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Lonewolf's MR2 Bathurst ed.

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Lonewolf
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Re:Lonewolf's MR2 Bathurst ed. 2015/04/26 20:11:23 (permalink)
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Made up a plate that goes under the inter-cooler which supports the pipe near the filter... It was rigid in there without it but definitely solid now... also the only pipe in that part of the engine bay is the fuel filler pipe... wasn't brave enough to re-route that sucker lol.

'95 Bathurst SW20 + '96 Gen3 3S-GTE = MR2 Bathurst GT :)
#16
Nik_Lee
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Re:Lonewolf's MR2 Bathurst ed. 2015/04/27 08:06:09 (permalink)
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Cant wait to see your thoughts on the EFR, I would like to go with an EFR on mine one day as I think it should be a very responsive turbo as well as being very capable of producing good numbers.

Current ride, 2010 TT RS
Previous ride, 1994 JDM MR2 Turbo hardtop
http://www.mr2australia.c..r2play/tm.aspx?m=105959
 
#17
B24
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Re:Lonewolf's MR2 Bathurst ed. 2015/04/27 16:35:21 (permalink)
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Looks like a crazy build. Well done!
Are you going to fit a stainless oil return line? I would recommend as the braided line will fail.
 
#18

Lonewolf
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Re:Lonewolf's MR2 Bathurst ed. 2015/04/27 18:03:49 (permalink)
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Yup, made up a drain pipe... the way the manifold sat when the hose was dummied up I wasn't happy with how it would drain so opted to use pipe instead so that it was always going downhill, couldn't do that with the hose.
 
Actually had to redo a fair bit due to that manifold as it wanted to foul on everything haha, dipstick tube, drain pipe, oil cooler fittings, even the oil/coolant bypass initially fouled... but got there in the end and then heatshielded everything for good measure... so yep... that was fun making a custom dipstick tube and dipstick lol


'95 Bathurst SW20 + '96 Gen3 3S-GTE = MR2 Bathurst GT :)
#19
B24
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Re:Lonewolf's MR2 Bathurst ed. 2015/04/29 09:11:37 (permalink)
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Ah yes, brings back a few memories of a similar path of modifications to my 3STGE. I blew the oil return line at the MR2 Trackday Challenge 2013. The car was (supposedly) tuned and run in. During the run it, the manifold heated the oil return line until it turned it into a brittle plastic 'like' hose encased in the braided line (Earls line). I did a few laps then the oil just went everywhere causing a lot of smoke but no fire. After that, I had a bunch of modification to the thermostat housing, dip stick and oil line to resolve the issue. After that, there were issues with turbo mounting studs coming loose. Turns out the way Ric Shaw solves this for his RX7 which ran in Nurburgring 24hr was a Inconel gasket for the exhaust manifold on the turbo and Inconel studs as both components did not suffer stretching or blow out (my stainless steel gaskets blew out like paper during the Wakefield 300). If you are running V Band, you will be fine.
What power are you expecting to see? I know a few guys with similar set ups are getting around the 300rwkw mark. These guys were at MTC. While I was releasing the cars for the Hillclimb (great job!) you could see exactly how the cars deliver the power. The bigger hp cars certainly had a degree of lag before they would light up the wheels when they came on boost (pretty good sight to see). It did effect the times of the cars as they had to wait for the power to arrive. Is that an issue for you? Is the car a road warrior or a trackday weapon or a bit of both?
 
 
#20
Lonewolf
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Re:Lonewolf's MR2 Bathurst ed. 2015/04/29 10:52:23 (permalink)
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The EFR is a twinscroll so Vband is out, But i've got a high quality MLS gasket there so "Hopefully" it'll stand up to what get's thrown at it...
 
It's on 258rwkw on 16psi and we only went to the factory 7200rpm where power was still going up. What will it make once cams dialled in, higher redline and 30psi... not sure? 
 
comparing it to the CT20, the dyno run with the CT20 was on 6psi by 2800rpm and the 16psi by 3500-4000rpm as I recall. I dont have the info with me but from memory the EFR was on 16psi by at least 4700rpm, probably sooner. Launch control , anti-lag and shift cut not yet set up either so got that up the sleeve too 
 
It'll be road reg, actually just waiting for the engineer to do the IM240 test on it and sign it all off, But I love doing hillclimbs and track runs, you can push yourself so much harder than you could ever safely do on public roads.

'95 Bathurst SW20 + '96 Gen3 3S-GTE = MR2 Bathurst GT :)
#21

Lonewolf
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Re:Lonewolf's MR2 Bathurst ed. 2015/06/19 17:10:12 (permalink)
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Update:
Unfortunately I didn't get to Qld for the meeting as I was quite keen on going, actually saw 2 SW20's heading south through Coffs, presumably on their way home from the event, one silver one and a navy blue one, both travelling together.
 
So 4 fuel pumps later... It is now running again... and it turns out the fuel tank was clean as a whistle anyway and that I just had a dying stock pump, a new 044 that failed with 3 hours on it, the replacement leaked out of the pump chassis... so I went with an aeroflow equivilant instead... car is running again now even if the pump is noiser than the bosch. I'll probably goto a fuel lab prodigy later on as they look to be a real good pump that'll handle flow better when I eventually bump the turbo up to 30psi.
 
While the fuel tank was out I pulled the exhaust manifold, turbo housing and downpipe off and sent them off to coating king in Newcastle and they did a nice job of coating them. It'll be interesting to see how it affects spool up on the turbo now. Also for those interested I had a look at the Boost Map of the EFR8374 and it seems to sit about 1000rpm behind the stock CT20b. I Imagine the coatings will put it somewhere in between the 2 points.
 
 
 
So having driven it now I'm really keen to iron out the last few niggles:
- Clunking noise when turning with load on driveshafts. Going to put the standard CV cages back in and see if the clunking persists as the only changes done that I could see that POSSIBLY could cause this are the ATS CV's and the roll centre adjusters that were installed.
- Throttle Sticking. probably just needs to be properly set up as it's responsive when you play with the throttle body directly, but is sticking when you use the pedal. Issue is there somewhere, just need to isolate it.
- The Wolf is seeing some electrical noise that was being sorted when the fuel pump died.

'95 Bathurst SW20 + '96 Gen3 3S-GTE = MR2 Bathurst GT :)
#22
Fast Eddie
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Re:Lonewolf's MR2 Bathurst ed. 2015/06/19 21:48:40 (permalink)
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That would of been John and David heading south
#23
Lonewolf
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Re:Lonewolf's MR2 Bathurst ed. 2015/08/24 22:22:14 (permalink)
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So after implementing near on every known form of noise attenuation that exists in human knowledge to sort out the mysterious electrical noise that the wolf was experiencing... pulled the plugs out and noticed the tiniest of hairline fractures on one of them... replaced plugs... runs perfect now... not going to say we pulled the plugs out and inspected them twice already and missed it but anyway...third time's a charm they say, right?
 
More troubleshooting on the throttle issue has seen a new throttle being installed, the one I had was "Good" Crap and has been replaced with a much better fitting unit that has no air gap around the throttle plate, and operates a lot cleaner. It's better now but still not happy with it. The remaining stickiness appears to be coming from the pulley that was fabbed up that joins the factory throttle cable to the extension that was needed. If there's a good way of extending the throttle cable properly can someone put me on the right path at all?
 
The CV is looking to be more and more the culprit for the "clunking" when turning with any load on the drive-line. pulled the RHS axle and appeared to be fine so put it back in. pulled the LHS axle and appeared to be fine... then we noticed it would bind when rotating on full thrust... pulled it apart and cleaned all the grease out to inspect. I believe it to be a manufacturer issue but until that has been resolved I've got the factory one back in... Shame I ran out of time to get the brakes bled and test it out, but the binding appeared to be gone when checking the range of motion which was a promising sign. 
 
Touch wood that is all it is and I don't have an excuse to put a Quaife diff in haha.
 
Anyway just thought I'd put an update up before I head overseas for a few weeks... Alaska, Canada and Hawaii are on the agenda for September!

'95 Bathurst SW20 + '96 Gen3 3S-GTE = MR2 Bathurst GT :)
#24
Lonewolf
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Re:Lonewolf's MR2 Bathurst ed. 2016/01/14 20:46:59 (permalink)
+4 (4)
MR2 Trackday Challenge 2016:
 
Sorting out the clunky noise which turned out to be the wrong type of gearbox oil... I had 75-80w GL5-6 Oil and after changing to 75-80w GL4 gearbox oil... and some penrite limslip additive, the clunk went away in about 10 seconds, so was happy with not needing to pull the diff apart, I was finally able to make it down to wakefield for the trackday challenge.
 
After a rather exhausting trip made it down to wakefield and even with what ended up being over 11hrs of driving starting at 9:30am, I was extremely excited to finally not only give my SW20 it's first drive since the rebuild. On top of that It would also be it's first time competing on a full circuit and with other cars, also the first time it's seen all it's brother and sister MR2's in their various guises since a group from QLD came to coffs to say hi back in... 2006?
 
There was alot of excitement on sunday night as everyone was anticipating weather and how awesome their driving was going to be amidst all the general banter of the BBQ where everyone was either catching up or introducing themselves, even well into the morning hours of monday. I'm not sure I slept, as I remember waking up several times before the sun was up and when It was and I saw the first car was able to access the pits, it was game on.
 
As soon as Drivers Briefing was out of the way I think I was halfway ready before my group was called up for the hillclimb stage. Went and lined up with everyone and did our scouting lap, get the tyres warmed up on the way down, I'm thinking, "Yeah, I got this". 1st run was a quick scout and the car felt good, that boost was giving a serious kick even at 14psi. There was one low speed corner where you turn off the track onto the hillclimb part but it flowed nicely. 2nd run was my good one... launched great... 2nd gear was great, on 3rd gear my car decided to disconnect the intercooler pipe and end my fun for the hillclimb till I got back to the garage.
 
With the pipe inspected and re-installed and tightened "That much" more I was ready just in time to do the clubman sprint. I quickly found the limits of grip with the cheap street tyres I had on there and after locking up, nearly having a lose on the last corner... actually running out of traction and finding the sand I decided I better put the semi-slicks on, as I had tyre smoke waft in through the cabin... More concerning was the smoke coming up from the engine bay as I pulled into the garage ... Molten plastic on the downpipe? but theres only an engine lid above it? Oh wait... here's an untrimmed partially melted zip tie... right, not sure how you got missed but let's fix you up and scrape that crap away.
 
The Semi's had a whopping 10 - 14 psi in each corner and pumped them up just in time for the Tarmac Stage. Tyres felt a ton better and was alot more confident but left my brakes wanting for more stopping power, I think the EBC's are getting ditched for the project mu's next time. After a warm up/orientation lap I went to have a crack and... surprise... the other intercooler pipe says no. It really didn't like that change from 2nd to 3rd.
 
Fixing up the other intercooler pipe and checking out everything else along the intake... I was right to go and suss it out in the passenger session... not competitive, but need to make sure it's good for tomorrow when the full track is used... car was feeling good and finished up the day confident it was good for Tuesday.
 
At the end of the day everyone lined up for that awesome photo along the main straight and some group photo's all sweaty and weary from the day but overall everyone was happy to have made it through the day, though I think few weren't scarred from some drama from the day be it minor and stupid (zip ties on downpipes) or major (breaking a wheel and moving the suspension points on the chassis... or a dead alternator), though there were plenty of heat related issues as well.
 
The Night was enjoyable with pretty much everyone at the bbq. I've never seen spontaneous evaporation but pretty sure most of us didn't feel the first drink go in, let alone hit the sides for the heat of the night.
 
 
 

'95 Bathurst SW20 + '96 Gen3 3S-GTE = MR2 Bathurst GT :)
#25
Lonewolf
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Re:Lonewolf's MR2 Bathurst ed. 2016/01/14 20:50:00 (permalink)
+3 (3)
The 2nd and main competitive day of the trackday challenge was shaping up in the morning to be another scorcher as we finished the drivers brief. Quickly took the engine lid off to make sure I had no cooling issues as well.
 
Went out with the first session and had a good outgoing lap, 2nd lap in I threw a bit more speed into it, I'm not sure if my car really just wants to play or if it is secretly plotting to kill me, but the car was going "Let's Play!!!" (i.e. coming on boost) right on some of the bends... didn't quite have the balls to hold on fully just yet, but still feeling the car out too. And then coming onto the main straight for lap 3 lost power suddenly going up the straight.... making boost hmmm... back to the garage... spark plug lead on #1 hit the eject button and ruined the party...
 
Second session came around and was able to go out there and finally have a go!!! Car felt good and strong and finally pulled a few laps in a row, no heating issues, no burst plumbing or wiring... happy days! I was able to stay out for the whole session and had no issues when I came back in. 
 
It was short lived though, after coming in from the passenger session I heard a metallic rattle in the engine bay that had me worried, put the stands under it and got underneath...after a bit of looking underneath I noticed a few things that made me err on the side of caution:
- The boots on the back of the rear wheels whilst not split had ejected grease on the inside of the wheels and suspension
- The front engine mount, the solid urethane block was melting from the manifold heat...
- fresh oil on the starter motor power cable... where did you come from?
- After checking the exhaust bolts and a few others I thought it might have been I didn't want to push it in case it was internal.
 
Unfortunately I missed the regularity event and the hot lap shootouts, but now having come home and had a proper look I've also had a fuel system issue as well as I have low fuel pressure, which could have been really bad. 
 
So got everything packed up to head off in the morning and we went off to watch the group from my cabin have a go at the chilli burger challenge. To all that were there, my dad was feeling the heat from his slice, he didn't say it at the time but since leaving the event he's been saying how it's the hottest thing he's ever eaten.
 
It was a great event and I really think a big congrats needs to be given to the guys sweating it out on the track with timing equipment and camera's alike and so that we were able to go out and be hoons and enjoy driving our cars competitively and for those like me who haven't been either too the track or haven't driven their MR2's in a while, for giving us a chance to go and learn how they behave when pushed (i.e. which bolts weren't tight enough)
 
The to-do list just got a few items for the next outing:
- Exhaust system getting some heat wrap and heat shields
- In-car cameras (the only real disappointment of the event)
- Beef up the brakes
- fix up some annoying ECU signal issues that I had.
- Gonna bring 18 psi next time ;)
post edited by Lonewolf - 2016/01/15 00:12:33

'95 Bathurst SW20 + '96 Gen3 3S-GTE = MR2 Bathurst GT :)
#26
robk
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Re:Lonewolf's MR2 Bathurst ed. 2016/01/15 09:16:50 (permalink)
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What a story teller you are haha! Good read 
 
No wonder I got a bit of a shock when I saw your engine bay at the event...it turns out that I somehow missed this build thread entirely until yesterday. 

There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
#27
rikkir
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Re:Lonewolf's MR2 Bathurst ed. 2016/01/16 12:06:52 (permalink)
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Great write up!

    Silver 1997 SW20 Bathurst with      

#28
Lonewolf
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Re:Lonewolf's MR2 Bathurst ed. 2016/01/21 21:26:57 (permalink)
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Having had a look over the car after the trackday I've found myself with the car apart again to sort out some of the issues that showed themselves at wakefield.
 
Thankfully most of the things that caused me concern were non events.
- I did have the fuel pump fail... again... That makes 3 faulty fuel pumps now from 2 different manufacturers... thankfully it's the external one so nice and accessible.
- Engine bay heat was pretty nasty as demonstrated by my twosrus engine mount... thankfully its a solid unit but the melted urethane has stayed all gooey. Pretty sure that stuff melts at like 400-600 degrees celcius so it was pretty damned hot. Will be making up a heatshield for it and those 2 bolt's are looking like a great spot to mount it to.

 
Also to keep the engineer happy and ensure it's fine for emissions I've proceeded to wrap the manifold and downpipe up to the cat converter.

- Modified the cylinder head a bit to allow quick removal of the manifold.
- Noticed the locking tabs that hold the turbine housing to the turbo cartridge... of the 6 of them 2 had come loose and 1 was completely gone... they are getting loctite this time.
 
With the bad news out of the way I've got the whole exhaust out so have been able to fit the AFR sensor to the exhaust to finish off the install of my shiny new gauges. Still need to locate where I can tap into for oil pressure... Boost is easy and now reads up to 45psi ;)
 
 
 

'95 Bathurst SW20 + '96 Gen3 3S-GTE = MR2 Bathurst GT :)
#29
5SGTE
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Re:Lonewolf's MR2 Bathurst ed. 2016/01/21 23:54:53 (permalink)
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Factory OP is located in the head, pass side towards the front.
#30
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