Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

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Jonno
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by Jonno »

DR_GEM wrote:Custom gauges. Why?
might be cause the speedo cable location on anything other than that dumb 4 speedbox can be an issue
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by GEMWRC »

Exactly .
You can make a gearbox mount work with a TX flat floor and 5 speed but the speedo cable cant be used

I was thinking you could use a custom speedo with gps
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

Is that the only issue?

I'm thinking of using the microtech ltc pro digital dash with GPS speed sensor

Did some measuring and sizing up today - the trimatic itself fits in the flat floor tunnel, but the top part of the transmission mount (the one with two bolt holes) is a very tight squeeze between the original tx transmission tunnel mount points.

Was thinking about a custom trans mount, but it would also seem the box would be sitting too low, and thus the mount needs to be stepped. Hard to desribe but will try draw a pic and upload.
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

So some may have seen my other post where I was looking for a running g161.

This was to go into what was once my granny spec te.

The coupe needs alot of my time and dedication for bodywork / welding the floor pan and trans tunnel in - which I haven't had the time for working 70 hours a week and a couple of kids etc.

So back to the TE sl/x, which now needs a respray as the paint has faded due to being in the sun for too many years. Other than that the car is quite clean - 4 rust bubbles in total - 3 around the windscreens (2 front 1 rear), and 1 in the front passenger door skin (on the inside).

Very easy fixes and so cutting out those rust sections, rubbing back and having it resprayed by a mate in the next few weeks.

Engine and driveline can then go in and start enjoying.

This will hopefully motivate me to get the coupe finished and transplant all the running gear etc into it when I need to actualy go racing.

Will update this thread as I go.

Mick
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by Jonno »

Cool
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

So I need a new seatbelt reel for the front driver's seat. The current one isnt retracting cos its been sitting there for so long.

Anyone know if you can get aftermarket new ones or others that would work?

Mick
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

So went digging a little and found some holes in the boot floor. Cut out, a
Plated and welded them today. Have them in primer at the moment.

Need to grind the welds and clean them up then will spray / body deaden

Onto the passenger front door next week too.

s*#t is getting done with this one

Mick
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

So been working on the te and wish i ended up doing this imstead of the coupe ages ago. The car wouldve been finished.

Anyway - rust bubbles around front windscreen ended up extending a bit too far under the windscreen rubber for my liking. So we pulled the windscreen out and ground back all rust and redressed it all with rust proof properly. Well worth removing the windscreen to do a proper job.

Also - ground the welds in the boot so its mostly finished except I ended up cutting out the wheel well section in the boot - have now tacked a new piece of sheet metal in there. Did 3 of the 4 sides before my mig welder s*#t itself today. Stupid thing.

Will buy another one hopefully this week and continue work on it next week.

Mick
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

Rust work on te all done!

Engine now assembled - need to pick it up and can't wait!

Bought a 4ze1 short block with a auto flexplate attached - was rare as rocking horse s*#t to get one so really glad I found it.

Reason for buying the short block - need the 2.6 crank for when I put the 2.6 forged setup back together. I ended up using my old 2.6 crank in my stroker 4zd1 setup, as well as all pulleys etc. So cheapest and easiest way was to grab this short block.

I sold the precision 6466 some time back (was dead money and I'm going to use a bw turbo for the big power setup later - got my money back for it so worked out well).

Plan is to run the d1 turbo in the TE with a gtx3071 I've got spare here. Should make 250-270 rwkw which should keep me occupied until the coupe is ready.

At that point I will take the head off the d1, grab a new head, have that worked to same standard as my current head, then drop the 2.6 into the TE and have it engineered (only model able to be legally engineered with a 2.6 turbo). D1 with new head then goes into coupe and bw s366 sxe twin scroll.

TE first though.

Mick
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by F3ARED »

How come you didnt end up going with the precision??? Supposedly a decent huffer
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

Sold it for cash flow but also have been super impressed with latest bw products (s257sxe twin scrollgoing on the liberty next week)

Compressor flow from the compressor maps are incredible. And reliability of journal bearing fully rebuildable.

Precision doesn't exacty have the reputation for reliability.

Mick
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by Jonno »

I've heard a lot of pros and cons with precision turbos. Falcon guys are 50/50 on them.
Borg Warner is a top choice man!

Let us know how you go.
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

Yeah will do.

The compressor maps on the sxe series are unbelievable.

For the spool potential, and surge resistance, combined with the high choke point, you can't get any better unless you step up to the EFR. However I'm still not sold on reliability of the EFR series due to the bearing design and gamma Titanium rear wheel (which massively assists in spool capability but seems to be transferring considerable heat to the Chra and thus shortening bearing life).

The sxe series is ridiculously priced for the specs.

On my 2.4L stroker, the s366sxe should make 30psi by just over 4000rpm. Calculated as follows:

Engine Airflow in cfm = capacity (in Litres) x RPM x VE x PR
-----------------------------------------
5660

Engine is 2.4L
VE I have used is 90% for my engine (should be better than this) - you generally use the Peak N/A VE of the engine
30psi target boost for reference = just over 3.0 PRessure Ratio

So:

2.4 x RPM x 90 (VE) x 3.00
Airflow (in cfm) = -------------------------------------
5660


From the compressor map, 3.0 PRessure ratio on the surge line equates to 32.5 lb/ min

To convert cfm to lb/min, divide by 14.27 (or multiply lb/min to get to cfm),

So 32.5lb/ min (which is the compresor's flow at 3.0 PR [30psi]) = 463.775 cfm

Therefore, working back from this,

464cfm = 2.4 x RPM x 90 x 3.0
----------------------
5660

RPM = 5600 x 464
------------------
2.4 x 90 x 3

= 2,626,240 / 648

= 4052

That is the theortical spool potential of the compressor assuming complete turbine efficiency at which the compressor map was built. Unfortunately BW don't issue turbine flow maps for their housings, but from experience, the twin scroll t4 housings in 1.00 onward flow fantastic, and shouldn't be a restriction or too inefficient (laggy). This assumes a proper, true twin scroll setup.

Even if we sensitise for inefficiencies and conservatism, it should make 30psi by 4500rpm and go on to reach my peak boost of 45psi by 5000rpm (4600 on the comp map, PR of 4.06)

For a 87lb/ min compressor, that is insane spool, and should make for a great powerband assuming a rev limit of 8300rpm.

At 87lb / min, this engine should make roughly 950 crank hp or 800-850whp

For fun, I have calculated efficiency at 45 psi @ 8300rpm on my engine for this turbo:

2.4 x 90 x 8300 x 4.06 / 5660

= 1286 cfm

Or 90lb / min

That's past the choke line on the compressor so technically will only hold that boost to about 8000rpm.

For a $1500 turbo (using current aud / usd conversion rate and shipping from the states), that is ridiculous.

Mick
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by DR_GEM »

So I've decided on the direction to take with the two projects as follows:

TE will be finished first, with the following:

- 2.6 forged 4ze1
- 8.5:1 compression with the mls headgasket
- The big cam
- borgwarner s257sxe on Gemracing manifold
- tial 44mm wastegate plumbed back
- 3" turbo back exhaust
- custom plenum using rodeo bottom half and VN 5L throttle body and 8 13bt injectors
- 4ze1 cas with aem trigger disk conversion and quad ls1 coils
- microtech lt10s
- e85 setup with single in tank walbro no lifter or external surge
- MUA 5 speed manual with hydraulic clutch setup, custom clutch
- altra 9 LSD and billet axles

Body and interior will be stockish / sleeper look for a fun street car rolling on 15" interceptors with VT commo front brakes and VN rear brakes. With the manual it can also be used for circuit racing too, and since it isn't caged will never really go faster than a 10 at the drag strip so may as well set it up with the good handling stuff (konis, swaybars, camber kit etc) to enjoy.

Should still make over 450rwhp with that setup and make for a very fun engineered and completely legal street car.

Coupe will then get the 4zd1 stroker which I will then buy a new kidney shaped China head, have it ported and decked out with the same gear as my current head (but better flow out of the box). Since I'm using my plenum and manifold on the 2.6, the 2.3 stroker (2.45L) will then receive a Custom sheet metal manifold and TB / fuel rail etc to run 4 x 2200cc injectors
Haltech elite 1500
Trimatic will go in this one
Altra 9 for street and full spool for track duties
Borgwarner s366sxe with Gemracing manifold and turbosmart ultragate

The coupe is caged and tech inspected so can go to 8.00 at the strip without any further work required. I will need to finish the floorpans and transmission tunnel which is a prick of a job.

I'm hoping to be ready with the TE by mid April and hopefully join you guys for the gemi nationals

Mick
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Re: Pre adr TX coupe 4ze1 turbo build (was project TC coupe)

Post by F3ARED »

I'm hoping to be ready with the TE by mid April and hopefully join you guys for the gemi nationals
f*#k yeah. Quoting it so you have nowhere to hide now :lol:

Get cracking!
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