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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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Had seen you have entered .... hope its dry .
Will you be there?

It's driving the hill I go for, not the record, but if it's dry then it would be rude not to try and take the record north :D

I don't have wets or intermediate tyres, only slicks. I run the slicks in the wet as only standing water affects them. In 5 years there's only been a coupe of runs I wouldn't have gone out on track due to water running down the track.

Good luck and hope to see a PB/new record.
Thanks, I'll give it my best shot :smthumbup

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.
Hardly the event of the year. I'm looking forward to a battle though. Always quicker if there's someone to push me ;)

The new torque and power curves that the Twincharger system is producing will certainly make a substantial difference to her pace. 0-60 time dropped from my previous best of 3.09s to 2.70s after the last dyno session :D

All he best Sir.

Jon.
Thanks Jon :smthumbup
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Will you be there?

It's driving the hill I go for, not the record, but if it's dry then it would be rude not to try and take the record north :D

I don't have wets or intermediate tyres, only slicks. I run the slicks in the wet as only standing water affects them. In 5 years there's only been a coupe of runs I wouldn't have gone out on track due to water running down the track.

Thanks, I'll give it my best shot :smthumbup
Yes am there for both sat and sun , the faster times will be on sunday .. more rubber down ... looking forward to it :smthumbup
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Yes am there for both sat and sun , the faster times will be on sunday .. more rubber down ... looking forward to it :smthumbup
Ok, see you there :smthumbup
I had a visit to harewood last month and thought what an amazing track it was . Locals were welcoming too and I can't help thinking your car will be a weapon around there . Any updates ?
I had a visit to harewood last month and thought what an amazing track it was . Locals were welcoming too and I can't help thinking your car will be a weapon around there . Any updates ?
Yea i like Harewood but don't get many chances to go there. Every year there's a 'Scottish invasion' which I try and join.

Unfortunately yesterday my engine let go. As yet I haven't assessed the damage. Logs show it was at only 6800rpm and 0.8bar boost so at this stage it looks like either a spun shell or simple rod failure. The rods are almost 10 years old but were crack tested last rebuild and new crower bolts fitted when I replaced the bearing shells before the 2014 season. It's had a lot of hard work done on simons dyno recently and 3 or 4 years since the engine was last built so i'm surprised it's lasted this long.

Unsubstantiated rumours started by someone on facebook imply the engine let go immediately after I had the laptop hooked up. Whilst I did indeed have it connected I have to pull the logs out every 2 runs as I only have the 1 meg M800 logging capacity. P1 run all was normal boost and performance but after launch on P2 the boost never went above 1.8bar and I was looking for a reason in the logs which pointed to a boost leak.

It means my season is likely over unless it's just a bottom end it needs.

I'll tear it apart today and all will become clear no doubt.

I'm looking for a 4G63 block cradle and sump if anyone has one for sale?
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I am sorry to hear that , 1.8 bar of boost isn't huge and am guessing there's some underlying issue or simply the engine said " enough is enough " . I always admire the builds that are extreme like yours and love seeing the times laid down at hills around the world . Good luck with the repairs and hope it's not too expensive to repair . Glad in many ways mines only 600 hp still .
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time to put something up in the wanted section.
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I am sorry to hear that , 1.8 bar of boost isn't huge and am guessing there's some underlying issue or simply the engine said " enough is enough " . I always admire the builds that are extreme like yours and love seeing the times laid down at hills around the world . Good luck with the repairs and hope it's not too expensive to repair . Glad in many ways mines only 600 hp still .
Thanks. It gives me a reason to build a better engine I guess but if damage extends to turbo, supercharger or intercooler then I may re - evaluate the whole setup or perhaps move on from evo's. There's enough in the car to break and buy a single seater ready to race and it would be a lot cheaper to own. That's a very tempting thought at the moment to be honest.

I'll know more later today
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Sorry to hear that Donald. Hope it's just bottom end.

You can't go down the route of single seaters - they are ten-a-penny while your Evo is unique and attracts a whole load more interest than any OMS, Empire, etc, does. Added to that, you get wet and cold in single seaters when the weather's bad. ;)
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Sorry to hear this news fella, I hope it's not the end of tiddles as that would be a huge shame. Hopefully you find the enthusiasm and lust to continue regardless of the outcome... would be nice to see it do MLR sprints too.
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Sounds like you had monies worth out of the last short motor. Hope you've been lucky on the aftermath
Sorry to hear this news fella, I hope it's not the end of tiddles as that would be a huge shame. Hopefully you find the enthusiasm and lust to continue regardless of the outcome... would be nice to see it do MLR sprints too.
It probably won't be the end of tiddles but this on top of other crap I've had to put up with from some in the tuning community just makes me want to move away from saloons altogether. All will be revealed in due course but it's not my place to spill the beans yet.

I've dropped the sump and it looks like an easy enough diagnosis. The rod bolts on cylinder 3 have sheared off. There's zero evidence a shell has spun and the one bolt head I've found shows a fatigue crack starting and eventually failing with the head dropping off. This is backed up by the 2 puncture holes in the sump where the rod bolts punctured and they are the diameter of the bolt shanks. The crank is damaged but not as bad as I thought it would be. Also half the piston is lying in the bore on its side with the little end of the rod still attached and I haven't found the missing bit of rod.

The annoying thing is these rod bolts were replaced last time I did the shells as the previous set were on their 4th tighten. Genuine crower bolts too :wallbang:

now my main concern is how bad the head is damaged and if the turbo has survived unscathed
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Wow! In this day and age with the latest tech materials and tightening procedures you wouldn't expect the bolt to ruin your season :(
That's a bit of bad news there mate. :blah:
Out of interest - what material and tensile strength were the rod bolts rated to? Got any pics of the failed bolts?

Onwards and upwards - this is a damn fine excuse to build her bigger and better.
Was great to see you again Donald. Shame you had problems and I hope it's not too bad a fix.
Gutted for you Donald.

Must say very unlucky.

Jon.
There's enough in the car to break and buy a single seater ready to race and it would be a lot cheaper to own. That's a very tempting thought at the moment to be honest.
You tried that, albeit briefly, a few years ago and Tiddles got upset ;) don't do it again!

When did you sell it? Nothing has raised it's head in my part of the world :confused:

Grant :)
You tried that, albeit briefly, a few years ago and Tiddles got upset ;) don't do it again!

When did you sell it? Nothing has raised it's head in my part of the world :confused:

Grant :)
I think the problem was it just wasn't the right car for me at the time. I sold it a couple years back. The new owner said he was hoping to have it out on the track quickly but I haven't heard any more since. It was in Buckinghamshire.
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