M1tch's long term 1ZZ build - Project 11

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

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m1tch

Still waiting for more PS fluid to arrive but there is still some in the tank so have been able to drive it a bit here and there.

Have roughed out an open loop boost table and have used it for the closed loop table, setting up the PID as a default setting.

Closed loop worked well and the car boosted to 177kpa or around 11psi,think this is a far as the closed loop went as its limited to adding up to 15% duty cycle to the MAC valve - have adjusted the table with this knowledge as I can see what duty cycle was needed at what RPM and boost levels.

Turbo seems to be at full boost at around 3.5-4k rpm, closed loop initially runs the wastegate at 90% duty cycle to spool up the turbo as quick as possible before moving to the closed loop setup.

I have also setup boost by gear as well, plan is the following in terms of boost targets:

1st gear - wastegate spring pressure
2nd gear - 12psi (stock 2nd gear so don't want to put too much torque through it)
3rd + 4th gear - currently 12 psi but might bump to 14 psi
5th gear + 6th gear - currently 12 psi and might keep at this level, won't really be using these gears during the 1/4 mile

Fuelling it also being adjused using logging and the mixture map to adjust individual cells, initially very rich vs target AFR but is a safer place to be to then remove a bit of fuelling. Also good news that at 11-12psi of boost the fuel system can still deliver a lot of fuel so plenty there as I increase the boost levels.

thetyrant

Ex-2005 roadster  owner, i will be back :D

m1tch

PS fluid has arrived and toppped up, no leaks so far which is good!

Only done a few tweaks to the car over the weekend, mainly cleaning and fitting a windscreen aerial.

I also have a Blitz Nur spec exhaust to fit, ideally wanted a Kakimoto exhaust but this one will do for the time being, will look to fit that soon, probably easiest to take the front bumper off as the midpipe is on at the moment.

I have also got some slightly more flexible 19mm hose as one of the connections on the charge cooler is fairly tight and basically loops back on itself so might look to try and remove some of the tension on the fitting by running a line under the charge cooler and round. Works fine in its current configuration but working through possible issues in the future.

Next few things on the list will probably be front brakes and pads and continue mapping it for the current boost levels.

m1tch

Went out to do some logging again last night, steering felt good with the new fluid and I didn't see any leaks but will check the level and pipework later now its had time to sit for a bit.

Currently dialling in the wastegate base table for the closed loop, its almost there in terms of boost vs target, have the base table a bit too low as a starting point at the moment but it does hold around 11psi of boost.

Need to work on a better intake to the turbo next (pipes and connectors have arrived), I can see the intake air temps post intercooler getting slightly warm (although not hot), currently there is just a filter on the front of the turbo as a starter for 10, plan to get some pipework in there and feed air in from behind the passenger light or anywhere else that isn't right next to a hot exhaust and turbo!

On the up side I can see the intake temps just creep up during the drive rather than suddenly spike on boost - shows that the charge cooler is working but just needs to be fed colder air to begin with.

Current boost level is set to 180kpa or around 11.6psi boost, I believe I have a 6-7psi wastegate spring in there so might be at the limit of what the spring can cope with, will plan to get a base table sorted for this spring and then swap out to a slightly heavier spring for higher boost at a later date when I get some dyno time booked in.

Currently the closed loop is maxxing out at its maximum of +20% wastegate duty cycle on top of the base figures from around 4k rpm upwards, have tweaked the table to start at a higher base from mid RPM as I think it might only need slightly more wastegate duty to get to a stable 180kpa (which is the target).

If the turbo is running at that boost level, checking the compressor map on the efficency islands it should be flowing enough for between 280bhp and around 325bhp or so.

Next up will be intake and change over the exhaust though (although no rush on the exhaust as its actually heavier than the one I currently have). Also want to do a slight replumb of one of the charge cooler lines but the intake is the next main thing on the list.

m1tch

Minor update, 180kpa seems to be mapped happily, have sorted out boost by gear and am running 180kpa in 1st, 2nd, 5th and 6th and 200kpa in 3rd and 4th. Mapping in terms of fuel seems to be ok up to 4k rpm but can't road map any further owing to the speed the car is at above that (I always keep within the speed limits, although might get to them quicker than others!).

Charge cooler has been sorted, I actually needed to leave a small air gap in the filler neck setup for air to escape to - intake temps are now so cold that in some cases the air intake temp fuel correction is adding a small bit of fuel even when the charge cooler is in the hot engine bay its cold to the touch.

Using the Borgwarner matchbot for turbo sizing it also shows the possible BHP and torque at different boost levels as well as the air flow through the engine.

Looks like at 12psi the engine will be making around 270-280bhp with 14psi slightly higher at the 280-310 mark, if this is the case and the car weight being around 1 ton I might be able to dip into the high 11s at this power level.

I think the current stock (7psi) wastegate spring might be able to take slightly more boost as it was controlling 200kpa ok but might just run with this and see what I can do on the next run what ya brung.

Call the midlife!

How have you configured your boost by gear settings David? Have you fitted a sensor to the box somehow or just by approximation/extrapolation?
60% of the time it works everytime...

m1tch

Quote from: Call the midlife! on May  3, 2022, 08:11How have you configured your boost by gear settings David? Have you fitted a sensor to the box somehow or just by approximation/extrapolation?

The Link ECU works out the gear using the RPM vs speed - I have gone through the logs and manually set these from the data gathered from the road tuning so far but there is an option to do it automatically. I wanted to make sure that it didn't try and boost above 12psi in 2nd gear to avoid issues with the torque going through the box.

Drove the car into work this morning logging as I went, a nice increase in the number of logged values to average out each cell, think most of the off boost table is either sorted of tweaked slightly to target - most were spot on or very close so happy with the map.

I can run the closed loop lambda setting in the Link ecu to adjust the fuelling on the fly if its off target but trying to get things as close as possible without it switched on - drove fine this morning without any auto fuelling options enabled.

Only issues I have come up with so far is some of the manifold and turbo bolts coming slightly loose - have some locking washers to hopefully sort this and the charge cooler is sorted and happy now so thats a win.

Only thing standing between the engine going to full power now is a wastegate spring change and some changes to some figures in the ECU.

Looking at the logs in terms of fuelling, the engine needs an extra 5% of fuel for every 20kpa of boost based on the mapped out 180kpa data and the data I have for the 200kpa line. Will need to get it dyno tuned for the higher RPM figures but will be able to log these on the drag strip. Fuelling map is currently running rich so its more of a case of pulling fuel out rather than worrying about the engine running lean.




Call the midlife!

Tidy, I wondered if there was anything from the SMT side of things to determine gear position that was also on the standard gearbox.
60% of the time it works everytime...

thetyrant

Glad to hear the chargecooler has worked out in the end, i thought it should do the job but as you know i never got to try it myself.

Keep up the good work :)



Ex-2005 roadster  owner, i will be back :D

m1tch

Quote from: Call the midlife! on May  3, 2022, 13:20Tidy, I wondered if there was anything from the SMT side of things to determine gear position that was also on the standard gearbox.

There might be an additional gear sensor for the SMT setup, probably on the actuator, I don't think there is any sort of gear position on the standard box.

m1tch

Quote from: thetyrant on May  3, 2022, 14:38Glad to hear the chargecooler has worked out in the end, i thought it should do the job but as you know i never got to try it myself.

Keep up the good work :)

Yeah, its working really well actually, its ice cold even after the drive to work, actually having an issue where its too cold and the ECU is adding fuel to correct it!

m1tch

Plan to go to Santapod tomorrow to see what the car will do, still have a few leaks at the moment owing to the turbo to manifold bolts loosening slightly - will be rechecking everything after I get there anyway.

Another annoying leak is actually from the turbo compressor housing that is inline with the bracket for the wastegate actuator - means there is very little space for the clamps so might need to rethink where that is in its current clocked orientation - might be able to flip the bracket.

thetyrant

If not already sorted i can recommend Nordlock washers for the turbo/manifold etc bolts if they keeping coming loose.
Ex-2005 roadster  owner, i will be back :D

m1tch

Quote from: thetyrant on May 13, 2022, 09:16If not already sorted i can recommend Nordlock washers for the turbo/manifold etc bolts if they keeping coming loose.

Yeah Nordlocks are on the list, gradually working through the various issues and working out which parts I might need to redesign/support differently. The exhaust manifold is now happy and nothing has loosened off since sorting a few spring washers on them so the next part to loosen off is the bolts between the turbo and manifold.

Will probably also look to upgrade the engine mounts as well as I think some of the issue is that the engine rocks every now and then if the clutch is pulled in too quickly as it grabs due to the higher torque rating (although is still light on the pedal).


thetyrant

I can recommend the Lotus elise/exige Powerflex void filler engine mount inserts which fit the Mr2 as well, i ran the rear one on my car helped stabilize engine and sort gearchange issue midcorner due to engine flapping about on stock mounts, i never got around to fitting the front one so if you fancy going that route ive got a new unused front kit in garage just let me know, its this one: https://www.powerflexsuspensionbushes.co.uk/powerflex-front-engine-mount-insert-pff34-603-for-lotus-exige-series-2-90081-p.asp

Rear mount insert i left in car but this is it: https://www.powerflexsuspensionbushes.co.uk/powerflex-rear-engine-mount-insert-pff34-602-for-lotus-exige-series-2-90080-p.asp

Much easier and more compliant for nvh than solid mounts.

If you havent already its worth fabricating a mount to support the turbo from underneath, helps take the strain off manifold and exhaust.
Ex-2005 roadster  owner, i will be back :D

m1tch

Quote from: thetyrant on May 13, 2022, 11:36I can recommend the Lotus elise/exige Powerflex void filler engine mount inserts which fit the Mr2 as well, i ran the rear one on my car helped stabilize engine and sort gearchange issue midcorner due to engine flapping about on stock mounts, i never got around to fitting the front one so if you fancy going that route ive got a new unused front kit in garage just let me know, its this one: https://www.powerflexsuspensionbushes.co.uk/powerflex-front-engine-mount-insert-pff34-603-for-lotus-exige-series-2-90081-p.asp

Rear mount insert i left in car but this is it: https://www.powerflexsuspensionbushes.co.uk/powerflex-rear-engine-mount-insert-pff34-602-for-lotus-exige-series-2-90080-p.asp

Much easier and more compliant for nvh than solid mounts.

If you havent already its worth fabricating a mount to support the turbo from underneath, helps take the strain off manifold and exhaust.

Awesome! Yeah I have seen some of those inserts but didn't know the exact part number, I wouldn't go 100% solid and I think BRD does different poly mounts with different hardnesses but not wanted to go that route yet.

A turbo mount is in the pipeline - have got some support bars with rose joints but think I can probably make something using the OEM lift points or the OEM NA exhaust manifold points from the bottom. Was always on the cards to sort out a mount for the turbo but wanted to get everything together first and working so I can see if I need to change any of the routing before adding brackets etc.

m1tch

Still having severe issues with the connection to the turbo - there isn't enough room for the boost pipe to really fit fully onto the turbo due to the bracket for the wastegate - its just come off again after securing it after it came off yesterday.

Car has been working fine with multiple days going to and from work but has decided to have this issue the day before I am booked in.

Will spend all my remaining spare time on trying to sort the issue today, car is mapped for the boost as its been fine for weeks, might just have to turn it down tomorrow if it keeps coming off.

Alex Knight

#617
Have you tried Mikalor Supra hose clamps?

m1tch

Quote from: Alex Knight on May 13, 2022, 14:05Have you tried Mikalor Supra hose clamps?

Its already running those T clamps - made sure I fitted those to as many fittings as I could, think the issue is that I can't get the hose and clamp on far enough due to the bracket in terms of where the compressor outlet is located.

I am going to have to try and remove the bracket (there is the oil feed line in the way of 1 of the bolts), fit the hose and clamp and then reattach the bracket and hope it holds.

m1tch

Minor update on the build, the drag day didn't go that well in terms of times but I have learnt a fair amount.

The day before I went I basically reconnected up the turbo to charge cooler hoses, needed to take off and bend the wastegate bracket slightly for clearances to get the hose and clip onto the compressor housing fully. I believe this has now sorted the issue of the hose blowing off at higher boost levels. The issue this then causes that that the bracket was slightly bent so the preload on the wastegate flapper was now not correct so it didn't make the same levels of boost as it did previously - it boosted ok to 12psi but couldn't go more than around 14psi whereas before it was boosting up stably to 18psi.

I ran the car on the lower boost at the drag strip, 12psi as the base boost and then whatever boost the car made in 3rd and 4th.

Times were terrible as I couldn't get a good launch - I've never actually tried to launch from 1st as I have been mapping in 2nd and 3rd for higher boost runs, coupled with the clutch being fairly grabby.

I have logged each of the runs but didn't really have a chance to change much at the track as I wanted to get as much data in as I could. I found that I had the boost control still in full force in 1st gear so the reason why it was getting no traction is the fact that the clutch was engaging, loaded up the engine and trigger the closed loop boost control so was basically engaging the clutch at something like 200bhp in 1st trying to go through 225 rear tyres.

Safe to say that I have now turned off boost control in 1st gear as much as possible so it should now only run up to stock spring pressure and hopefully further up the RPM range.

I also heard a few odd noises at certain boost level on the gearbox side of the engine so after about 8 back to back runs I decided to stop - it was actually really quiet so I could have done a huge number more but didn't want to break anything!

When I got back yesterday I started correcting fuelling maps, needed to pull about 6% of fuel out above 5k rpm which was to be expected.

I then readjusted the preload on the wastegate and it still didn't 100% work, worked through all of the pipework again and found that I believe my original Baileys DV26 BOV might have been the issue. The BOV is fairly old now and I don't know what preload spring it has in it but I doubt its very heavy. I believe that what might be happening is that the BOV is being forced open slightly at higher boost levels meaning its actually bleeding off boost with the turbo trying to make more to compensate.

I have now swapped it out for a different one which is much stouter, cleaned and rebuilt it a few months back and fitted it yesterday, it has made a difference so I think the BOV might have been leaking slightly.

I have also got a slight leak on my cam cover gasket, might be due to pressure build up, I am now looking at other options for additional breathers to be added to avoid this issue.

Alex Knight


m1tch

Car just passed its MOT with no advisories at 180k miles, sports cat fitted as well so happy with the result.

This year I plan to get it fully mapped on a dyno and try and get to Santapod more - might still get a chance soon to go again and make sure its not trying to make 200+bhp in 1st gear so I can get off the line!