My turbo mini of 25 years

Started by Turbodave, March 16, 2018, 09:27:09 AM

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Turbodave

As someone asked to see it,  I figured I'd start here.

I purchased it at 18, and spent 3 years building it, to have it sideswiped after 21 days (and a trip to ER for concussion as my head rattled the B-pillar and knocked me out cold). Rebuilt again, 21 days later lit a cat that required a new front panel. 21 days after being on the road again, it stayed on the driveway and I drove the Cortina!

Anyways, it's been turbo'd since I first built it, was increasingly better developed every year for many years until I moved to the USA where development slowed. A lot. It started on a carb, then went EFI in 2001, then different EFI in 2003, then back to a carb - EFI on an A-series is a pain to perfect, and there were few folks working on it at the time.
This was what the engine looked like for many years:


http://www.turbominis.co.uk/uploads/i/wh1632-oe1/turbodave-4206.jpg



Two years ago, the engine came out and the block fell onto the mill:
http://www.turbominis.co.uk/uploads/i/wh3264-oe1/turbodave-4013.JPG


Then this:
http://www.turbominis.co.uk/uploads/i/wh3264-oe1/turbodave-4014.JPG


Leaving me with this:
http://www.turbominis.co.uk/uploads/i/wh3264-oe1/turbodave-4015.JPG


The problem now, is that the A-series head wouldn't fit. Luckily I found one that did  4.gif
Also started playing with an intake plenum design, to accommodate the existing intercooler positioning, and that'd work with the drive-by-wire throttle body (no more cables, replaced with a bunch of wires LOL).
http://www.turbominis.co.uk/uploads/i/wh2016-oe1/turbodave-4209.jpg


Then I knocked this little thing up over a couple of evenings (I did buy the flanges ready made mind):
http://www.turbominis.co.uk/uploads/i/wh756-oe1/turbodave-3790.JPG


It started looking a little different:
http://www.turbominis.co.uk/uploads/i/wh2016-oe1/turbodave-4207.jpg


Almost ready for MME2017
http://www.turbominis.co.uk/uploads/i/wh2016-oe1/turbodave-4208.jpg
But an annoying issue with the timing belt walking would scupper that plan, leaving me making the trip in my F150!


Finally ready for the road:
http://www.turbominis.co.uk/uploads/i/wh1600-oe1/turbodave-4020.JPG
But first road test revealed way too much crank case pressure, and a catch tank needed fabricating.
Not much room, so made this unit. Can't tell, but there is a separator plate 1/4 the way down inside, to encourace the droplets to "separate" from the fumes.
http://www.turbominis.co.uk/uploads/i/wh1089-oe1/turbodave-4210.jpg


Pic as of a few days ago - engine about again to come out (!) for the new clutch I'm building up:

http://www.turbominis.co.uk/uploads/i/wh2016-oe1/turbodave-4205.jpg


2018 will be the year of finding the weaknesses - as I wind up the redline and boost.
Aiming for a solid 6800 rpm and 20psi. You can pretty much make an approximation that 1 bar (14.5psi) of boost will approximately double the power output of a nat-asp engine, so that is pretty much able to show where this is heading. 77.gif

The ECU I'm using has the ability to map boost against RPM, and in each gear, and the throttle butterfly can be mapped independently against the pedal, which should aid drivability. It also has traction control, and launch control (with the push of a button it retards ignition, allowing engine to build boost, but holds the engine speed steady, meaning there is a ton of boost off the line). Looking forwards to seeing what can be done in the future on the strip.

2018/19 winter will be to get some weight out of it with a self-made rear beam / arms, and replace a lot of the heavy glass, and then have another year of fun, by which point It'll be time to pull it apart and fully rebuild the body - which is bubbling a little in a few naughty places.



94touring

Very cool, about to read up on this. Also, to post pics better, there is a tiny icon that looks like a mona lisa. When you click it you can insert image links and they show up like so..


94touring

I think we're about to start up a sub forum on fuel injection. Sounds like you have a lot of experience and information to share also.  Turbos and mapping via computers has been my thing way before minis. I've toyed with doing something crazy to my basketcase clubby wagon. 

Regarding glass, if you've recently followed my 74 refurb post I'm doing a number of things to reduce weight.  Including polycarbonate windows and slider door conversions.  Plus I went with some fancy kad parts.  I wish someone made an alloy front subframe, that thing is heavy built up.  I've seen force racing front subframe but a bit pricey.  I will be going with force wheels however.

MiniDave

#3
Yeah, £2300 for the Force titanium front subframe is spendy, also because if you do that you just about have to buy all the other lightweight components to go with it - I could see over £5K to do it all!

I wonder if you could save some weight building one similar to theirs only out of DOM chrome molly steel?
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

Turbodave

#4
Front subby on mine will stay standard for now. Weight on the front end is not exactly detrimental for drag racing.
Well, standrdish as I already lowered the engine 1/2", have triangulated the tie rod mounts and have chassis dyno tie-down eyes welded to the frame...

The rear end will simply be tubular trailing arms, and coilovers, in DOM with spherical mounts. All pretty standard unconventional stuff.

joakwin

For daily driving I like bushings, straight drag car, heim joints work good

Minitec uses stock Honda control arm bushings for the rear beam suspension I have on my car
The arms has the bushings
D16z6 Automatic, 4 wheel disc brakes, deseamed shell

94touring

How are transmissions holding up and running that much boost have you looked into any h20 and/or meth injection? 

Turbodave

It's got a quaife, sc synchro box, 2.95 and sc drops.
No Probs as yet!
Drive it without sympathy, and I'm sure the box won't last as long. Shift hard into gears and I'm sure the synchros won't last long, etc.
The boost (torque) management is something I'm hoping will aid in longevity.

Absolutely no intention of meth injection. Tried water injection many years ago using the aquamist system, but found it lacking in that you simply need twice the water for twice the RPM, and more water for more boost. Fully mapped is definitely available, but relying on something that may have a single point failure (many in fact) leading to meltdown is no longer something I'll tolerate.

E85 is something that offers MUCH better returns, is cheap, and Easily available. My ECU can store three different maps, live switchable, so an E85 map is simple to do for race day, draining it all out at the end of the day to avoid the nasty side-effects.

94touring

I run a devils h20 injection.  Kicks in at 8psi, full h20 by 18psi, and the pre turbo injector on at 19psi. I run about 23psi on a rotary at 50/50 water meth.  Best thing for reliability on a rotary and otherwise impossible to run that much boost on pump gas.  Had looked into e85 but seemed like a lot to convert my system over and not something I wanted for a weekend driver.

MiniDave

Turbodave, what nasty side effects from E-85?
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

Turbodave

 Simply put, E 85 is corrosive.
It will eat away at non-anodized alloy, and every single rubber fuel line, seal, o ring that has not been intended for use with E 85.

Aside from that it is great !!!

As cheap as chips and an octane of something like 103/105 !

94touring

What's your fuel consumption on e85? Seems like I recall guys who converted had to use larger injectors to up the flow. 

MiniDave

Yes, I've heard it has about 25% less BTUs of energy as gasoline......so mileage suffers accordingly.
Complete failure at retirement

1989 Cooper Racing Green
2009 Clubman S
2014 Audi Allroad

MPlayle

My mom had a Hyundai Sante Fe that was supposed to be " E85 compatible".  She normally ran it on standard 87 octane unleaded pump gas (typically E10).

On a trip she and my dad were doing years ago, there was one place (in Iowa I think) where all they could get was E85.  The car's performance and mileage suffered almost immediately - the mileage dropped by 1/3!

As soon as they could, they got it back to being filled with her normal choice of fuel.  Shortly after getting it back to normal gas, the performance returned and so did the mileage.


Turbodave

I've not yet Run E85, but yes, approx 25% more fuel is needed.
I opted for the Bosch 42lb injectors and 4 bar fuel pressure, which I think will be towards the upper limit (but not at it) for crazy power, even with the E85.

94touring


Turbodave


jedduh01

Turbo Dave... How much trouble or fun will this create?

Project underway.