9k it would make anther 50hp but I doubt i'll need any more.

New front driveshafts are fitted, am still waiting for the rears to arrive, exhaust completely rebuilt as the boxes literally split apart on the dyno :eek:

New carbon front bumper and floor section needed to be made after running out of talent at Doune :blah:. I was 0.2s up from last years record split time during the accident so it's fair to say I was pushing on :blush:

Alford Sprint this Sunday. Will be the first time i've driven her with the new map :D

I'll update with more when I get a chance as there's a lot gone on since I last updated.
So can we have a look at your graphs and in car crash? Now that would be interesting :lol:
So can we have a look at your graphs and in car crash? Now that would be interesting :lol:
Simple answer, no video :blush:

I'll post up the graph when I get a chance to scan it and update the thread as there's a few things to mention at the same time.

I'm on a deadline for a contract this week so I'm up to my eyes again with the signmaking
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I got the replacement front bumper made in carbon at only 1.9kg then doubled that weight with the splitter (plywood), however I managed to break the splitter unloading the car at Alford :blush:

This was my first chance to drive her yesterday, at The Alford Sprint. I only do this event as it's local and good for my sponsors to be seen locally. Previous class record was mine at 54.64s from last year.

The weather stayed good all day so I got some decent seat time. Practice I used last years slicks to preserve the good tyres for the competition runs. T1 time was a 52.11s, still half a second away from the record. I increased front end bump setting and went out for the last competition run and stopped the clock on a 51.49s to take a new class record :D.

0-60 time has dropped by 0.4s from my previous best 0-60 time. Can't wait to get her somewhere to stretch her legs. Alford only has 100m long straights and much of that distance is needed to brake

The exhaust was re-packed last week but I left the wastegate exhaust alone so she's sounding very different now, certainly nothing like as raw as she did last year.

No breaks, issues or failures and she's back home in one piece again which is always the best result :)

In-car vid:

Next event in 3 weeks :naughty:
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Cracking result then... well done!
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Great result. Well done, Donald.
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I have my entries to Harewood this weekend :smthumbup

The stronger rear driveshafts are fitted, alignment done and a few small jobs complete . Last year I got within 0.04s of the class record - with boost cut.:wallbang: frustrating!

I only get the chance to get down to Harewood once a year due to the distance and cost.
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Had seen you have entered .... hope its dry .
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Good luck and hope to see a PB/new record.
I have my entries to Harewood this weekend :smthumbup

The stronger rear driveshafts are fitted, alignment done and a few small jobs complete . Last year I got within 0.04s of the class record - with boost cut.:wallbang: frustrating!

I only get the chance to get down to Harewood once a year due to the distance and cost.
The showdown between you and the Banana will be the event of the year! People out to come and watch. It's going to be great.
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