Originally Posted by ukoldschool
1. Why a 1.6? surely the 2.0 engine is a better option given that its pretty much the same physical size and weight.
2. What turbo are you using and why have you used such a large intercooler on a 1.6 engine?
3. What head bolts are you using and what size are they?
4. Why are you lowering the CR? modern turbo cars (mitsubishi etc) now run CR of around 9:1 safely. Ive even seen 'old tech' engines such as Integrale with high CR engines running at 1.4 bar safely.
Do a search on why Im using a 1.6 block and you will find the complete answers and reasone.When I bought the car,I bought the 1.6 as it was almost as quick as the 2 litre but much cheaper on insurance here in Ireland.That was 3 years ago,within 2 days of ownership I started to modify/change her.
G-Reddy/Trust Hybid T05D, with modified compressor side and bigger turbine blade installed for maximum airflow to intercooler.Good turbo for big power with minimal lag.No internal wastegate in this turbo so maximum flow from exhaust side of turbo.Tial 42mm external wastegate and screamer pipe installed.
This keeps the turbo spooling better than an internal wastegate and also dumps unwanted boost/exhaust gases better and quicker too.Will possibly be going for a GT 28 rs hybrid or possibly a G-Reddy T06D hybrid soon.
Custom designed(by myself) Pace front mount intercooler is only chilling the intake temp to 50+ degrees C.This intercooler and hardpipe kit was perfect when the car was 220bhp,but now that shes pushing 280-300 at 12-15 psi boost,the intercooler isnt up to the job.The Pace intercooler would be perfect for a Glanza turbo or a Mitsi GSR turbo engine running 200-220bhp
So I wanted/needed to have a bigger front mount intercooler with biger core and larger fins fitted to give an intake temp of around 30-35 degrees C.This means I can safely run a constant 1 bar boost and also run up to 1.2 bar aswell and I will also pick up another 10+bhp and some more torque.The colder/denser the intake temp and air is then the more power the engine produces.
I used an ARP uprated headbolt/stud kit and have also have used the headbolts from a 147 JTD as they are slightly stronger than the petrol engine bolts.Compression was already lowered by Autodelta 2.5 years ago when the car was first turboed.They lowered it to 8:9-1 by machining the standard pistons,but my present mechanic lowered to 8:5-1 to suit the spec of the engine.
Also running custom made low comp. Forged J.E racing pistons and Corrillo rods.It took 8 6 weesk for J.E(USA) to make and ship them to Ireland,but well worth the wait.
Also is a cutom made/engineered 2 mm solid copper head gasket.Copper is a great heat conducter and copper gaskets are now used on big bhp YB cosworth race engines and Feriday Cosworth rally engines.
My mechainc built/blueprinted/machined/honed the engine with the 2mm gasket and custom pistons/rods so that the 2mm extra would alow the car to have a slightly longer stroke.This is how this little 1.6 litre of mine is running with so much power/torque.
Black Beauty(A.O Member) can testify that my car is a bit of a rocket in a straight line and around corners(thanks to Race Logic traction control and launch control).I took him out for a little spin on Sunday and he thought it was great.Big grin on his face from it.
Any more questions then just ask away.Thanks for the comments/questions aswell.
P.S - Pics of Engine block honing machine in action,Custom 2mm copper gasket,G-Reddy Hybrid Turbo and Tial external wastegate with screamer pipe.
Also you can clearly see the difference in core/fin size between the old Pace intercooler on the car and the new intercooler.The new intercooler has an 80mm core and 20% bigger/wider fins for maximum cooling/airflow.