M1tch's long term 1ZZ build - Project 11

Started by m1tch, April 8, 2017, 19:12

0 Members and 1 Guest are viewing this topic.

lamcote

#275
Without going into detail, I suspect your theory about how to implement the MAP/MAF options is a bit too simplistic. It's probably a good idea to have that discussion with a tuner at an early stage.
Silver 2004 MR2 -  Unmodified but very shiny.

m1tch

I have now test fitted the turbo and manifold to the engine temporarily to see how things look, will be upgrading the head to manifold studs, using copper fasteners and also bracing the turbo probably using the stock heat shield brackets etc.

Will be sending off the block for machine work probably next week - think mine will be the first ever CSS 1ZZ block in the world :)

shnazzle

Must feel like you've made progress when you see it all test-bolted up
...neutiquam erro.

m1tch

Quote from: shnazzle on February  2, 2018, 13:25
Must feel like you've made progress when you see it all test-bolted up
Indeed, was good to see it together, although I won't be turboing the engine initially I was happy with the setup. Looking forward to getting the block sent off and back again, will order the bearings etc in the next few weeks and after that I can start to put it all together.
Need to get a piston ring file but other than that it should go together fairly quickly - ARP studs are on the way as well.

m1tch

The block is being send off today to have the CSS fitted, I have asked the machine shop to take some photos of the progress, will be great to see how it comes together.

m1tch

Parts update, arrival of parts :D

ARP main stud kit
ARP head stud kit
ARP flywheel bolts

Link G4+ plug and play ECU harness

New TCB steering UJ

Currently in the process of cleaning up the stock head ready for gasket matching, seems like it is a 4zz head as I can see that there are valve seat inserts - will only be doing light work to the ports and will look to polish up the combustion chamber.

Need to order bearings at some point but its all coming together, I have plenty of time however as I won't be looking to install this engine until near the end of the year, still need to get the spare gearbox rebuilt with JUBA gears first.

m1tch

Quick update on the car, its all running well now, found that I had an intermittent air leak due to the evap solenoid!

I have also plugged in my Link Xtreme to the car, just to get the ECU unlocked, won't be needing to run it for a while as the stock ECU will suffice for a while, I do also have the PFC and Dastek which I might look to try out more as well but I don't feel there is much point tuning NA.

I have some seafoam in the oil at the moment which is really working it seems as the oil is much darker even with around 60 miles on it - its meant to be kept in the oil for around 125 miles or so as its not an oil flush as per say.

Next on the list is probably to sort out removing the soft top from the car, I have modded OEM brackets which will replace the ones in the car as the soft top and seatbelt brackets are attached to each other.

I also have an oil cooler which I might look to install soon, no rush on that though, plan to drive the car around a bit more over the next few weeks.

shnazzle

I wouldn't rest until that Link was talking to the car and starting it.
Don't know how your could just plug it in and leave it at that :)
...neutiquam erro.

m1tch

Quote from: shnazzle on February 17, 2018, 18:49
I wouldn't rest until that Link was talking to the car and starting it.
Don't know how your could just plug it in and leave it at that :)

I will have another go today regarding the link, there aren't any base maps for the engine but have been informed to use a monsoon base map and tweak it from there. I have a feeling that the stock ECU or the PFC might have a better tune in it when running NA, the Link ECU is mainly for the turbo setup due to the knock protection etc.

m1tch

The project engine block has been damaged by the courier on route to the machine shop - will have to see if its repairable or if I need to source another engine for the work to be done.

I was planning to personally take the block to the machine shop but went for the courier arranged by the machine shop as this would mean I wouldn't need to take holiday from work etc to take the block over to them. So far the only thing that has gone wrong so far has been the only thing that hasn't been in my control!

The damage is on the sump side so might be weldable - the rest of the block seems fine though so fingers crossed!

tomaky

Let me know if its scrap bud, got a 65k one sat in the garage. im starting to shift the stuff out of there.
Westfield Seiw
2011 Skoda Superb Estate 170 CR Daily Driver
2005 Porsche Cayman S
Ex - 2003 Sable
Ex- 2000 Pre FL Blue THOR RACING Ex- TURBO
Ex 2004 Blue  Roadster RIP

m1tch

Quote from: tomaky on February 21, 2018, 12:21
Let me know if its scrap bud, got a 65k one sat in the garage. im starting to shift the stuff out of there.

Thanks, I am located near Bedford - typically everyone who seems to have a spare engine seems to be in another part of the country!

tomaky

itll post if its packed well :)
Westfield Seiw
2011 Skoda Superb Estate 170 CR Daily Driver
2005 Porsche Cayman S
Ex - 2003 Sable
Ex- 2000 Pre FL Blue THOR RACING Ex- TURBO
Ex 2004 Blue  Roadster RIP

m1tch

Quote from: tomaky on February 21, 2018, 12:56
itll post if its packed well :)

No longer trust couriers with anything engine related anymore, I have sourced another block and will be collecting it tonight - nothing is even local it seems!

The machine shop might be able to use the damaged block for the machine work as only the lower part of the block has damage - might be able to simply swap out the lower part of the block from the spare engine.

Unsure of the condition of the short block I am collecting tonight though, but it should be fine as its being machined +0.5mm over so will take out any issues if the whole block is needed - doubt it will be in a good condition as the block already sent though.

m1tch

After a fairly horrific trip after work I have now got another spare engine block along with some modded seat rails so I can fit aftermarket seats at some point as well.

Plan is to strip this current engine this week - its just a short block so shouldn't take long! - and get it to the machine shop on Friday, will be hand delivering this one. The bores on this spare engine look to be in fairly ok condition - eg I can still see the hone marks and nothing looks to be polished etc. Its been sat for a while so will need to loosen off the pistons but will soak them over the next few days.

Hopefully that is the last block I need to buy for the project!

m1tch

Started to strip the engine down, took the sump off which was a nice silver colour with lumps of bearing in it. I have broken the engine down further and I can see 1 of the con rod bearings has been utter destroyed and also wiped out the crank. I am not too worried though as I just need the block - as long as the bearings took all of the damage the block will be fine, was hoping to be able to have a spare crank.

Oddly the oil control rings are perfect but I can see that the bores are slightly polished (but I can still see hone marks) so the bores are still good.

m1tch

The spare block is now at the machine shop - took it there personally and had a chat with the owner and asked a fair number of questions in terms of other builds and his personal experience over the years he has been tuning cars etc.

Just using the Borg Matchbot to look at various turbos they offer and to give me an idea of the lb/min the project engine will need at certain RPMs. Plugging in the engine displacement (1816.8cc with the 0.5mm overbore), ground level at around 15c and a top RPM limit of 7,500, 21psi, its showing 44.1 lb/min air requirement up at 7500, dropping this down to 7,250 rpm its at 42.6 lb/min. Its predicting around 425 bhp at the upper RPM with max torque being around 316 ft/lbs.

Both of these seem to make sense - it looks like there is a 20 ft/lb increase if I went to the larger 82mm bore with around 25bhp more at the same RPM - basically happy that I didn't go for the 82mm as it would save the gearbox! Although saying that if I up the boost to around 28psi the power level is at around 500bhp but at 350 ft/lbs torque - corrected lb/min jumps to 52 lb/min. Looks like I might be looking at a Borg airwerks S257 as even at 28psi boost its still within a fairly good efficiency island - not sure if I can go to an EFR turbo as its twice the cost!

The plan is still to run this engine NA for a year or so, some Supertech valve seals have arrived as well which are slightly slimmer to allow for double valve springs if needed, still deciding on if I want to run the 4zz head or look to source another 1zz head - it would seem that the head was running 32mm valves so should be fine to use.

1979scotte

EFR or GTX for me mate.
With your setup why go for anything second rate.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

m1tch

Quote from: 1979scotte on March 10, 2018, 17:56
EFR or GTX for me mate.
With your setup why go for anything second rate.

You make a good point, still looking into various turbo, won't be fitting anything until probably next year. Looks like some of the gtx28 turbos with a large wheel might be in the frame or a smaller gtx30 sized turbo like the GTX3067R. I won't be running 21psi all the time so need to find a turbo happy to run on lower boost but is still large enough to be efficient at higher boosts from time to time.

shnazzle

See I always liked the Td05 for that. TD04 might be better for a 1.8 but I do love the way a subaru pulls
...neutiquam erro.

m1tch

Quote from: shnazzle on March 11, 2018, 19:06
See I always liked the Td05 for that. TD04 might be better for a 1.8 but I do love the way a subaru pulls

I have a T3 manifold (with a t25 adaptor if needed) so I would need to source/get custom made a TD flanged manifold but I do agree with the TD turbos, also looked at some of the K04 turbos as those are fitted to the 1.8t/2.0TFSi VAG engines so are about the same size.

shnazzle

Quote from: m1tch on March 12, 2018, 07:10
Quote from: shnazzle on March 11, 2018, 19:06
See I always liked the Td05 for that. TD04 might be better for a 1.8 but I do love the way a subaru pulls

I have a T3 manifold (with a t25 adaptor if needed) so I would need to source/get custom made a TD flanged manifold but I do agree with the TD turbos, also looked at some of the K04 turbos as those are fitted to the 1.8t/2.0TFSi VAG engines so are about the same size.

K04 is a great turbo but the k03s would suit the 2 better I think. The k03 af 240hp on the VAG block was always found to be more flexible and responsive than  the K04 at 240. And that's on a 2.0.
K04 is easier to get ahold of though.
...neutiquam erro.

m1tch

Quote from: shnazzle on March 12, 2018, 19:07
Quote from: m1tch on March 12, 2018, 07:10
Quote from: shnazzle on March 11, 2018, 19:06
See I always liked the Td05 for that. TD04 might be better for a 1.8 but I do love the way a subaru pulls

I have a T3 manifold (with a t25 adaptor if needed) so I would need to source/get custom made a TD flanged manifold but I do agree with the TD turbos, also looked at some of the K04 turbos as those are fitted to the 1.8t/2.0TFSi VAG engines so are about the same size.

K04 is a great turbo but the k03s would suit the 2 better I think. The k03 af 240hp on the VAG block was always found to be more flexible and responsive than  the K04 at 240. And that's on a 2.0.
K04 is easier to get ahold of though.

Will look at turbos again in a bit - I do already have a T3 manifold though so would need to work out a way to adapt to a different flange.

The block is away at the moment so I am starting to concentrate on the cylinder head a bit more, I might need to get another head though, need to recheck that this 4zz head is ok for the standard 32mm 1zz valves - I believe that it is though but has a standard valve seat rather than the laser clad ones on the 1zz heads.

Need to look into springs as I might want to run double springs or see if there are beehive springs available - the Supertech valve stem seals are able to run either- would be interesting to see if the 1zz and 2zz heads can take the same springs.

As mentioned before I will be running the car NA for a bit, not ideal on the lower 8.8:1 compression ratio, there will be around a 5% drop in power like for like, however I will be running around 1.2% larger capacity and a higher rev limit so it might make up for it.

Nvy

Quote from: m1tch on March 12, 2018, 07:10
Quote from: shnazzle on March 11, 2018, 19:06
See I always liked the Td05 for that. TD04 might be better for a 1.8 but I do love the way a subaru pulls

I have a T3 manifold (with a t25 adaptor if needed) so I would need to source/get custom made a TD flanged manifold but I do agree with the TD turbos, also looked at some of the K04 turbos as those are fitted to the 1.8t/2.0TFSi VAG engines so are about the same size.

Nissan silvia has T3 turbo but u could look for TD05 -16G or 20G turbo with 7cm hot part. It would spool good on 1.8 and will make some boost, also im not sure but some of the Evo turbos have titanium wheel which will give u better spool but you would need another manifold coz of twin scroll design. If i had to choose id go GTX2863-67(these can be found new for 1100-1300 dollars not sure if the hot part is in the price, the cheapest i found are on turbokits.com) or if some OEM id go Evo one with titanium wheel its a bit hard to find but worth it IMO.

m1tch

Quick update on the project so far, things are progressing:

2nd block is now with the machine shop for CSS work - UPS dropped the first block on the way to the machine shop and shattered a corner so basically junked it

Power goal for this engine is around 400bhp - boost for full power run will be set to 21-28psi

Engine build will hopefully be the following:

CSS block bored to 79.5mm - stock sleeves, CSS is rated to 700whp on this engine so more than needed
4zzA3 head with light porting to gasket match
Supertech Nitride valves
Supertech valve stem seals
Supertech dual valve springs/retainers
Crower stage 2 forced induction cam
ARP head studs
ARP main studs
ARP flywheel bolts
Molnar rods
Traum custom pistons - 79.5mm, 9.5:1 compression - will probably bump up slightly when the block and head as skimmed/decked
King racing main bearings - still deciding vs ACL (same as 2zz so a few options)
King standard conrod bearing - still deciding vs ACL (no race bearing options for big end bearings on the market)
OEM oil pump with hopefully upgraded oil pump gears
Fidanza lightweight flywheel
Baffled sump - either Morose or eliseparts
Clutch - TBD
Gearbox - standard 6 speed with JUBA 3rd and 4th gears

The engine will be run NA once installed for a year or so for break in and enjoyment of the car and also for me to collect all of the turbo parts, have already started collecting parts but will take a while to get everything together.

Other aspects of the car currently in progress:

Coilover install
LED bulbs for the rear lights
Reinstall of the Link Xtreme ECU to get it up and running, have configured the ECU on a basemap but have yet to plug it in and fire it up
I have 2 new rear calipers on the shelf ready for install
Check driver side rear caliper as I think its seized slightly
15 Ohm 25w resistors on the O2 heater cables to stop engine check light
Replacement steering UJ
Discs to be changed all round
Pads to be changed - still deciding on pads
Change over of cone filter - current cone filter fitted behind battery is a bit past it, looking to change to an enclosed filter
Removal of softtop
Race seat for track day/drag strip, looking to run Celica seats for a daily drive

Tags: