Gary's Track Day/Fast Road Weekend Car (1ZZ turbo) Now 2zz Turbo

Started by Gaz2405, March 11, 2019, 20:39

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Gaz mr-s

Quote from: Gaz2405 on June  6, 2019, 09:48

The stuff I ordered from Megillian still hasn't turned up with various delivery dates missed, "48 hours from the powder coaters blah blah blah!!" I paid for them in full in March........Its now June!!

Not uncommon.  Anybody else reading this, I wouldn't pay fully in advance.

Gaz2405

Change of plan re: engine management, Apexi PFC came up on the forum so grabbed that.

There's several mappers round me that use it.

Long term I probably won't keep it, as plan on going k20 turbo or 2zz turbo in the future.

Just need to get an extension finished at home first!
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

shnazzle

Quote from: Gaz2405 on June  7, 2019, 20:27
Change of plan re: engine management, Apexi PFC came up on the forum so grabbed that.

There's several mappers round me that use it.

Long term I probably won't keep it, as plan on going k20 turbo or 2zz turbo in the future.

Just need to get an extension finished at home first!
The apexi will see you right for a while. Well done
...neutiquam erro.

thetyrant

Good choice as while pfc is old tech compared to latest kit but with good mapper more than capable :)  saves me pondering buying that one anymore as well!
Ex-2005 roadster  owner, i will be back :D

Gaz2405

Little hit more done in the car today.

AEM wide band installed, put the gauge where the cig lighter goes, will get a photo up later.

Fiat seicento radiator fitted in front of the standard rad for the charger cooler.

Charge cooler 19mm ID pipe ran under the car, down into the engine bay, around the petrol tank and then follows the rest of the pipe work down the centre.

Got a slight coolant leak where the reducer meets the coolant line for the turbo, only a slight drop but won't nip up anymore. I've ordered some more braided hose, which is coolant specific rather than a do it all, so should have a bit more give in it to tighten up around the reducer.

Hopefully take the thing out at the weekend in very low boost. Keeping an eye on AFR, then get it booked into RS tuning in Leeds for mapping.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Quick ten minutes tonight.

Changed the chain tensioner seal as it had been weeping previously by the looks of it.

Received Apexi pfc today in the post along with some new braided coolant lines and Maf sensor, so will try and get that fitted next week.

1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Got my Apexi pfc installed today.

Loaded a base map using the fc hako it came with.

Started on the button but with rough idle, will go through self learn idle set up tomorrow if I've got time.

Plugged in the new maf prior to this which made no difference, so I've obviously outside of the range for the standard ecu to deal with.

As soon as maf is unplugged with pfc, it stalls straight away.

Will link up my wide band to the hako later in the week.

Got some plumbing to do for the charge cooler rad at the front just waiting on some hose reducers form auto silicone hoses.

Depending on how rough the map/idle stays I may just plug in the factory ecu to drive to the mappers and change over once there. Undecided yet.

I have noticed I may have slight oil creep past the turbo seals, I thought I may encounter it as my oil return pipe is quite short and with the t3 to t25 adaptor on the turbo sits quite low.

I'll monitor and if I need to go new manifold, to bring the turbo higher I can do. Or may have the 2zz holes in the manifold welded up and then redrilled to suite 1zz in that configuration so the turbo sits on top.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

1979scotte

Make sure your return to the sump isn't too low.
This can cause oil to back up and pass the seals.
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 🇺🇦

Gaz2405

Yeah return is as high up in pan as possible.

I knew it would be touch and go and there's not much in it.

Like I said, options around it should the need occur. * crosses fingers
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Couple of hours tonight.

Replacement braided hose had come for the coolant pipes for the turbo so swapped those over.

What a ball ache to do with the turbo insitu!

I'll get some longer banjos at some point so it's easier if needed in the future.

Anyway all fitted and car ran up to temp to check for leaks.


1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Ok, so took the car for a gentle drive on the stock ECU, waste gate held open.

Couple of reasons:

1.General shake down as the car had been in bits and put back together so many times.
2.Check to see how smokey it was, with my potential oil seal issue.
3.Just to get out and drive the ting again.

Took it steady and didn't really get above 3k, once the initial smoke had gone it ran clear. Result!

Stock ECU cut fuelling if I got a little too exuberant, would expect that anyway.

Had forgotten to nip up the screws on the front wheel arch cover at the front bumper, so had a bit of a scrape on the way back.



So back home, content with how everything went I got Apexi PFC out.

2 Minutes to install.

Laptop open, HAKO connected. Loaded a base MAP, let the ECU do its self idling thing.

Came back to it and adjusted correction table on inj map to get AFR's to a more sensible figure whilst on various idles.

All in all quite an easy piece of kit to use (for idling anyway!)
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

The wife's out tonight so I've just come back in from finishing up the charge cooler pipe work at the front bumper.

All plumbed up and ready to go now, just need to wire in the switch for the pump now.

Front bumper back off and now back on again!

OEM Exhaust heat shield for the back bumper fitted.

Checked the Apexi PFC on cold start and all was fine, set the Hand Controller to monitor: Knock, Air Temp and Inj Duty.

Away with work for a while now, so won't be touching it for a while. So all back under cover in the garage.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Quick hour tonight playing with the Map after hours and hours of reading over the last couple of days, retarded the ignition table and played about with the ignl table too.

I think I might take a slightly different approach on the tuning side of things now and look to try and Map this myself.

Hold up a few of you might say. looking for trouble there!!

However, a bit of back ground on myself to start with:

This isn't the first foray into tuning for me, I've built A series Mini's in the past and engine swapped newer engines into older cars before. So I'm not afraid to use a spanner or pass up any opportunity to buy an new tool! I've dabbled with adaptronic ECU's some 10 years ago back when you had to make your own harness for them.

Although I don't do it as a profession (I run a construction and offsite manufacturing company) I do actually have a degree in Automotive Design Technology and i'm surrounded by engineering concepts day in day out.

My brother in law also has his own tuning shop/garage that prep all sorts of Race cars, so we thought worst case we'll turn it into the ultimate sleeper and K20 turbo it.

The car to me also is a weekend/track car, so if it goes pop it isn't the end of the world.

Most of all though I enjoy the learning process and I'm hands on in everything I do whether it be work or outside, also being a tight Yorkshire Man if I can do it myself rather than pay someone I will!

Should hopefully get some logged runs done next week to see where the map is under some load.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

thetyrant

Good progress :) still not sure what to do power wise with mine so keen to see how this develops.
Ex-2005 roadster  owner, i will be back :D

Gaz2405

Frustrating evening with the car tonight.

Went go bleed the charge cooler system, I'm pretty sure the pump I have is knackered!

Just doesnt seem to have enough in it, I'm getting a trickle at the header tank all pipe work is 19mm id.

Will try and pick up a new one tomorrow and go again.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

One final test this morning before going to get a new pump and all seems well. Can only think the air has come to the top of the header tank over night and finally got rid of the air lock.

Had planned on logging some data today on some runs, but the weather is terrible so that will have to wait.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

It lives!! Sod it went out anyway!

Did around 8 miles in it this morning logging multiple runs with the laptop on the passenger seat and changing fuelling/ign timing as I went.

WOT doesn't seem to be a problem, main issues was on part throttle at lower speeds.

I was having an issue at part throttle running lean, but that's now sorted for the most part but will monitor and try some logs just to pin point that driving characteristic. (was running high 16s AFR on part throttle)

AFR's are in the 11-12ish range WOT, highest knock reading was 40 adjusted timing and fuelling in that cell.

Most knocks are now in the 10-15 range on max.

When I have more time I'll look to bring the timing back in to until Knock start to creep.

Boost is at waste gate pressure at the moment at 7psi, comes in lovely and smooth so far so good and loving the turbo fluter.

Intake temps maxed at mid 50's but I went out with the charge cooler pump off, so should drop considerable when this is up and running.


1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Another play with the car tonight.

The last time I took it out i was having intermittent "overheating" issues, I suspected it was a dodgy radiator bleed by myself as I wasn't getting any heat in the heater matrix.

So firstly sorted that....

Then as my knock readings were low across the range and timing was very conservatively set (due to being super cautious about knock!)

I had a play around with the timing offline at work today upping it by 1-2 degrees in places, minimum 1 degree across the whole map.

Well, what a difference!

It now feels like a boosted car properly, had one knock reading of 41 under load low down in the revs, that was my highest on the previous settings so wound that back down and added a little more fuel.

It made such a difference in fact, that i can't go WOT without major clutch slip.

So the car is back in the garage for a bit now whilst i have a read up on what clutches are available!

Overall it put a massive smile on my face tonight though.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

thetyrant

Stop it! you got me looking for turbo manifolds now! :D

Sounds good and once you sort clutch so you can fine tuning mapping will be a beast :)

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

Gaz2405

#69
I've actually been quite surprised at "how easy" the process has been.

Admittedly it still needs some bits sorting to be ready for the track.

1. Down pipe to be fully tig welded. (my mig job is holding up fine, but its always in the back of my mind)
2. New clutch
3. Charge Cooler pump to be switched
4. Full brace kit to be fitted (which ever year it turns up!)
5. Track focused tyres
6. Still need to wire up the oil temp sender
7. Heat wrap the exhaust to help with engine bay temps a little
8. New discs and pads

There's probably lots more, but that'll do for the time being.

Just been reading the how to's on clutch replacement, looks fairly straight forward but a ball ache none the less!

I might just throw it into a garage for it doing, but then I'll want to make sure that all the charge cooler and associated pipe work is put back on again properly, so will most likely end up doing it myself!

So far I it think it probably stands me at about £2.5k, I'll try and do more of budget when I've got some more time.

So, car at £2.5k plus £2.5k for the set up. Don't think you could go this fast in a mid engine RWD for less!



1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

JB21

Nice build, looking forward to seeing how this goes on track. What figures are you expecting it to put out once fully mapped?

If interested I have a set of FL wheels with NS2R tyres that i'm looking to swap for FL wheels and road tyres, PM if interested.

shnazzle

Nicely done! And kudos for the home-mapping.
...neutiquam erro.

Gaz2405

#72
Cheers guys,  not sure what I'm hoping for power wise 220bhp plus would be nice to start.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Chriss

Really like this build, will be watching with interest. Love the seats.

Gaz2405

Finally an update with some pictures!

Spent an hour or two this morning getting the charge cooler pump switched into an ignition live.

Managed to get the hard top back on in a cramped garage by myself, ball ache!

Then went out for an hour or so of logging drives, stopping, adjusting the map, checking knock, checking inj duty, timing, air temp.

Even though the clutch slips at WOT it was a good opportunity to get some partial throttle stuff done, to try and aid the drive ability of it. To be fair it drives superb for a home brew map.

Knocks are now all averaging under 10 with a spike at higher revs to 18/19 ish.

AFR's settling at around 12.3ish, I'll probably make this a little richer with the new injectors in just for a precaution.

Once the car was fully warm and the clutch was holding a bit better I opened her up a bit more, I'm now at 100% injector duty at the top end, so the 630cc's will be going in next, just need to alter the harness.

Intake temps all averaged in the low thirties with a peak of low 40's, so the charge cooler is doing its job, it will be interesting how it fairs when its given some hammer on the track. I also need to make some other cooler mods to the engine bay, better ventilation, heat wrap etc.

The engine bay needs a bit of a general tidy up and I may swap my blue silicone hoses for black as the blue is a bit 2000's!

My homemade down pipe which is connected onto a Malian sports cat, has started to knock/vibrate the roll bar slightly on tick over sometimes, I knew it was close when i made it but may need some slight persuasion/alteration for the time being.

On the look out for a new clutch, don't want to go stupid and over do it and ruin the driving experience, so anyone who's running an uprated one hit me up with your suggestions.



I love how it will be such a sleeper and surprise so many people.

1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0