So here's the latest. I picked the car up last weekend, which was fantastic after almost 6 months! Scrubbed up well with a wash, and feels so good to drive! Dyno showed 280 hp (209 kw) at a debatable boost level - ECU and guauge were showing 16psi, the dyno showing about 18. Anyway, a solid improvement over the previous 185 kw at 15ish and leaning out! Still a bit bumpy there on the AFRs...
Work done includes...
Engine rebuild: Bored & honed, crankshaft grind & balanced, Block decked, O'haul Oil pump, head serviced, head & manifold ported, new water pump, thermostat, plugs. Parts inc CP forged pistons (.020" oversized), Eagle Rods, Cometic metal HG, ARP head studs, ARP main studs, ACL bearings main, rods& thrust(main & rods 0.010"), Full OEM gasket & timing kits, OEM crank pulley (harmonic balancer), Fidanza Lightweight flywheel.
Fueling & IC upgrade: Frozenboost W2A IC (type 3) and front mount heat exch (type 100 = 24x12x1 inch), cheapo Rule water pump, Walbro 255 Lph fuel pump, Wolfkatz Top Feed Fuel Rail, Bosch(ID) 900 cc/min High Imp. Inj. + Clips.
ECU: EMS EM70 & MSD Ignition unit
AirCon deleted, 4pt harness installed.
Took it to Wakefield on Wednesday, and almost cried on the way down - 4 gear pulls produced much earlier boost than before, but quickly changed into the flutter I now know as compressor surge! The day wasn't wasted, but I could only power up gradually out of corners, and recorded fairly limp 1:17's (there's some serious driver improvement potential here also to be honest :-). Acceleration down the main straight was great though, matching most of the cars there and it sounded good! The compressor surge probably wouldn't be an issue if I took more corners in 2nd but it's very offputting. So hopefully can sort that with some tuning tweaks or else turbo/cam work (or other suggestions?)
The W2A was flawless, after each session I felt the intercooler and it was cold, so really pleased with that. Should be able to get some logs off the tuner in a couple of weeks to see how the intake temps etc went.