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  • AW11 SC - Full Rebuild (and I mean full!)**************** FINISHED *********************** (p.10)
2012/01/11 18:41:15
ZEROGK
Love the paint colour, look fantastic.
 
How did you sort the handbrake with the new Wilwood setup?
2012/01/11 20:07:54
MK1corse
Awesome!!! Looking absolutely brilliant!!! 
2012/01/11 20:47:40
ozhummer
Good point, I need to speak to them about this, no handbrake is no option!
2012/01/15 21:39:27
ozhummer
Well it's taken a hell of an effort to date .. and this weekend the engine (finally) fired into life! - using a modified startup map I finally got the computer sync's and trigger working in the right order and it really sounds good!!!! - Some supercharger noise, and plenty of intake noise! 
I've uploaded a video to youtube
 
http://www.youtube.com/watch?v=46SENlzKZ5A&feature=youtu.be
 
Although I don't want to run the car too muc, I did want to make sure all my computer outputs and controllers were working, I have custom config for Intercooler water pump, intercooler fan, engine bay fan. They all work - The V4X is very easy to configure these outputs.
 
I also wanted to run a log and see what boost the Rotrex makes .... WELL!!!!!!!!!! - TRY 22 PSI @ 6500 rpm !!!!!!!!!! May need to restrict this down but will leave that to the tuner.
 
Notice I have put the catch can in the boot - plumbed back into the intake - all legal!..
Electrics done for the EMS - and now I am moving on to body.
 
Here are some photos..
 
2012/01/18 19:08:10
RdS
really excellent work! looking ****hot!
from the few pictures of the outside so far, it looks like whoever did the paint did a damn fantastic job of it!
 
lucky aw11. :P
2012/01/23 12:58:58
ozhummer
Nearly there ......
 
Off to Dyno today for a week of tuning ...
 
2012/01/24 20:26:47
ozhummer
 
DYNO RESULTS - DAY 1 -
 
 
A new engine with as many mods as this one would always pose a challenge when it comes to tuning. Tuning properly anyway .. I'm not chasing HP, but drivability, reliability etc. HP is important too - but not first ..  Do I sound convincing ?  - Well day one the tuner concentrated on sub 4000 rpm tuning, no power runs, just smooth power delivery and a nice hot idle.
 
Firstly, the Rotrex SC is very a different beast to turbo - we sort of expected a sharp rise in boost and then a level out, sort of like a WRX.. What we have found is the Rotrex is perfectly linear! - at 2000 rpm we are making 0.1 PSI. @ 3800 it's in the area of 8 PSI. Estimate for redline will be 16 PSI. Although no real power recording were made it was observed that at 2000 rpm dyno limited, (so foot flat to the floor but the dyno holding the car at 2000 rpm) we saw 105 RWHP. This is pretty good as it would represent something like 130 Flywheel HP (97 KW). The tuner could not get over the efficiency of the intake system including cams.
 
What we have found is the Wolf is a bit of a 'pr--k' to tune. Tomorrow he is going to alter the sync and ref triggers to give more timing through the wolf which is limited at 20 degrees currently as it can't keep up with the signals.
 
Also al signs are pointing to the injectors reaching their limits, so I have the company I got them from sourcing a set of 600's.
 
Compression ratio is pretty low at a calculated 8:1 - I don't really want to, but I think it will be off with the Commetic 1.2mm mls and replace with a 0.4 mm mls. This should take the compression up to 9:1 or maybe slightly higher.
 
Although no power figures are yet available for a final run the estimate is in the area of 300 FWHP. which was always my target(ish) - we may need to wait till the compression has been raised and the SC pulley reduced by 10mm to see this, but we will get there...
 
BTW: IT SOUNDS ABSOLUTELY AWESOME!!!... I will post a dyno video of a power run once complete.....
2012/01/25 20:59:10
ozhummer
DYNO RESULTS - DAY 2 -
 
I'm guttered! ... Got a call this afternoon from the tuner telling me the ECU has 'died' - just died.... no warning, just doing some timing adjustments and it died.....
 
Leading up to the death of the ECU, the engine woudl not rev to redline. It got to abotu 6500 and then started to miss fire - not a miss fire that resembled spark, ignition, timing etc - more it like a rev limiter! ..
He could not tune it out ! - even with 30 deg of timing ... The computer was struggling .. The question is - is it a programming error?  - is it a software error ?  - is it hardware ? - I don't know and neither does the tuner.
He is going to call the support line and see where we go from here.
It's already had 7 hours of dyno running, so wiring will not be the issue - if we don't get a favourable warantee result then look out !... I'm very dissapointed! ... I'm paying near $200/hour for the dyno so am already approaching $1500 - If I have to throw the ecu away and replay it then I'm up for another $2K (ECU) + another $2K for tuning - one thing is for sure is that it will not be the same brand !!!!!!!!!!!!!!!!!..
 
Watch this space!
2012/01/25 23:00:40
nuk1ear
7 hours doesnt mean wiring is not an issue. Thats not good logic, look into it still. Which ECU are you using? i thought u said u were going to use a haltech?
 
Honestly doesnt sound like an ecu issue, missfiring at high RPM etc
2012/01/25 23:28:10
dasic1
With the Autronic in my car it had a major misfire (at 5700rpm I think it was) Turned out I had to put a resistor inside the ECU because it couldn't read the 60-2 trigger wheel  once it got to that RPM.
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