'01 Silver - The daily commute smile machine! (Turbo build)

[J88TEO]

Cheers, yeah I don't think it's the arms.. just a bolt.

I have a few sets of bolts for the rear arms.

[jvanzyl]

I have a few sets of bolts for the rear arms.

Hey cheers for the offer- will come back to you for future ones!

[jvanzyl]

Got the car back from the local garage today - wheels and steering waaaay better.

I intend to email RRR middle of the week to confirm this saturday... if anyone is in the local and wishes to see and observe what actually happens on one of these sessions they are most welcome.

[Alex Knight]

Got the car back from the local garage today - wheels and steering waaaay better.

I intend to email RRR middle of the week to confirm this saturday... if anyone is in the local and wishes to see and observe what actually happens on one of these sessions they are most welcome.

Last time I had a car mapped (ST205 on a Power FC at Thor racing), I sat there most of the day, with a few status updates now and again. There's really not much for you to do.

[jvanzyl]

Last time I had a car mapped (ST205 on a Power FC at Thor racing), I sat there most of the day, with a few status updates now and again. There's really not much for you to do.

Fair enough... I'm taking the camper van so I'll have facilities to make some food and I guess!

[jvanzyl]

Today's update in summary was a SUCCESS!



I got to RRR for about 0730- Greg got there a bit later. Started the initial inspection and we soon discovered that there was some kind of misunderstanding in our communications.

Greg thought I was turning up with a car with a pre installed ecu master black and he was just going to do some tidy up tuning... 

BUT in a testament to his work ethic and desire to help, he provided an ecu which is a sort of prototype that is plug and play ( I have to return it for a different one in 2 weeks) and did the mapping on this.

Put the 630 injectors in ( took a couple of goes to ensure no leaks) and got started with idle etc. I made us both sausage, bacon and eggs for brunch and then started in the dyno after lunch.

This is where it got super stressful, that watergate actuator I painstakingly altered to fit the turbo is actually set to 25psi!!  So I then set about swapping this for another that I'd brought (that we tested to 10psi and will still need replacing in the future) which was quite painful as everything was so hot, but I managed to get it done.
Play resumed and Greg was happy with the results, surprisingly so. He went through and showed several previous dyno maps that were getting substantially less than he was able to achieve with mine. I do not have any reason for this.



Took it out for a spin, and my word ... I'll need a large safe space to take it past 3.5k.. it's flipping quick.

All in all, I'm exhausted, burned and very dirty but pleased with the results. I've still got more work to do to ensure longevity with everything- but the important thing is it WORKS 

As this is a public forum, Dm me for actual figures.

[Gaz2405]

Today's update in summary was a SUCCESS!



I got to RRR for about 0730- Greg got there a bit later. Started the initial inspection and we soon discovered that there was some kind of misunderstanding in our communications.

Greg thought I was turning up with a car with a pre installed ecu master black and he was just going to do some tidy up tuning... 

BUT in a testament to his work ethic and desire to help, he provided an ecu which is a sort of prototype that is plug and play ( I have to return it for a different one in 2 weeks) and did the mapping on this.

Put the 630 injectors in ( took a couple of goes to ensure no leaks) and got started with idle etc. I made us both sausage, bacon and eggs for brunch and then started in the dyno after lunch.

This is where it got super stressful, that watergate actuator I painstakingly altered to fit the turbo is actually set to 25psi!!  So I then set about swapping this for another that I'd brought (that we tested to 10psi and will still need replacing in the future) which was quite painful as everything was so hot, but I managed to get it done.
Play resumed and Greg was happy with the results, surprisingly so. He went through and showed several previous dyno maps that were getting substantially less than he was able to achieve with mine. I do not have any reason for this.



Took it out for a spin, and my word ... I'll need a large safe space to take it past 3.5k.. it's flipping quick.

All in all, I'm exhausted, burned and very dirty but pleased with the results. I've still got more work to do to ensure longevity with everything- but the important thing is it WORKS 

As this is a public forum, Dm me for actual figures.

Great work, glad all your hard work paid off.

[jvanzyl]

Great work, glad all your hard work paid off.

Thanks man- btw I'd assumed that I'd be able to pass a mot with the deka 630 injectors, were you able to on yours? 

[jvanzyl]

To do list:
Sort out bend of charge coolant pipe where it gets thin.
Source new 10psi wastegate actuator
Rework wastegate hose to go direct to turbo
Remove old o2 sensor (x3) wiring and replace with bungs
Refit under trays
Get it through an mot
Work on oil drain leak.. more.
Return current ecu for new one in 2 weeks time.
Buy new tyres (AD08)
Enjoy it

[jvanzyl]

Popped the car back on the lift and removed the stock pre cat O2 sensors. Hooray less wires!
And put in the O2 bung


Rerouted the wastegate actuator hose from the turbo- still a bit long but I can sort that later.


Refitted the engine cover!


Need to buy another O2 bung to remove the post cat O2 sensor..


Then started work removing the unneeded  wiring and vacuum related stuff.




I think I'll retain the boost sensor for now as it'll be good to learn how everything performs.

Been thinking more about my wastegate issue. And I'm thinking I'm just going to spot weld it together... I may have to slim some items down so it can come off as one unit though..

[puma2]

  you must be happy man with how this is working out despite the burns  and stress overall   
this is what make a project hay  

[jvanzyl]

you must be happy man with how this is working out despite the burns  and stress overall   
this is what make a project hay  

Combination of happy relief and happiness,  yes! Still in the "relief" stage.  I think the fun will really be when I get to start driving it again properly and I'll be finding excuses to get out more..

[J88TEO]

Need to buy another O2 bung to remove the post cat O2 sensor..
I have 2 you can have for free - came with my header.

[Topdownman]

Will we be seeing the car at the DC National day?

[jvanzyl]

Need to buy another O2 bung to remove the post cat O2 sensor..
I have 2 you can have for free - came with my header.

Ah thanks!  appreciate that! I'll send you my address.

Will we be seeing the car at the DC National day?

Can't make this day unfortunately I'll be travelling.

[Topdownman]

Thats a shame.

Look forward to more reports once you start getting some miles on it.

[J88TEO]

Ah thanks!  appreciate that! I'll send you my address.

Found them!

In the post today.

[jvanzyl]

Thats a shame.

Look forward to more reports once you start getting some miles on it.

Yeah I'm looking forward to it being daily usable!

Found them!

In the post today.

Awesome!

[jvanzyl]

Fitted the O2 bung into the post cat position. Big thank you to @J88TEO




MOT booked for Friday, the list is as follows:

• make sure wheel nuts are locked
• Mark the waste gate length, remove, make mounting plate bigger, weld the arm together
• investigate the coolant piping in the front and fit 90 degree bends
• fit rear trays
• refit interior
• clean it

[thetyrant]

Getting there good work

 Will be interesting to see how you get on with emissions for the MOT or did RRR set it up and check it would pass ok ?   its one of those areas in mapping that can take some time and i know a lot of mappers dont do much with it, although the closed loop control if turned on should get it pretty close.

[jvanzyl]

Getting there good work

 Will be interesting to see how you get on with emissions for the MOT or did RRR set it up and check it would pass ok ?   its one of those areas in mapping that can take some time and i know a lot of mappers dont do much with it, although the closed loop control if turned on should get it pretty close.

Yes it will be interesting. It may require moving down to 440 more modern injectors and remapping. Will have to see!  🤞

[thetyrant]

Yes it will be interesting. It may require moving down to 440 more modern injectors and remapping. Will have to see!  🤞

It shouldnt need different injectors as long as they are in good health and ecu/mapping etc is good   oh and your CAT is a good one as well ?  i cant remember what you have in that regard ?

[jvanzyl]

It shouldnt need different injectors as long as they are in good health and ecu/mapping etc is good   oh and your CAT is a good one as well ?  i cant remember what you have in that regard ?

Well the Greg at RRR suggested finding a "friendly" MOT guy.. CAT is a brand new 200 cell high flow.. bearing in mind it's a 3" pipe I'd hope that this should be sufficient.

I managed to do the wheel nuts today (the one's holding the hub to the driveshaft), I managed to find my stud thing.


Next up will likely be the turbo actuator.

[thetyrant]

Hmm doesnt sound good on emisson tuning if he made that commment, friendly mot testers are hard to come across these days but hopefully you will manage

 CAT wise its more about the quality of it than anything else, was it a cheapy or did you pay a decent amount for it thats usually a good guide?

[jvanzyl]

Hmm doesnt sound good on emisson tuning if he made that commment, friendly mot testers are hard to come across these days but hopefully you will manage

 CAT wise its more about the quality of it than anything else, was it a cheapy or did you pay a decent amount for it thats usually a good guide?

Yeah I know.. 
well I bought it a long time ago.. it was £70 back in Nov 2022..

Best I can do is try I guess!