Was lucky and got the PP lid off someone selling one locally.
Yeah, after I rang you Justin and yuo said you had things to do my day went to poo poo anyway.
Exert from my MR2OC post:
What a weekend.
Full of ups and downs.
On the up side the car runs, and seems to do so quite well. On the down side, I have some serious heat management issues.
I cooked the paint real bad on the phoenix power engine lid. It doesn't seem to radiate heat as well in traffic as the factory lid. Just traps it in there and it builds up and causes the paint to peel off/bubble up.
I was driving to a mates house to assist on his car. On the highway it was fine, I got into suburban area and after about 10 minutes of 60km/hr driving, and lights and traffic and what have you I saw the paint on the engine lid bubbling up in the rear view mirror, I decided to pull over and investigate to ensure I didn't have an engine fire on my hands. I pulled over, stopped the engine, and opened the engine lid. Saw the cracked paint and assessed any other damage. I noticed the plastic 5SFE location (5sfe block in use) dip stick handle had melted off, it was about 1" from the collector of the exhaust manifold so it wasn't too suprising. The black split conduit containing the fuel pump power wiring and a few other bits and pieces (o2 input etc to the ecu) had also melted, luckily the cables therein were fine. I went to start the car up to drive the remaining 1km to my mates place. I could no longer get fuel pressure. The radiant heat had obviously caused vapourlock whilst there was no fuel flowing in the lines and no airflow in the bay. I walked to my mates place and returned later. Was able to realise fuel pressure again and drive it to his place.
Was quite unsuccessful in what we were attempting to do on his car (another story all together). I got a heap of aluminium foil out and made some makeshift heatshields to get me the 50km home without causing much more damage. I also richened up the mixtures about 10% to try lower EGT's. They were running at what would probably be considered a good tune before that, at around 14-14.5:1 at cruise and between 11.5 and 12 under load (up to 7psi). Now they sit around 13.5 @ cruise and 11:1 under load, there is still an arseload of excess heat being generated though.
Today a went to a mates shop, he was nice enough to let me borrow his turbo blanket (a little oversized for my turbo, I think its for a T04Z sized turbo) and also gave me some scraps of heat wrap to try shield the fuel pump a little with. I also ordered up some ACL heat shielding (http://www.aclperformance.com.au/prod_heatshield.htm) that I'll fab up a heat shield over the manifold and in front of the fuel pump with. The 700x580mm sheet was around $70AUD, so not too expensive. I'll probably invest in my own turbo blanket as well. I think if I had of had one fitted from the get go the paint damage wouldn't have been done.
I also think a major contribution is airflow, at speed I dont seem to have issues, in traffic or low speeds the engine bay cooks. Im going to invest in a shroud and some fans when money permits to help move some air out of the engine bay. Will probably also fit a 7.5" fan to the oil cooler in the sidevent (factory IC location) to help get some air through there also.
Today I spent 4-5hrs refitting the firewall heatshields (which was quite a huge job thanks to the turbo and other bits getting in the way) which required removing half the gear in the bay to get back in. Also fixed up a couple of minor oil leaks from a fitting on the sandwich plate and a fitting on the oil thermostat block. These seem to be fixed now, cross fingers. Refitting these heat shields should help with fuel temperature and prevent another event of vapour lock.
Getting away from the issues, the car appears to be performing quite well. My IAT temps however around or just above 30 degrees at a ~25 degree ambient. They heat up more when the car is at a standstill (due to radiant heat into the pipes etc) then when the car is on song (only running 7psi of boost at the moment) so the intercooler seems to be operating satisfactorily.
The car pulls nice and hard and has bundles of torque. More torque then I expected actually, and the largish throttlebody means its a bit wild to drive, not being used to such small throttle movements bringing on the power so hard. I almost landed the car on a traffic island tonight after it got a little enthusiastic turning right at a stop sign. Either way, its making arse loads more power @ 7psi then it used to make on 7psi, I'd really of had to try to make it kick sideways running 7psi previously (same turbo mind you) whereas it seemed to let loose all too easily (and somewhat caught me by suprise) tonight. I was only running crappy cheapy 205 wide tyres before as well. Now i've got a lot more rubber on the ground (275 RT615 Azenis) and it still let go so easily. The quaife diff seems to behave slightly differently to how I remember the factory LSD behaving as well, which had me a little by suprise when the rear end let go.
All in all, minus the obvious heat issues, all appears to be going well. A few rogue noises (main one of concern I think is to do with the flex pipe being up against the sump and causing rattly grindy noise on engine braking). This used to fit, however, with the block girdle there is now no clearance, so I'll have to have it modified.
Might throw it on the dyno for a base run @ 7psi with current less then perfect tune once I sort out my heat issues to get a baseline value on power.
A few pictures -
Crackly paint :
Incinerated plastic dip stick handle:
Current situation of affairs, make shift heat management :
Got my hands on some ACL heat shielding material today, so going to make some heatshields out of that, buy my own turbo blanket and hope for the best! :)